REJECTION REDUCTION
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REJECTION REDUCTION PowerPoint PPT Presentation


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REJECTION REDUCTION. OLD METHOD Component Name: Bearing Housing Component weight: 20Kgs Number of Castings per Mold : 1nos. Total Good Casting wt : 20Kgs Total Pouring wt : 30.5kgs Yield : 65.5%. REJECTION DESCRIPTION

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REJECTION REDUCTION

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Rejection reduction

REJECTION REDUCTION

OLD METHOD

Component Name: Bearing Housing

Component weight: 20Kgs

Number of Castings per Mold: 1nos.

Total Good Casting wt : 20Kgs

Total Pouring wt : 30.5kgs

Yield : 65.5%

REJECTION DESCRIPTION

Component getting rejected at customer end after machining due to shrinkage problem


Rejection reduction

Picture shows Solidification at various intervals

The colour scale shows the % of Liquid metal available


Rejection reduction

Picture shows Hotspot inside the Casting & Feeder

Hotspot specifies the isolated regions and solidification time

Hotspot inside the casting


Rejection reduction

Picture shows the possible Shrinkage area

Shrinkage location

This defect location exactly matches with customer complaint


Rejection reduction

REJECTION REDUCTION

  • Corrective Action

  • Process changed to Furan Fast Loop Line from High Pressure Molding line

  • Feeder position and neck size corrected.

  • Number of Castings per Mold increased to 2 from 1


Rejection reduction

Picture shows Metal Filling at various intervals

The colour scale shows the temperature at each location


Rejection reduction

Picture shows Solidification at various intervals

The colour scale shows the % of Liquid metal available


Rejection reduction

Picture shows Hotspot inside the Casting & Feeder

Hotspot specifies the isolated regions and solidification time


Rejection reduction

Finding after implementation of this method

Hotspot moved to feeder and there is no defect noticed inside the casting.

Yield also increased by 7%


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