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Improvement Proposal against Quality issues in LHCC KWP HMSI

Improvement Proposal against Quality issues in LHCC KWP HMSI. Die Name : LHCC KWP Crankcase. Problem In Endurance Die Casting : 1. Non Filling at Oil Gallery Hole. 2. Casting Broken In Fix Side. 3. Warpage Problem In Casting. Problem At Customer End (HMSI) :

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Improvement Proposal against Quality issues in LHCC KWP HMSI

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  1. Improvement Proposal against Quality issues in LHCC KWPHMSI

  2. Die Name : LHCC KWP Crankcase Problem In Endurance Die Casting : 1. Non Filling at Oil Gallery Hole. 2. Casting Broken In Fix Side. 3. Warpage Problem In Casting. Problem At Customer End (HMSI) : 1. Body Leakage In Casting

  3. Analysis For Non Filling Analysis : Why Non Filling : Due to Cold Molten Mat’l Filling In Deep Area. Why Cold Metal Filling : In Front Of Gate Oil Gallery Punch is There Filled Molten Mat’l Not Coming Out. Why Not Coming Out : There is No Over Flow In This Area. Why No Over Flow : Design as Per Customer ( HMSI ) Root Cause : Overflow to Be Provided In This Area Action Plan : Over Flow Provided In LHCC KWP – Die No : 3 Die Ran 15/11/09 to 24/11/09 & Total Shots Taken : 8306 Shots. Total Non Filling Rejection : Minor Non Filling Found In 22 Pcs. (40Lx12w x 10Deep)New Over Flow Non Filling Area ( Oil Gallery Hole ) Oil Gallery Punch. Gate Area

  4. Analysis For Casting Broken & Warpage Problem. Analysis :(Analysis Done Reason Except PowerCut, Molten Mat’l & Die Temp. Low) Why Casting Broken : At The time of Die Opening Casting is Getting Bend. Why Getting Bend : Due To Deep Casting Area In Fix Side Compare to Moving Side. Root Cause : No Grippers In Opposite Side ( Moving) Action Plan : Grippers To Be Provided In Mov. Side. To Bring The Casting In Moving Side At The Time Of die Opening & To Avoid Casting Bend/Broken. Results After Provision Of Grippers : Casting Broken In Fix Side Controlled. Warpage Before Grippers : 1.0 ~ 1.2 mm. Warpage After Grippers : 0.3 ~ 0.4 mm Grippers Dim Details Grippers Location Details In Next Slide

  5. GRIPPERS DETAILS IN KWP CCLH DIES Grippers No 1 & 2 Top Side Of The Die. Grippers Position : 15.0 ~ 18.0 mm Above Parting Line. Grippers Dim. : Length : 25.0 ~ 30.0 mm Width : 3.0 mm Depth : 0.75 ~ 1.0 mm 1 2 Grippers No 3 & 4 Bottom Side Of The Die. ( Runner Side ) Grippers Position : 15.0 ~ 18.0 mm Above Parting Line. Grippers Dim. : Length : 25.0 ~ 30.0 mm Width : 3.0 mm Depth : 0.75 ~ 1.0 mm 4 3 Grippers No 5 Hanger Area Of The Die – RH Side Grippers Position : 15.0 ~ 18.0 mm Above Parting Line. Grippers Dim. : Length : 40.0 ~ 50.0 mm Radial. Width : 3.0 mm Depth : 0.75 ~ 1.0 mm 5

  6. Analysis For Leakage Problem. Analysis : Why Leakage : Leakage Due To Prefilling Why Prefilling : Less Gate Area. 45.0 x 3.0 / Non Filling at Oil Gallery Pin Why Less Gate Area : Die As Per Design at Customer End. Root Cause : Gate Area Found Less. Action Plan : Gate Area Increased By 55.0 x 3.5 In LHCC KWP Die No : 3 Results After Increased Gate Area : Non Filling at Oil Gallery Hole Area & (Leakage) Prefilling at Engine No Punch Area Controlled. Results Still Under Monitoring Gate Before Gate After

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