5 Whys

Problem Statement: Cam screws loosening and backing out several turns on mortise cylinders
Why: Joint is not good Why: The joint is a flat head, which is least preferred for screw joints & incompletely tightened Why: The actual contact point of the cam is the back surface leaving a gap at the bottom of the slot. When tighten completely the cam deforms, compressing the back of the plug, binding the normal clearance of the cam, plug and body fit Why: reduce rattle failures and increase torque for locked lever test - The catch has also has a chamfer on the window to reduce emergency force for unlocking

Problem Statement: Why does the supplier send F605-322 parts out of specification?
Why: checked 17 features on this die, fork legs where checked 2 parts every roll of material used (.212, approx. 2 parts every 10k parts ran) Why: initial reports where set up to only check to 2 parts Why: No history to support that this dimension was an issue Why: This feature was not identified on the print or the PIP? The PIP may have not been sent to supplier (supplier to check for copy of PIP). Why: The tolerance for the fork legs where thought to be capable at the time the die was built. The dimensions were set +- .005 on the first released print. The design may be more sensitive then originally thought. The tool design may not capable of +-.005 for long term production. Notes: - This is a transfer die from PPM

5 Whys

Problem Statement: Why is the F605-322 classified as a B-die

Why: less expensive way to build a die (purchased die set) Why: use tool steel vs. carbide Why: This is a transfer die at the current supplier and they have no history (paperwork) to understand why this was designed and built in this method. Why: Notes: - Burr direction is opposite on the existing plunger fork from pre-Conquista product. The current part has the burr condition on the outer edge of the plunger fork legs, which provide the worst condition. - Die design is less expensive to build a die that cuts the material and forums the die from the opposite direction

Problem Statement: Why did the .212 plunger fork leg dimension change in the stamping process.
Why: The originally punch was deflecting during the stamping process. Why: The punch was not located correctly in die. Why: Tooling wear, components misaligned, tooling design Why: The tool did not come with any spare details for PM. Notes: - CA - The die punches where moved to compassionate for inaccurate tooling design and wear.