Process development of die casting in a production line

Ahmad Rozelan, Aina Dalila (2022) Process development of die casting in a production line. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

These days, most of the manufacturing industry are on the verge to produce products at high variety at a low cost with better quality due to the increasing competition in the sector. The issue can be countered by endorsing the most suitable manufacturing process for the industry to achieve flexible and lean manufacturing. A door hardware company in Melaka, Malaysia has implemented phase 3 of Advanced Product Quality Planning (APQP) to minimize the cost and improve quality of Beacon Baseline 83 (BL83) product. The objectives of this study are to investigate various factors, involve in gravity die casting (GDC) and pressure die casting (PDG) in the production line, to analyse the process and quality of the product involve in gravity die casting (GDC) and pressure die casting (PDC) process and to propose the most suitable manufacturing process in the production line. This study was only focused on process and quality aspects. The Ishikawa Diagram used to determine the issues of GDC process by collecting the data through brainstorming session. By implementing phase 3 APQP, the quality of the product can be obtained by using several analyses such as Failure Mode and Effect Analysis (FMEA), Process Capability Analysis (PCA), Control Plan and Cost-Benefit Analysis (CBA). Thus, the most suitable manufacturing process was determined by the analyses result. Therefore, PDC process was determined as the most suitable manufacturing process as the process achieved the main objective to minimize the cost and improve the quality of the product. Validation of the decision making resulting in low RPN number and high Cost-Benefit Ratio (CBR) which is 860 and 1.08. Clearly, this study proved that Advanced Product Quality Planning (APQP) is one of the most effective methods for decision making for the company.

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