1
Why was the uncontrolled document not removed?

1.1
An additional fixture that rotates the camera (shift Cpk) is created after the SOP.
This was not calculated in the initial phases of the project.

1.1.1
The roll angle of the final assembly was inaccurate. (out of tolerance).

1.3
The production team didn't inform the Process engineer to remove the document.

1.1.1.1
Due to warping/springback of mainly the injection molded Arm Lower, the roll angle of the final assembly is out of tolerance.

1.1.1.1.1
In the GD&T of document number D070890, we find clampingpoint A3, which doesn't reflect the mating surfaces of the powerfold.

1.1.1.1.1.1
The supplier didn't carry out a compensation loop (or did it wrong) to adjust for the springback of the part.

1.1.1.1.1.1.1
The quality has been accepted by the Quality department of Stoneridge Orlaco

1.3.1
The production team didn't notice the obsolete and uncontrolled document

1
Why was the problem not detected by the existing inspection or quality control processes?

The inspection processes or quality control checks in place were possibly not comprehensive enough to catch uncontrolled documents, perhaps due to no inspections being planned for this kind of change.

1.1
Why were the inspection processes or quality control checks not comprehensive enough?

There might have been missing quality controls or checks due after SOP, leading to a gap in the detection system where new elements like the fixture change were not incorporated into the inspection routines.

1.3.1.1

1.4
There was a paper document in the first place.

1.4.1
The screwing sequence is introduced as a supposed countermeasure for spread in the yaw and roll.

1.4.1.1
The sequence introduced because we assumed it was the rootcause of our variation

1.4.2.
Orlaco Global requested to introduce paper information carriers

1.4.1.1.
A proper rootcause analyis hasn't been performed

1.1.1
Why are inspections after SOP not taking into consideration uncontrolled documents

Normally process changes are done before start of production. in case there are changes made to existing processes, this will be done with change management.

1.1.1.1
Why did the team not used change management?

In the current department instruction it says that change management is done for changes to the part or to the assembly sequence.

Implement a Robust Change Management System: Strengthen change management processes to ensure all changes are documented, reviewed, and integrated into the existing quality and inspection frameworks efficiently and comprehensively.

Revise and Update Inspection and Quality Control Processes:
Ensure that any process or equipment changes are immediately followed by a review and update of inspection and quality control processes to include these changes.

The production team might be insufficiently aware of their ability to inform the productionlead of inconsistencies in the production line