Power Windows Leakage Containment & Rework

Automotive
OEM

CUSTOMER

  • Automotive OEM - Pickup Trucks and Truck Beds

 

TARGET

  • Segregate and re-work all non-conforming parts to pass water leak testing and fed back into production line

NATURE OF SERVICE

  • Power Windows - contain and rework parts to fix water leak condition

 

TASKS

  • Do water test on all incoming product and segregate all non-conforming parts.
  • Rework each part with urethane syringes and conduct water test again.
  • If part passed water test, inspect to make sure part was free from urethane on all cosmetic surfaces and feed to the line.
  • If part failed the water test, rework to conformance. If part water leak was too severe to attempt rework, part was to be scrapped.
  • Inspectors tracked where the water was leaking and specify if condition was a big or small leakage.  A daily report was provided to customer directly to help facilitate long term corrective action planning and results.

LOCATION

 

  • Tijuana, Mexico
Mexico Tijuana

KEY FIGURES

  • August – October 2016 Project
  • 17,117 Parts Inspected
  • 13,266 Non-conforming Parts
  • 13,266 Parts Reworked
  • 892 Parts Rejected

TEAM

  • 1 Program Manager
  • 1 Site Supervisor
  • 1 Engineer
  • 9 Inspectors Daily

KEY ACHIEVEMENTS & RESULTS

  • Identified root cause of issue and developed long-term corrective action to eliminate problem completely.
  • Contained all defective parts from getting to the line and maintained production.