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JL Control Plan & Inspection Record

Current Controls and inspection rcords


Broaching process was considered as potencial operation where a burr could have occurred, if the failure mode would have been an
overlap that would have been a pass through characteristic

Dana 2017
Broaching Operation

Broach
Reciprocant sliding

Fixture

Yoke

Dana 2017
JL Constant Front shaft
Frequency
spec PAP, Cada 30 min
S/R
Span interior de orejas 1 Pieza
1 2.4110"-2.4075" CPL001-001-64 Set up, each 30

Control plan
Inner span ears 1 Pc
minutes (Does not
require record)
PAP, Cada hora Method
JL_Prototype
S/R Verificacion de puesta a punto
Altura primer escaln Caliper Go - No Go 1 Pieza
2 0.471"-0.451" Set up, each 30 CA-FC-0126
Height first stair CTG214-001-61 1 Pc
minutes (Does not Set-up sheet (CA-FC-0126)
require record)
PAP, Cada hora
S/R
Run out Brochado Caratula indicator 1 Pieza
3 0.006" MAX Set up, each 30
Run out broaching CIC004-003-63 1 Pc
minutes (Does not
require record)
Hoja de verificacin de
ultrasonido CA-FC-0191 cada 3
horas.
100% PAP
Check List mantenimiento
Verificacin de proceso 100% Set up
Inspeccion por Piezas libres de UT-VOGH Ultrasonic verification sheet CA-
Set up Red rabbit FC-0191 every 3 hours.
4 ultrasonido automtico fisuras (Inspection 24 hrs.
Process verification RED Check List maintenance
Ultrasonic Inspection Pieces free cracks After Tempering)
RABBIT Set up
PAP (Lab. Liberacin de Ultrasonido
1 Pieza Metalrgico) CA-FC-0160
1 Pc Set up Ultrasonic Liberation
(Metallurgical Lab) CA-FC-0160
Si se detecta material no conforme:
Clave de forja o colada Ver DOC Detener produccion
1 Pieza Puesta a punto.
5 Key and heat code See Operation and Visual Notificar al supervisor o ingeniero de calidad
1 Pc Set up
forge Control Diagram Separar el material sospechoso
Ancho de slot Lab. Dimensional 1 Pieza Puesta a punto. Revisar el material desde la ultima
6 0.350"-0.450"
Slot width Dimensional Lab 1 Pc Set up inspeccion hecha
REBROCHADO
M0707 Altura de slot Lab. Dimensional 1 Pieza Puesta a punto. Verificar la operacin la operacin y ajustar
DE SPAN 7 1.190"-1.300"
M0708 Slot height Dimensional Lab 1 Pc Set up Validar el ajuste
90 INTERIOR
M0707 Microacabado Lab. Dimensional 1 Pieza Puesta a punto. Dar disposicion final al material sospechoso
INNER SPAN 8 120 MICROINCHES
M0708 Microfinish Dimensional Lab 1 Pc Set up If non conforming material is detected:
RE-BROACHING
ngulo de rebrochado Lab. Dimensional 1 Pieza Puesta a punto. Stop production
9 45 2 Notify to Production Supervisor and/or
Rebroaching angle Dimensional Lab 1 Pc Set up
Verificacion de puesta a punto Quality Engineer
Long. Lnea de centros (CA-FC-0126) Sort 100% the parts
a chafln de Set-up sheet (CA-FC-0126) Adjust Machine / Process
Lab. Dimensional 1 Pieza Puesta a punto.
10 rebrochado 0.580"-0.540" Identify and scrap bad parts
Dimensional Lab 1 Pc Set up
Length line to chamfer
rebroaching centers
Long. Lnea de centros
a tope para seguro Lab. Dimensional 1 Pieza Puesta a punto.
11 0.380"-0.340"
Center line length to Dimensional Lab 1 Pc Set up
snap ring top
Span de chafln de
rebrochado Lab. Dimensional 1 Pieza Puesta a punto.
12 2.505"-2.486"
Rebroaching chamfer Dimensional Lab 1 Pc Set up
span

Vida util de herramienta Cada tres turnos


13 6000 - 7000 piezas Visual 1 revision
Useful life of tool Every three shifts

Dana 2017
JL Constant Front shaft

Process
Sheet
Quality record
According to the
control plan
above

Inspection
Go / No Go

Dana 2017
FORGE vs BROACH OPERATION(10)

After Broaching ;
Forge Previous Broaching Inside and outside

FORGE OP 10 BROACH IN SIDE-OUT SIDE


SPAN
IN SIDE SPAN ( 2.380-2.384)
OUT SIDE SPAN ( 3.614-3.629)

Dana 2017
JL Variable Front shaft

spec Frequency
Puesta a punto /
Span inteior de
Marposs CTR001-001-64 1 Pieza Cada hora S/R
1 orejas 2.4110"-2.4075"
Code patron CPT002-001-64 1 pc Set up / Each hour (Does
Inner span ears
not require record)

Long. de chafln de
rebrochado Laboratorio Dimensional 1 Pieza Puesta a punto
2 2.486"-2.506"
Rebroaching Dimensional laboratory 1 pc Set up
diameter chamfer

Method
ngulo de
Laboratorio Dimensional 1 Pieza Puesta a punto
3 rebrochado 43-47
Dimensional laboratory 1 pc Set up
Rebroaching angle
1. Detener la operacin
2. Separar el material sospehoso
3. Identificar con boleto de material
detenido
4. Avisar a supervisor o ingeniero de
calidad
REBROCHADO Long. Lnea de 5. Corregir falla en operacin
Puesta a punto
DE SPAN centros a chafln de 6. Verificar correcciones y ajustes
(CA-FC-0126)
100 INTERIOR M0729
4
rebrochado
0.561"-0.4991"
Laboratorio Dimensional 1 Pieza Puesta a punto Set-up sheet
7. Inicar acciones correctivas y dar
INNER SPAN Length line to Dimensional laboratory 1 pc Set up disposicin al material
(CA-FC-0126)
REBROACHING chamfer broaching If non conforming material is detected:
centers Stop production
Notify to Production Supervisor and/or
Quality Engineer
Sort 100% the parts
Adjust Machine / Process
Identify and scrap bad parts

Distancia centro de Puesta a punto /


orejas a escalon 1 Pieza Cada hora S/R
5 Go / No Go CTG263-001-62
Distance from ears 1 pc Set up / Each hour (Does
center to stair not require record)

Clave de forja o Puesta a punto /


colada Clave de forja Visual 1 Pieza Cada hora S/R
6
Key and heat code Heat code Visual 1 pc Set up / Each hour (Does
forge not require record)

Dana 2017
JL Variable Front shaft

Quality record
According to
the Control
Plan

Dimesional
Dimesional
Inspection
for span in
Marposs

Dana 2017
Failure Mode ,regarding this Burr or Overlaping issue

Currently neither
the Burr or the
Overlap is
considered

Dana 2017
Current Controls for snap ring presence

Characteristic Method Frecuency


Snap ring Presence Error detection camera 100%
Snap ring Correct
Visual 100%
Seated
Span Go Nogo Gage / Marposs 100% / each hour

Dana 2017
Current Conclusions (31-05-2017)

The problem reported from FCA, is not an snap ring missing issue

The burr was not generated by CARDANES, once the zone where the
burr appears, is not machined.

Apparently the visible defect could have come that way, since it was raw
material, this because it is closer to be a material overlapping instead
being a burr issue.

To have fully confirmation of the hypothesis above described, to have the


part on hand and perform further analysis is necessary to determine the
root cause and the permanent corrective actions.
Root causes derived from this analysis will be considered in the PFMEA

Dana 2017
End

REGARDS!!

Dana 2017

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