Some Computer Applications in the Drop Forging Industry

Abstract

The cost estimating and production planning techniques at a jobbing Drop Forge were examined with a view to developing improved, computerized alternatives. Regression analysis was used to develop mathematical models capable of predicting the production variables (i.e. flash weight and production rate) for any forging. The accuracy of the models was found to be better than that presently obtained using the traditional technique based chiefly on human experience. A way in which this improved accuracy of prediction could result in financial benefits has been discussed. A computer simulation study was used to investigate these benefits. The possibility of using Discriminant analysis to aid the selection of optimum production unit for any forging has been explained. This avenue of research proved fruitless due to the lack of suitable records at the study forge. An alternative approach to the hammer selection problem was briefly outlined.4 computerized production scheduling system was devised, capable of planning both Forge- and Die Shops. This computerized system was tested and found to reduce the planned lateness of late jobs by 30%, typically. This was achieved by adopting 2 more logical, rigorous approach to the scheduling problem. The role of the developed scheduling system in an overall, fully integrated production management end control system has been assessed, together with the anticipated costs and benefits of such a fully integrated system.