Defect Analysis and Improvement of Forged Component (Rocker Arm) to Improve Overall Productivity by Using Quality Tools

Forging is the method of producing high-strength components like pistons, gear wheels, crankshafts, and hubs used in automotive and nonautomotive industries. Forging is less time-consuming and has higher productivity compared to casting and machining. During this process, due to different variables like temperature, the position of the billet, stroke, cut weight, cut length, power, speed of billet while traveling through induction, etc., hence there is the possibility of introducing defects. These defects may reduce the strength of the forging. The defects are not only introduced while forging but while every post-forging operation, like trimming, coining, shot blasting, heat treatment, etc. These defects increase the rejection and lead to loss. Here, the focus is given to the application of quality tools like the Ishikawa Cause and Effect diagram to observe defects in the rocker arm while forging. The result shows total rejection of all the defects was reduced from 5.27 to 0.74%.