Control Phase Blog

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.