The fact that manufacturing companies are continually looking for ways to improve their bottom line isnot surprising, especially with the current economic climate. Companies are challenged to do more withless and increase their competitiveness. This was no different for Precision Propeller Industries (PPI).A recent area of focus at PPI was the evaluation of the use of a high percentage of zircon in the primaryslurries. The price escalations in zircon made this a focus area for potential cost savings through zirconreduction as replacement seemed unlikely. A Design of Experiment (DOE) study was developedbetween PPI and Ransom & Randolph (R&R) and extensive lab work was performed to provide a basisfor process changes that would reduce overall costs and improve shell performance while maintainingthe high surface finish requirements for a marine propeller.This paper will present the detail surrounding the various phases of this process optimization and willgive the results found to date. The results of the DOE and lab work and the confirmation productionresults will be discussed as well.
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