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40 ORÇUN ASLAN

 Visual defects can be only visual and not harmful, but also they can effect roughness
and again performance/abrasion

 If hardness values won’t match, it can cause malfunction of engine due to wrong timing
of a valve with worn tip-end

 Wrong structure of material also may lead to failure of the valve and also failure of
engine

 If welding stress relief is not suitable, it will cause welding to crack and eventually
break

5. FMEA Sheet

Since the FMEA sheet for this manufacturing process is very long, because it contains way
more risks, a little part for the FMEA sheet will be shared in this article as a screen, to give you
an idea what it looks like to make one for this process.

POTENTIAL POTENTIAL CURRENT CONTROLS S O D R RECOMME
(Prevention)
EFFECT(S) OF CAUSE(S) OF CURRENT CONTROLS (Detection) E C E P NDED
V C T N ACTIONS
FAILURE FAILURE

Possibility of a Incorrect set up Visual Control 5pcs set up Visual Control 5pcs 2 hours 8 2 4 64 N/R

premature engine Crack Control 100pcs set up Crack Control 100pcs day

failure due to Crack Control 100% Final
Visual Control 5pcs 2 hours
valve head cracks Incorrrect blade Visual Control 5pcs set up 8 2 4 64 N/R

Crack Control 100pcs set up Crack Control 100pcs day

Crack Control 100% Final
Inspection
Reduction of Incorrect set up Dimensional 5pcs set up Dimensional 5pcs 2 hours 5 2 5 50 N/R
5pcs set up 5pcs 7 2 5 70 N/R
production rate Control Control 2 hours
Scrapped valve Incorrect set up Dimensional Dimensional

due to length Control Control

undersized.

Possibility of Incorrect Upsetting 100% poke- Upsetting 100% poke-yoke 8 2 3 48 N/R
engine failure due every shift
to cracks,head upsetting speed- temp. check yoke temp. check

temperature bUypps.yTroemmepter 1pcs unit bUypps.yTroemmepter 1pcs

Check by setup Check by hand

Fighuanrde 6. Screen sample from tphyeroFmMetEerA sheet.

Acknowledgement

I would like to express my special thanks of gratitude to my teacher (Prof. Dr. Hakan Akyıldız)
as well as our company (Supsan – Borusan Holding) who gave me the opportunity and
knowledge to do this studies.

References

[1] "History of Technology: Internal Combustion engines". Encyclopedia Britannica.
Britannica.com. Retrieved 2012-03-20.

GiDB|DERGi Sayı 5, 2016