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

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 D2. Problem Statement and description

Inverted Taper

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 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 Australia was aware regarding this issue, Cardanes didnt ship material ALFONSO OCHOA
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 D3. Evidence
Quality alert current on the production on line
Customer voice VisualAid

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 D3: Evidence Air gage validation 100%

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 D3 Evidence

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D3 Evidence Suspect Window, Shippment, Clean Point

Material
Certified using
Air Gage 100%
May 6th

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D3: Evidence

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 D3 Evidence Crossville Containment.

Total: 21,114pcs

Total Inspected untill

May 22nd: 17,718pcs
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D4 Root Cause Analysis - Detection

WHY 1: Why Inverted taper could not be detected?

The Trunion was not turned during the inspection and INVERTED Taper
could not be detected in that position

WHY 2: The Inspection Instruction does not require to turn the trunion
during the inspection

WHY 3: the ovality was not considered for the validation process and it is
significat contribuitor for the inverted taper issue and was not
considered for the validation process

WHY 4: This failure mode is not considered in the control plan and Process sheet
Further Details regarding the MSA are described in the slides below
Method Improvements , Equipment used and Efectiveness
 Measurement System,

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

Air Gage / Z-Mike/

05/05/2017 Four Trunnion 100% Effective Effective
P40

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 D4. Root Cause Analysis Detection Method

Equipment Effective Resolution

Equipment Resolution Tolerance Readability Rule of

thumb
Z-Mike 0.000001 0.0005 0.0001 100 to 1

Micrometer 0.000050 0.0005 0.0001 2 to 1

Air Gage 0.000050 0.0005 0.0001 2 to 1

P40 0.000001 0.0005 0.0001 100 to 1

CMM 0.000001 0.0005 0.0001 100 to 1

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 D4. Define and verify Root Cause (Manufacture)

Root cause analysis: Inverted Taper

The last Test performed : New
WHY WAS MADE? Diamod Kit, bearing shaft
W1: Diamond profile out of specification rectified and aligned gave us
W2: Wrong taper alignment on the diamond a good better taper
performance
W3: Natural Diamond Wear
W4: Diamond life has come to an end
W5:: Diamod shaft was missaligned
The interaction between the Diamond worn out and shaft missaligment produced the taper condition Issue

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, in terms of machining deformation.

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 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.
W2: PFMEA did not consider an aditional device to make correlation for the
same characteristic.
W3: Occurence in the PFMEA was too low.

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 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.
W2: PFMEA did not consider an aditional device to make correlation for the
same characteristic.
W3: Occurence in the PFMEA was too low.

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 D4. Define and verify Root Cause (Maintenance)

Shaft aligment and bearing

Root cause analysis: Inverted Taper rectifying frequency inspection
during preventive maintenance
WHY WAS MADE? Routine Will be define after a
W1: Diamond roller bracket got damaged. performance study
W2: Diamond roller bracket crashed against the dressing wheels.
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

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 D5 .- Key ACTIONS

SYSTEMIC
FMEA Inverted Taper, Causes ,
occurrence, Detection Updated.
LPA inverted taper set up validation
MANAGEMENT will be include in the LPA questionare.
Management frequency Audit one per
month for this operation.

CONTROL PLAN:
ENGINEERING Dressing frequency was Increased from 15 to 8
P40 Validation for every set up
Bore Gage 1 pice /Hr. 4 Trunnion 0-90,
Roundness Validation P40 set up.
PROCESS INSTRUCTION
Process sheet modified according to the control plan.
WORK SHOP Checking aid will include new method (roundness 0-90)
New Equipment (New Electronic Bore Gage have been
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bought and Will placed at the production Line) .
D5. Define and verify permanent corrective actions

12- jun-17

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 D5. Define and verify permanent corrective actions

done

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 D5. Define and verify permanent corrective actions

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