Factory Tour Report 120309

Factory Tour Report Dec 3rd, 2009 Prepared by Stephen

1. General Information ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

2. Detailed Job Scope ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

3. Questionares for the Heat Treatment ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

4. Step 1- Check the hardness tester ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Ref: Wrong Hardness Tester which the manufacturing is using NO CALIBRATION RECORD Unfortunately the engineers didn't test and calibrate it before using it last time either, so got the wrong values.

2. Step 2- Use a reliable tester for the inspection ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Refer: The hardness tester which is used by heat treatment shop, it's calibrated on Dec 1st, 2009 with the record, and tested by the hardness standard too. so all values are reliable

Result 1: Inspect Datas for Worm Gears ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Note: 1. Select 20 pcs parts out of total 300 pcs parts at random for inspection. 2. Measure 3 points on top and bottom surface which are 120 deg array around. total 6 points. 3. When consider of some deviation and test error, all dates should be between HRC 32-35, very fine and even datas

Result 2- Inspect Datas for Worms ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Note: 1. Select 20 pcs parts out of total 300 pcs parts at random for inspection. 2. Measure 3 points on the teeth area for inspection 3. When consider of some deviation and test error, all dates should be between HRC 32-35, very fine and even datas

Step 3- My conclusion and Suggestions ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Step 4. Some Other Issues 1. Painting: Regarding the part "Housing ROD ROTATOR 3020". I see there remarked that "O-ring Surface shall not be painted" and " all other external surfaces shall be painted..." but the manufacturer didn't apply paint to upper circle surface. I am not sure whether it's necessary. as it's inside another part. 2. I also found some small rust area in no painting surface, have asked them remove it and apply some anti-rust grease before delivery.

Factory Tour Report 120309

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