The Foundation of a Defect Tracking Matrix and Corrective Measures for Defect Reduction in the Crankshaft Forging Industry: A Path Toward Sustainable Manufacturing Practices & Driving Innovation in Quality Control

Abstract

Throughout the first decade of this century, the forging industry has experienced rapid expansion, with an increased demand for high-quality forged products requiring zero defects. This article lays the groundwork for limiting forging defects in the crankshaft forging industry sector. Success in this field demands a small rejection or scrap percentage, shortened lead times, and minimal waste in part production. Using a defect tracking matrix, this study identifies common defects such as underfills, laps, and cracks, which are primarily caused by improper material handling, inadequate die design, and insufficient process control. This defect tracking matrix, or cause effect matrix, has the ability to serve as a profound aid for both the design engineer and the producer for any and all aspects of forging and work piece topography that are destined for use in industry sectors that deal with crankshaft production. Key strategies to address these issues include optimizing die design, enhancing process monitoring, and improving operator training. The implementation of corrective measures led to a significant reduction in defects, with the final rejection rate decreasing from 4.57% to 1.93%. The most notable reductions were in defects like underfills, laps, and cracks. This approach not only improves product quality but also enhances overall efficiency in crankshaft manufacturing. The methodologies and strategies outlined can be broadly applied across the forging industry to achieve similar improvements in defect reduction and process performance.