ZPM™ Framework

The ZPM™ Ecosystem

Since practically and physically, it is near to impossible to achieve zero porosity levels, when we talk of zero porosity management, we refer to a die-casting process that enables you to minimize instances of porosity. Minimizing porosity, ideally, is reciprocated with maximizing profitability. This book illustrates how it could be done.

The book answers the Why, How, and What of zero porosity management.

• Why must ZPM™ become one tool, one goal, and one objective for your company?

• How do you implement ZPM™?

• What do you need to do for ZPM™?

What is the Zero-Porosity Goal?

It is the systematic nurturing of an organizational culture that helps your business minimize porosity and, as a result, maximize Profits.

The entire command chain, including the top, middle, and lower layers of your management and workforce, is responsible for containing porosity.

There can be two approaches towards minimizing porosity.

1. Corrective approach

2. Preventive approach

You follow a corrective approach when trouble manifests, and you troubleshoot. Although this approach gives you a short- term solution, it doesn't prevent the problem from occurring in future. It will occur again and again; you will be correcting it, and the cycle will go on.

The various stages of the corrective approach include:

• Identifying the problem.

• Measuring the extent of the problem.

• Analyzing the source.

• Troubleshooting.

The preventive approach goes to the root cause and solves the problem once and for all. It requires prior data. The data must be tested, and the results must be known. The various stages of the preventive approach include:

• Monitoring to observe various inputs and outputs and gather data.

• Identifying the problem.

• Analyzing the source and gathering insights.

• Troubleshooting according to a framework to make sure that the same problem doesn't repeat.

Decoding the ZPM™ ecosystem

Aside from the preventive and corrective processes, you can approach the ZPM™ ecosystem in different ways:

• Prioritizing the goal for zero porosity throughout your organizational hierarchy.

• Design and optimization framework that enables you to obtain real-time feedback and implement safeguards against porosity.

• It involves product design, tool design, gate design, process control, and feedback.

This framework follows the above-mentioned approaches.

Then comes viewing and analyzing ZPM™ through a 360° angle (ZPM™ 360°) that views the entire process through product design, tool design, die casting process, production & quality, as well as die & plant maintenance.

Finally, we come to the maintenance and nurturing of a ZPM™ culture that associates collaboration, the dignity of purpose, talent & skill development, execution, agility, and innovation with the decrease in porosity.

All three combine and form the ZPM™ Ecosystem as shown below: