Improvement and reduce risk of failure part -casting by multi-domain matrix- process failure modes and effects analysis based verband der automobilindustrie and design of experiment

Abstract

Nowadays, each industrial process like installation, manufacturing and service industries process possesses the risk of process failure. The risk of process failure is collected from initial supply chain to final supply chain and the potential failure can affect the supply chain from one to another which is considered as a major problem in industries. In automotive motorcycle industry, the spare parts supply chain supports to generate the automotive vehicle spare parts that require the integration of a supply chain system to avoid delay from one supply chain to another supply chain. The installation process failure occurred due to the damage of one cylinder head product namely perforated cap camshaft so the assembly mechanism is used in the cylinder head for removing cracks on the torque. To overcome the failure and cracks in Cap Camshaft process, the Process Failure Modes and Effects analysis based Automotive Industry Action Group-Verband der Automobilindustrie (PFMEA-AIAG-VDA) version is proposed. The objective of this proposed method is to analyze the casting process and failure of cap camshaft on the cylinder head assembly parts such as camshaft and bolt flange. The optimization result improves the casting process over the porous camshaft cap by using casting process parameters and design of engineering factor analysis. The proposed method shows a positive impact on product output, wherefrom the monitoring is done by casting production for 20,000 shot castings, and there are no spray holes and cracks found in the suspect cap camshaft area so the production targets are achieved.