1. MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d PROBLEM SOLVING OLD METHOD Component Name: Gear Stay Component weight: 182Kgs Number of Castings per Mold: 1nos. Total Good Casting wt : 182Kgs Total Pouring wt : 310kgs Yield : 58.5% PROBLEM DESCRIPTION Component getting rejected in Ultrasonic testing for back wall echo loss.

2. MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d Picture shows Metal Filling at various intervals The colour scale shows the temperature at each location

3. MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d Picture shows Solidification at various intervals The colour scale shows the % of Liquid metal available Isolated region

4. MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d Picture shows the possible Shrinkage area Shrinkage location This defect location exactly matches with customer complaint

5. MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d Corrective Action Gating changed Feeder size increased and number of feeders reduced 2 PROBLEM SOLVING

6. MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d Picture shows Metal Filling at various intervals The colour scale shows the temperature at each location

7. MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d Picture shows Solidification at various intervals The colour scale shows the % of Liquid metal available

8. MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d Picture shows the porosity locations There is no defect inside the casting

9. MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d Finding after implementation of this method 1.Hotspot moved to feeder and there is no defect noticed inside the casting. 2.Yield also increased by 10% 3.100% UT o.k and mold erosion problem eliminated.