LOTUS 1.FMEAgreen 0-99 yellow 100-199 red 200 and more

green 0-3 yellow 4-7 red 8-10

green 0-3 yellow 4-7 red 8-10

green 0-1 yellow 2-3 red 4-5

Item / Function Potential Failure Mode(s) S Potential Cause(s)/ Mechanism(s) of Failure P Current Design/Process Controls D RPN

1

pattern and core box(es) dimension(s) of part out of tolerance scrap 10 wrong machining of pattern and core box(es) 10 at starting of sample production 100% dimensionally by marking and visually according to drw. 2 200high/low machining allowance insufficent raw thickness 10 not enough control frequency during working of pattern and core box(es) 3 for each advise note from workshop,grinding, moulding,core making shop 100% dimensionally by marking and visually according to drw. 2 160not harmony between core and mold high cost of machining 5 wrong fixing of figure to the pattern 3 for each customer advise note 2 100core moving high cost of grinding of part 5 wrong fixing of pattern and core box(es) 3 with mentioned frequency during working of pattern and core box(es), 100% dimensionally by marking according to drw. and visually 2low raw thickness difficulty during moulding 5 wrong storage of pattern and core box(es) (damaged of them) 3 for each time pattern or core box(es) revision or re-producing 100% dimensionally by marking and visually according to drw. 2mould broken cost for grinding of core 3 not enough draft angle 3unfilled core re-producing cost of pattern and core box(es) 8 not enough filter on core box 3

2

gating system for GJS macro or micro porosity scrap 10 wrong or/and not enough gating design 8 at starting of sample production 100% by cutting, by UT and by visually 2 160high weight of waste metal If not functional, visiually non-conformity 5 for each time pattern or core box(es) revision or re-producing 100% by cutting, by UT and by visually 2 100difficulty during casting high cost of machining 5 for each advise note from workshop and grinding shop by cutting, by UT and by visually 2difficulty during shaking-out, and grinding high cost of grinding of part 5 for each customer advise note 2

re-producing cost of pattern and core box(es) 8

3

gas pipe system gas hole scrap 10 wrong or/and not enough gas pipe on pattern or on core 5 at starting of sample production 100% by cutting, by UT and by visually 2 100If not functional, visiually non-conformity 5 for each time pattern or core box(es) revision or re-producing 100% by cutting, by UT and by visually 2 50

for each advise note from workshop and grinding shop by cutting, by UT and by visually 2for each customer advise note by cutting, by UT and by visually 2

4

green sand preperation unacceptable surface quality scrap 10 sand properties out of specification 8 1/10(mixer) (permability, compactibility, mouisture, shear and compressive strength,mould hardness) 3 240sand defects on part inclusions 10 for each advise note from workshop and grinding shop by visually 120gas hole high cost of machining 5 for each customer advise note ≥90dimension(s) of part out of tolerance high cost of grinding of part 5porosity difficulty during moulding 3

waste of sand 2

5

sand preparation for core unacceptable surface quality scrap 10 sand properties out of specification 3 automatically ajust by core machine 3 ≥90sand defects on part high cost of machining 5 prepared with mentioned ratio according to the instruction (resin and catalyzer ratio)gas hole high cost of grinding of part 5 check bending strength a week

for each advise note from workshop and grinding shop by visuallyfor each customer advise note

6

dimension(s) of part out of tolerance scrap 10 wrong dimensions of pin and bush or their harmony 8 for each advise note from workshop and grinding shop by visually or/and by marking according to drw. 1 ≥80misalignment high cost of machining 5 box distortion 8 for each customer advise note

high cost of grinding of part 5difficulty during moulding 5

7

moulding 700x700 macro and micro porosity scrap 10 operator 8 for each advise note from workshop and grinding shop by cutting, by UT and by visually 2 160gas hole high cost of machining 5 not enough traning 5 for each customer advise note 2 100inclusions high cost of grinding of part 5 breaking of mould sand 3 ≥80misalignment difficulty during moulding 5 no core 3dimension(s) of part out of tolerance difficulty during machining 5 no filter 3

no riser 3putting of core wrong way 3no enough weight on mould 3no cooler 3wrong closing of moulds 3no clamp using 3wrong box height 3

8

chemical analysis out of specification scrap 10 non acceptable raw material 5 for each furnace according to the quality plans (each properties) 1 150microstructure non conformity high cost of machining 5 non accetable liquid chemistry 5 for each advise note from workshop and grinding shop by visually or/and by machining 3 ≥75hardness value out of specification waste of molten metal 10 for each customer advise note 3tensile strength out of specification ut control 1impact value out of specification cutting control 1macro and micro porosity 1gas hole

9

casting chemical analysis out of specification scrap 10 high or low casting temperature 3 for each ladle or lot according to the quality plans (each properties) 1 ≥90microstructure non conformity high cost of machining 5 unsufficent casting height 3 for each advise note from workshop and grinding shop by visually or/and by machining 3hardness value out of specification waste of molten metal 10 very earlier or very late magnesium treatment 3 for each customer advise note 3tensile strength out of specification not sufficent inoculation 2 ut control 1impact value out of specification not true way inoculation 3 cutting control 1macro and micro porosity too long casting time 2 for each lot leakage testing with mentioned frequency 1gas hole incompleted casting 3

10

shaking out unacceptable breaking of gating from piece scrap 10 wrong gating and gas pipe system 5 at starting of sample production 100% visually 1 ≥50unacceptable breaking of gas pipe from piece high surface hardness value 6 operator 3 for each time pattern revision or re-producing 100% by visually 1shaking out before enough cooling not enough traning 3 for each advise note from workshop and grinding shop 1

for each customer advise note 1

11sand blasting unacceptable surface roughness scrap 10 over loaded of machine 2 before grinding after sand blasting visually 100%-casting defects 1 ≥20

granule in the piece re-blasting 5 low or high duruation blasting time 2 for each advise note from workshop 1re-grinding 5 machine breakdown 1 for each customer advise note 1

12grinding unacceptable grinding scrap 10 operator 4 before painting or packaging visually 100%-casting defects 2 ≥80

re-grinding 5 traning 4 for each advise note from workshop 2for each customer advise note 2

13 unacceptable surface roughness scrap 10 over loaded of machine 2 before grinding after sand blasting visually 100%-casting defects 1 ≥20granule in the piece re-blasting 5 low or high duruation blasting time 2 for each advise note from workshop 1

re-grinding 5 machine breakdown 1 for each customer advise note 114 rust because of raining re-blasting 5 not cover of case or truck 2 before painting visually 100%-casting defects 1 10

15painting unacceptable surface quality re-blasting 5 paint properties out of specification 4 painting viscosity and thickness measured according to the instruction 2 40

re-grinding 5

16

method for machining dimension(s) of part out of tolerance scrap 10 wrong machining fixture(s) 1 at starting of sample production 100% dimensionally by marking and visually according to drw. 3 120long machining time 8 not enough control frequency during working of fixture(s) 3 for each time pattern or core box(es) revision or re-producing 100% dimensionally by marking and visually according to drw. 3 ≥96

wrong selection of tools 3 for each advise note from workshop by visually or/and by machining 3wrong machining cycles 3 for each customer advise note 4

17

1.turning dimension(s) of part out of tolerance scrap 10 wrong drawing 5 at starting of sample production 100% dimensionally by marking and visually according to drw. 2 270re-machining 5 wrong fixing of piece 5 for each time pattern or core box(es) revision or re-producing 100% dimensionally by marking and visually according to drw. 2 180re-working 5 operator 9 for each advise note from workshop by visually or/and by machining 3 150

wrong control frequency 9 for each customer advise note 2 135machine breakdown 5 for each lot according to the quality plans (each properties) 3 ≥75burrs between fixture and piece 5

18

2.turning dimension(s) of part out of tolerance scrap 10 wrong drawing 5 at starting of sample production 100% dimensionally by marking and visually according to drw. 2 270re-machining 5 wrong fixing of piece 5 for each time pattern or core box(es) revision or re-producing 100% dimensionally by marking and visually according to drw. 2 180re-working 5 operator 9 for each advise note from workshop by visually or/and by machining 3 150

wrong control frequency 9 for each customer advise note 2 135machine breakdown 5 for each lot according to the quality plans (each properties) 3 ≥75burrs between fixture and piece 5

19

1.machining dimension(s) of part out of tolerance scrap 10 wrong drawing 5 at starting of sample production 100% dimensionally by marking and visually according to drw. 2 270re-machining 5 wrong fixing of piece 5 for each time pattern or core box(es) revision or re-producing 100% dimensionally by marking and visually according to drw. 2 180re-working 5 operator 9 for each advise note from workshop by visually or/and by machining 3 150

wrong control frequency 9 for each customer advise note 2 135machine breakdown 5 for each lot according to the quality plans (each properties) 3 ≥75burrs between fixture and piece 5

20 deburring burrs, unacceptable chamfer re-working 5 wrong control frequency 5 for control visually 100% 2 50

21washing particles on piece re-washing 5 operator 7 for visually 100% 3 120

oil on piece 5 not sufficent temperature 3 for each customer advise note 3 105liquid non conformity 8 ≥45

22

packing wrong case dimensions scrap 10 operator 7 for each lot irregular 4 280wrong alignment re-cleaning 7 for each customer advise note 1 196wrong seperation ≥70rust

FMEA using instruction

1. This FMEA is current for all cast parts and their machining. And it has been prepared according to the experiences. 5. Red section must be filled, cancelled or chossen according to the part which has a core, moulding resin or green sand moulding, core painting, washing, machining If not included.

2. For new product, according to this FMEA, new FMEA for related part must be prepared before during sampling, and it will be used for sample, pre-serial and for 3 lot of serial production. 6.This FMEA is master FMEA,which is use for each part and If necessary value of P, D, S can be change.

3. All RPN must be lower than 100 after 3 lot serial production. If not FMEA must be worked until RPN lower than 100.

4. In this FMEA, RPN is calculated for all version of S,P and D for current application. For after recommended action, S is calculated maximum like in current application.

PROJECT :0.654.0303.00-CMR162-3 DATE : february/2015 RISK PRIORITY NO =S*P*D

APPROVED BY : Leman Özgüler/Quality Manager REVISION : 0 SEVERITY S(1-10)

TOTAL PAGE : 1/1 PROBABILITY P(1-10)

DETECTION D(1-5)

Potential Effect(s) of Failure

≥60

≥80

moulding aparatures (box, pin)

melting include raw supplying step of raw material

2.sand balsting by fine granule

packing for taransporting from Cankırı to Ankara

unacceptable machining surface quality (burrs, chamfer etc.)

unacceptable machining surface quality (burrs, chamfer etc.)

unacceptable machining surface quality (burrs, chamfer etc.)