Reduction of Flywheel Housing Failures in Field by Process & Design Optimization

Through this research paper a case study conducted at Swaraj Tractors, Mohali, is presented. This study was on subject of failures of flywheel housing in field. Flywheel housing is a structural component which is used as coupling between Engine & Gear box housing of tractor. The problem was severe because it is fatal to customer & brings bad repute to organization. An analysis was done using Six Sigma technique. Pareto analysis was used to prioritize the problem. The cause and effect diagram was used to explore possible causes of flywheel housing failure through a brainstorming session and to determine the causes which had major effect. Each root cause was validated by DOE. The CAD model of component was made & subjected to FEA. Through FEA results it was concluded that flywheel housing design was not appropriate & factor of safety came out to be 3.8 which was very less. The design of flywheel housing was modified & new CAD model was subjected to FEA. The factor of safety was increased by 40%.The modified design of housing was implemented.