explanations and descriptions can be accomplished efficiently.
A Case Study In one metalcasting facility,
machined aluminum castings were being provided to the automotive market and were required not to leak air. Te aluminum wall thickness with this requirement was often at 0.11 in. (3mm), and process capability for this requirement was not 100%. Various methods were used over the years until the metalcaster settled on a helium leak detection system. Considering the end user’s high level of dissatisfaction with even one product that leaked, an FTA was constructed with a team of production, maintenance and quality staff. Te team initially presented this to the customer after receiving four hours of FTA training over several months. In a series of six team meetings, an FTA was constructed with 64 basic events, and a “top event” probability of 1.25 x 10-4 events/hour of
production was calculated. Te customer was impressed with the causal analysis and commitment to further reduce the incidence rate by way of objective contri- bution analysis. Revision B of the FTA succeeded
in reducing the probability to 6.23 x 10-5 events/hour, about five months later. A third revision was undertaken after a year of further experience and data collection. Revision C has a projected incidence rate of 2.82 x 10-5 events/hour, a 77% reduction in roughly two years of work. An added benefit of the communication with the customer through FTA is the understanding that the defect rate will never be zero, and it is unneces- sary and unhelpful to initiate standard corrective action documents at each occurrence. Te foundry is commit- ted only to annual, serious review of the FTA with a Pareto contribution analysis. Individual claim parts are received as they occur and simply reviewed to ensure no obvious assign-
2014
COLLEGE INDUSTRY CONFERENCE
Nov. 20-21, 2014
Westin Michigan Ave • Chicago Career Information Session
November 20 • 4:30 p.m.-7:00 p.m.
This is an opportunity to meet with students who are interested in the metalcasting industry and are looking for employment with companies like yours. This event also gives the students insight into the many facets of our industry. As stated by one of the 2013 delegates, “If not for the career fair I wouldn’t have known of all … the opportunities with each company.”
General Session November 21 • 9:00 a.m.
We have 3 speakers scheduled addressing the following topics: automation & robotics in the aluminum foundry, Magmasoft Solidifi- cation software, and 3D printing.
Awards Luncheon November 21 • Noon
This is one of the highlights for the students – over $40,000.00 in scholarships will be presented.
Annual Reception November 21 • 5:30 p.m.
During the reception, the EJ Walsh Award will be presented; this is also a nice opportunity to visit with old friends and engage the students in conversation about their future plans.
Visit our website —
www.fefinc.org ‘Like’ our Facebook page at
facebook.com/fefinc
able causes acted to create the defect. The metalcaster reports internal
benefits from a clear understanding of what matters in the control of this defect and a much better team environment in problem solving between maintenance, quality and production staff. Maintenance also reported a better objective basis for spare parts inventory levels as a result of the close scrutiny the records received through the failure probability determination effort. Te use of this method was devel- oped as a part of an overall improve- ment cycle for warranty. Casting suppliers and purchasers can consider this method a means of combating not only warranty claims, but ineffective, superficial responses to such claims. Te increase in customer understand- ing and appreciation for the investiga- tion is a welcome side benefit.
Tis article was adapted from a Paper 14- 048 presented at the 2014 AFS Metalcasting Congress.
September 2014 MODERN CASTING | 39
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