Background
A certain international automotive parts supplier has reported that their purchased batch of silicone rubber sealing rings had dimensional deviations (± 0.3mm) during customer assembly, resulting in unstable sealing performance. The production line was forced to stop screening, and the customer requested urgent rectification.
Problem positioning
After receiving feedback, our quality center immediately initiated a case library comparison analysis:
Historical data retrieval: Searching for production records of similar products in the past 3 years, it was found that this batch of raw material suppliers had experienced similar problems for the first time after replacement;
Process parameter verification: There is a fluctuation range of 5 ℃ between the vulcanization temperature curve and the mold pressure data, which deviates from the standard control range;
Mold wear detection: 3D scanning found 0.1mm wear on the key positioning groove of the mold, and the cumulative production has reached 120000 molds.
Solution
Develop improvement plans through cross departmental collaboration (technology/production/supply chain):
✅ Raw material optimization: Restore the original supplier's high-precision silicone rubber compound and add viscosity sampling for incoming batches;
✅ Process parameter upgrade: adopting a dynamic temperature control system to control the fluctuation of vulcanization temperature within ± 1 ℃;
✅ Mold maintenance iteration: enable backup mold replacement for production, while strengthening the old mold with PVD coating treatment;
✅ Quality traceability enhancement: Attach a unique traceability code to each batch of products, linking them to the full data chain of raw materials/processes/equipment.
Presentation of Achievements
Quality indicators: The defect rate decreased from 8% to 0.5%, and the CPK value increased from 0.8 to 1.67;
Customer feedback: Zero customer complaints for 6 consecutive months, awarded as "Annual Best Quality Contribution Supplier";
Efficiency improvement: By using mold coating technology, the service life is extended by 30%, and the single line production capacity is increased by 15%.
Value extraction
Through the systematic problem management mechanism of the case center, we have achieved:
Capitalization of Technical Experience: Transforming Implicit Knowledge into a Reusable Solution Library
Pre positioning of quality risks: establishing a similar problem warning model to prevent potential losses
Strengthening customer trust: using data-driven improvement reports to enhance supply chain discourse power
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