ZPM (Zero Porosity Management) is a revolutionary concept that links your approach to die casting with the sustenance and growth of your business. It is a concept that every diecasting business can apply to everyday production.

The book walks you through the complete understanding of what zero porosity management can achieve for your business. It presents a 360° approach to achieving “near to zero” porosity. Since ZPM is a holistic approach that nudges you to understand not only the technical aspects of minimising porosity but also the national and international circumstances under which your business operates, it binds together every aspect of production management into a combined philosophy.

Here is an outline of the book:

◙ The origin and the philosophy behind the concept of zero porosity.

◙ The challenges your business faces and the opportunities it can leverage.

◙ The global environment in which your business needs to survive.

◙ The relationship between profitability and the degree of porosity your die casting products have.

◙ The relationship between top-down management and the levels of porosity.

◙ Critical consideration for optimal die casting production.

◙ How zero porosity can become the ultimate growth goal for your company.

◙ The unavoidable question of carbon neutrality.

◙ The mega die casting machines and how they are overhauling the die casting industry.

◙ The technical and managerial ecosystem that leads to minimal porosity.

◙ How to facilitate and sustain such an ecosystem.

The book is a complete, step-by-step blueprint if you want to implement the concept of zero porosity within your organisation.

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 minimise instances of porosity. Minimising porosity, ideally, is reciprocated with maximising 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 organisational culture that helps your business minimise porosity and, as a result, maximise 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 minimising 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.

◙ Analysing 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.

◙ Analysing 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:

Prioritising the goal for zero porosity throughout your organisational 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 analysing 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:

Dynamics that are having an impact on the diecasting industry:

Employees’ attitude towards their jobs is changing, especially after Covid-19. They are aggressively looking for better opportunities. Many prefer to work from home. There is scarcity and accessibility of talent depending on where you are placed.

Organisations are coming together to form bigger entities to tackle global competition and work on larger projects.

Easier global reach enables OEMs to source high-quality die-casting products from those die casters who can manufacture them, leaving fewer opportunities for die casters who haven’t been able to upgrade their quality.

Due to expensive logistics, reverse globalisation is also happening where OEMs prefer die-cast products either within their countries or from neighbouring countries so that the cost of logistics can either be avoided or significantly reduced.

By switching over to Giga Press, EV manufacturer, Tesla is forcing many car manufacturers to switch to gigantic die-casting facilities to die-cast huge parts instead of their individual components. Many die-casters are going to have to upgrade their die-casting facilities due to this shift.

These events, and many more, illustrate that your diecasting business does not exist in isolation, and both regional and global phenomena affect the level of competition you face and the degree of quality you need to achieve.

The entire focus of the book is to help evolve a ZPM ecosystem that enables you to almost manufacture products automatically with minimal porosity. This will make you globally competitive and profitable both in the short run and long run.

The intention of this book is to sensitise you to the limitless benefits of aspiring for zero porosity.

I have stayed away from deep technicalities because porosity

has got more to do with management and less to do with technologies and technicalities. It is about the decisions that you make. It is about the choices that you opt for.

This book is on Amazon.in pre-order Link:- https://www.amazon.in/dp/9355544227

Just drop me an email at rahat@ragagroup.com, and we can

share the soft copy of the book FREE before 31st December 2022

Wishing you a Profitable, Zero Porosity venture and happy reading time.