magna m a g n a d i g i t e c h i n d i a p r i v a t e l i m i t e d rejection reduction old method...
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![Page 1: MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d REJECTION REDUCTION OLD METHOD Component Name: Bearing Housing Component weight:](https://reader035.vdocuments.us/reader035/viewer/2022070412/5697bf851a28abf838c877ca/html5/thumbnails/1.jpg)
MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d
REJECTION REDUCTIONOLD METHODComponent Name : Bearing HousingComponent weight : 20KgsNumber of Castings per Mold : 1nos.Total Good Casting wt : 20KgsTotal Pouring wt : 30.5kgsYield : 65.5%
REJECTION DESCRIPTIONComponent getting rejected at customer end after machining due to shrinkage problem
![Page 2: MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d REJECTION REDUCTION OLD METHOD Component Name: Bearing Housing Component weight:](https://reader035.vdocuments.us/reader035/viewer/2022070412/5697bf851a28abf838c877ca/html5/thumbnails/2.jpg)
MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d
Picture shows Solidification at various intervalsThe colour scale shows the % of Liquid metal available
Picture shows Solidification at various intervalsThe colour scale shows the % of Liquid metal available
![Page 3: MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d REJECTION REDUCTION OLD METHOD Component Name: Bearing Housing Component weight:](https://reader035.vdocuments.us/reader035/viewer/2022070412/5697bf851a28abf838c877ca/html5/thumbnails/3.jpg)
MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d
Picture shows Hotspot inside the Casting & FeederHotspot specifies the isolated regions and solidification time
Picture shows Hotspot inside the Casting & FeederHotspot specifies the isolated regions and solidification time
Hotspot inside the casting
![Page 4: MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d REJECTION REDUCTION OLD METHOD Component Name: Bearing Housing Component weight:](https://reader035.vdocuments.us/reader035/viewer/2022070412/5697bf851a28abf838c877ca/html5/thumbnails/4.jpg)
MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d
Picture shows the possible Shrinkage areaPicture shows the possible Shrinkage area
Shrinkage location
This defect location exactly matches with customer complaint
This defect location exactly matches with customer complaint
![Page 5: MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d REJECTION REDUCTION OLD METHOD Component Name: Bearing Housing Component weight:](https://reader035.vdocuments.us/reader035/viewer/2022070412/5697bf851a28abf838c877ca/html5/thumbnails/5.jpg)
MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d
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
![Page 6: MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d REJECTION REDUCTION OLD METHOD Component Name: Bearing Housing Component weight:](https://reader035.vdocuments.us/reader035/viewer/2022070412/5697bf851a28abf838c877ca/html5/thumbnails/6.jpg)
MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d
Picture shows Metal Filling at various intervalsThe colour scale shows the temperature at each location
Picture shows Metal Filling at various intervalsThe colour scale shows the temperature at each location
![Page 7: MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d REJECTION REDUCTION OLD METHOD Component Name: Bearing Housing Component weight:](https://reader035.vdocuments.us/reader035/viewer/2022070412/5697bf851a28abf838c877ca/html5/thumbnails/7.jpg)
MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d
Picture shows Solidification at various intervalsThe colour scale shows the % of Liquid metal available
Picture shows Solidification at various intervalsThe colour scale shows the % of Liquid metal available
![Page 8: MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d REJECTION REDUCTION OLD METHOD Component Name: Bearing Housing Component weight:](https://reader035.vdocuments.us/reader035/viewer/2022070412/5697bf851a28abf838c877ca/html5/thumbnails/8.jpg)
MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d
Picture shows Hotspot inside the Casting & FeederHotspot specifies the isolated regions and solidification time
Picture shows Hotspot inside the Casting & FeederHotspot specifies the isolated regions and solidification time
![Page 9: MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d REJECTION REDUCTION OLD METHOD Component Name: Bearing Housing Component weight:](https://reader035.vdocuments.us/reader035/viewer/2022070412/5697bf851a28abf838c877ca/html5/thumbnails/9.jpg)
MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d
Finding after implementation of this method
1.Hotspot moved to feeder and there is no defect noticed inside the casting.2.Yield also increased by 7%
Finding after implementation of this method
1.Hotspot moved to feeder and there is no defect noticed inside the casting.2.Yield also increased by 7%