Date: 01.

August 2019 Level 4

Revision: 4
Doc #: L4_G20_F10_OSSE 8D Workbook
ZF Passive Safety Systems
Concern Title Reference No Start Date Status Date
Broken thread 14461080/14487812 / 14568776/ 30.01.2023 08.09.2023
14636578/ 14734630/ 14755180 /
14768503
Customer Product Name Product Number
8W0419091 GF JAH, FP INU, GK NOQ; 4M8419091AL QQT , N MJM
Audi Warranty Audi B9 / Q8
D1: Team (name, function)
Team leader: Bogdan Purice - PQE ABU LW
Lucia Muntean - CQE Audi
Marius Chiriac - PQE ABU LW
Darius Turcin - CQE Audi
Radu Simin - Leather wrapping expert
Balica Ovidiu - Production unit manager Quality for production
Adrian JuravleDescription
D2: Problem - Quality manager
What object has the fault? Assembled steering wheel
What is the fault? Damaged thread
Add picture
On which position of the object did you Different area
see the fault?
In which location/lab/factory/… do you Audi Warranty
see thedid
Where fault?
you see it since then? Other Audi sites
When did you find it first? 30.01.2023
Occurence since then? Yes
How many affected objects? 5
Degree of the fault? Low: visual issue
Number of the fault per object? 1
Trend Positive
D3: Immediate Containment Action(s) % Effect Responsible Impl. Date
Team informed about the error pattern 100 Lucia Muntean 03.02.2023
14461080 Visual check - not OK - several scratches visible 100 Team 06.02.2023
Internal control stock - 50 pcs - 0 NOK / 100 Bogdan Purice 06.02.2023
Team informed about the error pattern 100 Lucia Muntean 20.03.2023
14487812 Visual check - not OK 100 Team 20.03.2023
Internal control stock - 50 pcs - 0 NOK / 100 Bogdan Purice 20.03.2023
Responsible personnel informed, analysis scheduled. 100 Lucia Muntean 30.03.2023
14568776
Visual check - not OK 100 Team 30.03.2023
Responsible personnel informed, analysis scheduled. 100 Lucia Muntean 26.04.2023
14636578
Visual check - not OK 100 Team 07.05.2023
Responsible personnel informed, analysis scheduled. 100 Lucia Muntean 26.06.2023
14734630
Visual check - not OK 100 Team 10.06.2023
Responsible personnel informed, analysis scheduled. 100 Lucia Muntean 26.06.2023
14755180
Visual check - not OK 100 Team 10.06.2023
Responsible personnel informed, analysis scheduled. 100 Darius Turcin 11.07.2023
14768503
Visual check - not OK 100 Team 20.07.2023
D4: Root Cause(s) % Contr. Add document(s)
Occurrence: Work instruction not followed - thread damaged during heat application process - possible 80% 5 why & Ishikawa
influence by rework in order to get rid of small wrinkles

Detection: 20% 5 why & Ishikawa

The thread was not fully melted thus the seamline was still intact at the moment of control. Detection was
impossible.

D5: Chosen Permanent Corrective Action(s) Verification Responsible Pl.Impl.Date

Retraining of Heat Gun operators responsible for the defect 100% Purice Bogdan 25.08.2023
Gage R&R Purice Bogdan 30.08.2023
New tool implementation for detecting broken thread. The tool will be used at all final Balica Ovidiu 30.09.2023
control stations in the assembly process.

D6: Implemented Permanent Corrective Action(s) Validation Responsible Impl. Date

Retraining of Heat Gun operators responsible for the defect 100% Purice Bogdan 21.08.2023
Gage R&R Purice Bogdan 30.08.2023
New tool implementation for detecting broken thread. The tool will be used at all final Balica Ovidiu 30.09.2023
control stations in the assembly process.
D7: Actions to Prevent Reoccurence (FMEA, CP, Process, etc.) Responsible Impl. Date
Implement in Leather Wrapping Multicode single defect evolution monitoring. Purice Bogdan 30.09.2023
Daily monitoring of burned thread defect on operator level. Purice Bogdan 04.09.2023
Daily Quality meeting with leather wrapping production sites for reviewing of actions. Purice Bogdan On going
D8: Team and Individual Recognition Champion Closed Date Report by Department
Thank you ! Adrian Juravle 08.09.2023 Darius Turcin Quality

Author / Function or department Process Owner / Function or department

QAC / Continuous Improvement S. Kleinschmidt / VP Quality Division R

ZF TRW Proprietary: Printed copeas re for reference only - controlled copy located in the BPM
 Control stock - 14461080/14487812

Re-training - heating application process

Re-training sewing process

Retraining final control

 Man power Machine Milieu

external influence,
lack of training in heat gun
NOK heat gun deterioration after delivery
threatment
to the client

lack of training in manual

NOK pre sewing machine humidity, temperature, light
sewing

NOK tools: sewing needle,

Lack of training in
croocked owl, scissors, 5S
presewing
crep gum, bone

Insuficient experience of the

internal movement of the
final control operator
part between stations
operators

Lack of training in final

control

6Add

brioken thread
New/temp operator on line
Remove Add
has been trained but still
# required supervision

NOK cleaning of the part

Problem confirmed but no
root cause established

Visual aids
NOK thread (from supplier) NOK Manual sewing
missing/incomplete

lack of human resouces

NOK rework

no correct rework method

defined

Material NOK heat gun application

Standard work instruction
missing/inadequate

NOK heat gun application

lack of enforcement of Wi
and IS

Method NOK flow of reworked SW Management

Cause Effect
 Reason for "No" in
Category Cause Action to evalaute influence Responsible Target Date Result Influence "Influence"

Extract traceability info and

Man power lack of training in heat gun threatment Mioara Sava 21.08.23 OK No
check for training
Extract traceability info and
Man power lack of training in manual sewing Mioara Sava 21.08.23 OK No
check for training
Extract traceability info and
Man power Lack of training in presewing Mioara Sava 21.08.23 OK No
check for training
Insuficient experience of the final control
Man power AAA (Gage R&R) Bogdan Purice 30.08.23 NOK Yes
operator operators
Extract traceability info and
Man power Lack of training in final control Mioara Sava 21.08.23 OK No
check for training
1. Check if the heat gun used by operator is
OK. If it had been in maintanace in the period
Machine NOK heat gun of production of the SW. Lazea Cozmin 17.08.23 OK No
2. NOK calibration of the heat gun

Machine NOK pre sewing machine check for maintanance and first off last off Lazea Cozmin 17.08.23 OK No
NOK tools: sewing needle, croocked owl,
Machine check for tool change frequency Marius Chiriac 17.08.23 OK No
scissors, crep gum, bone
Check for signs of mechanical damage in the
Mechanical damage
external influence, deterioration after imediat zone.
Milieu Darius Turcin 18.08.23 visible near the claimed Yes
delivery to the client Signs of heavy wear by end customer.
issue
Signs of dirt on the SW.

1. where was the car used (country where the

car was used) Cars used in Germany and
Milieu humidity, temperature, light Darius Turcin 18.08.23 No
2. based on the period of prodtion check for China
signs of humidity or heavy season exposure.

Milieu 5S LPA, Gemba Walk, Trasca Razvan 18.08.23 OK No

internal movement of the part between
Milieu LPA, Gemba Walk, Trasca Razvan 18.08.23 OK No
stations
Check with SQA if the thread delivered by
supplier in the production perriod has OK
Material NOK thread (from supplier) Carciumaru Valentin 11.08.23 OK No
results in incoming, comformity certificate for
batches delivered.

check for signs of NOK heat gun application:

high temperature - by the leather structure
Relies very much on
signs of nok bone handling by the operator
Method NOK heat gun application Trasca Razvan 18.08.23 operator manufacturing Yes
etc.
skills.
NOK temperature (check productivity for the
production date)

Check for signs of other issues on the part,

Method NOK rework that could indicate recosmetisation rework on Darius Turcin 18.08.23 OK No
the part.
check for signs of overtensioning of the sewing
Method NOK Manual sewing Marius Chiriac 11.08.23 OK No
line.
check for signs of overcleaning
Method NOK cleaning of the part Marius Chiriac 11.08.23 OK No
signs of fluffy thread.
Check the flow in the production:
Management NOK flow of reworked SW Maybe the part was declared NOK and was Marius Chiriac 11.08.23 OK No
misshandled.
Management lack of enforcement of Wi and IS to be checked Mioara Sava 30.09.2023
Management no correct rework method defined to be checked Marius Chiriac 30.09.2023
Management lack of human resouces to be checked Trasca Razvan 30.09.2023
Gemba walk for production. Check work
Standard work instruction
Management instruction in system. Check process flow/wi
missing/inadequate
implementation. Bogdan Purice 30.09.20223

Seite 5
 Gemba walk for production. Check visual aids
Management Visual aids missing/incomplete
in system. Bogdan Purice 30.09.20223
Part analysis confirms that the claimed part left
Problem confirmed but no root cause
Management ZF facility within specifications. Further analysis
established
cannot be performed. Bogdan Purice 30.09.20223
New/temp operator on line has been
Management Check matrix of qualification.
trained but still required supervision Bogdan Purice 30.09.20223

Seite 6
 Broken thread 30.01.2023
Concern Title: Open date:
14461080/14487812 / 14568776/ 14636578/ 14734630/ 14755180 / 14768503 08.09.2023
Reference No.: Modification date:
8W0419091 GF JAH, FP INU, GK NOQ;
Audi B9 / Q8
Part description: Part no.: 4M8419091AL QQT , N MJM

Problem description - Technical

What object has the fault?

Prevent, Occurrence Protect, Non-Detection

Why did the manufacturing Why did the manufacturing
process not prevent the occurence of the defect ? process not detect the defect ?

The final control operator failed to detect the

"1st Why" The thread is deteriorated due to heat application
deteriorated thread

"2nd Why" The heat gun operator disregarded work instruction Defect was barely visible

Thread was not completely broken at the moment of

"3rd Why" Work instruction not followed
final control

"4th Why"

"5th Why"

Generic Root The thread was not fully melted thus the seamline was
Cause Work instruction not followed still intact at the moment of control. Detection was
impossible.

Seite 7
Claim Nr. microscopic pictures conclusion
The thread was affected by high heat. Possible influence by rework in
order to get rid of small wrinkles. The thread was not fully melted
thus the seamline was still intact at the moment of control. Detection
was impossible.

14487812

14636578 Due to external influence, the thread was forced and broken.
 The thread was affected by high heat. Possible influence by rework in
order to get rid of small wrinkles. The thread was not fully melted
14568776
thus the seamline was still intact at the moment of control. Detection
was impossible.

The thread was affected by high heat. Possible influence by rework in

order to get rid of small wrinkles. The thread was not fully melted
14734630
thus the seamline was still intact at the moment of control. Detection
was impossible.
 Thread severly deteriorated by high heat. Defect occurred due to
ABU LW manufacturing process. Due to the contrast colour of the
14755180
thread and the fact that the thread was not just partialy damaged,
final control operator did not perform correctly the task of control.

Due to external influence, the machine stitch part of the sewing line
14768503
was forced and broken.
New tool implementation for detecting broken thread.