Title: Improving the quality and yield in the casting of compressor pulley through the application of total failure mode and effects analysis

Authors: P.R. Senthilmurugan; C. Jegadheesan; S.R. Devadasan

Addresses: Mechatronics Engineering Department, K.S. Rangasamy College of Technology, Tiruchengode – 637 215, Tamil Nadu, India ' Mechanical Engineering Department, Chettinad College of Engineering and Technology, Puliyur, Karur – 639 114, Tamil Nadu, India ' Production Engineering Department, PSG College of Technology, Coimbatore – 641 004, Tamil Nadu, India

Abstract: In the research reported in this paper, a technique called 'total failure mode and effects analysis' (TFMEA) was applied in a foundry producing casting of compressor pulley. TFMEA facilitates to carryout failure analysis in a simple manner and connect the departments and employees for gathering their knowledge for providing solutions to prevent the occurrence of failures. According to the recommendation evolved in this TFMEA project, the gating system of mould was newly designed. Subsequently, it was found that the usage of the new gating design resulted in the increase of yield by 10%. Subsequently conducting of X-ray test revealed that the casting of compressor pulleys were free from shrinkage. Thus, TFMEA was useful in enhancing productivity without compromising the quality of the casting of compressor pulleys.

Keywords: FMEA; total failure mode and effects analysis; TFMEA; total quality management; TQM; casting; continuous quality improvement.

DOI: 10.1504/IJSOM.2018.088472

International Journal of Services and Operations Management, 2018 Vol.29 No.1, pp.42 - 58

Received: 22 Jan 2016
Accepted: 06 May 2016
Published online: 11 Dec 2017 *

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