Method for Analysing Quality Problems of Automotive Castings

Abstract. The use of multifaceted quality analyses contributes to increasing the efficiency of production processes and quality control as part of maintaining competitiveness. The aim of this research was to develop an integrally configured method for the analysis of quality problems in automotive aluminium castings based on the methodological triangulation of NDT tests and quality management tools. The verification of the model was performed in one of the foundry companies against an engine block casting used in the automotive industry. The detection results obtained (VT and X-ray examination) allowed for the identification of a critical nonconformity - the presence of gas porosity, the description of the problem (5W2H method) and the identification of the root cause of the problem (5WHY method), which was the lack of up-to-date work instructions and a low level of employee competence. Corrective actions were proposed. The measures taken in the implementation of the quality problem analysis method were a new solution for the company – until now, in-depth analyses using a sequence of diagnostic methods and quality management technique tools had not been performed.