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Content
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1. Control Plan & PFMEA – July 2016
2. PFMEA Training at Blanking Supplier – August 2016
3. PFMEA Training at Casting Supplier – August 2016
4. PFMEA Training at TRX Assembly Supplier – October 2016
5. FMEA Training at STA Workshop – October 2016
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1.0 Control Plan & PFMEA Training with TRX Supplier & Changan HQ
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Dates: Monday 25th July 2016
Location: Transmission Assembly Supplier
Training Type: Workshop
Duration: 3 + 4 hours
Attendees: Process Engineering, Changan QA & Design
Background: Supplier requested help on particular key common processes with
the transmissions :
• Gluing / sealant application
• Gear pressing
• Bolting of the two housings together
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1.0 Control Plan & PFMEA Training
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Bearing Ass’y onto Diff. Body Bolt Ass’y & Pre-Load Torque Final Bolt Torque & Seal
Analysing the existing PFMEA Highlighting & preventing new potential issues
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2.0 PFMEA Training with TRX Suppliers & Changan HQ
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Dates: Thursday 11th & Friday 12th August 2016
Location: FineBlanking Supplier - Suzhou
Training Type: Workshop
Duration: 3 + 2 hours
Attendees: Engineering, Tsingshan STA & Changan QA
Background: The team focussed on the new equipment & processes for :
• Insertion & assembly of the Plastic Tips.
• Coil pin insertion for Shift Fork & Rail Assembly.
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2.0 PFMEA Training
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Focusing on the what could go
wrong – potential failure modes
Understanding the Shift / Rail / Pin Assembly Identifying the Product & Process Characteristics
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3.0 PFMEA Training with Supplier, Changan HQ & TRW Assembly Supplier.
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Dates: Tuesday 16th August 2016
Location: Diecasting supplier - Chengdu
Training Type: Classroom
Duration: 2 hours
Attendees: Supplier Team (~40 people), STA & Changan Design
Background: The audit highlighted a weakness in this area so the following
familiar process was used so everyone could relate to it:
• Blasting (high pressure media deburring).
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3.0 PFMEA Training
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Defining the Process Requirements Group Brainstorm – Identifying potential modes
Identifying Effects & Scoring SeverityLarge Group Interest Encouraging Engagement.
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4.0 PFMEA Training at TRX Supplier (High Volume Assembly Line)
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Dates: Wednesday 19th October – Saturday 22nd October
Location: TRX Supplier – Chongqing
Training Type: Workshop
Duration: 4 days
Attendees: Engineering, Equipment Supplier & Changan HQ Quality
Background: The FMEA methodology was illustrated to critique the DCT270
high volume assembly line plans with support from the
equipment supplier. In doing so, 74 additional potential failure
modes were highlighted so the team can hopefully prevent them
from occurring or reduce the risk – thus showing, the benefit of
doing work up-front, instead of intense, corrective activities as
required on DCT170.
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4.0 PFMEA Training (High Volume Assy Line)
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Reviewing the Design of the Process Identifying Potential Failure Modes
The Team MembersA Finished Brainstorm of one Process
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5.0 FMEA Training at the Supplier Quality Workshop
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Dates: Wednesday 26th November
Location: TRX Assembly Supplier – Chongqing
Training Type: Classroom
Duration: 1 day
Attendees: STA Team and representatives from 16 of their suppliers
Background: A day of training was provided on certain principles of the FMEA
tool as this has proven to be a weakness in the supply chain from
audits in China.
It also acted an extra incentive for the suppliers to attend the 3-
day “Supplier Quality Workshop” event.
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5.0 FMEA Training at the Supplier Quality Workshop
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Giving feedback to the class of suppliersTraining was delivered in English & Chinese
