APPLICATION OF QC TOOLS FOR CONTINUOUS IMPROVEMENT IN AN EXPENSIVE SEAT HARDFACING PROCESS USING TIG WELDING

The present study is carried out to improve quality level by identifying the prime reasons of the quality related problems in the seat hardfacing process involving the deposition of cobalt based super alloy in I.C. Engine valves using TIG welding process. During the Process, defects like stellite deposition overflow, head melt, non-uniform stellite merging, etc., are observed and combining all these defects, the rejection level was in top position in Forge shop. We use widely referred QC tools of the manufacturing field to monitor the complete operation and continuous progressive process improvement to ensure ability and efficiency of quality management system of any firm. The work aims to identify the various causes for the rejection by the detailed study of the operation, equipment, materials and the various process parameters that are very important to get defects-free products. Also, to evolve suitable countermeasures for reducing the rejection percentage using seven QC tools. To further understand and validate the obtained results, we need to address other studies related to motivations, advantages, and disadvantages of applying quality control tools.