Activity Engineering Purchasing / Supplier Quality Supplier Plant Quality Manufacturing Customer Care Site Management

^ VAL-N910248 and VAL-N910243 were replaced by VACDE- ^ Supplier qualification rating prior to sourcing.
00000C2329-S (rel "A" 27JAN19) and VACDE-00000C2330-S
(rel "A" 27JAN19) in response to failures in customer plants
(Ford, FCA, and GM).
^ Caster Concepts Wheel design was revised to tighten bore
diameter tolerance and keyway width as part of the response
to the same failures.
^ Shaft analysis (2016) corrective actions considered in new
What was done
design.
^ Shaft diameter and tolerance remained unchanged for new
design.
^ Included Product Quality in new design meetings.
^ Coordinated testing of new design.
^ Analyized and prepared Report showing results of new
design testing.
^ Supplier 1724 Power Industries manufactured
^ Issued PO 10133942 on 7/23/2019 for (78)
VACDE-00000C2329-S and (78) VACDE-
00000C2330-S for multiple (2) projects and
multiple (6) delivery dates.
^ PO Text requiring make to print detail
identification with detail number, revision level,
serial number, supplier code, last three digits of
PO.
^ One incoming detail inspected and recorded
details VACDE-00000C2329-S and VACDE-
00000C2330-S to PO 10133942.
^ Delivered details on dates:
xx/xx/xx
xx/xx/xx
xx/xx/xx
^ Delivered details that did not meet PO Text
requirements
^ Delivered details that did not meet
dimensional requirements.
^ Assembly was more difficult to
nominal dimensions on 8/30/2019.
^ "?" recorded where supplier documentation
requirement was supposed to be verified.
^ Became aware of difficulties experienced by
Manufacturing during assembly.
^ Shaft diameter was measured with calipers and
determined to be larger than drawing tolerance.
^ "Green tagged" assemblies for shipment on
1/22/2020.
^ Became aware of difficulties experienced by
assemble than what had been historically Manufacturing during assembly.
experienced due to tighter fit of revised ^ Authorized the shipment of details with
design (shaft bore change) knowledge of reason for revisions.
^ Verified dimensions to print upon
difficulty.
^ Shaft diameter was measured and
determined to be larger than drawing
tolerance.
^ Contacted Quality to address issue.
^ Manufacturing determined the course
of action was to modify the shaft
diameter.
^ Initiated NC 61282 due to modification
of shaft details.

^ Coordinate with Purchasing, Manufacturing, and Site
Management (regarding kit installations) prior to release to
communicate the design changes and probable impacts to
their activities.
^ Coordinate with Customer Care prior to release regarding
probable impacts to maintenance and replacement due to
new design.
What should have been (but was not)
done
^ Source to supplier that follows PO ^ Contact Comau Supplier Quality for inspection
requirements. criteria.
^ Make to print details identification according
to PO requirements.
^ Make details to print dimensions
^ Provide report showing measured data for
100% of dimenisions identified as KPC on
drawing.
^ Completed "GCL-MFG-105 Fabrication,
Machining, and Paint" checklist.
^ 100% first part inspection and avery 20th part
per run.
^ Incoming inspection should record measured ^ Assemble the details to design intent. ^ Kick Off meeting with Manufacturing for kits to
dimensions to validate acceptability within ^ Measurement of shaft and wheel bore introduce the new design intent.
tolerance. to determine source of non-conformity. ^ Contact Engineering when Manufacturing
^ Multiple incoming inspection reports based ^ Contact Engineering when difficulty was difficulty was experieinced to determine course of
upon multiple (6) delivery dates. experieinced to determine course of action.
^ Validation of supplier reporting documentation action.
^ Vaidation of 100% KPCs within tolerance.
reported on supplier documentation.
^ Validation of make to print detail identification
requirements (detail number, revision level, serial
number, supplier code, last three digits of PO).
^ Validation of completed "GCL-MFG-105
Fabrication, Machining, and Paint" checklist.
^ Validation of 100% first part inspection and
avery 20th part per run.
^ Reject incoming nonconforming items from
any requirements listed above.
^ Initiate NC to P6 regarding nonconforming
details.
^ Measure shaft diameters and wheel bores with
equipment capable of the accuracy required
(micrometer vs. caliper, electronic 3-point bore
gages, Faro Arm, CMM).
^ Contact Engineering when Manufacturing
difficulty was experienced to determine course of
action.

^ More detailed testing / reporting including various suppliers
and Manufacturing methods, greater control of variables.
^ Initiate NC to P7 regarding Manufacturing not assembling
details to design intent.
^ Investigate alternative design solutions (i.e. shaft materials,
key materials, fits, coatings {tungsten disulfide, etc.}, heat
treatments, Loctite bearing locker).
What could have been (or could be)
^ Additional requirements to wheel design (allowable surface
done
roughness, cylindricity, taper, etc.).
^ Collect other NCs regarding supplier 1724 and ^ Inform Purchasing / Supplier Quality of
their manufacturing quality (NC 61338).
^ Re-rate supplier 1724 Quality score based upon
non-conformities.
^ Suppliers of revised details contacted and the
changes reviewed during quoting process.
^ Emphasize inspection requirements to supplier.
^ Separate POs for Comau Standard Product
details (from non Standard Product details) to
delineate special requirements.
intention to not comply with PO reuirements.
^ Contact Customer Care to ensure they were
aware of modification to details prior to "Green
Tag".
^ Initiate NC to P7 regarding Manufacturing not
assembling details to design intent.
^ Update Inspection SOP with proper equipment
and methods required for measuring new fitting
process.
^ Details out-sourced for assembly if ^ Contact Engineering to determine course of ^ Initiate NC to P4 regarding
Comau Manufacturing does not have the action. difficulty in field installation of
capability to assemble according to design ^ Initiate NC to P7 regarding Manufacturing not new shaft design due to addition
intent. assembling details to design intent. of shoulder in new design (not
^ Prepare dedicated station for fitting and ^ Initiate NC regarding to P4 difficulty in field associated with NC 61282).
assembly operation. installation of new shaft design.
^ Request design of fixture for fitting
operation from Engineering.
^ Training on key fit and shaft fit, including
training records and only allowing trained
personnel to perform fits.
^ Update Assembly SOP for new fitting
process.