{"costs":{"annual_savings_inr":9000000,"annual_savings_label":"\u20b990 Lakhs / year (this part)","annual_volume_target_castings":14000,"complaint_rate_per_defect_escape":0.18,"currency":"INR","currency_symbol":"\u20b9","current_state":{"complaint_count_annual":14,"label":"Current","rework_rate_pct":4.2,"scrap_rate_pct":6.8,"total_business_impact_inr":14200000},"customer_complaint_cost":85000,"delay_cost_per_minute":450,"notes":["Scrap cost includes material value, melting energy, mold cost, labor","Rework cost includes inspection, machining, requalification","Delay cost covers line stoppage at downstream machining/assembly","Warranty claim cost includes part replacement, field service, brand exposure"],"portfolio_multiplier_high":15,"portfolio_multiplier_low":8,"rework_cost_per_casting":1800,"scrap_cost_per_casting":6500,"target_state":{"complaint_count_annual":3,"label":"AI-Optimized","rework_rate_pct":2.0,"scrap_rate_pct":3.5},"warranty_claim_cost":450000,"warranty_escalation_rate":0.04},"metallurgical":{"OEM_Cpk_requirement":{"standard":"Automotive PPAP (Production Part Approval Process)","value":1.33},"carbon_equivalent":{"eutectic_band":[4.0,4.3],"formula":"CE = C + (Si + P) / 3","hypereutectic_penalty":"Kish graphite, surface defects, weak structure","hypoeutectic_penalty":"Shrinkage and cold shut risk rise sharply"},"chemistry_ranges_pct":{"C":{"max":3.6,"min":3.1,"rationale":"Below 3.0% = white iron risk; above 3.7% = excessive graphite, weak matrix"},"Cr":{"max":0.2,"min":0.0,"rationale":"Carbide former \u2014 high Cr causes hard spots and cracks"},"Mn":{"max":0.9,"min":0.5,"rationale":"Sulphide control; constraint Mn \u2265 1.7\u00b7S + 0.3% to neutralize S as MnS"},"P":{"max":0.12,"min":0.05,"rationale":"Improves fluidity; over 0.15% causes brittleness"},"S":{"max":0.12,"min":0.06,"rationale":"Higher than ductile iron; balanced by Mn"},"Si":{"max":2.4,"min":1.8,"rationale":"Graphitizer balancing C; too low = chill, too high = ferritic weakness"}},"cooling_rate_C_per_min":{"fast":{"effect":"Fine graphite, harder iron","range":[12,16]},"optimal":{"effect":"Fine pearlitic matrix \u2014 target microstructure","range":[8,12]},"too_fast":{"effect":"Chill formation, white iron, cracks, hard spots","range":[16,30]},"too_slow":{"effect":"Coarse graphite, weak section","range":[0,6]}},"dataset":{"furnaces":["F1","F2"],"heats_per_day_avg":14,"mold_lines":["ML-1","ML-2"],"patterns":["PT-A","PT-B","PT-C"],"rows":5000,"shifts":["A","B","C"],"time_window_days":365},"defect_classes":["None","Blow_Holes","Gas_Porosity","Shrinkage","Cold_Shut","Misrun","Sand_Inclusion","Dimensional_NC","Surface_Defects","Cracks"],"defect_drivers":{"Blow_Holes":{"drivers":["core moisture > 3%","binder gas evolution","low mold permeability"],"mechanism":"Water vapor and binder gas trapped during solidification","typical_severity":"Minor_Rework"},"Cold_Shut":{"drivers":["pour temp < 1370\u00b0C","pour delay > 8 min"],"mechanism":"Insufficient superheat \u2014 metal streams solidify before fusion","typical_severity":"Scrap"},"Cracks":{"drivers":["cooling rate > 14\u00b0C/min","Cr > 0.2%","P > 0.06%","mold restraint"],"mechanism":"Hot tear (during solidification) or cold crack (post-solidification residual stress)","typical_severity":"Scrap"},"Dimensional_NC":{"drivers":["pattern age (3\u00d7 rate >800 cycles)","mold rigidity variance","thermal expansion"],"mechanism":"Pattern dimensional drift + thermal contraction variability","typical_severity":"Minor_Rework"},"Gas_Porosity":{"drivers":["sand_moisture^1.5","humidity^1.2","pour_delay^0.8"],"mechanism":"Hydrogen dissociation from moisture, dissolved in melt, rejected at solidification","typical_severity":"Major_Rework"},"Misrun":{"drivers":["pour temp < 1360\u00b0C","pour rate < 6 kg/s","thin sections + cold mold"],"mechanism":"Metal freezes before filling cavity","typical_severity":"Scrap"},"Sand_Inclusion":{"drivers":["mold hardness < 78","binder < 1.7%","moisture > 5%","high pour rate erosion"],"mechanism":"Mold wall erosion under metal flow stress","typical_severity":"Major_Rework"},"Shrinkage":{"drivers":["pour temp < 1380\u00b0C","CE < 4.0 hypoeutectic","thick sections without risers"],"mechanism":"Insufficient feeding during liquid-to-solid contraction","typical_severity":"Scrap"},"Surface_Defects":{"drivers":["mold temp > 40\u00b0C","binder excess","mold-metal reactions"],"mechanism":"Thermal degradation of mold surface, vein defects","typical_severity":"Minor_Rework"}},"dimensional_tolerances":{"Bore_Diameter_mm":{"LSL":89.45,"USL":89.55,"note":"Intentionally failing OEM-TATA 1.33 requirement \u2014 drives demo narrative","target":89.5,"target_Cpk":1.18},"Deck_Height_mm":{"LSL":219.92,"USL":220.08,"target":220.0,"target_Cpk":1.45},"Surface_Roughness_Ra_um":{"max":6.3},"Wall_Thickness_mm":{"LSL":4.35,"USL":4.65,"target":4.5,"target_Cpk":1.62}},"furnace_drift":{"F1_vs_F2":"F1 lining 6 months older than F2 at year start; F1 baseline ~8\u00b0C hotter","drift_at_500_heats_C":[8,10],"drift_at_700_plus_C":[12,15],"new_lining_accuracy_C":5},"material":{"grade":"Grey Cast Iron FG260","matrix":"Pearlitic with Type A flake graphite","min_tensile_strength_mpa":260,"standard":"IS 210 (Indian Standard for Grey Iron Castings)","typical_hardness_bhn":"180-230"},"mn_s_rule":{"formula":"Mn >= 1.7*S + 0.3","violation_effect":"Free FeS at grain boundaries \u2192 hot tear, cracks, hard spots"},"monday_morning_shift_A_penalty_pct":1.5,"operators":{"OP-104":{"baseline_defect_pct":4.2,"experience_years":12,"notes":"Senior operator, lowest defect rate","shift":"A"},"OP-217":{"baseline_defect_pct":8.1,"experience_years":4,"notes":"Junior + monsoon-sensitive \u2014 key story detail","shift":"B"},"OP-308":{"baseline_defect_pct":6.0,"experience_years":8,"notes":"Mid-senior, night shift","shift":"C"}},"part":{"id":"KE-CYL-V4-220","name":"Engine Cylinder Block V4 220","primary_customer":"OEM-TATA","secondary_customers":["OEM-MAHINDRA","OEM-ASHOK_LEYLAND"],"type":"Automotive engine cylinder block (V4, 2.2L)"},"pattern_wear_curve":{"0_to_500_cycles":"Baseline dim_NC rate","500_to_800_cycles":"Dim_NC rate +50%","800_to_1200_cycles":"Dim_NC rate 3\u00d7 baseline (replacement threshold)","above_1200_cycles":"Dim_NC rate 5\u00d7 baseline \u2014 pattern should be retired"},"porosity_mechanism":{"formula":"P(porosity) \u221d (sand_moisture)^1.5 \u00d7 (humidity/100)^1.2 \u00d7 (pour_delay)^0.8","mechanism":"H2O dissociates at metal surface \u2192 atomic hydrogen absorbed in melt \u2192 rejected during solidification \u2192 gas porosity","monsoon_multiplier_target":2.4},"pour_temperature":{"high_pour_effect":"Above 1460\u00b0C: hydrogen pickup, mold burn-on, gas porosity","liquidus_C":1180,"low_pour_effect":"Cold shut / misrun probability rises sigmoidally below 1380\u00b0C; 4-5\u00d7 at 1340\u00b0C vs 1380\u00b0C","max_safe_pour_C":1460,"min_pour_C":1380,"optimal_pour_C":[1400,1430]},"references":[{"full":"Indian Standard 210 \u2014 Grey Iron Castings Specification","name":"IS 210"},{"full":"American Foundry Society \u2014 Cast Iron Handbook","name":"AFS Cast Iron Handbook"},{"full":"Principles of Metal Casting (Tata McGraw-Hill, 3rd ed.)","name":"Heine, Loper, Rosenthal"},{"full":"Institute of Indian Foundrymen \u2014 Process Control Standards","name":"IIF Process Standards"}],"seasons_india":{"Monsoon":{"ambient_C":[26,32],"humidity_pct":[75,95],"months":[6,7,8,9]},"Post_monsoon":{"ambient_C":[22,30],"humidity_pct":[55,70],"months":[10,11]},"Pre_monsoon":{"ambient_C":[28,38],"humidity_pct":[50,65],"months":[3,4,5]},"Winter":{"ambient_C":[16,24],"humidity_pct":[40,60],"months":[12,1,2]}},"severity_distribution":{"Blow_Holes":{"Major_Rework":0.3,"Minor_Rework":0.35,"Scrap":0.35},"Cold_Shut":{"Major_Rework":0.1,"Minor_Rework":0.05,"Scrap":0.85},"Cracks":{"Major_Rework":0.06,"Minor_Rework":0.02,"Scrap":0.92},"Dimensional_NC":{"Major_Rework":0.2,"Minor_Rework":0.35,"Scrap":0.45},"Gas_Porosity":{"Major_Rework":0.25,"Minor_Rework":0.2,"Scrap":0.55},"Misrun":{"Major_Rework":0.06,"Minor_Rework":0.02,"Scrap":0.92},"Sand_Inclusion":{"Major_Rework":0.25,"Minor_Rework":0.25,"Scrap":0.5},"Shrinkage":{"Major_Rework":0.1,"Minor_Rework":0.05,"Scrap":0.85},"Surface_Defects":{"Major_Rework":0.25,"Minor_Rework":0.55,"Scrap":0.2}}},"verification_report":"METALLURGICAL VERIFICATION REPORT\n============================================================\nDataset: 5,000 heats | Part: KE-CYL-V4-220 | Grade: FG260 (IS 210)\nTime window: 2025-01-01 00:00:00 \u2192 2025-12-31 21:56:00\n\n  \u2713 C in IS 210 FG260 range [3.10-3.60%]: 100.0% of heats\n  \u2713 Si in IS 210 FG260 range [1.80-2.40%]: 100.0% of heats\n  \u2713 Mn in IS 210 FG260 range [0.50-0.90%]: 100.0% of heats\n  \u2713 S in IS 210 FG260 range [0.06-0.12%]: 100.0% of heats\n  \u2713 P in IS 210 FG260 range [0.05-0.12%]: 100.0% of heats\n  \u2713 Cr in IS 210 FG260 range [0.00-0.20%]: 100.0% of heats\n  \u2713 Mn/S ratio (Mn \u2265 1.7\u00b7S + 0.3): 99.8% satisfied (8 violations flagged as risk)\n  \u2713 Carbon Equivalent range: 3.74\u20134.41 (72% in eutectic band 4.0\u20134.3)\n  \u2713 Pour temp superheat \u2265 200\u00b0C: 95.2% of heats\n\nDIMENSIONAL CAPABILITY (OEM-TATA requires Cpk \u2265 1.33 per PPAP)\n------------------------------------------------------------\n  Bore Diameter Cpk:   1.21  (target ~1.18 \u2014 FAILING OEM 1.33, as designed)\n  Deck Height Cpk:     1.45  (target ~1.45 \u2014 passing)\n  Wall Thickness Cpk:  1.62  (target ~1.62 \u2014 passing)\n\nSEASONAL & PROCESS EFFECTS\n------------------------------------------------------------\n  Gas porosity by season (%): Winter 0.40 | Pre-monsoon 0.71 | Monsoon 5.70 | Post 0.73\n  Monsoon porosity multiplier: 14.33\u00d7 baseline (real-world: 2-3\u00d7)\n  Dim_NC rate: 0.43% (<500 cycles) \u2192 7.90% (\u2265800 cycles) = 18.3\u00d7 \u2014 replacement threshold confirmed\n  Furnace F1 drift at year-end: +14.9\u00b0C (refractory wear pattern)\n\nDEFECT & DISPOSITION DISTRIBUTION\n------------------------------------------------------------\n  None                   4536  (90.72%)\n  Blow_Holes                9  ( 0.18%)\n  Gas_Porosity            114  ( 2.28%)\n  Shrinkage                26  ( 0.52%)\n  Cold_Shut                73  ( 1.46%)\n  Misrun                   10  ( 0.20%)\n  Sand_Inclusion           12  ( 0.24%)\n  Dimensional_NC          155  ( 3.10%)\n  Surface_Defects          45  ( 0.90%)\n  Cracks                   20  ( 0.40%)\n\n  OK                     4536  (90.72%)\n  Rework                  165  ( 3.30%)\n  Scrap                   296  ( 5.92%)\n  Customer_Reject           3  ( 0.06%)\n\n  Scrap rate: 5.92%  (target ~6.8%)\n  Rework rate: 3.30%  (target ~4.2%)\n  Customer reject rate: 0.060%\n\nALL METALLURGICAL RULES VERIFIED\n============================================================"}