INVERTED TAPER Honesty & Integrity

Good Corporate Citizen
Dana Mexico Cardanes Plant
Open Communication
Root cause analysis and corrective actions
Continuous Improvement

© 2017 Dana Limited. This presentation contains copyrighted and confidential information of Dana Holding Corporation and/or its subsidiaries. Those having access to this work
may not copy it, use it, or disclose the information contained within it without written authorization of Dana Holding Corporation. Unauthorized use may result in prosecution.

D1. Team NAME POSITION Emmanuel Bonilla Production & Manufacturing Manager Valentin Rios Production Coordinator Benjamin Bajonero Maintenance Manager Jaime Gomez Maintenance Coordinator Mauricio Montes Manufacturing Engineer Juan M. Neri Quality Coordinator Pamela Soto Quality Engineer Javier / Abraham Team Leader © Dana 2017 .

Problem Statement and description Inverted Taper © Dana 2017 . D2.

Cardanes didn´t ship material AUSTRALIA ALFONSO OCHOA © Dana 2017 within the suspect window . D3. Containment actions CONTAINMENT ACTIONS DATE CONTAINMENT ACTIONS RESPONSIBLE IMPLEMENTED START FINISH INSPECT AND CERTIFY MATERIAL IN CARDANES 17/02/2017 IN PROCESS ARMANDO RIOS PLANT QUALITY ALERT AND VISUAL 17/02/2017 17/02/2017 FATIMA SOTO AID IN THE OPERATION DIFFUSE THE PROBLEM WITH 17/02/2017 17/02/2017 ARMANDO RIOS/ FATIMA SOTO STAFF SEMIPROCESS MATERIAL TO 25/04/2017 IN PROCESS LIMA TEAM LIMA AIR GAGE INSPECTION 100% IN 05/05/2017 IN PROCESS FATIMA SOTO / ARMANDO RIOS CARDANES AIR GAGE INSPECTION 100% IN 10/05/2017 IN PROCESS ANDRES GIL CROSSVILLE MATERIAL BACK FROM TOLUCA 26/05/2017 FATIMA SOTO Australia was aware regarding this issue.

Two 1 piece every 2 Failure mode not micrometer readability 22/04/2017 position (Up. Air Gage / Z-Mike/ 05/05/2017 Four Trunnion 100% Effective Effective P40 © Dana 2017 . D3. Z-Mike inspection. down Z-Mike / Micrometer hrs detected was not the correct one 0° y 90°) to validate this characteristic. just one Up detected down) trunnion considered Ovality measurement and the usage for the Four Trunnion. Two Low frequency 1 piece every Set Failure mode not 25/02/2017 position (Up. Evidence Inspection Method Improvement Frequency Issue Date Inspection Method Equipment Efectiveness Why was not detected? inspection One Trunnion.

000050 0.0001 2 to 1 P40 0.0005 0.0001 100 to 1 Micrometer 0. D3.0005 0.0001 100 to 1 CMM 0.0005 0. Evidence Equipment Effective Resolution Rule of Equipment Resolution Tolerance Readability thumb Z-Mike 0.0005 0.0005 0.000001 0.000001 0.000001 0.0001 100 to 1 © Dana 2017 .0001 2 to 1 Air Gage 0.000050 0.

Evidence Quality alert current on the production on line Customer voice Visual Aid © Dana 2017 . D3.

D3: Evidence “Air gage validation 100%” © Dana 2017 .

D3 Evidence © Dana 2017 .

Clean Point Material Certified using Air Gage 100% May 6th © Dana 2017 . Shippment.D3 Evidence Suspect Window.

D3: Evidence © Dana 2017 .

Total: 21. D3 Evidence Crossville Containment.114pcs Total Inspected untill May 22nd: 17.718pcs © Dana 2017 .

W3: Because it does not have a device that will keep it in position when the machine is out of power W4: Machine design did not consider a braking device in case of loss of energy Why was not detected ?: W1: Because there is no methodology for analyzing potential risks and their severity per machine. W2: Why it is done based on the experience of the electromechanical engineers W3: Because there is no general risk analysis for machinery © Dana 2017 . W2: Diamond roller bracket crashed against the dressing wheels. D4. Define and verify Root Cause (Maintenance) Root cause analysis: Inverted Taper Under validation WHY WAS MADE? process W1: Diamond roller bracket got damaged.

W3: Occurence in the PFMEA was too low. D4. Define and verify Root Cause Under validation process Why System failed?: W1: Control plan does not have a back up validation for the Z-Mike. © Dana 2017 . W2: PFMEA did not consider an aditional device to make correlation for the same characteristic.

in terms of machining deformity. © Dana 2017 . D4. Define and verify Root Cause (Manufacture) Root cause analysis: Inverted Taper Under validation WHY WAS MADE? process W1: Diamond profile out of specification W2: Wrong taper alignment on the diamond W3: Natural Diamond Wear W4: Diamond life has come to an end Why was not detected?: W1: Because there is no regular review of the diamond W2: Because it was not considered as a critical tool for the process W3: Because it was not considered as a potential cause of failure in the PFMEA.

D4. Define and verify Root Cause Under validation process Why System failed ?: W1: Set-up released with single-die data W2: Control plan did not indicate verification of 4 trunnions W1: Because in PFMEA it is not considering 4 trunks for this mode of failure © Dana 2017 .

Define and verify permanent corrective actions © Dana 2017 .D5.

D5. Define and verify permanent corrective actions © Dana 2017 .

Define and verify permanent corrective actions © Dana 2017 . D5.

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