DAWOOD ENGINEERING Pvt Ltd

DIE CASTING

PROCESS ISSUE

By: Hasan Waqar

Process Issues:
• Following are the Main Process Issues
• Part Stuck In Cavity
• Pin Damage
• Ejector Pin Impression
• Furnace Temperature
• Tip Change
• Hydraulic wire leakage
• Burs
 Process Issue (Last Week) :
Overall 13 to 19 Dec
Efficiency 43%
OR 76%
Process B.D 9%
Maintenance B.D 3%
Mold Change Time 1%
Absenteesm 23%

Date
Process Total
13 14 15 16 17 18 19
Furnace Temperatre Issue - - - 140 680 280 640 1,740
Mold Issue/Core Pin Broken 540 360 - - 300 360 420 1,980
Part Stuck 620 300 - 520 120 - 240 1,800
Ejector Pin Height Issue - - - - - 300 - 300
Tip/Plunger Issue 530 300 - 420 - 80 240 1,570
Hydraulic Lead Leakage issue - - - - - - - -
Burs - - - - 360 - - 360
Total 1,690 960 - 1,080 1,460 1,020 1,540
Process Issue %age 12% 7% 0% 8% 10% 7% 9%
 Root Cause Analysis
Machine Men

Mold Not aligned Improper Spray

Mold
Issue/
Weak Core Pin Inappropriate Temp. Core
Pin Broken
Improper Spray Crack In Core Pin Issue
Low Mold Temp
Ratio
Pin Hardness Issue

Method Material
 Root Cause Analysis
Machine Men

Furnace Blower Faulty Furnace Not ON

Furnace Leakage New Operator

Furnace Gate N/A
Furnace
Temp.
Casting w/o gate Issue

Excessive charging Gas shortage Material not as per Standard

Set Temp is low

Method Material
 Root Cause Analysis
Machine Men

Mold Design Issue Inappropriate Training

Part Stuck

Spray issue Improper spray by

Operator High Fe content
Spray Lube ratio
issue Soldering
Mold Not Preheated

Method Material
Preventive Action:
•Mold issue/Core Pin Broken Issue:
• Proper Training will be provided
• Spray Mixing Ratio will be revised for selected parts.
• Material Hardness and standard imported pins will be required.
•Furnace Temperature Issue
• Proper gate will be required that prevent gas leakage.
• Proper furnace cleaning planning along with the cleaning will be done.
• Furnace Maintenance will be done timely.
•Part Stuck;
• Proper Training will be provided
• Spray Mixing Ratio will be revised for selected parts.
• Proper Mold Pre-Heating will be done.