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Metal Casting Technologies : December 2006
METAL Casting Technologies December 2006 41 measures how much of the movement in the dependent variable is explained by the independent variables. It is a statistical tool that attempts to explain changes in the dependent variable as function of the independent variables through the quantification of a single equation. Based on the values from Table 8 the following quantification of a single Linear Regression Equation has been developed: Y = 4959.78 + 0.0466 X [Eq. 1] (X = Annual production, Tones and Y = Energy consumption, MJ/T) The above function in which a dependent variable is Energy consumption, MJ/T and independent variable is annual production in terms of tones. Based on the actual data for four foundries (Table 8), the linear regression model (Fig 1) has developed. ● The regression analysis provides best fit curve and a relationship was developed in the form of quantification of single equation [Eq.1]. ● It is observed that the above model gives the positive correlation between the annual production and energy consumption (Regression co-efficient is 0.68). ● In this equation [Eq.1] is useful to forecast the Energy consumption with respect the Production rate. ● Based on the above analysis, to increase the capacity utilization the energy consumption is optimized 5. DISCUSSIONS ● It is observed that the major consumption of electrical energy is occurring in the melting division of the foundry. ● Foundry III is operating with 92.86% of capacity utilization. So it can be observed that the specific oil consumption is minimized when the foundries are running with more capacity utilization. ● Referring to articles 3.2, it is observed that the rejection rates of both rough castings and finished castings are minimum for Foundry I (5%, 5%), while that of Foundry III are high (10%, 10%). ● Based on the qualitative assessment of resources, conducted by the authors, it is observed that Foundry III employs unskilled laborers who are lacking in knowledge about the best practices to be followed for minimizing the rejection rate. ● Referring to articles 3.4, it is observed that Foundry I employs induction furnace and rotary furnace. The specific power consumption of induction furnace is 3.1% higher and the specific oil consumption of the rotary furnace is 48.15% higher than the CII specified standard norms. Figure 1 Linear Regression Model for Energy Consumption Pacific Rim Foundry Services Pacific Rim Safety Products Pacific Rim Foundry Equipment Tel: 61 2 9639 6677 Fax: 61 2 9639 6560 Mobile 0419 433 238 Email: firstname.lastname@example.org PACIFIC RIM FOUNDRY SERVICES Exclusive Representative for Mancuso Chemicals (Canada) in Australia and Southeast Asia Chemical Binder Systems State of the Art Technology at Competitive Prices Furane Resins and Catalysts Phenolic Urethane No-Bake Binders Phenolic Urethane Cold-Box Binders Photo courtesy of John Heine & Son Foundry PACIFIC RIM SAFETY PRODUCTS Marketing safety products from: Paramount Safety, Elliott Australia, Protective Industrial Products, Defender Safety Safety Equipment Leather Gloves, Cotton Gloves, Terry Cord Gloves, Welding Gloves & Aprons, Ear plugs, Safety Glasses, Respiratory Masks, Furnace Clothing, High Visibility Clothing, Disposable Overalls, Work Jackets PACIFIC RIM FOUNDRY EQUIPMENT Buying and Selling Second Hand Foundry Equipment Foundry Equipment Asset Liquidations