Location: Anhui Province, China
Mission: Improve the production process of casted gearbox cover. Eliminate pouring defects. Establish best practice.
Context: Factory producing gearbox cover for heavy industry construction equipment. Occlusions occur which weaken the final product. Our team was sent to investigate and propose corrective actions. After a thorough industrial audit, FMEA study, we helped the factory to:
- Control sand mold moisture and create press pressure charts based on temperature and humidity.
- Create SOP (start of Product) process to validate status of mold matrix and press setting validation based on previously defined charts and quality control measurements.
- Monitor metal fusion temperature, define tolerances and set a countdown of maximum transportation time between oven and mold.
- Monitor cooling time, create dedicated area for different production steps.
- Create temporary poring inspection workspace.
- Record data and charts for detected defects and analyze the consequence of changes.
- Train engineers on experience planning.
