Improvement Activity and Effe

Sr. No. Supplier Critical Component Major Defects Root cause

1. slag removal
improper
1. Blow hole
2.Degating
2.shrinkage/cold
improper
shut
1 XXX xxx Adaptor 3.Die
3.As cast
maintenance
damage
improper
4.Chip off
4.part handling
not ok
Activity and Effectiveness

Action
Area Actions

1. material handling training/awareness provided to all stage operators.

Man 2. Die matching verify to eliminate flashing issue.
3. Fettling training and awareness to operator
30
1.machine setting and process parameters monitor and record it in check
sheet
2. daily machine maintenance by operator verify by supervisor.(any 25
leakage, damage of die parts,movement of movable die, etc)
Machine 3. Verify machine settings like-stroke velocity,metal filling rate.
4.Addition of water channel and air escape ways will be provide to eliminate
gas entrapment. 20

REJ%
5. Radius increased at pipe to avoid air leak.
6.New die manufactured.
15
1. after every shot die coating and water sprayed on die cavity followed, to 13.78
reduce and soldering
2. closing velocity of movable die monitored and followed as per pre-define.
3. slag removal frequency defined as after every 15 min instead of 1Hr 10
4. .die lubtricant use as per require level, avoid excess use of it.
Method 5. Degassing process improve
6. Degating method improved by training and awareness regarding air leak 5
issue.

0
No any change in material APR.18 MAY

Material
 Rejection Trend

30
XXX_REJ % TREND_APR.18 ~JUN.19
28.47

25

20
REJ%

15
13.78
12.45

10
9.33
8.31 7.9
6.73 6.24
6.08
5 5.39
3.76 3.67 3
2.55 2.96

0
APR.18 MAY.18 JUN.18 JULY.18 AUG.18 SEPT.18 OCT.18 NOV.18 DEC.18 JAN.19 FEB.19 MAR.19 APR.19 MAY.19 JUN.19

MONTHS
 Photos / Evidences

slag removal method Die temp monitoring

improve

REJ%
LIMI
T

7.9
6.24
NEW DIE MANUFACTURED
3.61
2.96

19 APR.19 MAY.19 JUN.19

dences

Die coat monitoring

CTURED