1. IDENTIFY (Problem Definition/History):
On Oct/08/2016, From GM notified Prime Wheel that they found wheel hub centric ring is painted black of part 23400142 (Prime 683). Need a clear point and sort of stock. Please see below. 1 wheel has this condition, this wheel has two paint date, so this is the reworked wheel.
2. ANALYZE (Root Cause):
Specific:
-This wheel has two paint date, so this is the reworked wheel.
-Fresh wheel process: CNC rough cut without cap finishing→Helium test→ Pretreatment→ Base coating→Color paint→Machined face（cap geometry will be finished completely）
→Clear coat→Finished wheel→Appearance check; Skin cut path is as below:
-Reworked production process:
Pretreatment → Base coating →Color paint
→Machined face
（machining  Surface only ）→Clear coat
→Finished wheel →
Appearance inspection
We finished complete cap geometry in first skin cut process, when we rework them after painting process, the inside of cap will not be cut anymore, reworked wheels will be with color in cap center hole.
Detection:
No specific requirement about this defect was requested to appearance inspector in the past.
3. PLAN (Quick Fix/Corrective Action):
1. A certification label was issued on 10/08/16 and wheels are being checked at Prime
wheel (China).
validation verification2. A Quality alert will be released, all related operator will be trained
3. A specific appearance check instruction will be issued to all the appearance inspector
and related production people, they all will be trained.
4. Stop rework process until we can find a solution.
5. Add this failure into FMEA documents as a lessons learned for process design of new
skin wheel in the future
4. IMPLEMENT (EWO):
1. A certification label was issued on 10/08/16 and wheels are being checked at Prime
wheel (China).
2. A Quality alert has been released, all related operator has been trained.
3. The specific appearance check instruction has been issued to all the appearance
inspector and related production people.
4. Stop rework process, a protection masking for cap center hole will be under studied
for skin cut reworked wheels
5. The PFMEA has been modified, add this failure into PFMEA documents as a lessons
learned for process design of new skin wheel in the future.
5. EVALUATE ( Verification / Validation ):