ANALYSIS OF THE CAUSES OF INCOMPATIBILITY OF GEARBOX HOUSING CASTING

The purpose of the conducted tests was to apply an integrally configured method of quality control of the condition of modified helicopter gearbox housing castings. The use of this innovative method (consisting of the following techniques: Pareto-Lorenz diagram, Ishikawa diagram and 5WHY method?). would contribute to identifying the causes of non-compliant castings and, consequently, to eliminating non-compliant castings. As part of the analysis of the efficiency of checkpoints, a non-conformity test was carried out on the gearbox housing castings under analysis, including the identification of sensitive areas in terms of the number of defects. Transmission housing casts have become the subject of research due to significant problems with maintaining their desired level of quality after the introduced structural and technological changes. The proposed method has helped to identify the root cause of non-compliance. These were: inadequate flooding of moulds due to insufficient employee qualifications and inadequate human resources management. The study shows the advisability of using an integrated approach to finding the causes of quality problems on the example of a foundry. This was a new solution for the company, as no in-depth analyses of quality problems using a sequence of quality management techniques have been conducted so far. The improvement actions taken so far have been sufficient in a stabilised production process, but the modification of the process has shown the need to seek other more advanced techniques. This configured and integrated method was proposed and the expected results were achieved. The sequential method developed in the study is a universal way to prevent future non-compliance in this or other companies.