Suspension Adjustment Gears Issue: Threaded Components Bind Up After Fabrication and Paint

Process

Component Fabrication Threaded Nut is Radius Welded onto Plate

Threaded Nut is Radius Welded onto Plate

Component Fabrication Bolt is Radius Welded onto Gear

Bolt is Radius Welded onto Gear

Inventory Parts Stored in Large Bin

Parts Stored in Large Bin

Loaded for Paint

Paint

Causes of Binding

Baseline - Room for Growth Original threading assembly is a loose fit allowing for paint coverage.

Wiggle room – Cont’d

Material Flaws Brand New Bolt has Obvious Machining Flaws

Weld overlap causes slight distortion in nut

Weld causes slight distortion the bottom threads on the bolt.

Thread Size Inconsistency

Debris does not get fully removed in Paint Line wash cycles. Adds more height to the threads.

Inventory Storage Damage Gear Tooth Impact Marks

Recommendations Material Work with Bolt Supplier on Preventative Maintenance (PM) for Bolt Fabrication Equipment Ensure thread size consistency Ensure thread quality – no manufacturer defects

Material

Work with Bolt Supplier on Preventative Maintenance (PM) for Bolt Fabrication Equipment

Ensure thread size consistency

Ensure thread quality – no manufacturer defects

Recommendations Method Review and assess proper inventory levels and storage methods. Smarter storage methods to reduce thread damage in house Smaller amounts of inventory on hand to reduce dust/debris contamination before paint

Method

Review and assess proper inventory levels and storage methods.

Smarter storage methods to reduce thread damage in house

Smaller amounts of inventory on hand to reduce dust/debris contamination before paint

Recommendations Method Consider covering threads of bolt during the painting process and rely on the grease applied at assembly to provide rust protection. Example of a plastic cover to insulate bolt from paint

Method

Consider covering threads of bolt during the painting process and rely on the grease applied at assembly to provide rust protection.