Design and Development of Quality System for Incoming Material: Gear Case Casting

Abstract

To sustain in today’s competitive world, it is mandatory to maintain the quality of the product that the organization delivered to the customer. To sustain the quality of a product a documented quality system should be there which ensure the quality of the product. The Quality System design should consists all the critical stages require to maintain the quality of a product i.e. starting from incoming material, in process, assembly of product, dispatch, and after sale service. The objectives of the quality system must be defined; also it should ensure that the cost should be minimum. In this project the main focus is to develop a documented Quality System for an incoming material from different vendors named ‘Gear Case Casting’ of an organisation who manufactures the Gear Box which is used for industrial purpose. Here, the organization was facing problem frequently from the incoming casting of the gear case. The company was interested to find out the root cause and permanent solution of the problem. The quality of the casting was poor and the rate of occurrence of the similar defects was repetitive in nature. Therefore a Quality System has been developed to ensure the required Quality of incoming material and also it should be defect free. In any Quality System, inspection at different stages helps to find out the defect in the product and it also helps to find out the root cause of the defect. In this project, investigation is carried out to find out the root cause of casting defect that occurred repetitively. To find the root cause of the defect and to develop a system that can prevent the defect to occur in future various steps are taken and various quality control tools such as Quality Matrix, Pareto Chart, Vendor Rating, CAPA are used. Analytical study is carried out to decide at which stage, the inspection should be carried out to minimize the repetitive defective products.