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    PROJECT:0.654.0303.00-CMR162-3 DATE: February/2015 APPROVED BY: Leman Özgüler/Quality Manager Revision: 0 Total Page: 1/1

    Uploaded by

    Metin Demircioglu
    This document is an FMEA (Failure Modes and Effects Analysis) for LOTUS dated February 2015. It identifies potential failure modes for various processes in casting production, potential causes and effects of failures, current process controls to address failures, and risk priority numbers. The highest risk items include issues with patterns/core boxes like dimensions out of tolerance, gating system design problems, and issues with sand preparation affecting part quality. Detection methods and control frequencies are outlined to minimize risks.

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    © All Rights Reserved
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    PROJECT:0.654.0303.00-CMR162-3 DATE: February/2015 APPROVED BY: Leman Özgüler/Quality Manager Revision: 0 Total Page: 1/1

    Uploaded by

    Metin Demircioglu
    158 views1 page
    This document is an FMEA (Failure Modes and Effects Analysis) for LOTUS dated February 2015. It identifies potential failure modes for various processes in casting production, potential causes and effects of failures, current process controls to address failures, and risk priority numbers. The highest risk items include issues with patterns/core boxes like dimensions out of tolerance, gating system design problems, and issues with sand preparation affecting part quality. Detection methods and control frequencies are outlined to minimize risks.

    Original Description:

    Örnek FMEA

    Original Title

    FMEA-CMR162-3-0.354.0303.00

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    © © All Rights Reserved

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    This document is an FMEA (Failure Modes and Effects Analysis) for LOTUS dated February 2015. It identifies potential failure modes for various processes in casting production, potential causes and effects of failures, current process controls to address failures, and risk priority numbers. The highest risk items include issues with patterns/core boxes like dimensions out of tolerance, gating system design problems, and issues with sand preparation affecting part quality. Detection methods and control frequencies are outlined to minimize risks.

    Copyright:

    © All Rights Reserved
    Download as XLSX, PDF, TXT or read online from Scribd
    Download as xlsx, pdf, or txt
    158 views1 page

    PROJECT:0.654.0303.00-CMR162-3 DATE: February/2015 APPROVED BY: Leman Özgüler/Quality Manager Revision: 0 Total Page: 1/1

    Uploaded by

    Metin Demircioglu
    This document is an FMEA (Failure Modes and Effects Analysis) for LOTUS dated February 2015. It identifies potential failure modes for various processes in casting production, potential causes and effects of failures, current process controls to address failures, and risk priority numbers. The highest risk items include issues with patterns/core boxes like dimensions out of tolerance, gating system design problems, and issues with sand preparation affecting part quality. Detection methods and control frequencies are outlined to minimize risks.

    Copyright:

    © All Rights Reserved
    Download as XLSX, PDF, TXT or read online from Scribd
    Download as xlsx, pdf, or txt
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    LOTUS

    1.FMEA

    PROJECT :0.654.0303.00-CMR162-3

    DATE : february/2015

    APPROVED BY : Leman zgler/Quality Manager

    REVISION : 0
    TOTAL PAGE : 1/1

    Item / Function

    pattern and core box(es)


    1

    gating system for GJS


    2

    Potential Failure Mode(s)

    dimension(s) of part out of tolerance


    high/low machining allowance
    not harmony between core and mold
    core moving
    low raw thickness
    mould broken
    unfilled core
    macro or micro porosity
    high weight of waste metal
    difficulty during casting
    difficulty during shaking-out, and grinding

    gas pipe system

    gas hole

    green sand preperation

    unacceptable surface quality


    sand defects on part
    gas hole
    dimension(s) of part out of tolerance
    porosity

    sand preparation for core

    unacceptable surface quality


    sand defects on part
    gas hole

    moulding aparatures (box, pin) dimension(s) of part out of tolerance


    misalignment

    moulding 700x700

    Potential Effect(s)
    of Failure

    macro and micro porosity


    gas hole
    inclusions
    misalignment
    dimension(s) of part out of tolerance

    sand blasting

    unacceptable surface roughness


    granule in the piece

    grinding

    unacceptable grinding

    11

    12
    13 2.sand balsting by fine granule unacceptable surface roughness
    granule in the piece
    14 packing for taransporting from rust because of raining
    Cankr to Ankara
    unacceptable surface quality
    painting
    15

    RPN

    at starting of sample production 100% by cutting, by UT and by visually


    for each time pattern or core box(es) revision or re-producing 100% by cutting, by UT and by visually
    for each advise note from workshop and grinding shop by cutting, by UT and by visually
    for each customer advise note

    2
    2
    2
    2

    160
    100
    80

    wrong or/and not enough gas pipe on pattern or on core

    10
    10
    5
    5
    3
    2
    10
    5
    5

    sand properties out of specification

    2
    2
    2
    2
    3

    100
    50

    scrap
    inclusions
    high cost of machining
    high cost of grinding of part
    difficulty during moulding
    waste of sand
    scrap
    high cost of machining
    high cost of grinding of part

    at starting of sample production 100% by cutting, by UT and by visually


    for each time pattern or core box(es) revision or re-producing 100% by cutting, by UT and by visually
    for each advise note from workshop and grinding shop by cutting, by UT and by visually
    for each customer advise note by cutting, by UT and by visually
    1/10(mixer) (permability, compactibility, mouisture, shear and compressive strength,mould hardness)
    for each advise note from workshop and grinding shop by visually
    for each customer advise note

    sand properties out of specification

    90

    scrap
    high cost of machining
    high cost of grinding of part
    difficulty during moulding
    scrap
    high cost of machining
    high cost of grinding of part
    difficulty during moulding
    difficulty during machining

    10
    5
    5
    5
    10
    5
    5
    5
    5

    wrong dimensions of pin and bush or their harmony


    box distortion

    8
    8

    automatically ajust by core machine


    prepared with mentioned ratio according to the instruction (resin and catalyzer ratio)
    check bending strength a week
    for each advise note from workshop and grinding shop by visually
    for each customer advise note
    for each advise note from workshop and grinding shop by visually or/and by marking according to drw.
    for each customer advise note

    80

    2
    2

    160
    100
    80

    10
    5
    10

    8
    5
    3
    3
    3
    3
    3
    3
    3
    3
    3
    3
    5
    5

    for each advise note from workshop and grinding shop by cutting, by UT and by visually
    for each customer advise note

    scrap
    high cost of machining
    waste of molten metal

    operator
    not enough traning
    breaking of mould sand
    no core
    no filter
    no riser
    putting of core wrong way
    no enough weight on mould
    no cooler
    wrong closing of moulds
    no clamp using
    wrong box height
    non acceptable raw material
    non accetable liquid chemistry

    for each furnace according to the quality plans (each properties)


    for each advise note from workshop and grinding shop by visually or/and by machining
    for each customer advise note
    ut control
    cutting control

    1
    3
    3
    1
    1
    1

    150
    75

    scrap
    high cost of machining
    waste of molten metal

    10
    5
    10

    1
    3
    3
    1
    1
    1

    90

    10
    6

    3
    3
    3
    2
    3
    2
    3
    5
    3
    3

    for each ladle or lot according to the quality plans (each properties)
    for each advise note from workshop and grinding shop by visually or/and by machining
    for each customer advise note
    ut control
    cutting control
    for each lot leakage testing with mentioned frequency

    scrap
    high surface hardness value

    high or low casting temperature


    unsufficent casting height
    very earlier or very late magnesium treatment
    not sufficent inoculation
    not true way inoculation
    too long casting time
    incompleted casting
    wrong gating and gas pipe system
    operator
    not enough traning

    10
    5
    5
    10
    5

    over loaded of machine


    low or high duruation blasting time
    machine breakdown
    operator
    traning

    2
    2
    1
    4
    4

    scrap
    re-blasting
    re-grinding
    re-blasting

    10
    5
    5
    5

    over loaded of machine


    low or high duruation blasting time
    machine breakdown
    not cover of case or truck

    2
    2
    1
    2

    1
    1
    1
    1
    1
    1
    1
    2
    2
    2
    1
    1
    1
    1

    50

    scrap
    re-blasting
    re-grinding
    scrap
    re-grinding

    at starting of sample production 100% visually


    for each time pattern revision or re-producing 100% by visually
    for each advise note from workshop and grinding shop
    for each customer advise note
    before grinding after sand blasting visually 100%-casting defects
    for each advise note from workshop
    for each customer advise note
    before painting or packaging visually 100%-casting defects
    for each advise note from workshop
    for each customer advise note
    before grinding after sand blasting visually 100%-casting defects
    for each advise note from workshop
    for each customer advise note
    before painting visually 100%-casting defects

    re-blasting
    re-grinding
    scrap

    5
    5
    10
    8

    paint properties out of specification

    painting viscosity and thickness measured according to the instruction

    40

    wrong machining fixture(s)


    not enough control frequency during working of fixture(s)
    wrong selection of tools
    wrong machining cycles
    wrong drawing
    wrong fixing of piece
    operator
    wrong control frequency
    machine breakdown
    burrs between fixture and piece
    wrong drawing
    wrong fixing of piece
    operator
    wrong control frequency
    machine breakdown
    burrs between fixture and piece
    wrong drawing
    wrong fixing of piece
    operator
    wrong control frequency
    machine breakdown
    burrs between fixture and piece
    wrong control frequency
    operator
    not sufficent temperature
    liquid non conformity
    operator

    1
    3
    3
    3
    5
    5
    9
    9
    5
    5
    5
    5
    9
    9
    5
    5
    5
    5
    9
    9
    5
    5
    5
    7
    3
    8
    7

    at starting of sample production 100% dimensionally by marking and visually according to drw.
    for each time pattern or core box(es) revision or re-producing 100% dimensionally by marking and visually according to drw.
    for each advise note from workshop by visually or/and by machining
    for each customer advise note
    at starting of sample production 100% dimensionally by marking and visually according to drw.
    for each time pattern or core box(es) revision or re-producing 100% dimensionally by marking and visually according to drw.
    for each advise note from workshop by visually or/and by machining
    for each customer advise note
    for each lot according to the quality plans (each properties)

    3
    3
    3
    4
    2
    2
    3
    2
    3

    120
    96

    at starting of sample production 100% dimensionally by marking and visually according to drw.
    for each time pattern or core box(es) revision or re-producing 100% dimensionally by marking and visually according to drw.
    for each advise note from workshop by visually or/and by machining
    for each customer advise note
    for each lot according to the quality plans (each properties)

    2
    2
    3
    2
    3

    270
    180
    150
    135
    75

    at starting of sample production 100% dimensionally by marking and visually according to drw.
    for each time pattern or core box(es) revision or re-producing 100% dimensionally by marking and visually according to drw.
    for each advise note from workshop by visually or/and by machining
    for each customer advise note
    for each lot according to the quality plans (each properties)

    2
    2
    3
    2
    3

    270
    180
    150
    135
    75

    for control visually 100%


    for visually 100%
    for each customer advise note

    2
    3
    3

    for each lot irregular


    for each customer advise note

    4
    1

    50
    120
    105
    45
    280
    196
    70

    2.turning

    dimension(s) of part out of tolerance


    unacceptable machining surface quality (burrs, chamfer
    etc.)

    scrap
    re-machining
    re-working

    10
    5
    5

    1.machining

    dimension(s) of part out of tolerance


    unacceptable machining surface quality (burrs, chamfer
    etc.)

    scrap
    re-machining
    re-working

    10
    5
    5

    burrs, unacceptable chamfer


    particles on piece
    oil on piece

    re-working
    re-washing

    5
    5
    5

    wrong case dimensions


    wrong alignment
    wrong seperation
    rust

    scrap
    re-cleaning

    10
    7

    packing

    Current Design/Process Controls

    200
    160
    100
    60

    10
    5
    5

    22

    green 0-1 yellow 2-3 red 4-5

    2
    2
    2
    2
    2

    scrap
    re-machining
    re-working

    20 deburring
    washing
    21

    Potential Cause(s)/ Mechanism(s) of Failure

    at starting of sample production 100% dimensionally by marking and visually according to drw.
    for each advise note from workshop,grinding, moulding,core making shop 100% dimensionally by marking and visually according to drw.
    for each customer advise note
    with mentioned frequency during working of pattern and core box(es), 100% dimensionally by marking according to drw. and visually
    for each time pattern or core box(es) revision or re-producing 100% dimensionally by marking and visually according to drw.

    dimension(s) of part out of tolerance


    unacceptable machining surface quality (burrs, chamfer
    etc.)

    19

    D(1-5)

    10
    3
    3
    3
    3
    3
    3
    8

    1.turning

    18

    green 0-3 yellow 4-7 red 8-10

    DETECTION

    wrong machining of pattern and core box(es)


    not enough control frequency during working of pattern and core box(es)
    wrong fixing of figure to the pattern
    wrong fixing of pattern and core box(es)
    wrong storage of pattern and core box(es) (damaged of them)
    not enough draft angle
    not enough filter on core box
    wrong or/and not enough gating design

    dimension(s) of part out of tolerance


    long machining time

    17

    green 0-3 yellow 4-7 red 8-10

    P(1-10)

    10
    10
    5
    5
    5
    3
    8
    10
    5
    5
    5
    8
    10
    5

    method for machining


    16

    green 0-99 yellow 100-199 red 200 and more

    S(1-10)

    scrap
    insufficent raw thickness
    high cost of machining
    high cost of grinding of part
    difficulty during moulding
    cost for grinding of core
    re-producing cost of pattern and core box(es)
    scrap
    If not functional, visiually non-conformity
    high cost of machining
    high cost of grinding of part
    re-producing cost of pattern and core box(es)
    scrap
    If not functional, visiually non-conformity

    melting include raw supplying chemical analysis out of specification


    step of raw material
    microstructure non conformity
    hardness value out of specification
    8
    tensile strength out of specification
    impact value out of specification
    macro and micro porosity
    gas hole
    chemical analysis out of specification
    casting
    microstructure non conformity
    hardness value out of specification
    9
    tensile strength out of specification
    impact value out of specification
    macro and micro porosity
    gas hole
    unacceptable breaking of gating from piece
    shaking out
    unacceptable breaking of gas pipe from piece
    10
    shaking out before enough cooling

    =S*P*D

    SEVERITY
    PROBABILITY

    RISK PRIORITY NO

    FMEA using instruction


    1. This FMEA is current for all cast parts and their machining. And it has been prepared according to the experiences.

    5. Red section must be filled, cancelled or chossen according to the part which has a core, moulding resin or green sand moulding, core painting, washing, machining If not included.

    2. For new product, according to this FMEA, new FMEA for related part must be prepared before during sampling, and it will be used for sample, pre-serial and for 3 lot of serial production.

    6.This FMEA is master FMEA,which is use for each part and If necessary value of P, D, S can be change.

    3. All RPN must be lower than 100 after 3 lot serial production. If not FMEA must be worked until RPN lower than 100.
    4. In this FMEA, RPN is calculated for all version of S,P and D for current application. For after recommended action, S is calculated maximum like in current application.

    240
    120
    90

    20

    80

    20

    10

    270
    180
    150
    135
    75

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