COST REDUCTION STUDY OF BRASS FAUCET BY

A Dissertation
Submitted in partial fulfillment of the
Requirements for the Degree of

Master of Technology in Mechanical Engineering

by
STUDENT NAME
(ROLL NO)

Under the Guidance of

Prof. GUIDE NAME

Department of Mechanical engineering

Lingaya’s vidyapeeth
Faridabad

June – 2021

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 CERTIFICATE

This is to certify that dissertation entitled, “Cost reduction study of brass faucet……….”, submitted by

Sumeet Gupta to the Mechanical engineering Department, Lingaya’s Vidyapeeth, Faridabad, in partial

fulfilment of the requirement for the award of the degree of Master of Technology, is a record of bonafide

work carried out by him under our supervision and guidance. The work has not been submitted in parts or

full to any other University or Institute for the award of any degree or diploma or for any other purpose.

Guide Name
Mechanical Engineering Department
Lingaya’s Vidyapeeth, Faridabad

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 ACKNOWLEDGEMENT

I would like to express my special thanks of gratitude to my guide, Dr. Iqbal Ahmed Khan

(HOD, Mechanical Dept.), who gave me an opportunity to do this dissertation and also

provided support & his valuable inputs in completing this dissertation.

I would also like to extend my gratitude to other faculty members for providing me all the

necessary information & resources that were required during my M. Tech. degree.

Sumeet Gupta
18PGME03

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 Index

Acknowledgement 2
Abstract 5
List of Tables 6
List of Figures 7
Notations & Abbreviations 8
1. Introduction 9
1.1. Product category & process 9
1.2. Overview of manufacturing process 11
1.3. Casting defects 12
1.4. Other disadvantages with brass casting 15
2. Literature Survey 16
2.1. Literature survey for cost reduction 16
2.2. Literature survey for laser welding 17
3. Project Background 19
3.1. Objective 19
3.2. Methodology 19
3.3. Presentation phase/ Implementation 27
4. Design Changes & Manufacturing Trials 29
4.1. Existing design & critical design features 29
4.2. Laser equipment used 32
4.3. Trial samples 32
5. Result and Learnings 33
5.1. Issues observed 35
5.2. Challenges 36
5.3. Learnings 36
6. References 37
7. Annexure A- Test Plan for Pillar Tap 39
 ABSTRACT

Brass casting is a traditional manufacturing process which is used in several industries to make different
articles. One of the major industry which use this process, is K&B industry. In this industry, brass casting is
primarily used to manufacture faucets. There are number of defects which make this process less
economical compare to other manufacturing techniques. One of the major defect is “Porosity”.

This study is based on cost reduction exercise of an existing product and highlights scope of using sheet
metal forming process in combination with laser welding to manufacture faucets. This study also touches
upon technical issues faced & learnings during this project. This study uses tools such as ABC analysis &
cause-effect analysis to identify components and causes which need to be targeted to achieve maximum
cost reduction. Various material and method alternatives were discussed for cost reduction. Based on pros
& cons of each alternative, sheet metal forming & laser welding was shortlisted for further study. Based on
manufacturing trials, following conclusions were drawn:

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 List of Tables

Table 3.1: BOM of July pillar tap 21

Table 3.2: ABC analysis of pillar tap BOM 22
Table 5.1: Standard cost with SS body 34
Table 5.2: Standard cost with brass body 35

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 List of Figures

Fig 1.1: Kohler July Range 10

Fig 1.2: Flow Chart- Faucet manufacturing process 11
Fig 1.3- Fig 1.8: Metal casting defects 13

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 Notations & Abbreviations

VC- Vitreous China

GDC- Gravity die casting

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 Chapter 1
Introduction

Sanitary ware & bathroom fittings industry is one of the high growth industry in India. Future prospects are
also very promising due to rapid urbanization happening in India. As per report published by B&K
international in 2014, Valuation of this segment is $427mn, in India. Rough estimates for today’s market
size is approx. $1.3Bn [4].
Apart from Indian manufacturers & brand, several multi-national brands also have their manufacturing
facilities in India. These facilities not only cater their domestic demands as well as their international
demands.
India as a nation wants to elevate the living standard of its citizen by becoming an industrial nation from an
agrarian nation but India also committed to reduce its carbon footprints & declared its ambitious targets. To
achieve both targets, we have to move towards clean manufacturing techniques which not only provide
high volumes with low wastage as well as cause less emissions.
1. cture internal details which are otherwise impossible to make. A core is essentially a body of
materials which forms components of the mold. It possesses sufficient strength to be handled as an
independent unit. Core is an obstruction which when positioned in the mold, naturally does not
permit the molten metal to fill up the space occupied by the core. In this way a core produces
hollow casting. Cores are required to create the recesses, undercuts and interior cavities that are
often apart of castings. Cores are employed as inserts in mold to form design features that are
otherwise extremely difficult to produce by simple molding. [7]
2. Permanent Die/ tool: Instead of using a sand mold/ die/ tool, a reusable metal die is used. The mold
is made from a high-temperature metallic material, such as cast iron or hot work die steel, which
can withstand the repeated heating and cooling involved with large volume production. [8]
Permanent mold casting produces metal with better dimensional tolerance, superior surface finish,
and higher and more uniform mechanical properties [8][9]. The disadvantages are design limitations
due to metal dies, higher initial die cost, and longer lead time for die construction and for changes to
the die caused by a casting design change [9].
Sawing & Tumbling: After casting, additional brass from cast body, is removed which is not required in
final product. After sawing, lot of faucet bodies are placed in a tumbler where sand cores break and come
out due to repetitive shocks.
Machining: A faucet body has several features for assembly of parts and contact surfaces to provide leak
proof assembly. These features are machined using CNC machines. These features include locating holes,
threads & sealing surfaces.
Polishing & Buffing: Polishing and buffing are finishing processes for smoothing a work piece’s surface
using an abrasive and a work wheel or a leather strop. Technically polishing refers to processes that use an
abrasive that is glued to the work wheel, while buffing uses a loose abrasive applied to the work wheel.
Polishing is a more aggressive process while buffing is less harsh, which leads to a smoother, brighter
finish.

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 Chapter 2
Literature Survey

Literature review for this study was conducted on 2 different aspects.

1. Cost reduction techniques and case studies conducted by other researchers.
2. Research studies by earlier researchers covering a spectrum of topics from basics of laser welding
systems, types of laser welding system to focused studies about effect of laser welding on different
materials & effect of various parameters on laser weld quality, etc.
2.1: Literature survey for cost reduction
David Meeker & F James Mcwilliams (2011) [16], presented a systematic methodology for assessing
product cost improvement opportunities. They described step by step method for cost reduction projects.
They discussed ABC/ Pareto analysis and its scope. They described various value engineering methods
which can yield quick results in product cost reduction.
Richard C. Chen, et al (2002) [17], studied the use of cause-effect analysis for target costing of products.
In their study, authors discussed target cost approach of costing, cost plus approach of costing & how target
cost approach is beneficial in this competitive era. They discussed about cause & effect analysis, how it can
be used for the purpose of achieving target cost. Authors took the reference of 2 case studies to establish
the role of target costing & cause-effect analysis to achieve substantial savings as well as competitive edge.
They suggested 3 engineering techniques for achieving this target cost reduction objective: value
engineering (VE), quality function deployment (QFD), and design for manufacture and assembly.

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 Chapter 3
Project Background
3.1 Objective
This study is based on cost reduction project of an existing SKU (Kohler July Tap). The objective of this
whole exercise is reducing the standard cost of the SKU by at least 25%. In order to do so, functional &
aesthetic performance must not degrade.
3.2 Methodology
By literature survey & case studies, we know that VAVE approach and techniques are very helpful &
effective in cost reduction projects. So, we used VAVE approach to systematically handle the given
project.
3.2.1: What is VAVE? Fig 3.1: July Pillar Tap
VAVE is a systematic process used by a multidisciplinary team, directed at
analyzing the functions of a project, product, process, system, design, or service for the purpose of
achieving the essential functions at the lowest life cycle cost consistent with required performance,
reliability, availability, quality and safety. VAVE is the process of reducing costs in a development project.
This process is achieved by assessing materials, processes and or products and offering alternatives [18].
3.2.2: Data Gathering
The first step in systematically evaluating cost should be to gather up all the relevant data. Relevant data at
a minimum includes the cost of every part in the product [16]. Apart from the financial data it is very
important to gather requirements from all the customers/ stakeholders of project. A CFT meeting was
organized and all requirements were captured, known as VOC. Out of all these requirements, those which
are critical, are prioritized first. These prioritized requirements are known as CTQ.

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 Chapter 5
Results and Learnings
10 samples were made in trials. Following observations were made after trials:
 Costing of Brass body halves were 100% higher compare to SS body halves.
 High laser reflection observed during brass welding. Causing high energy consumption and poor
welding results in brass welding. [26][27]
 Poor weld joint b/w brass and SS observed. [28]
 Brass samples failed due to poor weld joints.
 6 out of 8 SS samples were OK on performance criteria (Refer Annexure A for test plan)
 2 samples were rejected after welding process due to quality issues.

Pic 5.1: Rejected samples

 Alignment & Gap are critical during welding. Hence close dimensional tolerance & fixtures are
required for good weld joint. [29]

Pic 5.2: Gap observed after

welding

 Multiple job setups are required to complete a single operation during welding & trimming.
Increasing cycle time.
5.1 Effect on standard cost
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S.no. Description Material Qty Old Cost New Savings(₹ Comments
Cost(₹) )
1. Body half SS 2 - 158 +158 New Part
2. Valve Insert SS 1 - 110 +110 New Part
3. Aerator Housing SS 1 - 70 +70 New Part
4. Bottom Stud SS 1 - 150 +150 New Part
5. Connecting SS 1 - 50 +50 New Part
Sleeve
6. Laser operation 150 +150 New operation
cost
7. Body Brass 1 463.85 - -463.85 Part replaced
8. Aerator Plastic 1 19.02 19.02 0
9. Escutcheon SS 1 38.51 38.51 0
10. Plug Button Rubber 1 6.06 6.06 0
11. Washer Rubber 1 0.99 0.99 0
12. Connecting Plastic 1 1.58 1.58 0
Washer
13. Connecting Nut Plastic 1 2.84 2.84 0
14. Ring SS 1 11.14 11.14 0
15. Spline Adaptor SS 1 0.70 0.70 0
16. Set Screw SS 1 1.25 1.25 0
17. Insert CB 1 1.96 1.96 0
18. Box CB 1 28.56 28.56 0
19. Master Box CB 0.111 28.57 3.17 0
20. Valve ¼ CW Brass 1 83.76 83.76 0
21. Handle Zinc 1 166.09 166.09 0
Assembly Cost 36.59 36.59 0
Total Cost 866.07 1091.07 +225

Table 5.1: Standard cost with SS Body

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References
1. Vaibhav Ingle & Madhukar Sorte, “Defects, Root Causes in Casting Process and Their Remedies”,
Int. Journal of Engineering Research and Application, ISSN : 2248-9622, Vol. 7, Issue 3, ( Part -3)
March 2017, pp.47-54
2. Durgesh Joshi, Yashwant Modi & B. Rav, “Evaluating environmental impacts of sand cast products
using life cycle assessment”, Research Publishing ISBN: 978-981-08-7721-7
3. Christopher T. Mgonja, “A review on effects of hazards in foundries to workers & environment”,
International Journal of Innovative Science, Engineering & Technology, Vol. 4 Issue 6, June 2017
4. Overview of India‘s Bathroom & Kitchen Industry July 2014: Report by B&K International
5. https://www.spilasers.com/application-welding/the-top-5-benefits-of-laser-welding/
6. Taking advantage of laser welding by David Farson & Raymond F. Duhamel
(https://www.thefabricator.com/thefabricator/article/automationrobotics/taking-advantage-of-laser-
welding)
7. Dhairya S. Deore1, Gunjan B. Chaudhari2, Aman G. Chaturvedi3, Shrikant Uttam Gunjal, “A
STUDY OF CORE AND ITS TYPES FOR CASTING PROCESS”, International Journal of
Advanced Technology in Engineering and Science, Volume No 03, Special Issue No. 01, March
2015

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