Supplier Quality - Containment & Corrective Action

Problem Statements

• Screws specific to latching applications were failing without warning
  • Potential for customer down time in the field
  • Potential assembly down time
  • 18 week lead time on internationally procured screw with 3/4 million annual usage

Solution

• Facilitated cross functional root cause investigation meetings with design, quality, supplier management and screw vendor
• Participated in Root Cause Analysis which included mechanical testing to identify Hydrogen Embrittlement as cause of failure
• Facilitated the quarantine and disposal of all suspect nonconforming material
• Created short term field modification procedures
• Lead team in setting up procurement of the screw from a previous domestic supplier
• Communicated with the supplier and defined the PPAP requirements for all future material

Results

• No customers with down time in the field as short term corrective action was implemented prior to delivery of product from dealerships
• Assembly downtime was negated due to quick ramp up of domestic supplier
• Fully defined quality inspection plan was put in place along with testing to prevent future Hydrogen Embrittlement issues.