This problem-solving presentation is based on a practical approach to solving the chronic manufacturing problem of the forging process.

1. Practical Problem
Solving Presentation
Solving Chronic Problems.
Web - https://brassoforge.com/
Email - info@brassoforge.com

2. The Part

3. The Problem

4. UNDERSTANDING PROBLEM
Let’s know about problem

5. UNDERSTANDING PROBLEM
Part Name – Upper Bracket Part Number – JU121060
Customer – COLD FORGE Date – 26/06/2021
Problem Statement – LOGO chip-off from part surface cause bad appearance.
Define Problem –
WHAT – Bad Appearance
WHY – Logo Chip-off
WHO – Aakash Kumar (IQC COLD FORGE)
WHEN – 26/06/2021
WHERE – COLD FORGE production shop floor
HOW – Inadequate Milling Method
HOW MANY – 1000+ parts scrapped
Picture
Locate the Point of the Cause –
The Point of Cause – Wrong method of Machining cause chip-off in Part.
Slug
cutting
Deburring
Slug
Heating
Blocker Forging Trimming
Heat
Treatment
Vibro
Cleaning
Final
Inspection
Packing &
Dispatch
Machining
(CF)

6. IDENTIFYING POTENTIAL CAUSES
USING FISHBONE DIAGRAM

7. Logo Chip-Off from
part surface cause bad
Appearance.
MAN MACHINE
MATERIAL METHOD
Operational Shortcuts
Carelessness, Inadequate training
Die Condition
Improper Machine Capacity
In-adequate furnace Temp.
Improper Material Flow
Wrong Process Design
POSSIBLE CAUSES
Machine Parameter
Excess Material
Material size less/under weight
Poor Blocker Design

8. S. No. Potential Cause Validation Method Result
Significant/
In-Significant
1 Poor Blocker Design See the actual process No effect of Blocker In-Significant
2 Carelessness, Inadequate training Talk to operator
Operators are aware
about the process.
In-Significant
3 Die Condition Visual Inspection
Found under good
condition.
In-Significant
4 Improper Machine Capacity Talk to senior engineers
Found Suitable machine
capacity for the part.
In-Significant
5 Machine Parameter Check as per standard
Found as per
requirements
In-Significant
6 Improper Material Flow
Material flow can be cause for the
chip-off, Validation was difficult.
Material flow to be
improve
Significant
7 Wrong Process Design Process sequence as per requirement
Process design as per
defined
In-Significant
8 In-adequate furnace Temp. As per Digital Pyrometer
Temp. as per part
requirement
In-Significant
9 Excess Material Measure as per requirement
Material size adequate
found
In-Significant
10 Material size less/under weight Measure as per requirement
Material size adequate
found
In-Significant
POTENTIAL CAUSE VALIDATION

9. IMPROVING MATERIAL FLOW
PRACTICAL APPROACH

10. EXPERIMENT’S WITH FORGING
Problem – Bad Material flow Seeking possible Solution's - Vent Holes in letters, Made letters
more wider, Increase Radius, polish Numbers, Taper letters for
better material flow and so many things for better material flow.
Before
Forging Die
After
Made letters more wider and add Vent hole in Forging Die.
Result –
Nothing perfectly works. Our parts continuously chip-off during
machining and rejected parts return by customer. Take a look on
returned parts (Next Slide).
Next –
After lots of experiments with forging finally Dheeraj Sir discuss
New method of Machining. (Slide 13)

11. 0
695
235
355
0
100
461
172
0
21
305
15 4
498
454
0
100
200
300
400
500
600
700
800
Sale VS Customer Return “Part – Upper Bracket 060”
42%
REJECTION
TOTAL DESPATCH - 7974 nos
TOTAL REJECTION - 3315 nos
April 2020
to
June 2021
TAKE A LOOK ON THESE FIGURES

12. MACHINING
At COLD FORGE

13. EXPERIMENT WITH MACHINING
Problem – Chip-Off in parts logo During Machining. Action Plan – Perpendicular Milling to be done instead of
Parallel.
Before
Horizontally Milling
After
Vertical Milling
Result –
Perpendicular Milling works for it. Rejection level drops up to
95%.
Next –
Adoption of Perpendicular Milling. Perpendicular Milling to be
continuously done for this process.

14. TEAM CONTRIBUTION
Mr. Dheeraj Bhatia
CEO Brassoforge Group
Suggest Machining improvement idea.
Laxmikanta Giri
Production Manager
Material flow study conducted.
Subhash Yadav
Quality Engineer
Material flow study conducted.
Jayram
Production Engineer (COLD FORGE)
Machining improvement idea implementation.
Soamnath
Tool Room Engineer
Fulfil die rectification as per requirement
Vishal Singh
Quality Engineer
Made PPT and Perform Inspection

15. Thank You!
Web - https://brassoforge.com/
Email - info@brassoforge.com Made By – Vishal Singh (QA)