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Engineering data-guided brazing solutions for quality improvement
Faisal, Mohammad Awasthi, Harshit Parga, Ismael
Faisal, Mohammad
Awasthi, Harshit
Parga, Ismael
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2026-04-24
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Faisal, Mohammad; Awasthi, Harshit; Parga, Ismael; Mason, Cindi. 2026. Engineering data-guided brazing solutions for quality improvement. -- In Proceedings: 25th Annual Undergraduate Research and Creative Activity Forum. Wichita, KS: Wichita State University.
Abstract
This project investigates how data-guided process improvement methods can reduce brazing-related defects and scrap in HVAC manufacturing at BOSCH Wichita. The main research question is how can brazing process variation be reduced to improve joint quality, lower scrap costs, and increase overall process consistency. Current production data identified brazing as one of the largest contributors to defects in Building 3, accounting for approximately 40% of total defects and creating significant quality and cost concerns. The study uses root cause analysis, time-study evaluation, shop-floor observations, and qualitative cost-benefit analysis to examine the main sources of variation in the brazing process. Key factors include inconsistent torch angle, heating time, nitrogen flow, and part routing. Based on these findings, several improvement concepts were developed, including 5S, poka-yoke fixtures, standardized work instructions, improved brazing tips, controlled nitrogen flow, and earlier leak detection methods. The analysis also identified targeted kaizen improvements to the existing torch brazing process as the most feasible near-term solution, with an estimated potential reduction of 20 to 30% in brazing-related IPPM while requiring relatively low capital investment. Findings suggest that targeted improvements to the existing torch brazing process offer the most practical short-term solution because they address major variation sources while requiring relatively low cost and minimal disruption to production. The expected outcome is a more repeatable brazing process with reduced defects, lower scrap, and improved first-pass yield. The proposed solutions provide a scalable path for BOSCH to improve first-pass yield and move toward a more controlled and efficient brazing operation
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Presented to the 25th Undergraduate Research and Creative Activity Forum (URCAF) held in Woolsey Hall, Wichita State University, April 24, 2026.
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Wichita State University
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URCAF;v.25