Case studies of cost reduction through shape optimization by investigating the causes of frequent defects.

A case of cost reduction achieved by identifying the causes of frequent defects and optimizing the shape through VA (Value Analysis) and VE (Value Engineering).

There are often causes for parts that frequently fail, and by making these issues apparent and resolving them, it often leads to cost reductions. "Not producing defects" is a hidden method for cost reduction. In this part, there are frequent occurrences of cracking at the marked circular area, leading to defects, so we will investigate the causes and seek countermeasures. ■Examining the current issues We will consider where the cause of the cracking lies. It is believed that the sharp angles at the marked area and the extreme narrowness of the left side compared to other surfaces make it prone to distortion due to temperature changes during hardening, resulting in cracking. 【Before Improvement】 ●Material: SK3, Heat Treatment: 55 degrees HRC The corners were finished at 90 degrees, causing stress during hardening and leading to frequent cracking. 【After Improvement】 ●Successfully eliminated defects from cracking by dispersing the stress during hardening.

Mechanical Design