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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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Presentation Transcript
slide1
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

slide2
Picture shows Solidification at various intervals

The colour scale shows the % of Liquid metal available

slide3
Picture shows Hotspot inside the Casting & Feeder

Hotspot specifies the isolated regions and solidification time

Hotspot inside the casting

slide4
Picture shows the possible Shrinkage area

Shrinkage location

This defect location exactly matches with customer complaint

slide5
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
slide6
Picture shows Metal Filling at various intervals

The colour scale shows the temperature at each location

slide7
Picture shows Solidification at various intervals

The colour scale shows the % of Liquid metal available

slide8
Picture shows Hotspot inside the Casting & Feeder

Hotspot specifies the isolated regions and solidification time

slide9
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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