This document summarizes the process control and quality assurance methods used by Filter Expert Co., Ltd. It discusses how they use statistical process control (SPC) and control plans to monitor key metrics like thread quality and gasket integrity. Thread quality and gasket quality are monitored through inspection checks, with data collected and presented in monthly reports. Notable numbers like failures per million produced are tracked to identify issues and drive down defects, such as a problem with edge sealing that was addressed through machine maintenance.

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3. Process control and quality at Filter Expert Co.,Ltd.
A key element in process control and quality
assurance at Filter Expert Co.,Ltd.is the use
of statistical process control or SPC. This is
metrics driven buy a control plan which is then
followed by an assessment of the metrics
derived from the control plan.

4. SPC
SPC or statistical process control is the collection of
quantifiable assembly and inspection data which is
analyzed and used as the basis for the elimination of
variation and for the basis of process improvement.
Checking the thread size OD ID and checking the screw plate/base plate

5. Which Key items are monitored?
• The key items monitored are those related to :
– Thread Quality
– Seam Integrity (Double Seam or Lockseam)
– All Aspects of Gasket Quality
– Filter Element Quality
– Anti-drainback Valve Integrity

6. An example of what is monitored and why?
The control plan has check points for every
assembly and test operation. For this presentation
we will look at a two key line items thread quality
and how it fits into the control plan and gasket
quality

7. Thread quality is extremely important!
Because it is the primary interface mechanism to the vehicle. If the
threads are nicked or damaged; only partially threaded; rough; or, if there
is debris in the thread, the oil filter will not smoothly engage the center post
resulting in an improperly seated oil filter; improper loading on the gasket,
potential leaks, creation of metal shavings on the “clean” side of the filter
or possible damage to the center post. The analysis of field returns and
customer complaints showed that thread quality can manifest itself in
many forms:
Leno Good screw plate and cover plate
See the next page and
see how bad quality
Thread is

8. • Debris in Threads
• Nicked or Damaged
Threads
• Rough Threads
• Thread Perpendicularity
• Wrong Thread
Thread quality is extremely important!

9. How is thread quality monitored?
A Quality Control Plan is created to monitor all vital
processes for a product. The control plan will dictate
what, when and how a process is monitored and
measured
For this line, thread tapping is performed by a thread
tapping machine and is noted as a special characteristic
A plug gauge is used
% pieces are checked every 2 hours
The work instruction is identified
The data is collected on an inspection sheet by an
inspector
If an issue is found the required corrective action is
identified

10. Control Plan Sheet

11. • One of the key elements in the quality control
plan is incoming gasket quality
• Upon receipt, the gaskets are inspected and
several data points are taken from the inspected
gaskets
Gasket Quality is Very Important

12. Below is the gasket control plan, the following
slides demonstrate how the plan is followed

13. As per the QC plan:
• The inspector
will start with a
visual inspection.
Using a caliper
and jig, the
inspector
assures the part
meets the
dimensions of
the part’s
documented
specification

14. • Again refering to
the product
specification, the
inspector will
meausre the
shore hardness
hardness of the
gasket and
record the data

15. If a part is found to be outside of the tolerance listed in
the specification, LENO will follow the review process
where material is wrong positioned as rejected, concede
that it is useable or scrap.
Failure outside the ring
Failure assessment
Rejection Concession Scrapped

16. Where is the data collected and
how is it presented?
• A monthly report is prepared
which details
– Production projects
– The items analyzed per the
quality Control Plan
– Problems are highlighted
– The largest percentage of failures
are reviewed
– Parts per million are reviewed
– Failure analysis is detailed
– Corrective actions are assigned

17. What does this mean?
month
productionline
edgesealing
bad
edgesealing
crushing
damage
leaktesting
scratch
springproblem
bottomplate
problem
shellproblem
printingproblem
waterflowinto
whileleak
testing
filterpartomitted
others
total
monthqty
rejectionrate
‰
internalPPM
targets‰
Dec.2010
123
线 1107 0 42 574 25 144 151 5 46 0 156 2250 532253 4.227313 4
Jan.2011
123
线 488 1 24 426 39 33 121 1 59 6 117 1315 379711 3.4631601 4
Feb.2011
123
线 79 3 37 86 27 23 12 0 45 3 12 327 110300 2.9646419 4
Bad edge sealing failures were 1107 for December and
after failure analysis and corrective action were driven
down every month to an acceptable level

18. Which numbers are significant?
month
productionline
edge
sealingbad
edgesealing
crushing
damage
leaktesting
scratch
springproblem
bottomplate
problem
shellproblem
printing
problem
waterflowinto
whileleak
testing
filterpart
omitted
others
total
monthqty
rejectionrate
‰
internalPPM
targets‰
Dec.2010
123
线 1107 0 42 574 25 144 151 5 46 0 156 2250 532253 4.227313 4
Jan.2011
123
线 488 1 24 426 39 33 121 1 59 6 117 1315 379711 3.4631601 4
Feb.2011
123
线 79 3 37 86 27 23 12 0 45 3 12 327 110300 2.9646419 4
Knowing the total number of failures is important but more important is the number
of failures for a set population. Production levels vary from month to month. The
factory therefore looks to see what their failure rate is in parts per million
(PPM) for pieces produced. The acceptable level at this factory is 4 PPM. Note
that the December PPM was 4.227313 and then reduced to 3.463160 in January
and 2.9646419 in February

19. Bad
Edge
Analysis
From the fish bone it was found that the root cause for this problem lies in the
processing of materials and equipment maintenance The machine requires regular
maintenance to prevent the can from deforming during assembly process causing
potential leaks. Corrective and preventive measures are applied and noted:
1. Improve the shell mold so the shell is not deformed when trimmed flat
2. The shop foreman will be required to perform regular maintenance to the forming
wheel
Case trimming are not flat, there is edge collapses
Edge is not the normal maintenance of wheel
Badedge
Environment Materials Workers
EquipmentEnvironment

20. TEST ITEMS AND TEST STAND LIST

21. Results
By Improving the shell mold so the shell is not deformed when
trimmed flat and by the shop foreman performing added
maintenance to the forming wheel the PPM was driven down from
almost 4.25 PPM in December to less than 3 PPM in February
• The control plan was implemented
• The process followed
• Quantifiable data was recorded
• The data and metrics were reviewed
• Issues identified
• Corrective action was implemented Upon review the actions
were validated as effective
If you have any advice, feel free to contact us !
Filter Expert Co.,Ltd.
Email:sale@oilfilterexpert.com
Sales Manager: Balzac Wong