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
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 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 was aware regarding this issue, Cardanes didnt ship material
AUSTRALIA ALFONSO OCHOA
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within the suspect window
 D3. Evidence

Inspection Method Improvement

Frequency
Issue Date Inspection Method 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
Up detected
down) trunnion considered
Ovality measurement
and the usage for the
Four Trunnion, Two
1 piece every 2 Failure mode not micrometer readability
22/04/2017 position (Up, down Z-Mike / Micrometer
hrs detected was not the correct one
0 y 90)
to validate this
characteristic.

Air Gage / Z-Mike/

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

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 D3. Evidence

Equipment Effective Resolution

Rule of
Equipment Resolution Tolerance Readability
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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 D3. Evidence
Quality alert current on the production on line
Customer voice Visual Aid

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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. Define and verify Root Cause (Maintenance)

Root cause analysis: Inverted Taper Under validation

WHY WAS MADE? process
W1: Diamond roller bracket got damaged.
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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 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 (Manufacture)

Root cause analysis: Inverted Taper Under validation

WHY WAS MADE? process
W1: Diamond profile out of specification
W2: Wrong taper alignment on the diamond
W3: Natural Diamond Wear
W4: Diamond life has come to an end

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 deformity.

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 D4. Define and verify Root Cause

Under validation
process
Why System failed ?:
W1: Set-up released with single-die data
W2: Control plan did not indicate verification of 4 trunnions
W1: Because in PFMEA it is not considering 4 trunks for this mode of failure

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D5. Define and verify permanent corrective actions

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 D5. Define and verify permanent corrective actions

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 D5. Define and verify permanent corrective actions

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