male connector stator can't joint analyze report
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1. Customer Complaint Summary
3. Investigation Result<3.1. Part Investigation>
Production Investigation ReportBekasi, 11 October 2013
2. ConclusionBased on disassemble check found rotor friction material height is over standard (too high – Act : 0.106 Std : 0.015±0.010).Re- occurrence trial by make rotor with friction material over than standard and conduct transmission torque, found that the
transmission torque result is low than standard (similar with claim part).Based on re-occurrence test, rotor claim is from part initial setting at beginning of production or beginning of dandori process
(change model).To prevent re-occur this problem, TACI already conduct review abnormality procedure and add 100% check of height of
friction material starting 27 Sept 2013.
Part Name : Compressor With Magnetic ClutchDenso P/No : XI447160-6101Type : 10SE13 / 2CDLot. Production : 23 October 2014Found date : 23 January 2015Received part : Join check with DNTH 20 Sept 2013Qty Defect : 1 PcsFound at : TMT GWProblem : Compressor with clutch – male connector cant joint with female connector
No Item Standard Result Claim Sample Judge1. Appearance - No abnormality found such as burn,
damage, oil.- Parts compressor should be same with
drawing. no missing Part
Found Mg Clutch burn (confirm during joint check with DNTH) X
2. Air Gap 0.25 ~ 0.50 mm 0.45 mm O3. Concentricity of
compressor0.20 mm Max 0.05 mm O
4. Rotation torque of shaft 2.94 Nm Max 1.10 Nm O5. Stator resistance 3.6±0.2Ohm (measure at 20°C) 4.5 ohm Joint check -
3.67 using TACI Equipment O
Part Item check StandardResult
JudgeProd Lot : 8Q-3764
Comp Assy with Clutch
Comp Production Date -- 27 August 2013 --Air Gap Ave : 0.25~0.50 mm 0.45 mm OK
Mg Clutch Transmission Torque of Mg Clutch
Min 34 Nm (at rated of current 3.33A)
10.4 -- (measure with condition of Mg Cutch already
damage)
10.49.5
Average 10.1
Rotor S/A
Nakabeko/ Flatness 0.03mm Max Can’t check already had bearing --
Friction Material heightstd : 0.015±0.010
(measuring under drying condition
100°Cx60+100minute
0.106 NG
Roughness Ra 1.3~4.5 2.949 OK
Hub S/A
Hub Production Date -- 27 August 2013 --
Flatness 0.03mm Max 0.04-- *Hub condition
was burnRoughness Ra 1.0~4.5 1.705 OKRun out Friction surface 0.20 Max 0.04 OK
Compressor Assy Concentricity Max 0.20
(New Part) 0.04 OK
On Dimension Check result, Found abnormality on high of friction material
<3.2. Disassemble Parts and Check Dimension of Mg Clutch >
4. Possibility Area of Occurrence Problem
Possibility abnormality of Male Connector is happen on Terminal Process and Flow to next process due to miss Fitting Connector
Wire Enameld Copper
Winding
Twisting
Soldering Lead Wire & Crimping Fuse
Soldering Terminal FusePress Bord Assy
Housing Assy
Final Check1.Test Fitting Connector : - Install terminal connector and terminal eyelet ( Connector must be full until stopper)2. Quality Check : - Coil Conduct - Resistance Check - Voltage Resistance and Layer Short CheckFinish Good
Interval Check 4/Shift for dimension clip height & Insurare height.Interval Check 100% for appearance terminal & plug not broken and not damage
Possibility Problem Flow Out due to miss
Fitting Connector
Possibility Problem Occurrence
Epoxy Assy
Terminal Assy
No Trial Condition Result Judge1 Possibility if wrong assy the
terminal connector (Terminal connector assy not in line with housing connector).
X(No Possibility – different with
NG Part)
2 Possibility if wrong assy the terminal connector (Terminal connector assy not in line with housing connector).
X(No Possibility – different with
NG Part)
5. Re-Occurrence Trial
Test Fitting Connector
Male Connector (A) fit full until stopper of female connector (B)
10⁰
Standard / Actual terminal connector claimed
Trial Condition
0⁰ Can assy with housing connector but terminal connector position is wrong
position
Trial Result
AB
Standard / Actual terminal connector claimed
0⁰
Trial Condition
20⁰
Can assy with housing connector but terminal connector position is wrong
position
Trial Result
Actual Connector Claimed
Coil Conduct, Voltage Resistance Check, Resistance Check and Layer
ShortTest Fitting Connector
Coil Conduct, Voltage Resistance Check, Resistance Check and Layer
Short
GAP
NO GAP
AB
Bent Upward maximal can enter into housing
connector
Bent Upward
Can’t assy with housing connector (retainer bottle up by
retainer lock )
Retainer
Position of Retainer Lock
abnormal
Terminal of Male Connector
Actual Connector Claimed
Can’t assy with housing connector (retainer bottle up by
retainer lock )
Retainer
Position of Retainer Lock
abnormal
Terminal of Male Connector
Retainer of Female Connector bottle up by terminal of Male Connector
Position of Retainer Lock
Position of Retainer Lock
Terminal Connector
Terminal Connector
No Trial Condition Result Judge3 Possibility if wrong assy the
terminal connector (Terminal connector assy not in line with housing connector).
X(No Possibility – different with
NG Part)
4 Possibility if wrong assy the terminal connector (Terminal connector assy not in line with housing connector).
X(No possibility – difference
with NG Part)
5. Re-Occurrence Trial
Test Fitting Connector
Male Connector (A) fit full until stopper of female connector (B)
10⁰
Trial Condition
0⁰ Can assy with housing connector but terminal connector position is wrong
position
Trial Result
Actual Connector Claimed
AB
0⁰
Trial Condition
20⁰
Trial Result
Actual Connector Claimed
Standard / Actual terminal connector claimed
Coil Conduct, Voltage Resistance Check, Resistance Check and Layer
Short
NO GAP
Standard / Actual terminal connector claimed
Coil Conduct, Voltage Resistance Check, Resistance Check and Layer
Short
Test Fitting Connector
Bent down
GAP
AB
Can’t assy with housing connector (retainer bottle up by
retainer lock )
Retainer
Position of Retainer Lock
abnormal
Can assy with housing connector but terminal connector position is wrong
position
Can’t assy with housing connector (retainer bottle up by
retainer lock )
Retainer
Position of Retainer Lock
abnormal
Retainer of Female Connector bottle up by terminal of Male Connector
Terminal of Male Connector
Terminal of Male Connector
Bent down maximal can enter into housing
connector
Position of Retainer Lock
Position of Retainer Lock
Terminal Connector
Terminal Connector
No Trial Condition Result Judge5 Raw Material ( Retainer Lock
Male Connector abnormal )
O(Possibility –
same with NG Part)
5. Re-Occurrence Trial
Possibility of retainer lock abnormal caused by raw material from suplier was broken
Test Fitting Connector
0⁰
Actual Connector Claimed
Standard / Actual terminal connector claimed
Coil Conduct, Voltage Resistance Check, Resistance Check and Layer
Short
Can’t assy with housing connector (retainer bottle up by retainer lock )
Retainer
Position of Retainer Lock
abnormal
Retainer Terminal Connector
Position of Retainer
Lock
Standard
GAP
AB
Retainer of Male Connector bottle up by retainer lock
6. Caused and CountermeasureCaused Countermeasure
Why O
ccur
(Possibility :Terminal assy process)
> Rotor slippage due to high of friction material too high (out of standard).> Based on re-occurrence test rotor claim is the part initial setting at beginning of production or beginning of dandori (change model).> When setting offset program “setting person (MP)” bring the part to QC corner to check
the part.> After check inspector confirm that parts (initial part) still NG at Machine A and OK at Machine B. (Friction Surface Process had 2 machine).> But unfortunately the inspector miss to return part NG to machine A and scrap OK part from Machine B, these are due to no identity of part setting from Machine A & Machine
B (operator forgot to give mark at sample check).> Operator at friction surface process think that part setting is OK dimension because return by inspector.
To Prevent this problem occur, we do :1. Review abnormality procedure [ 27 Sept 2013] Before : no command to give label at part setting. So if part mixed
at QC corner, operator can’t distinguish the origin of part setting. After : Add label tag at setting part and add tacking procedure for
setting part .2. If found part not have identity and marking at QC corner should be
scrap.3. Change identification of machine at part initial setting, before : using crayon after : using Label Tag (To prevent part no identification due to the
mark erase due to handling).
Heating machine
Friction surface process M/c A
Friction Material
Assy
Friction surface process M/c B
Inside Diameter Bearing
Machining M/c
Balancing Check M/c
Insert bearing & caulking machine
Final Check
QC cornerBring to QC corner to confirm part (part judgment NG at machine A)
Sample m/c A
NG
Sample m/c B
OK
No marking
Miss return the part initial setting due to no marking
Scraping Box
Label Tag for part initial setting
Identification for OP3-1
Identification for OP3-2
Marking identification using crayon easy to
erase by hand
Before
After
1
2
6. Caused and CountermeasureCaused Countermeasure
Why Flow
out
Final check process can’t detected retainer not fit full until stopper because quality check m/c can work even though retainer not fit full until stopper.
Can’t hear a click continously while connector fit full until stopper because another sound effect of m/c (noise).
Can’t feel a click continously while connector fit full until stopper because operator use heat resistance gloves (black) and make thousands part every day.
Make a sensor for stopper connector jig.
Before After
Final Check Inspection items
Test Fitting Connector
GAP
AB
Test Fitting Connector
GAP
AB
Final Check1.Test Fitting Connector : - Install terminal connector and terminal eyelet ( Connector must be full until stopper)2. Quality Check : - Coil Conduct - Resistance Check - Voltage Resistance and Layer Short Check
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