male connector stator can't joint analyze report

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).


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


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


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



retainer lock )

Retainer


abnormal


Retainer of Female Connector bottle up by terminal of Male Connector



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).


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)



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


AB

0⁰

Trial Condition

20⁰

Trial Result




Short

NO GAP



Short


Bent down

GAP

AB


retainer lock )

Retainer


abnormal

Can assy with housing connector but terminal connector position is wrong

position


retainer lock )

Retainer


abnormal

Retainer of Female Connector bottle up by terminal of Male Connector



Bent down maximal can enter into housing

connector



Terminal Connector

Terminal Connector

No Trial Condition Result Judge5 Raw Material ( Retainer Lock

Male Connector abnormal )

O(Possibility –

same with NG Part)


Possibility of retainer lock abnormal caused by raw material from suplier was broken


0⁰




Short

Can’t assy with housing connector (retainer bottle up by retainer lock )

Retainer


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


GAP

AB


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

male connector stator can't joint analyze report

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