Optimization of Governor Cover Leakage Testing Process to Reduce the Rejection Rate at the Customer End

High Pressure Die Casting is an industrially valuable manufacturing process used in the production of light weight Aluminium alloy components in the automotive industry. The die casting process although highly reproducible suffers from defects that occur due to various process parameters. The leakage testing analysis of defective components is performed after the value addition processes like machining are already done on the die cast component. The inefficiency of the testing process ultimately results in the supply of defective parts to automotive manufacturers. This study aims to improve the leakage testing process efficiency for the Governor Cover part produced by a supplier to OEM in Bangalore, India. The quality control techniques like Ishikawa diagram, 4Ms and Measurement System Analysis (MSA) are employed to achieve an efficient testing process model. The improvements applied result in obtaining a more accurate defect data at the supplier and majorly an overall reduction of rejections at the customer end by 40% in a period of two months.