Airbag checks blown up out of all proportion

Project background

A first tier automotive supplier fitted purchased airbags into the sides of a car seat. Airbags have strict quality and safety controls and are a customer specified part. It is not the seat manufacturer’s responsibility to ensure the functioning of the complete airbag system, only seam tear strengths and bolt torque for fixing to the seat frame. However costly inspection had become institutionalised at a certain plant and resulted in scrap and rework exceeding €150,000 per year.

Problem

Whereas other plants in the group (who supplied car seat sets to different automotive OEMs) did no resistance checking of the airbag, (as this was the airbag supplier’s responsibility), at this site each airbag was checked for resistance at the airbag supplier’s plant, again at goods inwards and yet again at end of line assembly. The extra handling of airbags could cause damage to the airbag and increased the risk of accidental firing. There was conflict in some of the results from the 3 checks, resulting in good airbags being returned as defective. A Six Sigma project was set up. Measurement systems analyses were carried out at the 3 internal test stations. The results showed that the goods inwards system was acceptable, but the line test stations were unacceptable. The major factor was found to be wear and poor contact of the measurement probes.

Solutions

New probes were designed & fitted to all test stations, systems were re-calibrated and overhauled. New measurement system studies were carried out after these improvements and showed acceptable results. A new calibration and maintenance procedure was implemented. A failure mode and effects analysis was carried out and a number of other improvements were implemented to ensure all potential failures were eliminated or controlled. Improved safety procedures & equipment were implemented.

Business Benefits

Goods inwards inspection was eliminated from the process. The resulting space created was used for material storage for a new production line, saving in excess of €120,000 per annum. For the future introduction of a new model, the customer agreed the removal of end of line inspection. The project also identified a future project to improve packaging and handling of airbags.

Learn More

If you would like to know more about this Feature, its subject or the author, then please complete the form below:

Name: *

Email Address: *

Company/Organisation:

Message: *

CAPTCHA

This CAPTCHA form prevents spam

What code is in the image?: *

Enter the characters (without spaces) shown in the image.