Improving Quality and Profitability Through Iterative Problem Solving

This article will discuss how upfront engineering analysis can improve the profitability of low margin production parts. Due to the confidential nature of currently active production parts, a hypothetical gear box part will be used to demonstrate the iterative process. Because of the geometric similarities, it will be assumed that the encountered surface indications will be similar. These defects are pin holes, shrinkage porosity and sand inclusions.

The reader will note that the problem solving process is iterative in nature. Each iteration will aim to eliminate one category of surface indications at a time. Furthermore, each time the methoding is improved, the improvement will be reflected in the part’s cost of manufacturing. The financial figures and implications of each iteration are discussed at the very end of this article. These figures are meant to roughly quantify the degree of each improvement. Naturally, the dollar figures will vary for each individual foundry.

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