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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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
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
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
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
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
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
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
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
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%