Minimization Of Sand Cast Defect Through Integration Of Failure Mode Effect Analysis (Fmea) With Casting Simulation Case Study: At Akaki Basic Metals Industry (Abmi)

Abstract

This Paper Aims To Identify And Eliminate Current And Potential Defects From Foundry Process In The Company And Presents An Effective Tool For Solving The Problem Of Casting Process Quality Through The Application Of Failure Mode And Effects Analysis (Fmea) For Improving The Reliability Of Products, Ensuring The Quality Which In Turn Enhances The Bottom Line Of A Manufacturing Industry. Thus The Various Possible Causes Of Failure And Their Effects Along With The Prevention Are Discussed In This Work. Severity Values, Occurrence Number, Detection And Risk Priority Number (Rpn) Are Some Parameters, Which Need To Be Determined. Furthermore, Some Actions Are Proposed Which Require To Be Taken As Quickly As Possible To Avoid Potential Risks Which Aid To Improve Efficiency And Effectiveness Of Foundry Practice Processes And Increase The Customer Satisfaction Through Reduction Of Casting Defect. The Expected Quality Improvement Is Then Simulated Using Software (Procast), Which Can Minimize Repetitive Trial And Error Methods In Searching For The Best Technique For Eliminating Defect.