Crack Defect Reduction in Die Casting Process of Aluminium Alloy Motorcycle Crankcases

Abstract

In a world of intense and global competition, a company must, among other things, avoid wastages and reworks. A research study was performed in a local automotive component manufacturer that produces aluminium alloy motorcycle crankcases for local and global markets. The rejection rate at that time was 6.7%. The main objective is to reduce crack defects in the crankcase die casting process and therefore satisfying the above-said goal of staying lean. The research team employed planning and analysis tools such as Plan-Do-Check-Action Cycle (PDCA), Gantt Chart, Loss Matrix Analysis (LMA), Ishikawa Diagram and 4M method, and Why-Why Analysis. The results showed that crack defects in the castings products in the die casting process can be reduced by adjusting the temperature in holding furnace and improving the die design structure. After implementation of the countermeasures into the manufacturing procedures, the rejection rate dropped to 0.97% and the company realized a saving of approximately RM100K per year.