VW 276 - Action Plan

Confidential
STANDARD PROFIL MOROCCO
VW Presentation
18-11-2021
1
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Points to be presented
❑ Gloss Nok B & C -pillar.
❑ Irregular line of separation.
❑ The shape of the rubber lip Nok.
❑ Incorrect assembly of the C-Pillar profile.
❑ The shape of the rubber profile of the C-Pillar NOK.
2
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Gloss Nok B & C-pillar

Problem Description Analysis:
- Gloss Nok B&C -pilar (NOK polishing of Injection Pressure problem:
mold)
In the beginning we have the material in the nozzle with temperature
more than 230 degrees after the injection of material in a surface of
temperature Between 20 and 25 degrees this creates a thermal shock
at the time of the injection, it gives the traces (Gloss)
Action Plan Resp Due Date

Root Cause
Root Cause Non-Conformance :
1- Injection pressure problem 1-1. Enlargement of the injection point. Simo CW 42.04
( 95% impact )
1-2. Adjust the parameter (change the injection Simo CW 41.02
2- Injection area with dusty due to water
speed)
cooling installation ( 5 % impact )
Root Cause Non-Detection :
3 - Lack of operator attention.
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Gloss Nok B & C-pillar

Problem Description Action Plan Resp Due Date
- Gloss Nok B&C -pilar (NOK polishing of 2-1. Changing the mold cooling installation to Simo CW 41.03
mold) avoid water drops
The current Production :
Below the 3D of the sandblasting area :
Root Cause
1- Injection pressure problem
( 95% impact )
2- Injection area with dusty due to water
cooling installation ( 5 % impact ) 3.1. Create a visual aid of this issue & ismail CW 41.02
Root Cause Non-Detection : Sensitize Operators about the current
3 - Lack of operator attention. problem.
Delivery Note :1215883
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Irregular line of separation

Problem Description Action Plan Resp Due Date
- Sensitize Operators about the current 1.1 Change the frequency for cutting blades Simo CW44.04
problem. from 3 weeks to 2 weeks or 14000 cut (study
based on the number of cut).
2.1.Add material (red area at below pic.) to the Simo CW45.02

upper area of the mold to hold the profile to
avoid movement during high pressure
injection.
Root Cause
1-Profile cut is NOK (Cutting Machine)
2-Profile movement during injection
Root Cause Non-Detection : 3.1. Create a visual aid of this issue &
3 - Lack of operator attention. Sensitize Operators about the current Ismail CW44.01
problem.
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The shape of the rubber profile of the C-Pillar NOK

Problem Description Analysis:
- Visible differences underneath the 1.1 Groove lenght which is between the cruse and the end the extremity of the
chromed strip. molding is unchangeable. This lenght is always fix on the mold. See the 3D
picture below.
2.1.A small degradation detected on the Line -1 LHS during analysis at related
Root Cause area.
1.Groove lenght is NOK (AE analysis)
Action Plan Resp Due Date
2. Small deviation of the upper mold (line
1 left). (SP detected during the anaysis)
1.1. Checked groove lenght of 4 molds (all is same) Simo CW45.01
✓ Line-1 LHS and RHS
✓ Line-2 LHS and RHS
2.1. Remake the upper mold (Line 1 left) Simo CW45.01
2.2.Add the defect in the product audit sheet. Simo CW44.02
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The shape of the rubber lip is nok

Problem Description Action Plan & Analysis Resp Due Date
- The shape of the rubber lip is nok at that 1. Ensure the proper preparation. Khaled CW44.02
junction
1.1 We start the preparation on the inside area of C-
Pillar profile to reach better volcanization.
NB: Burrs which caused by cutting machine are

cleaned in order to avoid ripped or weak junction
The problem was caused by a bad preparation of

Root Cause manuel operation which is not cut straight by operator
1. Bad preparation of the part.
2. Variation of the profile section.
3. Degradation of the mold.
- Lack of operator attention. Inform and Sensitize operators to pay attention about
this problem and update the work instruction
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The shape of the rubber lip is nok

Problem Description Action Plan & Analysis Resp Due Date
- The shape of the rubber lip is nok at that 2. Ensure the section in Tolerance : Ghali CW44.05
junction 2.1 Ensure cross section in the tolerances
marqued in the design plan.
2.2. Control frequency increased; 100 % boxes

instead normal sampling.
Before : check 5 parts per delivery according to the
control plan (many containers)
After : check 1 part per container of whole delivery
Root Cause
1. Bad preparation of the part.
2. Variation of the profile section.
3. Degradation of the mold.

- Lack of operator attention.
3. Remake the shape of the mold. Simo CW45.02
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Incorrect assembly of the C-Pillar profile

Problem Description Proposed modification Resp Due Date
Profile and triangular rubber is not  2.1. Change cross-section step by step Enrique TBD
matching uniform from top to bottom Ruiz
Pascual
proposal is to make a new plate in the
extrusion die to keep the current design and to
play for the trials with this new plate.
6K€ and 4 weeks after commercial release
2.1.1.First improvement/trial acc. to red

change
2.1.2.Second improvement/trial acc. to
magenta change
2.1.3.Third improvement/trial acc. to yellow
Root Cause change
Root Cause Non-Conformance:
1 -AE Workers awareness according to C/C This change will be perform to adjust the
the PDM and assembly process SAB profile in a good level concerning the door.
2 - SP team anayzed the problem and

present proposal to improve assembly
condition

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Confidential

STANDARD PROFIL MOROCCO

❑ Gloss Nok B & C -pillar.

❑ Irregular line of separation.

❑ The shape of the rubber lip Nok.

❑ Incorrect assembly of the C-Pillar profile.

❑ The shape of the rubber profile of the C-Pillar NOK.

Gloss Nok B & C-pillar

Action Plan Resp Due Date

Gloss Nok B & C-pillar

Below the 3D of the sandblasting area :

Irregular line of separation

2.1.Add material (red area at below pic.) to the Simo CW45.02

The shape of the rubber profile of the C-Pillar NOK

2.1. Remake the upper mold (Line 1 left) Simo CW45.01

2.2.Add the defect in the product audit sheet. Simo CW44.02

The shape of the rubber lip is nok

NB: Burrs which caused by cutting machine are

The problem was caused by a bad preparation of

The shape of the rubber lip is nok

2.2. Control frequency increased; 100 % boxes

Root Cause Non-Detection :

Incorrect assembly of the C-Pillar profile

2.1.1.First improvement/trial acc. to red

2 - SP team anayzed the problem and

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