Improving Quality Control of Siluminial Castings Used in the Automotive Industry

Abstract

The aim of the study is to identify the causes of non-compliance of castings and ultimately, using quality management tools (5W2H I diagram Ishikawa), to reduce or eliminate the number of such non-compliance. The research was carried out using visual, luminescence and metallographic tests and the product was a diesel engine piston casting. The study identified clusters of rows in the area of sealing canals and specified their cause -inadequate quality of the charge. So far, no analyses of quality problems using a sequential quality management methodology have been carried out in the company, so that the implemented corrective actions did not lead to the full achievement of quality objectives. The sequential method presented in the paper, combining diagnostic and control tests and quality management tools, is a universal way to monitor the quality level of products and to quickly correct any nonconformities. The presented method can be used in enterprises producing products from ferromagnetic, non-ferromagnetic and non-metallic materials (due to the effectiveness of the luminescence method).

Reduction of Scrap in Electric Motor Manufacturing for the Automotive Industry: A case study using PDCA Approach

“…Similar tools have been employed by other researchers tackling non-conformity reduction in automotive parts. For instance, Czerwińska et al [30] successfully combined the 5W+2H method and Ishikawa diagram to identify non-compliance causes in automotive piston casting and finishing. In their study, Realyvásquez-Vargas et al [31] employed Pareto charts and flowcharts to achieve remarkable defect reductions of 65%, 79%, and 77% across three product models.…”

A Rank Model of Casting Non-Conformity Detection Methods in the Context of Industry 4.0

“…The products offered by manufacturing companies must be tailored to customer requirements, as quality is a key criterion for the success of companies [ 1 ]. The cited concept of quality management in the literature is captured as quality assurance, which explicitly emphasises mature management focusing on advanced quality planning [ 3 ], improvement of product design [ 58 ], processes [ 60 ] and services [ 61 ], improvement of control in relation to processes and products [ 62 ], as well as explicit involvement of management in motivating employees [ 63 ]. In the literature, there are studies of research work in the field of pairwise comparisons of some quality control methods [ 64 , 65 , 66 ], comparisons of traditional control methods with their automated versions [ 67 , 68 ] and comparisons of more quality control methods [ 69 , 70 ].…”

“…Quality control methods for aluminium castings include methods and diagnostic techniques from the non-destructive testing (NDT) group. These tests make it possible to recognise material inconsistencies, perform an assessment of material properties and measure the dimensions of objects, without generating changes in the functional properties of the diagnosed workpiece [ 3 , 4 ]. The implementation of this type of detection is necessary for the manufacturing industry to maintain an adequate level of quality and conformity of machinery, equipment and structures [ 5 ].…”

Numerical Analysis of a Pneumatic Cushion Operation Safety, including the Airflow Conditions

“…Therefore, it is necessary to develop scenarios for potential failures [17][18][19], prevent them, and mitigate their consequences when they occur. This places a requirement on the devices and their individual working components to exhibit high-quality characteristics [20][21][22].…”