Containment to Prevent Automotive Steering Column Electrical Failures
Control Phase
Date: 17 April 2016
Introduction
Following
installation of the second Nordson conformal coating machine into the line to improve
our process by adequately coating the Hall IC components in the steering
column electronic, it was necessary to put controls in place to ensure that the process continues to work well and
maintain high quality levels. These consisted of the following,
·
Establishing workmanship standards for Dam and Cure Gel
·
Establishing process parameter standards for Dam and Cure Gel
·
Establishing preventative maintenance frequency and activities on both conformal coating machines.
·
Establishing a method of checking Dam and Cure Gel thickness
·
Co-ordinating training for technicians and operators in Dam and Cure
Gel introduction on series production line
· On line flip chart for daily hourly ppm reviews live · Daily line meetings to review performance and identify issues · Weekly meeting with team · Quarterly formal meeting with operators and technicians to appraise performance All these controls should ensure the success of the introduction of an additional step in our process ie the Dam and Cure Gel application and should ultimately lead to our goal of a 95% reduction in field failure as a result of foreign metal debris causing shorts in the steering column electronic. This would equate with a financial saving of approximately €132,500 , a blue sky reduction of 100% would equate with a financial saving of approximately €137,800. We will not be able to fully investigate and quantify the exact reduction in associated field failure and the cost savings incurred until a full year has elapsed. |
