Development of a Hybrid Method for Identifying the Causes of Product Incompatibility in Metallurgical Manufacturing

Abstract. For the analysis of the quality of metallurgical products, it is important to use techniques that identify the internal and external unconformity of the product without destroying it. These techniques are non-destructive testing (NDT). Although these techniques identify the unconformity of the product, they do not indicate the source of their creation. The purpose of the study was to develop a hybrid method to make decisions about the causes of product incompatibility. This hybrid method was created as a combination of NDT and quality management techniques, i.e.: 5W2H method, Ishikawa diagram, 5Why method. The subject of the study was an unconformity detected in the tube made of the magnesium alloy AMS 4439. Research was carried out using the FPI method. In the analyzed case, its application allowed the detection of a linear indication in the product. To identify the root of the linear indication, the 5W2H method, the Ishikawa diagram, and the 5Why method were used sequentially. The main causes were bad casting and pollution. The root cause was defective supplier material. Integration of the FPI method, the 5W2H method, the Ishikawa diagram, and the 5Why method in the performance of a comprehensive qualitative analyze of products, after which it is possible to identify the unconformity and the root of its occurrence. The integration of FPI and quality management techniques can be practiced to analyze the quality of products (including metallurgical products) in manufacturing and service enterprises.