11-11-2014, 10:22 AM
Abstracts: Failure Mode and Effect Analysis (FMEA) is a technique to identify and prioritize potential failures of a process. This project reports the description of FMEA methodology & its implementation in a foundry. It is used as a tool to assure product quality & as a means to improve operational performance of the process. The problems identified in the form of blowholes, porosity and slag inclusion contributing to high rejection were studied & analyzed in terms of RPN to prioritize the attention for each of the problem. Each cause of the problem was given a severity number ranging from 1-10 based on a detailed analysis of the casing process including the rate of rejection caused due to each cause and the main causes of the rejection process were plotted in the form of a fishbone diagram to know the detailed cause and effect relation . Based on detailed brainstorming and observational studies revised RPN was calculated based on which appropriate suggestions were given to the company with the aim of reducing the rejection rate to a considerable amount.