39G Brush Carrier Crack at assembly

PRESENTATION ON PRACTICAL APPLICATION OF DOE in Root Cause Analysis

By A.M. Chandramohan

6 Sigma

Root Cause Analysis Team: AMC/DD/AM/JJ/RK

39G Brush Carrier Crack at assembly

160 Times Magnified View

6 Sigma

Root Cause Analysis Team: AMC/DD/AM/JJ/RK

39G Brush Carrier Crack at assembly

Man
Inspection Error Wrong setting

Machine
Assembly Pressure Carrier Crack

Process variation in Injection molding

Terminal width oversize

Carrier Gap width Undersize

Method

Material

6 Sigma

Root Cause Analysis Team: AMC/DD/AM/JJ/RK

39G Brush Carrier Crack at assembly

Possible Causes for Crack: Gap width undersize in Brush Carrier Terminal width Oversize. Excess load in assembly

6 Sigma

Root Cause Analysis Team: AMC/DD/AM/JJ/RK

39G Brush Carrier Crack at assembly

Customer Specification :
Carrier Gap Width Terminal Thickness Assembly Load 0.81-0.02 mm 0.810.1 mm 2.0 3.5 Bar

6 Sigma

Root Cause Analysis Team: AMC/DD/AM/JJ/RK

39G Brush Carrier Crack at assembly

Terminal Inspection

Carrier Inspection

6 Sigma

Root Cause Analysis Team: AMC/DD/AM/JJ/RK

39G Brush Carrier Crack at assembly

Factors considered for DOE
Carrier width ( Min ) 0.790 Carrier width ( Max ) 0.820 Terminal Thickness ( Min ) 0.78 Terminal Thickness ( Max ) 0.85 Assembly Load ( Min ) 2.0 Bar Assembly Load ( Max ) 3.5 Bar

Remarks: To reduce crack, Carrier width was increased up to 0.83 mm. 6 Sigma

Root Cause Analysis Team: AMC/DD/AM/JJ/RK

39G Brush Carrier Crack at assembly

To find out the interactions of these parameters DOE conducted

DOE LAYOUT
Trial No Carrier width
1 2 3 4 5 6 7 8
6 Sigma

Ter. Width
Min Max Max Min Max Min Min Max

Load
Max Min Max Min Max Max Min Min

Min Max Min Max Max Max Min Min

Root Cause Analysis Team: AMC/DD/AM/JJ/RK

39G Brush Carrier Crack at assembly Response variables considered for DOE
Pull out force (Drawing Specification - Min 16.7 N)

Terminal Position (Drawing Specification 17.27 to 17.57mm) No crack allowed

Remarks: To reduce crack, Carrier width was increased up to 0.83 mm. 6 Sigma

Root Cause Analysis Team: AMC/DD/AM/JJ/RK

39G Brush Carrier Crack at assembly

Results of DOE
Trial No Carrier width Terminal Thickness Load Crack Pull out 16.7 N min 1 2 3 4 5 6 7 8
6 Sigma

Ter. Pos 17.27 17.52 MM 17.427 17.403 17.445 17.262 17.411 17.295 17.387 17.41

Min Max Min Max Max Max Min Min

Min Max Max Min Max Min Min Max

Max Min Max Min Max Max Min Min

0 0 1 0 0 0 0 0

134 229 271 121 250 123 200 317

Root Cause Analysis Team: AMC/DD/AM/JJ/RK

39G Brush Carrier Crack at assembly

6 Sigma

Root Cause Analysis Team: AMC/DD/AM/JJ/RK

39G Brush Carrier Crack at assembly

OBSERVATIONS OF DOE:
1. Only at extreme conditions Trial 3 (Carrier Width Min; Terminal width max & Max load ) crack occurred. 2.Pull out force is 7 to 19 times more than required specification level 3.After assembly Terminal position is low in Trial 4, due to minimum terminal thickness (0.78mm) & maximum carrier width (0.825mm)
6 Sigma

Root Cause Analysis Team: AMC/DD/AM/JJ/RK

39G Brush Carrier Crack at assembly Clarification required on the following 1. The total tolerance of plastic carrier is 20Microns, Where as tolerance for terminal thickness is 200Microns. (Ref DOE Trial 4 for that actual terminal thickness is 0.78mm, in this case itself it is failing, if we take minimum specification of 0.71mm it will fell down). 2. From the DOE we can observe the pull out force is much more in the trials 2,3,5,8 (229N 371N). This Clearly shows the Interference is much more, where the plastic part might get crack.
6 Sigma

Root Cause Analysis Team: AMC/DD/AM/JJ/RK

39G Brush Carrier Crack at assembly

3. Above drawing clearly indicating that the groove shall be 0.81mm @

the top & 0.79mm @ the bottom (i.e) Degree draft given for easy ejection. This was provided in the tool insert itself . Now we are not having any tolerance for process variation.

6 Sigma

Root Cause Analysis Team: AMC/DD/AM/JJ/RK

39G Brush Carrier Crack at assembly

Conclusion:
* First slide clearly showing that the crack cannot be seen with naked eye, this is only segregated with the help of magnifier. The impact of this hair line crack at customer point of view has to be discussed further, for reducing rejection at assembly. * Interference to be reduced by increasing the carrier gap width.

6 Sigma

Root Cause Analysis Team: AMC/DD/AM/JJ/RK

39G Brush Carrier Crack at assembly

Improvement action:

Planned to increase the width 0.81mm to 0.84 mm of terminal

gap in the carrier to reduce interference and further crack. Improved Samples submitted to Brushcards and awaiting for feed back and drawing revision.

6 Sigma

Root Cause Analysis Team: AMC/DD/AM/JJ/RK

39G Brush Carrier Crack at assembly

THANK YOU!

6 Sigma

Root Cause Analysis Team: AMC/DD/AM/JJ/RK