An engine manufacturer was experiencing a failure rate of 1.27% at cold test due to faulty electronic throttles. Using Sciemetric''s QualityWorX, an advanced manufacturing process analysis software, the manufacturer was able to determine the root cause of the failures: 77% due to stuck or sluggish throttles and 23% due to false rejects.
Test algorithms and limits on upstream test stations were adjusted accordingly to reduce the number of false rejects. Manufacturing process changes were also undertaken to reduce the number of stuck or sluggish throttles from being produced.
Defect Detection Pinpoints the Problem
As a result, the failure rate was reduced dramatically to 0.05%, leading to a significant increase in first-time yield. The resulting ROI for the plant was 100 times the original investment in Sciemetric''s solution.
The engine manufacturer was able to identify and address its problems by using both Sciemetric test systems and QualityWorX software. The test and process monitoring solutions deliver superior defect detection using advanced signature analysis; QualityWorX collects this detailed production data, including waveforms, and enables the user to conduct real-time or historical analysis on parts. The insight gained is then applied back into the test stand.
Avoiding a Mass Recall
In another example, a serious engine defect was found in a customer vehicle. The plant was notified and management estimated that 10,000 other vehicles could potentially have the same defect.
Using QualityWorX software, the manufacturer entered the serial number of the defective part and reviewed the test signatures that had been captured by the Sciemetric test systems on the production line. The anomaly in the process signature that indicated the presence of the defect was identified -- it proved to be a result of a particular feature not being extracted.
Analyzing historical test data for all of the 10,000 engines using QualityWorX, the manufacturer was able to find an additional 6 engines with the issue. A focused recall of 7 engines, by serial number, was undertaken, saving an estimated $5 million, plus the negative impact of a public recall.
The manufacturer also adjusted the test algorithm on the production floor to ensure that the defect would be avoided in the future.
The Key: Process Signature Verification
In the above real-world example, the availability of Process Signature Verification (PSV) data made the difference, delivering a sizable return on investment. Having a complete picture of what is happening in the manufacturing process makes it easier to quickly pinpoint problem areas and determine how to address them. QualityWorX helps manufacturers identify the cause of the issue and the specific parts affected. And it is now available for anything from one to unlimited test stands.
QualityWorX helps improve the productivity and profitability of manufacturing operations by:
- Root cause analysis -- Identifying the root cause of manufacturing quality issues.
- Removing false failures by modeling a test algorithm before implementing in production.
- Proving manufacturing quality compliance to customers and enabling completion of test records on demand.
- Displaying and communicating detailed quality improvements.
- Demonstrating adherence to QS9000, ISO/TS 16949 and other quality standards.
- Validating ROI and improving visibility for quality programs such as Six Sigma.