1/15© 2015. Changan UK R&D Centre Limited. All Right Reserved. This document should not be copied or distributed in any form without written approval from Changan UK R&D Centre limited.

Quality Training in China - 2016

Transmission – Quality | 10th November 2016

By Simon Reynolds

© 2015. Changan UK R&D Centre Limited. All Right Reserved. This document should not be copied or distributed in any form without written approval from Changan UK R&D Centre limited.

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Content

1. Control Plan & PFMEA – July 2016

2. PFMEA Training at Blanking Supplier – August 2016

3. PFMEA Training at Casting Supplier – August 2016

4. PFMEA Training at TRX Assembly Supplier – October 2016

5. FMEA Training at STA Workshop – October 2016

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1.0 Control Plan & PFMEA Training with TRX Supplier & Changan HQ

Dates: Monday 25th July 2016

Location: Transmission Assembly Supplier

Training Type: Workshop

Duration: 3 + 4 hours

Attendees: Process Engineering, Changan QA & Design

Background: Supplier requested help on particular key common processes with the transmissions :

• Gluing / sealant application• Gear pressing • Bolting of the two housings together

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1.0 Control Plan & PFMEA Training

Bearing Ass’y onto Diff. Body Bolt Ass’y & Pre-Load Torque Final Bolt Torque & Seal

Analysing the existing PFMEA Highlighting & preventing new potential issues

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2.0 PFMEA Training with TRX Suppliers & Changan HQ

Dates: Thursday 11th & Friday 12th August 2016

Location: FineBlanking Supplier - Suzhou

Training Type: Workshop

Duration: 3 + 2 hours

Attendees: Engineering, Tsingshan STA & Changan QA

Background: The team focussed on the new equipment & processes for :

• Insertion & assembly of the Plastic Tips. • Coil pin insertion for Shift Fork & Rail Assembly.

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2.0 PFMEA Training

Focusing on the what could go

wrong – potential failure

modes

Understanding the Shift / Rail / Pin Assembly Identifying the Product & Process Characteristics

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3.0 PFMEA Training with Supplier, Changan HQ & TRW Assembly Supplier.

Dates: Tuesday 16th August 2016

Location: Diecasting supplier - Chengdu

Training Type: Classroom

Duration: 2 hours

Attendees: Supplier Team (~40 people), STA & Changan Design

Background: The audit highlighted a weakness in this area so the following familiar process was used so everyone could relate to it:

• Blasting (high pressure media deburring).

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3.0 PFMEA Training

Defining the Process Requirements Group Brainstorm – Identifying potential modes

Identifying Effects & Scoring SeverityLarge Group Interest Encouraging Engagement.

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4.0 PFMEA Training at TRX Supplier (High Volume Assembly Line)

Dates: Wednesday 19th October – Saturday 22nd October

Location: TRX Supplier – Chongqing

Training Type: Workshop

Duration: 4 days

Attendees: Engineering, Equipment Supplier & Changan HQ Quality

Background: The FMEA methodology was illustrated to critique the DCT270 high volume assembly line plans with support from the equipment supplier. In doing so, 74 additional potential failure modes were highlighted so the team can hopefully prevent them from occurring or reduce the risk – thus showing, the benefit of doing work up-front, instead of intense, corrective activities as required on DCT170.

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4.0 PFMEA Training (High Volume Assy Line)

Reviewing the Design of the Process Identifying Potential Failure Modes

The Team MembersA Finished Brainstorm of one Process

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5.0 FMEA Training at the Supplier Quality Workshop

Dates: Wednesday 26th November

Location: TRX Assembly Supplier – Chongqing

Training Type: Classroom

Duration: 1 day

Attendees: STA Team and representatives from 16 of their suppliers

Background: A day of training was provided on certain principles of the FMEA tool as this has proven to be a weakness in the supply chain from audits in China.

It also acted an extra incentive for the suppliers to attend the 3-day “Supplier Quality Workshop” event.

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5.0 FMEA Training at the Supplier Quality Workshop

Giving feedback to the class of suppliersTraining was delivered in English & Chinese

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