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ED CRAIG. www.weldreality.com.

The world's largest website on MIG - Flux Cored - TIG Welding


Automotive & Truck Industry. Manufacturing / Weld Issues.2.

Advanced TIP TIG Welding
TIP TIG Welding is always better quality than TIG and 100 to 500% faster with superior quality than TIG - MIG - FCAW.

 
 
   

 


Come on boys, all together,


2006: The big three continue to reduce USA manufacturing jobs and invest in China, Mexico and Canada and still the apathetic republicans do not react. Pehaps some one should explain to Washinton that for the goverment to recieve taxes, one has to create and maintain a society that recieves reasonable taxable income.

 

Manufacturing Ethics & Honesty Reflect
on a Companies Recall Statistics:

 


When one looks at the annual auto / truck recall numbers game, and find that the recall costs are measured in the billions, remember the recall statistics you read are the few defects that have come to the recall stage. For every defect that is recalled the consumer should remember the numerous defects that we are simply not made aware of.

With the different auto companies, product recall integrity and concern for human safety comes in different corporate packages. Before investing $20k - $35k in a truck or car, the consumer should give consideration to vehicle manufacturers past ethics and recall history, and be aware of those vehicle manufacturers who are aware of serious defects yet offer no recall or extended warranty. Today if you purchase a new vehicle and don't read the Consumer Report on that vehicle, you definately have more money than brain cells.




 


Daimler Chrysler: Manufacturing "Management" Issues?
From the BBC: March 2007: Chrysler is to recall almost half a million vehicles - the second recall by the company in two weeks. A total of 489,000 vehicles are being recalled including its new Dodge Avenger saloon, the US arm of German carmaker DaimlerChrysler said. Chrysler said it would notify owners of the affected vehicles which are suffering air conditioning, electrical and door lock problems. It is the latest problem to hit the troubled carmaker, which may be sold. Last month, parent company DaimlerChrysler said it would sell or spin off the unit which made a loss of 124m euros ($162m; £83m) in 2006. In an effort to cut costs at the US arm it also axed 13,000 jobs at Chrysler and closed down one of its plants. Two weeks ago the firm recalled more than 50,000 vehicles to resolve a problem with anti-lock brakes. The latest recall involves more 328,424 Durango sports utility vehicles - made between 2004 and 2006 - amid concerns that internal electrical circuits may overheat a potential for a fire. A further 149,605 Jeep Liberty vehicles, made between 2006 and 2007, are being recalled for air-conditioning glitches, while 10,994 of its latest Dodge Avenger saloon models need to have door locking problems fixed.


Daimler Chrysler: Manufacturing "Management" Issue

Aug, 2006

Chrysler recalls over 830,000 Jeeps for steering issue

Chrysler Group said it would recall an estimated 832,500 Jeep Liberty vehicles because of a potential steering problem. (2002 - 2006 vehicles) Daimler Chrysler AG said that in some of the vehicles, a ball joint in the the front suspension was prone to excessive wear and coming loose. The automaker said that, in some cases, that joint could separate entirely causing drivers to lose steering control.


Daimler Chrysler: Manufacturing Management Issue

[] 2006 Chrysler 300 Select Different Vehicle

Component: Power Train: Automatic Transmission

Defect Summary: ON CERTAIN PICKUP TRUCKS, SPORT UTILITY AND PASSENGER VEHICLES EQUIPPED WITH 42RLE AUTOMATIC TRANSMISSIONS, THE CUP PLUG THAT RETAINS THE PARK PAWL ANCHOR SHAFT MAY BE IMPROPERLY INSTALLED. IF THE SHAFT MOVES OUT OF POSITION, THE VEHICLE MAY NOT BE ABLE TO ACHIEVE 'PARK' POSITION.

Consequence Summary: IF THIS OCCURS AND THE PARKING BRAKE IS NOT APPLIED, THE VEHICLE MAY ROLL AWAY AND CAUSE A CRASH WITHOUT WARNING.


Daimler Chrysler: Manufacturing Management Issue.

2006.Chrysler group is recalling nearly 150,000 Jeep Grand Cherokees because cooling-fan blades may break, Automotive News reported. A broken fan could hurt people near the vehicle if the hood is open. The recall involves some 2000 and 2002 Grand Cherokees equipped
with 4.0-liter, 6-cylinder engines.

DaimlerChrysler is recalling 5,800 Jeep grand Cherokees to repair seat heaters that do their job too well. Transport Canada says the heating element in the front seats of the 2003-2004 models is defective and can heat to the point that it starts a fire. DaimlerChrysler mechanics will replace the element with one that is better at regulating temperature.

 

No problems associated with the heaters have been reported in Canada, but in the United States, more than 30 fires and 15 injuries have been reported. Its reported that at least six lawsuits have been filed against Chrysler.

Daimler Chrysler: Manufacturing Management Issue


Dec 05: Consumers hear rattle and may have problems passing a vehicle emission test:
Daimler Chrysler agreed to pay $94 million for repairs on 1.5 million Dodge and Jeep vehicles which may be subject to deteriorating catalytic converters. Chrysler will also settle Justice departments charges that it failed to disclose the defects. The settlement is the largest ever involving the failure to report an emission related defect to the Environmental Protection Agency. Talk to Chrysler about your catalytic converter and catalytic diagnostic system. Products: 96 to 2001 Jeep Cherokees, Wranglers, Dodge Dakota trucks, Dodge Ram vans wagons and pickups.


Chrysler: Manufacturing Management Issues


2000 or 2015 does nothing change?

 

They could not get it right in the year 2000, and as I write this, in 2015, its another AXLE recall for the RAM trucks..

CHRYSLER: AXLE SAFTEY RECALL N26 / NHTSA 13V-239 This notice applies to vehicles (VIN: xxxxxxxxxxxxxxxxx). This notice is sent in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

Chrysler has decided that defective welds, which relates to motor vehicle safety, exists in some 2012 model year RAM Truck Cab Chassis (4500/5500 series) trucks equipped with four wheel drive.

The problem is the front axle tube welds on the  trucks may not have been welded correctly during the manufacturing process. Improperly welded front axle tubes could allow the differential housing to rotate under high torque operating conditions while in four wheel drive. Should the front axle tube welds break, the differential could rotate and cause the front propeller shaft universal joint to break. This can result in a loss of motive power or damage to surrounding components if the propeller shaft continues to spin after separation. This could cause a crash without warning.



2000: Models: 2000 DODGE RAM PICKUP

The welds at the right side lower control arm (LCA) bracket-to-axle-tube attachment may have inadequate fatigue life due to poor weld quality. Inadequate fatigue life may lead to separation of the LCA bracket from the axle tube. If the bracket separates, the vehicle may experience reduced directional stability, braking degradation and/or vehicle pull under braking.

Correction: Front axle will be replaced with a properly welded front axle.

2015: CHRYSLER FIAT: AXLE WELD ISSUES, DODGE RAM SAFETY RECALL N26 / NHTSA 13V-239..

From Chrysler: This notice applies to vehicles (VIN: xxxxxxxxxxxxxxxxx). This notice is sent in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Chrysler has decided that a defect, which relates to motor vehicle safety, exists in some 2012 model year RAM Truck Cab Chassis (4500/5500 series) trucks equipped with four wheel drive. The problem is the front axle tube welds on the  trucks may not have been welded correctly during the manufacturing process. Improperly welded front axle tubes could allow the differential housing to rotate under high torque operating conditions while in four wheel drive. Should the front axle tube welds break, the differential could rotate and cause the front propeller shaft universal joint to break. This can result in a loss of motive power or damage to surrounding components if the propeller shaft continues to spin after separation. This could cause a crash without warning.


Daimler Chrysler: Manufacturing Management Issue.

Canadian Press posted August 6, 2004
WINDSOR, Ont. (CP) - Daimler Chrysler says there have been 17 "incidents" in Canada, but no injuries, that could be related to a potentially faulty part in the power steering units of hundreds of thousands of minivans being recalled by the automaker.


The automaker is recalling 681,000 minivans, including 150,000 in Canada, to replace the upper cooler hose on the power steering units of minivans equipped with V6 engines. The Dodge and Chrysler minivans - many of them made in Windsor, Ont, as well as at an assembly plant in St. Louis - are 2002 to 2004 model units that were made prior to August 2003.DaimlerChrysler said the hose could become damaged during use, particularly in cold climates."This damage could eventually cause a fluid leak, potentially resulting in an under-hood fire," the company said.While no injuries have been reported, there have been 23 "incidents" that "could be related to this issue," the company said. Seventeen of the incidents took place in Canada. In each incident, there was fluid leakage but not all of the incidents resulted in fires, said DaimlerChrysler Canada spokeswoman Kerrey Kerr."It was something that was identified in the field and as soon as we found out about it, we started to work on a fix to address the issue," she said.Kerr said the automaker successfully came up with a solution before winter, when the problem can occur due to cold temperatures.She said there would be no impact on the company's Windsor operations as a result of the recall.The recall is being voluntarily offered by Daimler Chrysler The upper power steering hose will be replaced at no charge to the customer.The company also is recalling immediately 2,000 Dodge Rams from 2004 with 4.7-litre engines. The company said an alternator wire can hit a valve, causing a short circuit and possibly a fire.

Daimler Chrysler: Manufacturing Management Issue.


CHRYSLER NEWS
Federal safety regulators asked Daimler Chrysler to recalled 600,000 vehicles
December 10, 2004
Federal safety regulators have asked Daimler Chrysler AG to recall 600,000 Dodge Durango and Dakota trucks because their wheels could fall off. The investigation includes vehicles from the 2000 to 2003 model years.

NOTE FROM ED: WHY DO FEDERAL REGULATORS HAVE TO ASK?


To Buckle Up or Not to Buckle Up.
2005: Class Action Status Granted to Seat Belt Lawsuit: A judge has granted nationwide class-action status to a lawsuit against Daimler Chrysler AG on behalf of owners of Chrysler, Dodge and Jeep vehicles that have a certain type of seat belt buckle. The so-called Gen 3 buckle is alleged to be prone to unlatching during accidents or from around child or infant car seats in sharp turns or sudden stops. At least three deaths have been blamed on the buckle, and four others are under investigation. The lawsuit seeks replacement of Gen 3 belt buckles on about 14 million Chrysler, Dodge and Jeep vehicles made since 1993. It also seeks reimbursement for inconveniences that may be caused during the replacements, up to $500 per owner. Daimler Chrysler still uses the Gen 3 belts in the middle and rear seats of their minivans.

Daimler Chrysler: Manufacturing Management Issue.

Chrysler recalls nearly 1 million minivans. Automaker says minivans with model years between '98-00 subject to recall due to electrical problem.October 12, 2004: 12:08 PM EDT NEW YORK (CNN/Money) - Daimler Chrysler said Tuesday it may recall up to 955,000 minivans due to potential electrical problems with the steering wheel column that may affect the driver's side airbag. The company's Chrysler Group said its Dodge Caravan and Grand Caravan, Plymouth Voyager and Grand Voyager, and Chrysler Town & Country minivans with model years between 1998 and 2000 are subject to the recall.


Daimler Chrysler: Manufacturing Management Issue
.

Car and Mini Van Recalls 11/2/04. Over a quarter million domestic mini vans and sedans are being recalled over safety concerns. The vans affected are Dodge Caravan and Chrysler Town and Country mini vans from the 2001-2002 model years. The auto maker says water seeping into the radio may create a short circuit and fire. But the defect is most likely in vehicles driven in hot, humid areas. The National Highway Traffic Safety Administration began investigating the defect in July - after reports of three fires and one injury. Chrysler is also recalling more than eleven thousand Sebring and Dodge Stratus sedans from the 2005 model year. An internal audit revealed improper installation of bolts in some rear seat belt retractors. Chrysler will perform repairs for free in both cases. Be sure to contact your dealer for more information.

Daimler Chrysler: Manufacturing Management Issue.

Minivan Recall
November 30, 2000
Daimler Chrysler recalled 1993-1994 Dodge Caravan and Grand Caravan, Plymouth Caravan and Grand Caravan, and Chrysler town and Country minivans because of a defective steering wheel. Chrysler had reports of 70 steering wheel failures.


Daimler Chrysler: Manufacturing Management Issue.

Daimler Chrysler recalls 216,000 U.S. pickups.
August 21, 2001
Dodge pickup trucks were recalled by Daimler Chrysler due to problems with the driver's side airbag. Some of the vehicles had sound muffling material inside the steering wheel that could become detached and wind up disabling the driver's side air bag system according to the NHTSA.

 

 

IT'S AMUSING TO READ ABOUT BIG THREE MANAGEMENT
AMBITIONS TO ESTABLISH GLOBAL BEST MANUFACTURING PRACTICES.

 

Joe why are you going on about Global Weld Best Practices / Process Controls when you have not been able to get the robots outside your office door under control? Lets face Joe the global weld reality is this. We have many manufacturing plants in North America and Mexico and at these facilities we robot weld similar carbon steel parts, yet for more than a decade each plant has;


* used different weld consumables,
* used different size weld consumables,
* used different weld gas mixes,
* used different MIG weld equipment,
* used different weld data,
* used different robots.


Joe, the lack of weld process, consumable and equipment conformity in our plants has created vast differences in the weld production weld quality attained at each plant. All of the plants have excess weld reject and rework rates. Joe before we can implement best practices, our management and engineers need to understand the process fundamentals, in your case Joe for gods sake learn to walk before you try to run.


JOE HAD A DIFFICULT TIME COMPREHENDING THE TWO CONTROL MIG PROCESS, SO HE TOOK HIS INEXPERIENCED PROCESS CONTROL PERSONNEL WHO WERE RESPONSIBLE FOR WELDING AT EACH PLANT AND CREATED THE "INEXPERIENCED PROCESS CONTROL WELD TEAM"

Daimler Chrysler: Manufacturing Management Issue.

Daimler Chrysler recalls 161,682 light trucks.
June 29, 2001
Daimler Chrysler recalled 161,682 light trucks because they do not comply with federal seat belt standards. The vehicles front seat belt retractor does not comply with federal standards and vehicle occupants could be injured if it doesn't properly work in a crash according to the NHTSA.



Daimler Chrysler: Manufacturing Management Issue.

Chrysler recalls 515,000 vehicles.
May 25, 2001
Daimler Chrysler recalled 2000 and 2001 model Neons in order to replace a brake booster vacuum hose. According to Chrysler, over time contact with oil can cause the vacuum's hose to swell and loosen from the intake manifold and result in a loss of power-brake assist and an increased idle speed. This Chrysler recall affects 515,000 Dodge and Plymouth Neons.



Daimler Chrysler: Manufacturing Management Issue.
.
Chrysler 11,000 minivans recalled.
April 25, 2001..
Chrysler announced a voluntary recall of their new minivans because of a possible front suspension problem. There have been 11,000 customers affected by the Chrysler recall and owners have been urged not to drive the minivans because a bolt on the lower control arm of the front suspension can break and the driver can lose control of the vehicle.

Daimler Chrysler: Manufacturing Management Issue.

Chrysler recalls 701,000 Dodge Ram pickups.
April 11, 2001
A spring problem with the hood latch, according to the NHTSA prompted a Chrysler recall of Dodge Ram pickups. This Chrysler recalls is more focused on Northeast or Midwest located pickups due to higher levels of metal corrosion rates due to road salt. This causes the mechanism to stick in the release position and allow the hood to unexpectedly open.


Daimler Chrysler: Manufacturing Management Issue.
.


Chrysler recalls 1.4 million Minivans
October 28, 2000
Chrysler recalled 1.4 million minivans that were built between 1996 and 2000 to fix the problems with a fuel rail seal that could leak. The Chrysler defect fix will not be available until March. The seal on the small pipe that carries fuel to the engine can fail in vehicles repeatedly operated at elevated temperature over many years. There were 43 reports of leaking fuel rail seals according to a Chrysler spokesman. Fires near the engine have caused a few minor injuries.

.

At Chrysler, it's always
time for weld reality.


An e-mail question to this site...
Mr. Craig.

 

The tier one automotive parts company I work for, has been told by the corporate Chrysler weld engineer that they have to use "self shielding flux cored wires" when welding their galvaneald parts. These self shielded flux cored welding wires cause us many welding issues. What is the logical, weld justification for using these wires?

Ed's Answer: I have seen more weld process knowledge in a Midas muffler shop than I have seen by the key weld decision makers at the Chrysler Corporation office.The bottom line, there is no justification for the use of these products on cars or truck parts. I believe the selection of these welding wires is based simply on " Chrylser Corporate Weld Enginnering ignorance" and that process ignorance was is fed by " weld consumable salesmanship"..

One of the biggest problems with arc welding in the auto/truck industry, is the selection of weld wire consumables poorly suited to the application. In many instances the weld wires selected are "too large" requiring weld current levels which are typically are too high for thin gage parts. The choice of the large consumables is typically derived from the "bigger the weld consumable the faster the weld" mentality that many managers and engineers have in this industry . The Self Shielding wires typically are available only in large diameters.

From a weld mechanical, weld chemistry, weld quality and weld productivity perspective, in contrast to MIG wires, the selection of the Self Shielded flux cored wires will always do more harm than good.

[a] In contrast to MIG, on thin gage applications the self shielded wires which do not offer short circuit weld characteristics, they provide a higher energy globular, open arc mode of weld transfer, and irrespective of polarity utilized this mode with the high current required can dramatically increase the weld burn-through potential on gage welds.

[b] In contrast to MIG, the weld fumes and grinding dust produced from the self shielded wires are much more hazardous and typically contain carcegenic components. When using these wires weld shops will have to invest in costly ventilation equipment that would not be required with MIG. Of special concern will be the health of manual welders that have to use these wire to do the weld repairs which will be necessary on robot welded gage parts.

[c] With MIG, weld spatter is controllable. These self shielded products produce erratic globular transfer and additional man power is typically required for extensive weld clean up. Also the robot weld cell equipment and fixtures will typically be contaminated with unnecessary excessive weld spatter.

[d] With the clean surface MIG welds, effective weld repairs should be simple to carry out. In contrast with the self shielded flux cored wires the resulting weld slag can be both excessive and difficult to remove. When repairing the self shielded welds with the slag in place, both the weld fusion and quality potential will suffer greatly. It's a common practice in automotive / truck plants to place a self shielded repair weld on top of a robot weld with the slag still in place, this practice is an invitation to product liability implicaions.

[e] The fact that the part welded are galvanealed or galvanized is irrelevant. I have had mechanical SS weld tests performed on these wires and also with MIG wires, the test results indicate that MIG provides the best weld quality reference weld / part mechanical needs than the SS wires.

TO FIND OUT HOW THE POOR MANAGEMENT - ENGINEERING DECISION TO USE THE SELF SHIELDED FLUX CORED WIRES HAS COST CHRYSLER AND IT'S SUPPLIERS MILLIONS OF DOLLARS EACH YEAR VISIT HERE;

 



WHEN A CORPORATE ENGINEERS AND MANAGERS LACK WELD PROCESS CONTROL - BEST PRACTICE EXPERTISE, THIS LEADS TO POOR OR INNEFECTIVE WELD DECISIONS THAT WILL BE MADE IN THE FACTORIES AND AT THE SUPPLIERS OF THEIR PARTS. THE ANNUAL COSTS CONSEQUENCES TO A CORPORATION AND TO THE SUPPLIERS WILL TYPICALLY BE IN THE MILLIONS OF DOLLARS.

IN THE CASE OF CHRYSLER, THE ENGINEERING MANAGEMENT AND THEIR WELD ENGINEERING PROCESS APATHY HAS HAD TREMENDOUS COST CONSEQUENCES IN LOST PRODUCTIVITY AND UNNECESSARY REWORK AND RECALLS . THIS PROCESS IGNORANCE WHICH IS STILL EVIDENT IN 2015 HELPS SUSTAIN THE GLASS WALLS THAT TOO OFTEN ISOLATE FRONT OFFICE PERSONNEL FROM PROVIDING THE PROCESS CONTROL TOOLS AND THE BEST WELD PRACTICES THAT HAVE ALWAYS BEEN NECESSARY FOR BOTH ROBOT AND MANUAL WELD QUALITY - PRODUCTIVITY OPTIMIZATION..

All they need is this resource and approx. 15 hours.


 

 

Daimler Chrysler: Manufacturing Management Issue.
.
Lawsuit against Chrysler for a 1995 airbag death
June 1, 2000
Chrysler has settled airbag lawsuits in the past but one man is insisting on taking Chrysler to trial because he has made safer airbags his mission. His daughter was killed in a Dodge Caravan minivan when their vehicle was hit by another car. Since then he has been organizing Chrysler airbag victim families to lobby against finding a safer device to save lives.




Daimler Chrysler: Manufacturing Management Issue.

Chrysler appeals a $262.5 million verdict.
March 8, 2000
Chrysler was told to write a $262.5 million check to the parents of a six year old killed as a result of a defective latch in the family's Chrysler minivan. A judge reduced the verdict by $3.5 million but left the rest of the damages to discourage Chrysler from using the same behavior that has led to the death of more than 50 people due to Chrysler minivan latch failures.


Daimler Chrysler: Manufacturing Management Issue.

Chrysler Recalls 652,000 SUVs.
January 24, 2000
Chrysler has recalled their SUVs because of wear issues to the fuel tank straps and expanded an earlier recall to replace brake rotors that corrode and crack in 15 rust belt states and Canada.

Daimler Chrysler: Manufacturing Management Issue.
.

Chrysler recalls 4.400 Mercedes.
December 2, 1999
Chrysler has recalled the 1997 Mercedes SL coupe / roadsters in 4,400 vehicles to replace the driver's side airbag modules. High humidity exposure can cause corrosion that causes the driver's front airbag to unintentionally deploy. Chrysler is recalling all of the 136,500 1998-1999 Mercedes M-Class SUV to inspect the front seat belt buckles and replace those that have been improperly manufactured.

Daimler Chrysler: Manufacturing Management Issue.
.

July 99: The European Union dubs Chrysler minivans the sorriest in Europe.

The European Union and European motoring organizations tested eights Chrysler Voyager minivans and found that the steering wheel and air bag was forced upwards into the driver's face hitting the head hard and putting strain on the neck. The Europeans believe it is the car manufacturer's responsibility to provide proper restraint for all the occupants of the vehicle. The Chrysler ratings were based on performance in frontal and side crashes, as well as simulated pedestrian impact. Of all the minivans that were tested Chrysler fared the worst.

THE GLOBAL WELD QUALITY MANAGEMENT FIASCO:


Today, manual MIG weld repairs on top of robot MIG welds has become so common that many suppliers of auto / truck parts don't even class this added labor cost as a weld rejects or "weld rework".

The robot weld reality is the manual MIG weld repairs are rarely done correctly and adding weld metal on top of a robot weld with poor weld fusion still leaves that weld with poor weld fusion and the additional weld also weakens the high strength steels.

.
Daimler Chrysler: Manufacturing Management Issue.

Chrysler sues lawyers, or the wolves attack the wolves.
November 19, 1999
Chrysler is suing for the third time for punitive damages because they feel lawyers have made claims against the safety of Chrysler auto seats that has harmed the company's reputation.


Note: I wonder how you can have the data as indicated at this web site and stil have a reputation worth protecting?


Daimler Chrysler: Manufacturing Management Issue.

Model 2005 Chrysler Dodge. Jeep SUVs pick up and passenger cars
Vehicles affected 256,409.

Problem Vehicle could roll unexpectantly even when its in park, good luck if you live in San Francisco.

Note from frustrated: I own a 2000 Chrysler Concord: Like so many others, I've found out the hard way that Chrysler makes a substandard product. My well-maintained 2000 Concorde now needs a new engine to the tune of $5K. This follows a varied repair job from just weeks ago that cost in excess of $800. The engine has less than 75K miles on it! Meanwhile, our GMC and Nissan, both with almost 200K on the engines, just keep chugging along. It makes NO sense that a 15-year-old car and a 17-year-old car are BOTH more reliable than my barely 4-year-old Concorde. Chrysler shame on you.
Posted By: goingnowherefast on 7/31/2004 (TX)

Daimler Chrysler: Manufacturing Management Issue.
.
Model: 2000 Dodge Ram Truck Year: 2000

Defect: Due to a lack of management manufacturing expertise, the welds at the right side lower control arm bracket to axle tube attachment may have inadequate fatigue life due to poor weld quality. This can lead to separation of the control arm bracket from the axle tube. If the bracket separates the vehicle could experience reduced directional stability, braking degradation and / or the vehicle pull under braking.


THE AUTO / TRUCK INDUSTRY
& DOUBLE MFG. STANDARDS:

We have a double standard in the manufacturing trades in which we expect an electrician or a machinist to be a professional in their trade, however when it comes to welding we allow welders, technicians, maintenance personnel to "play around" with the welding controls. To make the situation worse many managers appear to have no expectations of weld process control expertise from the engineers or managers in the same plant. We have another common major double standard. In manufacturing plants when a part is being formed in a press it will typically have part tolerances which are a few thousands of an inch, however if the parts are to be welded the manufacturing engineers are generous and frequently allow the welded part to have gaps that a mouse could crawl through.

 

 

WHEN DID THE WORDS "PLAYING AROUND" BECOME PART
OF AN ENGINEERS OR MANAGERS WELDING LANGUAGE?

Before we allow those truck engineers to touch
the new robots we are going to cut out
their "play around" organs".

 

 



.
Daimler Chrysler: Manufacturing Management Issue
.


Models: 2002 Dodge Grand Caravan.
Chrysler Town and Country:
Number Potentially Involved: 116,029
Dates of Manufacture: September 2001 – March 2002
Defect: Due to a lack of management manufacturing expertise, on certain minivans, the fuel tank control valve weld joint could separate resulting in a possible fuel leak. Fuel leakage in the presence of an ignition source can result in a
fire.



HOW COMMON ARE MEANINGLESS MANUFACTURING AUTO WELD SPECS.

Monroe, a a major tier one, USA shock manufacturer could not get his robot welded shock brackets to qualify for a Big Three standard "weld bracket load test". The load test weld spec, required that the robot MIG bracket welds on the shocks absorb at least a 13,000 lb test load. After welding with a robot and using the high energy spray transfer mode, the bracket welds on the 2 to 3mm gage steel shocks would fail typically at 7000 to 9000 lbs. I was called in to rectify the issue.

 

What was ironic about this application was the big three weld spec for the parts required a minimum test load of 13,000 pounds on the bracket welds. On evaluating the welds, it took me two days of manual welding and testing the parts to reveal that any test load of less than 19,000 lbs indicated a lack of weld fusion in the shock bracket welds.

The reason the shock manufacturer could not meet the test load requirements was;

[1]
the robot "weld speeds were set too high" for the round cold rolled parts,

[2] t
he required brkt "weld lengths" were "too small".

Once the weld issues were understood,
[a] I changed the robot weld parameters,
[b] I slightly slowed the weld speed,
[c] i slightly increased the weld lengths,
the resulting welded brkts on the shock on average failed at 21,000 lbs. The decrease in the robot weld speed was compensated for when I increased the robot travel speed between the welds.

 

Daimler Chrysler: Manufacturing Management Issue.
.

Models 2000-2003 Dodge Durango - Dakota: Bowing to pressure from federal safety regulators, DaimlerChrysler is recalling 600,000 Dodge Durango SUVs and Dakota pickup trucks because of a defect that can cause their wheels to fall off. The recall affects vehicles from the 2000-2003 model years. The National Highway Traffic Safety Administration recommended the recall after a 16-month investigation revealed that the vehicles' upper ball joints could fail. If that happens, the suspension can collapse and a wheel can fall off.


DO YOU BELIEVE THAT WHEN WHEELS START FALLING OFF, THE COMPANY WHO MAKES THE VEHICALS SHOULD HAVE TO BE PRESSURED TO PERFORM A RECALL?

SO MANY SERIOUS AND COSTLY MANUFACTURING ISSUES.
[] WHERE IS THE MANAGEMENT ACCOUNTABILITY?
[] WHERE IS DESIGN FOLLOW THROUGH?
[] WHERE IS THE PRIDE OF THE ENGINEERING TEAM?
[] WHERE IS THE QUALITY PROGRAM?
[] WHERE ARE THE MANUFACTURING STANDARDS?
[] WHERE ARE THE
BEST PRACTICES AND PROCESS CONTROLS?
[] WHERE IS THE SHOP FLOOR PRIDE IN AMERICAN WORKMANSHIP?



     

 


Throughout the weld world, for every MIG welding robot that is not welding at peak performance, there are likely twenty Resistance welding robots spewing out sparks indicating welds out of control.

If anyone has an interst in learning about process issues that do not need to o
ccur, they would simply have have to visit an auto - truck stamping plant, or visit a robot weld or paint line.


 

 



Review the '2001 Chrysler Prowler
Story is condensed.
Written by Dan Carney.

The Chrysler Prowler represents a bizarre dichotomy: it is simultaneously one of the best and worst new cars on the road. The Prowler is an all-time champion for attracting positive attention, from men and women alike. The car has been out long enough that most people have an idea what it is (though some think it may be a Viper), but it remains a rare commodity. Women in other cars at traffic lights and walking down the sidewalk yell, "nice car," and ask for rides. I wish I could say this was the case in all of the other test cars I drive - or with me - but sadly, the phenomenon seems restricted to the Prowler and a very few other cars.


Men gather 'round at the gas station and ask about the engine, and how much the car costs. The delivery service driver who brought the car to me for review said driving it made her feel "like a movie star."The Prowler's rakish, chopped-and-channeled styling evokes a fedora tilted low over the wearer's eyes. Some think it looks like a gangster's car, others think it is a sports car. Everyone thinks it looks great. Simply the best? Surely, a car that can put a smile on so many people's faces must be the best new car on the road. If only it was true. In fact, there are two reasons why the Prowler is such a rare bird. The first is its limited production alongside the Viper at DaimlerChrysler's Connor Avenue plant. If pressed, they could probably crank the cars out a bit faster. But the factory isn't pressed, because the Prowler isn't a very good car by any functional measure.


The Prowler has easily the roughest, most uncomfortable ride of any new car sold in America, and that includes the Viper. But there is no handling benefit from the ride penalty, as there is with the Viper and other sports cars. Handling on smooth pavement is acceptable, but the car skitters over bumps. This is sadly ironic for a car that features race car-style pushrod front suspension.Cowl shake, the twisting of the body when the car runs over bumps, is a problem on all open cars, but it makes driving the Prowler quickly a virtual impossibility because the steering wheel moves in the driver's hands as the body flexes. The rear-view mirror is useless on all but the smoothest road, because it too, is in constant motion.

Less impressive were some of the visible welds on the car's aluminum components.
If the welds that you can see on the Prowler are bad, imagine what the welds look like what you don't see. Skilled execution of mechanical details make or break any hot-rod, and the sloppy welds on a couple spots on the Prowler would send a demanding owner (who else spends $45,000 on a toy car?) back to the d
ealer seeking replacement with a properly welded component.


It hurts to hammer Chrysler for the Prowler's defects, because the Prowler was almost as important as the Viper in establishing the company's credentials as the only manufacturer bold enough to take such chances. Until the Prowler, the Viper could be dismissed as a fluke. Prowler confirmed the pattern established by the Viper, and paved the way for high-volume vehicles like the PT Cruiser. So from a strategic standpoint the Prowler is a success. Its styling is almost flawless It attracts more attention and makes the driver feel more special than cars costing several times as much. It is a huge success on so many levels, its a shame the Prowler is a failure as a car.

 

 

 

Daimler Chrysler: Manufacturing Management Issue.

[] 2002 Chrysler Jeeps. Chrysler-Daimler recalls over a million jeeps, 2000 models and later. Potential engine fire hazard

[] 2001 Chrysler Mini Van. Fed Government (NHTSA) found that Chrysler Mini Van gas tanks leak upon test impact collisions; wants Chrysler to recall and fix / replace gas tanks. Chrysler has redesigned gas tanks on newer models, but refuses to recall older collision-leaky fuel tanks.

From Ed. Do the people who work at Chrysler today, at one time work for Ford? Am I supposed to ask my wife when in a collision to try to avoid getting hit in the fuel tank area.

[] 2001 Chrysler Mini Van. Chrysler is replacing the side sliding door locks of some of its recent Mini-vans -- seems they pop off complete upon site impact tests.

 

Made in America.

 

 

 

 

Daimler Chrysler: Manufacturing Management Issue.
.

SMALL TIME CROOKS MAKING
DECISIONS IN LARGE CORPORATIONS.

From http://www.autobuyology.org/car6.html

Chrysler Motors paid fines in New York State for reselling vehicles bought back from original owners and reselling them to second owners without disclosing the lemon status, prior use and condition of the vehicles. It did the same thing in Pennsylvania. Chrysler claimed these were "good faith" repurchases and therefore technically the vehicles were not lemons. Chrysler repeated this lemon laundering stunt in California where it faces similar charges, again involving hundreds of vehicle sales through its "licensed" or "authorized" dealers. · · Chrysler is currently being threatened with a sixty day (subsequently reduced to 45 days upon appeal) sales suspension in California for reselling lemons without proper labeling and disclosures. Unfortunately, Governor Wilson's Director of DMV wants to soften the proposed wrist slap against Chrysler, even though Chrysler previously laundered lemons in New York and Pennsylvania (and God only knows where-else?) prior to its California offenses or marketplace and consumer abuses. One might rightly wonder where else Chrysler or whether other auto manufacturers and dealers may have laundered or be laundering lemons? With the auto industry, what goes around, comes around, and around, and around, and around, and around. CARveat Emptor. · · Chrysler, you may remember was caught and dinged (wrist-slapped) previously for disconnecting odometers while its "executives" drove them around on personal errands and use, and sold the vehicles without disclosing the mileage tampering, as new cars. Slick customer service, eh. Out of sight, out of mind. Hey, it wasn't illegal was it? Apparently with Chrysler, little difference it would have made. · · The California DMV spanked Chrysler recently by revoking Chrysler's California driver's license to sell cars in California for 45 days as punishment for fender skirting the lemon laws and dinging customers by reselling lemons without proper disclosures. Chrysler denies the charges and promises to appeal the decision.



 


The manufacturing manger directed the HR person to look for a manufacturing engineer to work with the MIG welding robots. The HR requested that the engineer must have experience with some of the following.



HAVE YOU GOT EXPERIENCE WITH THE FOLLOWING?

Dynamic Control Plans.
TOPS.
DOE.
FMEA.
LEAN MANUFACTURING.
KAIZEN.
KANBAN.
MRP.
J.I.T.
T.Q.M.
SPC.
POKE.
YOKE.


During the interview no one asks the engineers or managers about their
WELD PROCESS CONTROLS - BEST WELD PRACTICE expertise for the robot weld lines.

 

 

 

 

Daimler Chrysler: Manufacturing Management Issue.

Ethics and Corporations.


Chrysler negligently waited until August 1999 to issue a recall for this potentially life threatening defect. Chrysler issued a reinforcement bracket assembly to keep vehicle subframes from cracking and causing potential loss of control.

Approximately 560,000 1993-1995 Chrysler (LH) Dodge Intrepid, Eagle Vision, Chrysler Concorde, New Yorker and LHS vehicles are affected by this defect. As usual, Chrysler downplayed the recall as "potential loss of power" being the result of the failure when actually it can cause a loss of vehicle control being that a Suspension control arm is connected to where the failure occurs. Luckily for this consumer, the failure occurred at slow speeds while in a parking lot. Note there was no bent metal other than from the failure. There is a small perpendicular crack in the middle where it started. The crack propagated over time (note the rust), and followed the massive weld around the outside. (sounds like too much weld heat weakening the HAZ) In this consumer's opinion the irregularity and size of that weld helped cause the problem. The consumer points out that additionally the material seems thin for its application. Consumers would like to know why Chrysler waited until August 1999 to determine this might be a safety problem, recall notification began in February 2000? It appears they were aware of the problem as they redesigned the components for 1994 vehicles. A structural fatigue problem like this is a serious safety problem. At freeway speeds the vehicle could have pulled hard left or right with loss of handling.




Dodge Intrepid:

Metal too weak, metal too thin, welds too large, poor design or weld defects?
Whatever it was it was. it was simply another poor management decision.

Please remember, ff you drive a Chrysler, do not go over bumps or rough terrain.,
and if you want to remain safe, the best place for your vehical is in your drive way.

 

 

E-Mail Feb 05/07

I worked as a technician at a local garage and one of the cars we worked on was a 93 Intrepid with the subframe cracking issue. As the owner described it, she went to the car in the morning, started it, and put it in reverse to back out of her driveway. There was a clunk, one side of the front end dropped, and the car wouldn't move. The control arm (and bracket) had torn away from the subframe and pulled the drive axle out of the transmission.

PE. PA.


 



Daimler Chrysler: Manufacturing Management Issue.
.

Chrysler 1998 Neon: Recalls on the '98 Neon included a fan relay in the engine's cooling system that may fail causing the engine to overheat; and a crossmember in the rear suspension should be inspected for missing

Read the brilliant decision by the Chrysler corporate management to recommend the world's worst weld consumables for coated steels, a decision that cost Chrysler corporation millions on weld rework / loss productivity on Neon cross members.

 

Daimler Chrysler: Manufacturing Management Issue.

2005 Chrysler 300 SRT8


Component: SEAT BELTS:REAR Potential Units

ON CERTAIN PASSENGER VEHICLES, A SPOT WELDING OPERATION FOR THE REAR FLOORPAN REINFORCEMENT MAY NOT HAVE BEEN PERFORMED. THIS COULD CAUSE THE REAR SEAT BELT ANCHORS AND / OR THE CHILD SEAT ANCHORS TO SEPARATE IN CERTAIN CRASH CONDITIONS, WHICH CAN INCREASE THE RISK OF INJURY TO REAR SEAT PASSENGERS.

 

 

 

Daimler Chrysler: Manufacturing Management Issue.

Recall Data From GE Insurance Solutions

[] DaimlerChrysler Cherokee Brake problems JAPAN 6/1993
[] DaimlerChrysler 11000 Cherokee Jeep Danger of overheating in catalytic converters U.S.A 6/1990
[] DaimlerChrysler 56000 Dodge Dakota Truck Failure to comply with US emission standards U.S.A 3/1991
[] DaimlerChrysler 1200 Jeep Excessive carbon monoxide emissions U.S.A 6/1993

[] DaimlerChrysler 1.6 m Jeep Grand Cherokees Vehicles roll backward when the transmission appear to be set in park U.S.A 11/2001
[] DaimlerChrysler 300,000 Jeep Wranglers Parking brakes may fail to keep the vehicles from rolling away U.S.A 11/2001

[] DaimlerChrysler 4,5m Minivans Defective lock on rear door U.S.A 0/1995
[] DaimlerChrysler 34400 Passenger cars Impaired fuel flow U.S.A 0/1984
[] DaimlerChrysler 106,000 Passenger cars Excessive exhaust emissions U.S.A 10/1990
[] DaimlerChrysler 19000 Passenger cars Defective steering linkage U.S.A 3/1992

Daimler Chrysler: Manufacturing Management Issue.
.
[] DaimlerChrysler 15000 Passenger cars Defective electrical cables U.S.A 3/1994
[] DaimlerChrysler Station wagon Check on back seats U.S.A 6/1990
[] DaimlerChrysler 600,000 Vehicles Failure to comply with US emission standards U.S.A 0/1989
[] DaimlerChrysler 57000 Vehicles Defective catalytic converter U.S.A 0/1990
[] DaimlerChrysler 3700 Cherokee Jeep Flaw in ABS braking system WORLD WIDE 10/1991


[] DaimlerChrysler 675,000 Minivan, Dodge Shadow, Plymouth Sundance (91/92 models) Material fatigue can lead to shearing of the steering wheel WORLD WIDE 1/1997
[] DaimlerChrysler 380,000 Passenger cars Replacement of carburetor components due to excessive emission of pollutants
WORLD WIDE 5/1990

[] DaimlerChrysler Passenger cars Faulty transmission gaskets WORLD WIDE 2/1991,
[] Daimler-Benz E-class Screw in the steering spindle coupling not tight enough Germany 9/1995
[] Daimler-Benz 100000 Passenger cars Defective trailer hitch Germany 11/1991
[] Daimler-Benz 60000 C-, E-, S-class Defective parking brake release EUROPE 12/1995

Daimler Chrysler: Manufacturing Management Issue.
.

[] Daimler-Benz 19300 Passenger cars Damage to airbag system JAPAN 5/1995
[] Daimler-Benz 96000 Mercedes 190 Faulty lock-release button on handbrake U.S.A 10/1991
[] Daimler-Benz 1500 Passenger cars Replacement of plastic component in air conditioner U.S.A 0/1990
[] Daimler-Benz 128000 Passenger cars Check on accelerator pedal U.S.A 7/1993
[] Daimler-Benz 545000 C-class Defective bonnet catch WORLD WIDE 0/1996
[] Daimler-Benz 86000 Mercedes 190, 190D, 190E Defective electrical insulation of cruise control
WORLD WIDE 0/1987.
[] Daimler-Benz 5500 Mercedes SL Check on roll-bar switch WORLD WIDE 6/1990
[] DaimlerChrysler 55000 Mercedes Benz A Class Possible brake system defect Germany 2/2001


Daimler Chrysler: Manufacturing Management Issue.

[] DaimlerChrysler 11000 Mercedes E class Oil leakage may cause a fire in the exhaust pipe JAPAN 7/2000
[] DaimlerChrysler 1230 Mercedes V280 Defective ignition switch may cause short circuit resulting in fire JAPAN 8/2000
[] DaimlerChrysler 350 Neon Malfunction in air intake controls within engine parts JAPAN 11/2000
[] DaimlerChrysler 88000. 1996 Chrysler Sebring The throttle control cable can fray causing the throttle to bind or stick U.S.A 7/2002
[] DaimlerChrysler 545311. 1997 Town and Country, Caravan, Voyager The rear seat belt may become inoperative. U.S.A 4/2002
[] DaimlerChrysler 77000. 2001 Chrysler PT Cruiser The restraint system fails to comply with standards for children U.S.A 7/2002

Daimler Chrysler: Manufacturing Management Issue.
.
[] DaimlerChrysler 268740. 2001 Dodge Truck Ram The alternator wire connection to the power distribution center can loosen, causing a vehicle fire U.S.A 2/2002
[] DaimlerChrysler 95000. 2001 Jeep Wrangler Water and impurities can enter into the ignition switch causing a short circuit U.S.A 4/2002

[] DaimlerChrysler 43000. 2002 Jeep Grand Cherokees and Chrysler PT Cruisers Computer software problem causes gauges and lights on the instrument panel to shut down U.S.A 12/2001
[] DaimlerChrysler 4000 AMC Jeep Screw in steering mechanism improperly tightened U.S.A 0/1984
[] DaimlerChrysler 51000 AMC Jeep, Ranger Defective handbrake, accelerator pedal and fuel line U.S.A 3/1987

Daimler Chrysler: Manufacturing Management Issue.

[] DaimlerChrysler 17000 Chrysler Cirrus, Dodge Stratus, Plymouth Breeze Childproof locks are improperly labelled U.S.A 3/2000
[] DaimlerChrysler 417000 Chrysler Cirrus, Dodge Stratus, Plymouth Breeze Brake tube could cause a fluid leak and the loss of brake capacity by contact with a clamp U.S.A 10/1999
[] DaimlerChrysler 3400 Chrysler Cirrus, Dodge Stratus, Plymouth Breeze Inadequate weld between the right front brake hose block and the standoff bracket may result in a half system brake loss U.S.A 7/2000
[] DaimlerChrysler 7600 Chrysler Concorde, Chrysler 300M, Chrysler LHS, Dodge Intrepid Seat belt retractor is not fully fail-safe U.S.A 2/2000
[] DaimlerChrysler 63300 Chrysler Neon, Dodge Neon Because of freezing condensation water throttle may work improperly U.S.A 7/2000

 

 

Daimler Chrysler: Manufacturing Management Issue.
.
[] DaimlerChrysler 91000 Cirrus, Dodge Stratus Faulty anchoring system on rear seat belts U.S.A 0/1996
[] DaimlerChrysler 600 Concorde, Dodge Intrepid Defect brake master cylinder U.S.A 7/2000
[] DaimlerChrysler 40000 Dakotas Left front brake tube and power steering hose are rubbing against one another and developing leaks U.S.A 9/2000
[] DaimlerChrysler 997000 Dodge Caravan, Plymouth Voyager, Chrysler Town Country Short circuit in wiring of airbag system possible U.S.A 8/1999
[] DaimlerChrysler 743000 Dodge Caravan, Plymouth Voyager, Chrysler Town Country Defective fuel pump U.S.A 8/1999
[] DaimlerChrysler 20000 Dodge Dakota Automatic transmission may expel fluid from the fill tube and cause a fire U.S.A 7/2000

Daimler Chrysler: Manufacturing Management Issue.

[] DaimlerChrysler 437000 Dodge Dakota Inadequate clearance between the rear axle vent hose and the brake hose can cause an abrasion of the rear brake hose, resulting in a leak and a loss of braking force U.S.A 7/2000
[] DaimlerChrysler 92000 Dodge Dakota Inadequate clearance between the fuel line and the cab under-body could cause a perforation in the fuel line, resulting in leakage U.S.A 8/2000
[] DaimlerChrysler 216100 Dodge Dakotas and Durangos, Dodge Rams A problem in the steering wheel could disable the driver-side air bag U.S.A 11/2001
[] DaimlerChrysler 150000 Dodge Durango Fuel tank mounting may loose U.S.A 1/2000
[] DaimlerChrysler 99000 Dodge Durango Defective rear brake tube U.S.A 1/2000
[] DaimlerChrysler 350 Dodge Intrepid, Chrysler 300M, Chrysler Concorde, Jeep Grand Cherokee Problems with passenger airbag U.S.A 1/2000

Daimler Chrysler: Manufacturing Management Issue.
.
[] DaimlerChrysler 204000 Dodge Intrepid, Chrysler Concorde, Chrysler 300M, Chrysler LHS, Jeep Grand Cherokee Improperly installed top mounting bolt on seat belt system may not hold in an accident U.S.A 2/2000
[] DaimlerChrysler 1500 Dodge Neon Label on tires specifies the wrong recommended size U.S.A 11/2000
[] DaimlerChrysler 2400 Dodge Ram Rear axle can be displaced causing a loss of vehicle control U.S.A 1/2001
[] DaimlerChrysler 2000 Dodge Ram Defective front brake hose assembly has to be replaced U.S.A 2/2001
[] DaimlerChrysler 700000 Dodge Ram Because of salt water a spring on a hood latch can corrode and cause the hood to fly up unexpectedly U.S.A 4/2001
[] DaimlerChrysler 76 Dodge Ram Truck Front axle needs replacing U.S.A 1/2000
[] DaimlerChrysler 690000 Dodge Ram Truck Ignition switch may overheat U.S.A 5/2000
[] DaimlerChrysler 400 Dodge Stratus, Chrysler Sebring Because of a defect the air bag door could separate and cause injuries U.S.A 10/2000
[] DaimlerChrysler 620 Dodge Viper Problems with five point seat belts for racing use U.S.A 3/2001
[] DaimlerChrysler 140 Doge Neon Incorrect tire placard U.S.A 2/2001
[] DaimlerChrysler 133000 Freightliner Dump trucks Possible break failure U.S.A 11/2000
[] DaimlerChrysler 685000 ia Chrysler Cirrus Problems with automatic transmission U.S.A 10/1998
[] DaimlerChrysler 474000 Jeep Cherokee Airbag control can corrode from contact with salt water U.S.A 5/2000

Daimler Chrysler: Manufacturing Management Issue.

[] DaimlerChrysler 638000 Jeep Cherokee, Grand Cherokee Salt water may impair brake effectiveness U.S.A 5/2000
[] DaimlerChrysler 1000 Jeep Grand Cherokee Faulty steering gear U.S.A 11/1999
[] DaimlerChrysler 1500 Jeep Grand Cherokee Inadequate vent tube welds may result in a separation and causing a fuel leak U.S.A 7/2000
[] DaimlerChrysler 38700 Jeep Grand Cherokee The onboard vapor recovery system vent hose may have been misrouted U.S.A 1/2001
[] DaimlerChrysler 72000 Jeep Liberty Knee blocker trim panel assembly can disengage, increasing the risk of a crash U.S.A 1/2002
[] DaimlerChrysler 1,4m Large-capacity coach cars Problems with windscreen wipers U.S.A 8/1999
[] DaimlerChrysler 16000 Mercedes Benz E Class Defects in the driver and front passenger side air bag U.S.A 1/2001

Daimler Chrysler: Manufacturing Management Issue.

[] DaimlerChrysler 3400 Mercedes Benz S Class, CL Class Sheathing material on the electrical connection of the heated windshield washer bottle hose could melt and cause the surrounding plastic and insulation to melt U.S.A 1/2001
[] DaimlerChrysler 65,731 Mercedes C class Batteries must be replaced U.S.A 12/2001
[] DaimlerChrysler 86000 Mercedes M class Seat belt buckles may unlatch U.S.A 11/1999
[] DaimlerChrysler 4400 Mercedes S class Airbag may inadvertently be deployed U.S.A 11/1999
[] DaimlerChrysler 52649 Mini Van Indication does not comply with standards U.S.A 1/2002
[] DaimlerChrysler 254000 Passenger cars Problems with brakes U.S.A 2/1998
[] DaimlerChrysler 3700 Plymouth Prowler Defective dashboarding warning light for the brakesystem U.S.A 10/1999
[] DaimlerChrysler 500 Plymouth Prowler Aluminium castings used in the frame do not comply with stability requirements U.S.A 1/1999
[] DaimlerChrysler 1.2 m Several models Owner?s manual might be missing instructions on attaching a child restraint system U.S.A 2/2001
[] DaimlerChrysler 46000. 2002 Dodge Ram The brake line could separate from the caliper U.S.A 6/2002
[] DaimlerChrysler 27863. 2000 SKL The owners manual does not meet safety standards U.S.A 6/2002

 

 

 


Daimler Chrysler: Manufacturing Management Issue.
.
[] DaimlerChrysler 26740. 2001 Dodge Ram The alternator wire connection to the power distribution center (PDC) can loosen, resulting a vehicle fire U.S.A 4/2002
[] DaimlerChrysler 268740. 2001 Dodge Ram The alternator wire connection to the power distribution center (PDC) can loosen, resulting a vehicle fire U.S.A 5/2002
[] DaimlerChrysler 116029. 2002 Town and Country Grand Caravan The fuel tank control valve weld joint could separate resulting in a possible fuel leak U.S.A 10/2002
[] DaimlerChrysler 97779. 2001 Chrysler PT Cruiser Potential for fuel leakage U.S.A 10/2002
[] DaimlerChrysler 3640. 2003 Dodge Dakota & Durango The low beam may become inoperative U.S.A 12/2002

Daimler Chrysler: Manufacturing Management Issue.
[] DaimlerChrysler 1066000 Concorde, Intrepid, LHS, 300M (1998-2001/2) On certain vehicles, seat back recliner bolt breakage can occur resulting in the seat back, reclining unexpectedly U.S.A 2/2003
[] DaimlerChrysler Pacifica The powertrain control module software may allow the engine to stall when it is warming up U.S.A 3/2004
DaimlerChrysler 10000 Several minivans Bolt on the lower control arm of the front suspension can break, resulting in a loss of control USA / Canada 4/2001
[] DaimlerChrysler 76000 Jeep Grand Cherokees Problem with the vehicles onboard refueling vapor recovery system USA / Canada / Mexico 1/2002
[] DaimlerChrysler 10000 Mercedes CLK-Cabrio Safety belts need to be reinforced USA / Japan / Germany 2/1999
[] Dodge 7500 Pickup trucks Defective main brake cylinder U.S.A 0/1984
[] Dodge 35.692 Model Caravan, Grand Caravan, Dakota Do not comply with safety standard U.S.A 12/2003

2005 IS WHAT YOU READ HERE A SIGN OF COST EFFECTIVE MANAGEMENT? THINK ABOUT IT. FOR DECADES, SO MUCH ENERGY HAS BEEN SPENT ON SAVING A NICKLE ON QUALITY / SAFETY SHORT CUTS, WHILE AT THE SAME TIME HUNDREDS OF BILLIONS HAVE BEEN SPENT ON LAW SUITS, PRODUCT RECALLS AND WARRANTY ISSUES. HOW CAN ANY EDUCATED MANAGEMENT GO ALONG WITH THIS CRAZY SITUATION?

 

Is this sane management logic? To achieve partially acceptable robot welds, many auto / truck companies would place a "mechanical or electrical engineer in charge of the welding robot weld line and make him the "Weld Team Leader". The same on the ball management would then place a skilled welder in the cell to operate a robot that provides the skills. Also to ensure consistent weld quality, personnel who have no process control expertise like maintainence electricians, millwrights are daily allowed to make unqualified robot weld changes to so called pre-qualified welds.


 

General Motors Announces Massive
Recall. Posted: April 2009.


As GM executives recieve instrutions from the US goverment on how to run their company and consider the implications on declaring bankrupcy, their manufacturing management and engineers should consider their influence on the GM bottom line.

GM is recalling almost 1.5 million cars because of possible engine fires. They were all made between 1997 and 2003. Included in the recall are the following cars:

Olds Intrigue
Pontiac Grand Prix
Buick Regal
Chevrolet Lumina
Monte Carlo
Impala

All owners and dealers should be getting a letter in the mail, concerning the recall, sometime next month, meanwhile Ed recommends they keep a fire extinguisher close by.

 


GM: Manufacturing Management Issue
.

1997 GM Pontiac Sunfire:
Recall Date:02/25/1998.

These vehicles were built with mis-located welds at the joint between the left rocker panel inner reinforcement and the body side ring. This does not meet the requirements of FMVSS no. 214, "side door strength. In the event of a vehicle crash, the sheet metal structure would not perform as desired increasing the risk of personal injury.

Note from Ed: From a logic perspective this type of recall should also apply to undersized welds and also welds with excess porosity. You will find that most vehicles have too many defective welds or defective robot welds with apathetic manual weld repairs.

GM: Manufacturing Management Issue.

2006 Chevrolet is recalling 2,000 2006 Impalas with manual passenger-seat adjuster because the adjuster mounting-bracket weld is located incorrectly. No best weld practices and no weld inspection?


EVEN WHEN GM MANUFACTURING MANAGEMENT BUILDS A SPECIAL PLANT TO BUILD SPECIAL SATURN CARS THAT ARE NOT SUPPOSED TO BE TAINTED WITH THE DETROIT MANUFACTURING MANAGEMENT AND UNION CULTURE, WHEN IT COMES TO WELDING THE SATURN MANAGEMENT STILL CANNOT GET IT RIGHT.



GM: Manufacturing Management Issue.

[] 1996-2002 Saturn Sedan / Wagon Reliability.
[] 1996 SW1/SW2: Welds between roof and reinforcement panels do not meet specifications; flange sides could partially separate in a crash.
[] 2000: Some rear-bumper fasteners could be loose or missing; rear bumper may not absorb energy as designed, in a rear-end collision.

 

 


2005: While total global auto / truck recall / warranty costs must be over 10 billion dollars annually and the auto industry must spend at least 250 million dollars annually on trades training, most of the training programs end up being a waste of time and money, the reason why.

With most automotive companies, the prime manufacturing or process issues that result in the plants are caused by factors outside the worker's control and few manufacturing managers have the ability to pin point the root cause of their manufacturing issues and identify the training programs that will enable effective process controls.


 


GM: Manufacturing Management Issue.

[] 2000 Saturn: Some welds in instrument-panel carrier assembly were not strong enough; occupant, especially if unbelted, may have increased risk of injury in frontal crash.

[] Saturn 1200 Passenger cars. Loose mounting of seats U.S.A

[] Saturn 1800 Passanger cars Defective cooling system. This recall was interesting in that, instead of taking the usual approach of replacing or repairing the defective component, the manufacturer provided customers with new cars. U.S.A

[] Saturn 239.993 L-Series 2000-03 A failure of ignition control module may cause deterioration in idle quality and the vehicle may be hard to start U.S.A

 


HOW DO YOUR ENGINEERS RESPOND TO ROBOT OR AUTOMATION ISSUES?


The MIG / MAG welding robot is a multi-axis, computerized controlled machine that manipulates a weld gun with a preset welding program.

In the big three and tier plants, it's not unusual to find dozens of highly paid engineers dispersed throughout the plants, yet when the robot line goes down and the auto or truck production comes to a grinding halt, many engineers will do the only thing they know and reach for their cell phones or two way radios while they try to find a lower paid robot technician to resolve the robot / weld line issue that's influencing the plants production.

ENGINEERING DEFINED BY WEBSTER'S DICTIONARY.

The "application" of scientific principles to "practical ends." It's a pity today that with arc welding robots, we see few engineers applying the "application of scientific principles to practical ends". We do see them applying their mouths to a cell phone.




GM: Manufacturing Management Issue
.

[] 2002 Saturn sedan: Welds between the door-striker and beltline do meet specifications. The seatbelt anchorage on the pillar could fail, increasing the risk of injury.

[] 2001: An inadequate weld at the top of the fuel tank could allow fuel leakage in a rollover.

[] 2002 Saturn sedan: Welds between the door-striker and beltline do meet specifications. The seatbelt anchorage on the pillar could fail, increasing the risk of injury.

[] 2004 Saturn is recalling 250,000 SUV VUEs. Something about rear-end problems. May involve significant issues involving wheels coming off while cornering. NHTSA recently experienced catastrophic wheel failure when testing this vehicles for roll-over potential.

 


GM: Manufacturing Management Issue
.

[] 1999. General Motors recalls 3.5 million automobiles (SUVs, Vans & Trucks), finally, due to faulty ABS (Anti-locking Breaking Systems). PS, General Motors has been plagued with complaints for years about problems with its ABSs... blaming the problem on inexperienced consumers and drivers.


[]
GM recalls 2004 Buick Rendezvous and Pontiac Aztek models due to defective fuel tank welds.

[] GM 1997 Make:Pontiac Model:Sunfire Recall Date:02/25/1998. These vehicles were built with mis-located welds at the joint between the left rocker panel inner reinforcement and the body side ring. This does not meet the requirements of FMVSS no. 214, "side door strength. In the evnt of a vehicle crash, the sheet metal structure would not perform as desired increasing the risk of personal injury.

 


GM: Manufacturing Management Issue.

Recall Data From GE Insurance Solutions.

[] General Motors 1.9 m Chevrolet, Pontiac Possible steering column problem Undefined 4/2002
[] General Motors 130000 Saab 9-5 Problems with electronic UNKNOWN 10/2000
[] General Motors 3000 Opel Astra Seat may detach itself from the position it is retained in U.K. 7/2000
[] General Motors 760000 Opel Vectra Problems with handbrake Germany 2/1998
[] General Motors 6400 Saab 9000 building series Faulty airbag electronics Germany 6/1999
[] General Motors 160000 Opel Astra Steering column needs checking EUROPE 11/1998
[] General Motors 900 Corvette Problems with seatbelts JAPAN 2/2001
[] General Motors 2000 Opel Astra, Astra Wagon, Astra Cabrio Defective brakes JAPAN 6/2000
[] General Motors 2300 Saab 9-5, 9-5 Aero, 9-3, 9-3 Viggen Defective motor JAPAN 7/2000
[] General Motors 2701 2003 Pontiac Vibe Potential loose bolts in the rear axle and brake U.S.A 4/2002
[] General Motors 18700 Buick Century, Buick Regal, Chevrolet Lumina Rear brake drum suspension could move, causing the vehicle to lose control U.S.A 5/2000

GM: Manufacturing Management Issue.

[] General Motors 35000 Buick Park Avenue Because of failure in wiper system microprocessor low-speed and high-speed may not work U.S.A 10/2000
[] General Motors 268000 Buick Regal, Oldsmobile Cutlass Supreme Corrosion of the air bag inflator?s internal wiring could cause an inadvertent deployment of the driver?s air bag U.S.A 8/2000
[] General Motors 150000 Buick Roadmaster, Chevrolet, Caprice, Cadillac Fleetwood Loosening of fuel tank U.S.A 12/1994
[] General Motors 470000 Cadillac Failure to comply with US emission standards in addition to the recall costs, GM was fined USD 11 million U.S.A 0/1995
[] General Motors 4800 Cadillac Fail to comply with requirements regarding tire selection and rims U.S.A 2/2001
[] General Motors 224000 Cadillac De Ville Side-impact airbag can deploy without a collision U.S.A 10/2000
[] General Motors 203000 Cars and trucks Problems with accelerator pedal U.S.A 0/1988
[] General Motors 78500 Chevrolet Corvette Defective seat belt U.S.A 4/2000
[] General Motors 118700 Chevrolet Express, GMC Savanna Fuel tank valve may stick open and cause fire U.S.A 5/2000
[] General Motors 10500 Chevrolet Expresses, GMC Savanna Power steering cooler hose may become detached and spray fluid on hot engine, causing a fire U.S.A 3/2000

 

2000: One of Ed's GM Applications:

.
The company was GM, the plant was located in Ohio. The job was simple, optimize a new multi-million dollar production line set up to automatically weld torque converters.

The problems generated,

[a] A two to four percent daily leak was generated from the MIG welds.

[b] Excess weld heat from the multi-MIG gun operation caused distortion / production assembly issues.


Four days into my visit I reduced the reject figure to zero and I eliminated the weld heat problems, as an
additional bonus I gave GM 20% more production. Not one GM manager in the plant took an interest in the welding results I provided for this eight million dollar production line.

What I found also foound interesting about this costly, high volume installation was the two weld production lines used six Lincoln Power Wave Pulsed power sources. The lines were not yet in the production mode, yet the plant engineers informed me that four of the six pulsed power sources had already been replaced. To optimize this line I switched the pulsed mode off and welded with a different wire size and spray transfer. GM could have paid 70% less for its welding equipment and purchased the Lincoln CV 400 amp units and had superior weld quality with the weld equipment problems, but lets face it, first the GM management would have to show an interest in welding.

GM: Manufacturing Management Issue.

[] General Motors 650000 Chevrolet Lumina, Buick Regal, Oldsmobile Cutlass, Pontiac Grand Prix Salt corrosion may loosen engine mounting bolts U.S.A 7/2000
[] General Motors 580 Chevrolet Monte Carlo, Chevrolet Impala Air bag sensing and diagnostic module could experience a memory error resulting in the air bag not deploying in a crash situation U.S.A 8/2000
[] General Motors 300 Chevrolet S10 Brake effectiveness may be impaired by corroded brake tube U.S.A 6/2000
[] General Motors 10700 Chevrolet S10, GMC Sonoma, Chevy Silverado, GMC Sierra Problem with anti-lock braking system U.S.A 2/2000
[] General Motors 1.4m Chevrolet Silverado, Chevrolet Tahoe, Chevrolet Suburban, GMC Yukon/XL, GMC Sierra Potential problems with a brake system component could result in a loss of brake fluid and pressure, making braking distance longer U.S.A 1/2001

GM: Manufacturing Management Issue.

[] General Motors 35000 Chevrolet Tahoe and Suburban, GMC Yukon Loose or missing rear wheelhouse plugs, exhaust gas can accumulate in wheelhouse and flow in passengers compartment, cause possible illness or death U.S.A 10/2000
[] General Motors 280000 Chevrolet Tahoes, GMC Yukons, Cadillac Escalades Defective airbags U.S.A 7/2000
[] General Motors 6000 Chevrolet Trailblazer, Envoy, Oldsmobile Bravada. Defective suspension part could fail and lead to a crash, U.S.A 4/2001
[] General Motors 34000 Chevrolet, Cavalier, Pontiac Sunfire Defective steering mechanism U.S.A 3/1995
[] General Motors 150000 Chevrolet, Chevette, PontiacT-1000 Defective crankshaft U.S.A 0/1986
[] General Motors 1400 Chevrolet, GMC Pressure relief valves may not seal, exhaust fume could enter into passenger cab and cause possible illness or death U.S.A 1/2001
[] General Motors 75816 Chevrolet, Pontiac Aztec &Montana Bench seats or captain's chairs fail to conform to the safety standard U.S.A 2/2002
[] General Motors 550000 Chevrolte Venture, Pontiac Tran Sport/Montana, Oldsmobile Faulty automatic sliding door could come open under special circumst
ances U.S.A 4/2001

 

An annual defence fund of 400 billion.
Some soliders call the Humvees, "Paper Coffins"

 


GM: Manufacturing Management Issue.

[] General Motors 111000 Chevy Blazer, CMC Jimmy Sports utility units suffered fuel leaks U.S.A 6/1995
[] General Motors 120000 Chevy S 10 Defective fuel line U.S.A 2/1994
[] General Motors 156000 Diverse models Seat belt buckle assembly does not comply with US standards U.S.A 8/2000
[] General Motors 65000 Diverse Saturn models Improper transaxle par lock cable assembly U.S.A 10/2000
[] General Motors 6000 Diverse Saturn models Inadequate weld of the vent valve on the top position of the fuel tank U.S.A 10/2000
[] General Motors 216100 Dodge Dakotas and Durangos A problem in the steering wheel could disable the driver-side air bag U.S.A 11/2001
[] General Motors 215000 Geo Storm Danger of steering wheel breakage in frontal collisions U.S.A 8/1992
[] General Motors 223000 GMC Sonoma, Chevrolet S10, Oldsmobile Bravada Payload shown on the label is greater than the maximum validated payload U.S.A 9/2000

GM: Manufacturing Management Issue.

[] General Motors 62000 Grand AM Danger of fuel line becoming brittle U.S.A 0/1990
[] General Motors 1m ia Chevrolet Cavalier, Pontiac Surefire Airbag may inadvertently be deployed U.S.A 12/1998
[] General Motors 400000 ia Chevrolet, Lumina, Buick Regal Emissions do not comply with US standards U.S.A 10/1998
[] General Motors 71677 Jeep Grand Cherokee Do not comply with safety standards U.S.A 3/2002
[] General Motors 204000 Light vans Defective seat belts U.S.A 4/1994
[] General Motors 678000 Minivans Defective front seats U.S.A 12/1993
[] General Motors 250000 Oldsmobil, Chevrolet, Buick Defective seat-belt system U.S.A 8/1992
[] General Motors 1,5m Oldsmobil, Pontiac, Buick Defective engine U.S.A 1/1992
[] General Motors 487400 Oldsmobile Aleros, Pontiac Grand Ams Control panel cover does not stay closed in a crash U.S.A 5/2000
[] General Motors 135000 Oldsmobile Intrigue Problems with rear seat belt U.S.A 2/2000

GM: Manufacturing Management Issue.

[] General Motors 77000 Passanger and vans Problems with seat belts U.S.A 0/1984
[] General Motors 3.4m Passanger cars Defective rear axle U.S.A 0/1984
[] General Motors 186000 Passanger cars Failure to comply with US emission standards U.S.A 0/1984
[] General Motors 750000 Passanger cars Defective catalytic converter U.S.A 0/1984
[] General Motors 225000 Passanger cars Defective catalytic converter U.S.A 1/1985
[] General Motors 500000 Passenger cars Failure to comply with US emission standards U.S.A 0/1988
[] General Motors 3200 Passenger cars Loosening of fuel return line U.S.A 0/1990
[] General Motors 460000 Passenger cars Questionable reliability of seat belts U.S.A 3/1991
[] General Motors 418000 Passenger cars Defective ignition coil U.S.A 4/1991
[] General Motors 24000 Passenger cars Failure to comply with US emission standards U.S.A 7/1992
[] General Motors 1,1m Passenger cars (83/84 models) Defective seat mounts U.S.A 0/1987
[] General Motors 307000 Passenger cars and light vans Defective brakes U.S.A 12/1994
[] General Motors 160000 Passenger cars and trucks Flaws in fuel tank protection and fuel gauge cable U.S.A 3/1987
[] General Motors 76000 Pickup trucks Defective brake pedal U.S.A 11/1993

GM: Manufacturing Management Issue.

[] General Motors 79000 Pickup trucks Danger of rolling when parked U.S.A 12/1994
[] General Motors 778000 Pontiac Grand Am, Buick Skylark, Oldsmobile Achieva Fire could occur in the steering system when key is been hold in the start position for an extended period of time, resulting in current flows and heat in the ignition switch U.S.A 3/2001
[] General Motors 814 Pontiac Montana The driver's air bag inflator modules could produce excessive internal pressure U.S.A 3/2002
[] General Motors 1200 Saturn Improper mounting of front seats U.S.A 3/1991
[] General Motors Saturn Danger of fire due to defective cables U.S.A 8/1993
[] General Motors 36800 Saturn L series Fuel tank relief valve may be exposed after an accident
and cause fire
U.S.A 1/2000
[] General Motors 1600 Saturn L-Series-Series Transaxle shift cable clip is missing or improperly seated U.S.A 10/2000
[] General Motors 15000 School buses Loosening of screws on brake drums U.S.A 4/1991
[] General Motors 14000 Sonoma, Chevrolet Blazer, Chevrolet S10 Daytime running light does not comply with US standards U.S.A 8/2000
[] General Motors 54000 Trucks Defective brakes U.S.A 0/1988
[] General Motors 30700 Trucks and school buses Defective fuel line U.S.A 9/1990
[] General Motors 300000 Vans Defective brakes U.S.A 11/1993
[] General Motors 16800 Vehicles Defective fuel system U.S.A 0/1989

GM: Manufacturing Management Issue.

[] General Motors 60044 Trailblazer, Envoy, Bravada A fuel filter fitting can become disconnected. U.S.A 5/2002
[] General Motors 2000 Cadillac DeVille The seat belt may not remain locked as designed during a crash U.S.A 9/2002
[] General Motors 72135 1994 Saturn Z Potential problem with the passenger seat U.S.A 11/2002
[] General Motors 1448 2003 Hummer H2 & Saturn L Windshield wiper problems U.S.A 12/2002
[] General Motors 72.135 1994-95 Saturn L Problems with the seat U.S.A 1/2003
[] General Motors 2600 Explorer, Chevrolet Astro, 1998 The light wires can overheat to the point where they may melt the running board U.S.A 2/2003
[] General Motors 18327 2003 Chevrolet Express On certain vans, during a crash the front safety belt buckles may not release U.S.A 3/2003
[] General Motors 312715 1997 Blazer, Jimmy, Bravada Problems with the seat belts U.S.A 4/2003
[] General Motors 239,993 Saturn L 2000-3 Problems with the engine U.S.A 8/2003
[] General Motors 102.212 Cadillac Deville & Seville, Aurora, Pontiac Bonneville; all: years 2002-3 The fuel tank pressure sensors are unusually susceptible to malfunctions U.S.A 9/2003
[] General Motors 66.299 Pontiac, Cadillac Do not comply with the safety standards U.S.A 11/2003


GM: Manufacturing Management Issue.

[] General Motors 95.690 Buick Park Avenue 1998-99 Fuel leak U.S.A 1/2004
[] General Motors 127.285 Saturn Ion 2003-4 Defective fuel filter U.S.A 3/2004
[] General Motors 183.922 Chevrolet Blazer/S-10, GMC Jimmy, GMC Sonoma. All: 2003-04 Do not comply with safety standards U.S.A 3/2004
[] General Motors 10000 Chevrolet, GMC Jimmy Payload shown on the label is greater than the trucks rated for CANADA 12/2000
[] General Motors 8100 ia Buick LeSabre, Park Avenue and Oldsmobile Intrigue Untight ABS hydraulics CANADA 4/2000
[] General Motors 15000 Holden VT and VS Commodore Fuel lines may leak AUSTRALIA 11/2000
[] General Motors 616000 Passenger cars Defective seat belts WORLD WIDE 9/1990
[] General Motors 520000 Passenger cars Defective electric switch WORLD WIDE 12/1990
[] General Motors 40000 Pontiac Firebird, Chevrolet Camaro Defective fuel line WORLD WIDE 9/1990
[] General Motors 293000 Pontiac, Olds-mobil, Buick, LeSabre Danger of fire WORLD WIDE 0/1996
[] General Motors 18400 Saab 9-3 Problems with retention of front seats WORLD WIDE 9/1999
[] General Motors 1159156 Cavalier, Lumina, APV, Venture, Silhouette bearing retaining tabs were not crimped properly WORLD WIDE 11/2002
[] General Motors 1.3m Opel Corsa, Opel Tigra Faulty buckle of the front seat-belt system Brazil / Ecuador / Europe 10/2000
[] General Motors 81000 Buick Park Avenue Defective seat belt USA / Canada 4/2000
[] General Motors 525254 2000 Chevrolet, GMC Yukon/Sierra Air bag sensing diagnostic module (SDM) contains an anomaly USA / Canada 8/2002
[] General Motors Chevrolet Malibu 2004 Do not comply with safety standard USA / Canada 1/2004
[] General Motors 900000 Opel Tigra, Corsa B Defective seat rails and seat belts Various countries 2/2001
GM 1707825 Alero, Express, Envoy, Savana Labelling does not comply with the safety standard U.S.A 7/2003

GM: Manufacturing Management Issue.

[] 1995 GMC JIMMY Recall Date: 1996: GASOLINE:STORAGE:TANK ASSEMBLY Estimated Vehicles Affected: 432183 1995 VEHICLE DESCRIPTION: 4-DOOR, 4-WHEEL DRIVE AND ALL-WHEEL DRIVE MULTI-PURPOSE PASSENGER VEHICLES. DURING DEVELOPMENT TESTING, THE PROP SHAFT CONTACTED THE INBOARD SIDE OF THE FUEL TANK ALLOWING FUEL LEAKAGE. THIS LEAKAGE WAS IN EXCESS OF THE AMOUNT PERMITTED BY FMVSS 301, "FUEL SYSTEM INTEGRITY."
IF AN IGNITION SOURCE IS PRESENT, AND THERE IS A FUEL LEAK, A FIRE COULD OCCUR.



2005: Note from Ed. A child could read these two sections and come to the conclusion that auto companies would do well to invest a few dollars and place a plastic container inside the fuel tank. I don't see engineering responsibility here, I do see engineering negligence and with all the deaths involved, any civilized person would call this a crime.

 

WHAT IS THE POLITICALLY CORRECT
TERM FOR BAD WELDS?


BE CONCERNED IF YOU CANNOT DRIVE IN A STRAIGHT LINE WITH YOUR LAND ROVER


VIN: LN600471 TO LN 622408
Build Date: 1 June 1997 to 1 June 1998
Numbers: 10477


Land Rover : Manufacturing Management Issue.

Defect: Land Rover has identified a "Weld Integrity Concern" associated with the rear suspension links on Freelander models. Should the weld fracture, the stability of the rear hub assembly could be impaired. This may cause the vehicle to deviate from a straight line under normal driving conditions. To protect the long term integrity of these components, Land Rover are implementing recall action.

Note from Ed. In England a Weld Management Screw Up is called a POLITICALLY CORRECT "Weld Integrity Concern"

Land Rover : Manufacturing Management Issue.

Land Rover: Recall 2004:ON CERTAIN SPORT UTILITY VEHICLES, AN INCORRECT WELD NUT WAS INSTALLED. LACK OF THIS BOLT COULD EVENTUALLY CAUSE THE SUBFRAME TO CRACK OR BECOME DEFORMED WHICH COULD POTENTIALLY LEAD TO INSTABILITY OF THE VEHICLE, RESULTING IN A CRASH.

Land Rover : Manufacturing Management Issue.

[] Rover 2500 All-terrain vehicles Flaws in engine U.K.
[] Rover 27500 Passenger cars Problems with handbrake UK
[] Rover 2800 Range Rover (6/94 and 3/95 models) Possible cracks in the joints between rear axle and chassis UK
[] Rover Land Rover Discovery Defective door locks Germany
[] Rover Rover 800 Defective seat belt mounts Germany
[] Rover Discovery Possible gearbox defect, because of loss of lubrication WORLD WIDE
[] Rover 20000 MGF Problems with seat belt WORLD WIDE

[] Rover 1000 Range Rover Loss of brake fluid WORLD WIDE
[] Rover 12000 Range Rover Defective brake line WORLD WIDE
[] Rover 30000 Range Rover Check on Goodyear Wrangler tyres which tend to deflate WORLD WIDE
[] Rover 2800 Range Rover Hairline cracks in the rear axle trailing arm WORLD WIDE
[] Rover 1000 Range Rover V8 Adjusting pulley on the fan belt for the power steering pump can break WORLD WIDE
[] Rover 4000 Rover 600 Loose screws on the steering box unit WORLD WIDE
[] Rover 22000 Rover 75 Defective crankshaft sensor WORLD WIDE
.

2006 Mini Cooper Convertible:
High Tech Welds with lack of weld process controls: On certain vehicles equipped with a continuously variable transmission (CVT), the connection between the transmission gear selector rod and the lock plate may not have been laser-welded correctly. If the weld were to break, the gear currently engaged would remain in position, and it would no longer be possible to shift the gear positions using the selector lever. The potential also exists for the vehicle to pull away from a stop in the opposite direction to that selected, or to roll away on an incline if the parking brake was not engaged.




WHO YOU PLACE IN CHARGE OF THE WELDS, IS TYPICALLY AN INDICATION OF THE QUALIFICATION OF THE MANUFACTURING MANAGEMENT FOUND IN GLOBAL AUTO / TRUCK PLANTS.


In many manufacturing plants, when it comes to the robot MIG welding, the management will often make the "unqualified maintenance" department personnel like electricians and millwrights responsible for the robot MIG weld process control issues.

In more than 1000 plants in ten different countries that I visited,
I never found a maintenance shop that employed a person who has had any expertise in Robot MIG Weld Process Controls.
I have however seen many maintenance personnel who believe they have some expertise with the MIG equipment after "playing around" with the two simple controls.


 


 

EVEN TOYOTA?


Japanese Morals or Greed?. Toyota dealers have been charged with improperly inflating vehicle invoices. This is known as double dipping in gorilla consumer speak. The Chronicle Sunday section of the San Francisco Examiner features a story entitled, "The Hidden Costs of Buying a Car Through Lease Agreements," and tells of a person who planned to buy a $12,000 Toyota from a Toyota Dealer and was "sold" a lease deal that cost the consumer $26,000 for the same $12,000 Toyota. Makes you just want to run right out and reward Toyota with your business, don't it? Consumers considering Toyotas are warned that even Toyota , perhaps especially Toyota (given this story) is not to be trusted in treating consumers fairly. CARveat Emptor. · · Newsweek (July 28, 1997) "Oh, What a Feeling: Toyota tries to teach dealers the soft sell", by Daniel McGinn and Tara Weingarten. Toyota tries to rein in its dealers, essentially admitting that its dealers have been mistreating its customers,more from,
http://www.autobuyology.org/car6.html


TOKYO 2005- Auto recalls surged 71 percent to a new record high in Japan last fiscal year, as automakers used more interchangeable parts in different models and an auto defect cover-up scandal led more motorists to report cases, an official said.
The number of Japanese vehicles recalled was 7,565,409 in the fiscal year ended March 31, up from the previous year's record of 4,416,471, Transport Ministry spokesman Toshihiko Kude said. The ministry began compiling auto recall statistics in 1969.

 

 

 

A Japanese Weld Reality:

Japan may make the world's best cars, yet "in-depth" MIG weld process expertise has for the last five decades been a rare commodity in the land of the rising sun. It's not just the unnecessary, complex and often inconsistent performing Japanese MIG equipment that has caused many Japanese and North American weld shops excessive headaches, the Japanese auto and truck weld specifications that I have previewed, frequently provide comical weld statements and ludicrous weld requirements for the thin gage auto / truck carbon steel applications. To be fair, I have to admit this also applies to the big three USA weld specifications I frequently work with.

 

There is a great MIG pulsed MIG and
equipment section at this site.


DAM IT JOE WE HAVE OVER A MILLION DOLLARS INVESTED IN THAT ROBOT LINE. WE HAVE SPENT TWO HUNDRED THOUSAND ON TRAINING AND YET THE WELD REWORK RATE IS OVER FORTY PERCENT AND OUR PRODUCTION EFFICIENCY STINKS. NOW LOOK ME IN THE EYE AND KEEP TELLING ME THE PROBLEM IS WITH THE WORKERS ON THE SHOP FLOOR.



 



With the introduction of robots into a traditional manual manufacturing facility, it's logical to assume the robots would influence the management, engineers and manual work force, or perhaps at least create changes to the existing weld shop culture and environment. It's also logical to assume that the manual weld shop environment, it's culture and practices could negatively influence and contaminate the performance potential of the robots. In this common manufacturing environment, management and engineers DO NOT REQUIRE A SIX SIGMA CRUTCH OR BLACK BELT,they do require a fundamental logical approach to employ personnel who understand processes utilized and can establish Best Practices and Process Controls. Dramatic changes are necessary when automation is presented, and with this in mind, it's not difficult to understand why many managers, engineers retreat behind glass walls and they and the shop floor workers retain their traditional culture and status quo .

 

 


 

Much of the Recall Data is From GE Insurance Solutions.

Toyota: Manufacturing Management Issue
.


In 2005 Toyota recalls are up 70 percent.

Toyota Motor Company Rear Axle Recall.
Toyota Avalon Year: 2000
Toyota Camry Year: 2000
Toyota Solara Year: 2000

Dates of Manufacture: March - April 2000

Defect: On certain passenger vehicles, due to a lack of management manufacturing expertise, improper heat treatment, the rear axle may not have adequate strength in some areas. The rear axle shafts could fail or break after extended use of the vehicle, increasing the risk of a crash.

Toyota: Manufacturing Management Issue.

Toyota recalls new Avalons for steering weld problems.
Control could be lost if weld breaks

By Robert Schoenberger
The Courier-Journal

Weeks after its debut, Toyota's Georgetown, Ky.-built Avalon sedan is being recalled for steering problems. Toyota spokeswoman Allison Takahashi said due to a lack of management manufacturing expertise the steering column on some early production models was not welded properly. If the welds break, drivers could lose control. Toyota will send notices to nearly 4,900 customers on Thursday. The recall comes on the heels of a larger Toyota callback. Last week it recalled 750,000 pickups and sport utility vehicles for suspension problems.

FIRST TOYOTA IN 1999 and then VW in 2015.

T
oyota is charged with rigging or calibrating its pollution emissions equipment so that it would not record excessive amounts of air pollution. I always thought the Japanese considered themselved above such practices.


Toyota: Manufacturing Management Issue
.

[] 2006 Owners of Toyota's 2004-2006 Prius are advised to bring their hybrid vehicles into the shop to be checked for potential steering problems. Transport Canada says a connection at the intermediate shaft or the intermediate extension shaft may crack or become loose, leaving a driver without steering. Dealers will replace the steering intermediate shaft. They'll also inspect the sliding yoke and the intermediate extension shaft and replace them if necessary.
[] Toyota Lexus GS 300 Premature wear on support joints UK
[] Toyota 1300 Lexus GS 300 (models before 1994) Replacement of suspension ball joints UK
[] Toyota 8400 Passenger cars Corrosion in steering mechanism UK
[] Toyota Land Cruiser Diesel Defective fuel injector pump Germany
[] Toyota 18500 Dyna 200, Toyoace G25 and other Faulty suspension part JAPAN
[] Toyota 8700 Hiace Quick Delivery, Quick Delivery 100 Defective suspension parts JAPAN
[] Toyota 33000 Trucks (5 different models) Defective front-wheel brakes JAPAN

DOES THE GENERAL TERMINOLOGY DEFECTIVE / FAULTY SUSPENSION PARTS, MEAN BAD WELDS, BAD STEEL, BAD PARTS OR BAD MANAGEMENT?


Toyota: Manufacturing Management Issue.

[] Toyota 1697 2002 Lexus ES300 Left front brake tube may be deformed U.S.A
[]Toyota 540 Avalon, Camry, Solara Rear axle may break U.S.A (yes its made out of steel)
[] Toyota 400000 Camry Defective brakes U.S.A
[] Toyota Camry Defective door locks U.S.A
[] Toyota 53000 Camry Defective accelerator cable housing U.S.A
[] Toyota 33800 Camry, Corolla, Tacoma,Echo E-clip which holds the speed control assembly to the accelerator linkage could break U.S.A
[] Toyota 540000 Camry, ES300 Screws on steering wheel cause vibrations U.S.A
[] Toyota 8483 Corolla The rear axle bolts may loosen U.S.A

Toyota: Manufacturing Management Issue.

[] Toyota 8000 Lexus Defective cruise control and brake lights U.S.A
[] Toyota 40000 Passenger cars Defective battery mount U.S.A
[] Toyota 3000 Passenger cars Failure to comply with US emission standards U.S.A
[] Toyota 1800 Priuses Faulty power steering torque sensor causing steering problems and warning light comes on U.S.A
[] Toyota 273743 Toyota 4Runners May lose directional stability if heavy loading U.S.A
[] Toyota 330000 Toyota, Lexus Computer to automatically measure emissions faulty U.S.A
[] Toyota 7000 Tundra Defect in trailer hitch wiring harness U.S.A
[] Toyota 8609 Tundra trailer hitch Possible short circuit within the converter U.S.A
[] Toyota 154593 2001-2002 Toyota Highlander It failed a NCAP test U.S.A
[] Toyota 397263 Subcompact Cars Improperly designed brake fluid pipes U.S.A

Toyota: Manufacturing Management Issue.

[] Toyota Toyota TACOMA DAMAGE TO THE FUEL INLET HOSE U.S.A
[] Toyota 34437 Sienna 2004 Do not comply with safety standards U.S.A
[] Toyota Corolla Missing bonnet mounts AUSTRALIA
[] Toyota 1,35m Passenger cars Defective ignition system WORLD WIDE

[] Toyota 515000 Passenger cars (13 different models) Poor mounting of handbrake WORLD WIDE
[] Toyota 17000 Echo Condensed moisture from positive crankcase ventilation port could seep toward the brake vacuum port inside the intake manifold at freezing ambient temperatures and star freeze USA / Canada


 

Much of the Recall Data From
GE Insurance Solutions.




Honda: Manufacturing Management Issue.

Honda is recalling 241 of its 2008 Element vehicles to check for a faulty rear-suspension weld. T
he front bushing bracket of the left trailing arm of the rear suspension may have been improperly welded and could separate from the trailing arm. "A separated bushing bracket could cause the suspension to release the lower portion of the wheel hub, causing a loss of control and damage to the brake system, which could lead to a crash," said the government agency in its summary of the problem.

 

Honda: Manufacturing Management Issue.

[] Honda Civic, CRX Defective lever mechanism Germany 6/1994
[] Honda 317000 Motorcycles Dangerous stand Germany 0/1986
[] Honda NX 650 Dominator motorcycle Problems with front-wheel hubs Germany 0/1988
[] Honda 160000 Accord, Ascot Defective engine JAPAN 3/1992
[] Honda Accord, Civic Defective oil-pressure lines JAPAN 2/1992
[] Honda 15000 Avancier, Inspire, Saber Defective switch on the seat-belt warning lamp JAPAN 6/2000

Honda: Manufacturing Management Issue.
[] Honda 10600 Life, Z, Vamos A joint connecting the fuel tank hose to a small pipe in an engine cylinder could leak JAPAN 9/2000
[] Honda 26000 Motorbike Defective brakes JAPAN 4/2001
[] Honda 10700 Motorcycle Forza Defective parts in the throttle grips JAPAN 4/2001

Honda: Manufacturing Management Issue.
[] Honda 556000 Prelude, Legend, Accord and other An electronic part in the audio equipment may heat excessively and catch fire JAPAN 9/2000
[] Honda 2900 2000 Acura Accord TL A component in the inflator of some passenger air bag modules was not welded properly U.S.A 4/2002
[] Honda 6000 Accord Defective voltage regulator U.S.A 0/1984
[] Honda 900000 Accord Leaky tank U.S.A 6/1993
[] Honda 19500 Accord Rear suspension lower arm could break due to improper welding U.S.A 7/2000

Honda: Manufacturing Management Issue.
[] Honda 16459 Accord, Civic Rear seat belt buckles were improperly manufactured U.S.A 2/2002
[] Honda 14300 Accura Legend Problems with lever of automatic transmission U.S.A 0/1991
[]Honda 47000 Acura Legend Transistor in the Bose audio system speaker amplifier could overheat, resulting in smoke or fire U.S.A 4/2001

Honda: Manufacturing Management Issue.

[] Honda 126000 ATV Rancher TRX350 and TRX400EX Mounting bracket on the front suspension could be improperly welded to the frame, causing a loss of steering control and brake pads could have been incorrectly assembled, causing the brakes to fail U.S.A 11/2000
[] Honda 10000 Civic Defective hood catch U.S.A 0/1984
[] Honda 3000 Civic Defective drive shaft U.S.A 0/1984
[] Honda 280000 Civic Replacement of fuel pumps U.S.A 0/1988
[] Honda 6200 Motorcycle CBR929RR Pressurized fuel hose can be damaged during routine maintenance U.S.A 9/2000

Honda: Manufacturing Management Issue.

[] Honda 8700 Motorcycle CBR929RR Clutch lever may not work properly U.S.A 1/2001
[] Honda 22000 Motorcycle XR50R Bolts that attach the handlebar can break U.S.A 12/2000
[] Honda 78000 Odyssey Defective ignition may substantially impair various functions U.S.A 2/2000
[] Honda 7100 Odyssey Sliding door does not close properly U.S.A 4/2000
[] Honda 78000 Odyssey Dimmer control for the instrument panel lights can fail U.S.A 7/2000
[] Honda 4900 S2000 Insufficient tension of seat belt U.S.A 1/2000
[] Honda 6,744 undefined Seat belt could unlatch U.S.A 12/2001
[] Honda 25765 2000 Acura 3.5RL Oil can leak into the brake stop switch and contaminate the electrical contacts U.S.A 5/2002
[] Honda 3617 3618 Leaking fuel tank U.S.A 3/2003

Honda: Manufacturing Management Issue.

[] Honda 247,019 Honda CR-V 2002-3 Defective shift cable linkage U.S.A 8/2003
[] Honda 570.120 Honda Odyssey + Accord, Acura CL + TL The ignition switch may wear excessively and prevent proper interlock operation, making it possible to turn the ignition key to the off position and remove the key without shifting the transmission to park U.S.A 11/2003
[] Honda 190000 Accord Replacement of airbag electronic control unit WORLD WIDE 0/1996
[] Honda 1.4m Accord, Prelude, Minivan Odyssey, Acura CL Defective engine oil seal WORLD WIDE 9/2000
[] Honda 27000 Cars Defective cooling system WORLD WIDE 0/1987
[] Honda 4500 Civic Idling problems WORLD WIDE 0/1988
[] Honda 1700 Civic Coupe Excess assembling paste sticking the return valve of the vacuum hose on the power brake unit WORLD WIDE 7/1996

Honda: Manufacturing Management Issue.

[] Honda 50000 Civic, Ballard Defective drive shaft WORLD WIDE 1/1986
[] Honda GL 1500, ST 1100 NR750 The engine can cut out during normal driving manoeuvres WORLD WIDE 7/1995
[] Honda 143000 Legend, Inspire, Saber Faulty latches may prevent car from driving WORLD WIDE 9/1999
[] Honda 77000 Pelude Problems with seat mounts WORLD WIDE 0/1989

Honda: Manufacturing Management Issue.

[] Honda 158000 Prelude Defective oil-pressure lines WORLD WIDE 0/1988
[] Honda 18000 S2000 The g-sensor for the belt retractor?s lock may lock and stop the belt being pulled out WORLD WIDE 10/0
[] Honda 110000 Civic, Integra Defective engine starter Europe / Japan 4/2001
[] Honda 600.000 Minivans and sport utility vehicles Defective transmissions USA / Canada 4/2004

Recall Data From GE Insurance Solutions.

Hyundai: Manufacturing Management Issue.

[] Hyundai 39000 Trajet, Starex, Galloper Leaks in power steering system and faulty suspension and ignition part UNKNOWN 1/2000
[] Hyundai 34086 2000 Hyundai Accent It fails to comply with certain occupant protection requirements U.S.A 7/2002
[] Hyundai 15241 2001 Santa Fe Inproperly manufactured crankshaft position sensors U.S.A 2/2002
[] Hyundai 1174 2003 Hyundai Tiburon Left lower instrument panel bracket was not installed, there may be an increased severity of injury in a frontal crash U.S.A 2/2002
[] Hyundai 16000 Accent Defective windscreen wiper U.S.A 3/2000
[] Hyundai 84000 Elantra, Tiburon Defective gas caps could cause crack in tank, leading to leaks and the potential of fire U.S.A 3/2000

Hyundai: Manufacturing Management Issue.

[] Hyundai 5000 Passanger cars Problems with tank safety U.S.A 12/1985
[] Hyundai 4400 Passanger cars Defective brakes U.S.A 3/1986
[] Hyundai 8500 Passenger cars Defective cruise control U.S.A 0/1989
[] Hyundai 7.382 2003 Tiburon The driver seat belt buckle wiring could be damaged by interference with the driver seat cushion height adjuster mechanism U.S.A 1/2003
[] Hyundai 145355 2001 Hyundai XG300/ 1999-2000 Hyundai Sonata A problem could prevent air bag deployment during a crash U.S.A 6/2002
[] Hyundai 17000 Mark 1 Lantra Safety checks on possible bolt failure in the rear suspension WORLD WIDE 0/1996
[] Hyundai 166000 Sonata, Elantra Engine stalls at low speed USA / Canada 12/2000


Hyundai: Manufacturing Management Issue.

E-mail to Ed March 2007:From Kevin kruptogeek@gmail.com

Ed.. My 2007 Hyundai Sonata was found to be missing welds in the rear portion of the car. Not sure exactly where but they had to remove my trunk lining rear window to weld it at the dealership. They said it inculded a "shelf" where the roof portion and the body meet.

I guess my questions center around safety and integrity. The car is very loud and appears to lack integrity. Could missing or poorly repaired welds cause this? The car is very loud and the rear glass sounds like it is under tension. It sounds like someone is throwing marbles at it.

Safety: Should I have safety concerns? I am uncomfortable that this was spot welded at the local dealership as well. What do you think?

Eds Reply:
It should be OK if you keep your road speed under 20 miles an hour. If the factory cannot make good welds good luck with the welds made by your local car dealer.


Mazda: Manufacturing Management Issue.


2006 Mazda MAZDA5 Sport Select Different Vehicle

Component: Engine And Engine Cooling: Exhaust System

Defect Summary: ON CERTAIN SPORT UTILITY VEHICLES, A HEAT BUILDUP IN THE EXHAUST SYSTEM CAN OCCUR THAT COULD RESULT IN A FIRE.

Mazda 3500 Capella, Telstar Timing belt s are not strong enough, cogs can be chipped off when driving at fast speed, can cause vehicle to halt
Mazda 940 Bongo Brawny Heating may overheat
Mazda 1200 Capella, Telstar Defective engine parts
Mazda 3500 Luce Defective brake lights
Mazda 14700 Passenger cars Checks of several systems
Mazda 31000 626 Timing belt tensioner spring breaks and may lodge in the belt and stall the engine
Mazda 14000 2002 MVP An incorrect gross axle weight rating was indicated on the label
Mazda 71000 Mazda 626 Defective reservoir tank caps
Mazda 40000 Mazda 626, MX6 Defective taillight
Mazda 4000 Mazda B 220 Failure to comply with US emission standards

Mazda: Manufacturing Management Issue.

Mazda 79000 Mazda Protege Defective headlights
Mazda 22000 Miata sportscar Defective non-return valve may cause refuelling problems
Mazda 39000 MPV Minivan Tyre labelling does not comply with federal standards
Mazda 195000 MPV Minivan Incorrect cold inflation pressure labelling on tyres
Mazda MPV Minivan Shock absorber test produces poor results
Mazda 19000 MPV Minivan Braking system does not comply with the safety standards
Mazda 16700 MX-5 Miata Check on catalytic converter
Mazda 6800 Navajo Faulty weld seams on levelling control system may cause sudden shifts in position
Mazda 200000 Passenger cars Defective steering idler arm
Mazda 22500 Pick-up trucks Defective cruise control unit
Mazda 630 Tribute Steering wheel may fall out
Mazda 1700 Tribute Four-wheel-drive rear hub is put on two-wheel-drive vehicle, wheels loosen and come off

Mazda: Manufacturing Management Issue.

Mazda 5700 Tribute O-ring seal in fuel line connector at the outlet end of the fuel filter is damaged and could result in fuel odor or fuel leakage
Mazda 5700 Tribute Child restraint anchorage systems does not comply with US standards
Mazda 24000 Tribute Defective windshield wipers
Mazda 49.000 Tribute 2001 Problems with the safety belt
Mazda 10200 Minivan The cruise actuator cable may be broken
Mazda 106.000 Tribute 2001-3 The engine may stall, resulting in a vehicle crash
Mazda 10400 MPV 2003 The tire inflation pressure indicated on the vehicle certification label is not correct
Mazda 103000 Delivery vans Leaking fuel line
Mazda 45000 Familia Defect in a brake hose
Mazda 25400 Familia, Laser Danger of crankshaft fracture and engine damage due to defective bolts
Mazda Mazda 121 (96 model) Abrasion of the front brake lines/impurities in brake fluid check on clutch cylinder
Mazda Mazda 323 Possible shearing of valve springs
Mazda 6700 Passanegr cars Defectives brakes
Mazda 93500 Passenger cars Defective tank mounts
Mazda 10600 Trucks Defective seat belts
Mazda 66000 Mazda 626, Capella Timing-belt tensioner may break and cause the engine to stall




 


http://www.mitsubishisucks.com/cars/recalls/japan/2004-06-4.html


Mitsubishi
recalls over a million of its vehicles self-admittedly stating they are poorly built vehicles.
Misubishi also reportedly acknowledges that it hid consumer safety complaints for the past ten years. Many of the subject vehicles were sold and used in Japan . Reportedly as many as 10,000 of these vehicles were sold and used in the US .


Mitsubishi: Manufacturing Management Issue.

June 2004

Mitsubishi Fuso and Bus Japan
Fuso Trucks
Number Potentially Involved:
Dates of Manufacture:
Defect: Fuel tanks and drive shafts detaching, parking brakes failing and steering wheels not working ...

Background: MMC found 41 defects since october 1992 that could lead to accidents; only four had been reported to the transport ministry. 21 accidents were caused by these defects and in nine cases, secret repairs were made

Mitsubishi: Manufacturing Management Issue.

[] Year 2006: Mitsubishi Eclipse GS Select Different Vehicle

Component: Service Brakes, Hydraulic: Foundation Components: Master Cylinder

Defect Summary: ON CERTAIN PASSENGER VEHICLES, ONE OF FOUR SEALS INSIDE THE MASTER CYLINDER MAY HAVE BEEN INSTALLED IMPROPERLY. AS A RESULT, THE MASTER CYLINDER MAY UNEXPECTEDLY BY-PASS HYDRAULIC BRAKING FORCE PRESSURE AND ALLOW A LONGER THAN NORMAL PEDAL STROKE.

Consequence Summary: SHOULD THIS CONDITION OCCUR, THE BRAKING DISTANCE REQUIRED TO STOP THE VEHICLE MAY INCREASE AND COULD LEAD TO A VEHICLE CRASH.


[] Year:2001 Mitsubishi Model:Eclipse

Defect Summary: A bulge in the fuel tank caused by the manufacturing process resulted in thinning of the material during a welding operation, increasing the risk of fuel leakage. Consequence Summary: Fuel leakage in the presence of an ignition source could result in a fire. Corrective Summary:

[] Mitsubishi Motors 120000 Galant, Eclipse, Colt, Lancer Causes of the recall
are different for each model EUROPE
[] Mitsubishi Motors 1600 Canter truck Insufficient strength of a bolt on a crankshaft JAPAN
[] Mitsubishi Motors 1000 Libero Defective electrical wiring JAPAN
[] Mitsubishi Motors 45000 Minicab Truck Already during former recall replaced fuel cap did not work properly JAPAN
[] Mitsubishi Motors 380 Several Canter models Defective engine JAPAN
[] Mitsubishi Motors 72000 Pajero Rear braking pipe wears easily and lead to hydraulic problems CHINA
[] Mitsubishi Motors 101000 Galant, Eclipse Multifunctional lever on steering wheel may break off U.S.A
[] Mitsubishi Motors 19800 Galant, Eclipse Battery cable may be damaged by heat and cause malfunctions U.S.A
[] Mitsubishi Motors 210000 Mirage, Montero Bolt securing the crankshaft pulley can become looses, resulting in a loss of power steering assist U.S.A

Mitsubishi: Manufacturing Management Issue.

[] Mitsubishi Motors 18630 Mitsubishi Mirage Bolt securing the crankshaft pulley can become loose U.S.A
[] Mitsubishi Motors 100000 Passenger cars Failure to comply with US emission standards U.S.A
[] Mitsubishi Motors 31000 2003 Outlander Ice can build up inside the engine during low temperatures U.S.A
[] Mitsubishi Motors 43.649 Outlander 2003 Water could enter and cause electrical corrosion U.S.A
[] Mitsubishi Motors 3000 Galant Possible defects in the front suspension rubber boot AUSTRALIA
[] Mitsubishi Motors 700 Nimbus A fault can trigger the airbag when the ignition is turned on AUSTRALIA
[] Mitsubishi Motors 650000 Cars (91-95 models) Replacement of faulty brake components WORLD WIDE
[] Mitsubishi Motors 1.52m Several models Water may penetrate the lower steering arm ball joints and could cause corrosion and accelerator wear WORLD WIDE
[] Mitsubishi Motors 810000 Various motor vehicles Problems with engine components, seat belts and brake tubes WORLD WIDE
[] Mitsubishi Motors 20.000 Trucks and buses Defective rear wheel hubs WORLD WIDE
[] Mitsubishi Motors 127000 Galant, Legnum (96-97 models) Checking of the steering assembly and replacement of fuel pump Europe / Japan

 

E-Mail. Ed. Below is information on recalls on Valley Industry Class III hitches.
Our hitch is a Class V and I did not find any information on any recalls for the Class V, however it appears that the defect is the same, inadequate quality on welded joint - as you can see in attached photograph above on my Ford truck . Needless to say our truck and trailer were totalled. (picture above) We are thankful that no one was killed in the resulting accident.

Nissan: Manufacturing Management Issue.

2005 NISSAN XTERRA Recall ID from NHTSA: 05V458000

Auto Recall Date: OCT 05, 2005
Vehicle Component: TRAILER HITCHES
Model Affected XTERRA
Estimated Vehicles Affected: 12500


Defect Summary:
ON CERTAIN SPORT UTILITY VEHICLES EQUIPPED WITH A NISSAN ACCESSORY TOW HITCH, THANKS TO POOR MANAGEMENT INADEQUATE QUALITY (LACK OF WELD FUSION) OF SOME WELDED JOINTS IN THE HITCH ASSEMBLY MAY RESULT IN SEPARATION OF THE HITCH FROM THE VEHICLE WHEN BEING USED TO TOW.

Defect Consequence:
THIS COULD RESULT IN THE TRAILER SEPARATING FROM THE VEHICLE AND CAUSE A CRASH WITHOUT WARNING.

Nissan: Manufacturing Management Issue.

[] Year 2006 Nissan Maxima SE Select Different Vehicle

Component: Seats: Front Assembly: Power Adjust

Defect Summary: ON CERTAIN PASSENGER VEHICLES EQUIPPED WITH THE DRIVER PREFERRED PACKAGE, THE WIRE HARNESS FROM THE DRIVER'S SEAT POWER LUMBAR SUPPORT SWITCH MAY BE ROUTED INCORRECTLY AND COULD BE PINCHED UNDER THE DRIVER SEAT.

CONSEQUENCES: A PINCHED HARNESS, IN COMBINATION WITH DRIVING VIBRATION, MAY RESULT IN A SHORT CIRCUIT IN THE HARNESS THAT COULD LEAD TO A FIRE IN THE SEAT.

[] Nissan Passenger cars Danger of loosening of screws on main brake cylinder U.K. 4/1991
[] Nissan Primera Check on brakes U.K. 5/1991
[] Nissan 4000 Almera Tino Defective air bag inflator Germany 12/2000


Nissan: Manufacturing Management Issue
.


[] Nissan 1,05m Bluebird, Cedrics Defective condenser and escape of hot gas in the pyrotechnic belt tightening unit JAPAN 5/1996
[] Nissan 6000 Cima Defective electrical wiring JAPAN 3/2001
[] Nissan 968000 Passenger cars Fire hazards due to radio components JAPAN 0/1996
[] Nissan 250 Primera, Bluebird Faulty accelerator pedals JAPAN 8/2000
[] Nissan 1800 Seven different models Defects in wiring, breaks and other parts JAPAN 10/2000
[] Nissan 6300 Terrano, Expert, Terrano Regulus, Familia, Subaru Leone Steering wheel has to be fixed JAPAN 12/2000

Nissan: Manufacturing Management Issue.

[] Nissan 120 Tino Defective transmission component JAPAN 11/2000
[] Nissan 161000 1997 Infinite I30, Q45, Maxima A diode may have be damaged during manufacture U.S.A 7/2002
[] Nissan 76000 Frontier, Xterra Automatic transmission shift cable lock plate may break U.S.A 10/2000
[] Nissan 9200 Infiniti QX4 Ignition lock cylinder cap could come loose and may cause the steering wheel lock to engage, preventing the driver from turning the steering wheel U.S.A 12/2000
[] Nissan 39000 Maxima The engine malfunction indicator lamp to come on and the engine speed to be severely limited could lead to a crash U.S.A 3/2002
[] Nissan 268000 Minivan Quest Fuel tank hoses can crack U.S.A 2/2001
Nissan 14800 Nissan Sentra Front coil spring corrodes in wintry areas and may break and puncture tyre U.S.A 3/2000

Nissan: Manufacturing Management Issue.

[] Nissan 21000 Nissan Sentra Bolts could fracture U.S.A 11/2001
[] Nissan 48500 Passenger cars Failure to comply with US emission standards U.S.A 0/1984
[] Nissan 67000 Quest, Frontier Defective stop lights and taillights U.S.A 1/2000
[] Nissan 9640 Sentra SER A small amount of mat movement could cause the mat to interfere with the accelerator pedal U.S.A 3/2002
[] Nissan 12000 Sports cars Defective main brake cylinder U.S.A 0/1984
[] Nissan 2003 Infinity G35 The fuel pump hose may not have been properly attached U.S.A 9/2002
[] Nissan 6500 2003 Frontier XE The spare wheel does not fit properly U.S.A 11/2002
[] Nissan 64562 Xterra 2002 On certain vehicles, the clock spring electrical connector may not be fully secured U.S.A 3/2003

Nissan: Manufacturing Management Issue.
[] Nissan Nissan Altina 1994-95 Passenger air bag deployments are causing a number of eye injuries U.S.A 5/2003
[] Nissan 377.000 Nissan Altima 2002-3 Problems with the engine U.S.A 9/2003
[] Nissan 276.000 Nissan Sentra 2000-3 Foam material emits sulfur as it cures U.S.A 1/2004
[] Nissan 13.757 Quest minivan 2004 Passenger air bag could deflate U.S.A 3/2004
Nissan 70000 Infiniti G20 (93-95 models) J30 (93-94 models) Fire hazards due to the safety belts NORTH AMERICA 0/1996
Nissan 220000 Passanegr cars Danger of corrosive failure of rear-wheel suspension WORLD WIDE 0/1988
Nissan 180000 Passenger cars Problems with automatic transmission WORLD WIDE 0/1987
Nissan 256000 Passenger cars Defective solder joints in fuel tank WORLD WIDE 0/1987
Nissan 60000 Primera Leakage of front brake lines WORLD WIDE 4/1994

 


As Ed teaches Jesse an 11 year old how to do a pipe weld,
Why cant the grown ups in the auto industry figure it out?

Subaru: Manufacturing Weld Management Issues.

Subaru announced a voluntary recall campaign on its 1996/1997 model year Legacy vehicles. The campaign involves improper welding on the front transverse link assembly on some 1996/1997 Legacy models. Improper welding on the part may result in weld fractures on the hanger (support) bracket which could cause partial (or complete, if the resulting noises are ignored,) separation of the bracket from the transverse link. Such separations may cause failure of the lower suspension mounting that could lead to a loss of vehicle control. The number of vehicles potentially affected is 29,442 although it is unknown how many vehicles actually contain the defect. All registered owners of vehicles potentially affected by the voluntary recall have been notified by first class mail. They have been asked to return their vehicles to a Subaru dealer for an inspection of both the front transverse links and replacement of the link assembly if improper welds are found.

WHY SOME MANUFACTURING AND CORPORATE MANGERS DESERVE TO BE IN JAIL

Kia: Manufacturing Management Issue.

My name is Lynn Alfano. I am a Law Clerk in Miami, Florida. I am currently working on a case where a 12 year old girl was sitting in the back seat of a 1999 Kia Sephia when it was rear ended by another car.
Just another car crash, right? WRONG!

The driver seat-back reclining system failed on impact, causing the driver's seat-back to hit the 12 year-old girl in the head and break EVERY bone in her face.
She is now disfigured and will require many painful operations for approximately the next ten years. What I want to know is whether you have heard of anyone else with such an experience with the Kia Sephia. I hope no one else has had such a devastating experience, but maybe someone has had experience with a Seat-back failure on the Kia that I can contact and talk to. I really need to know if any other lawsuits have been filed against Kia for a Seat-back failure. I need all the leads I can get. I like to see such a dangerous car removed from our roads.
Thanks,

More Kia

Note From Ed: Lynn is not aware that most car seats are manufactured from small thin tubes and they are often poorly designed, poorly fabricated, poorly mounted with poor welds. Robot bad welds on car seats and the seat attachements are too common. I wish you could get your hands on that seat and send it to me. I already know what I am going to see.

Kia: Manufacturing Management Issue.

From: dlw72 (dlw72@netzero.net)
My 98 Kia sephia has been to the shop more than 20 times since purchased in nov.98.
4 times for rotors and pads,2 times for headlights filling up with water,2 times for fuel pump wiring problems,mirrors and hub caps replaced for peeling paint,1 time(so far)for an annoying rattle sound they replaced the exhaust but that wasn't the problem,1 time for water leaking on the floor from under the dash,and another time for the starter relay and fuse going bad,wiper recall,and for the egr solenoid. As for the sportage its been in for an antifreeze leek,hubs recall ,brake line recall,alignment at less than 1000 miles,check engine light at least 6 times,one time resulting in a 9 day stay at the dealership to replace 2 defective coil packs,the heater is making a strange buzzing sound and smells like antifreeze when using the heater.And im sure there's more I have forgotten about. Bottom line don't buy a KIA unless your prepared to spend all your spare time in your local dealership waiting room.

From: OSTALLIONO102175@aol.com

Kia: Manufacturing Management Issue.

Just had to put my two cents in about Kia..... I drive a '95 Sephia, and although it has never left me stranded on a highway, it's been in the shop countless times and has more problems than I can name. So far I have had the brakes and brake rotors entirely replaced two times (once in 7/98 and once this month), i have had TWO axles in the car totally replaced, as well as the CV joints (didn't know that you even had to do that unless your car was in a major accident!), I have had the radiator replaced two times, i have had the horn replaced, I have even had to have the glove compartment totally replaced!!!! This is not factoring in all of the stupid little things like spark plugs, headlamps that lately I have had to replace once a month, etc. etc. Still, it chronically stalls (I used to live in Washington, DC, and it stalled every day when I was merging onto the beltway), it reeks of gasoline (I think there is a problem with the gas line related to the stalling, but surprise, surprise, the dealer was never able to find that problem), and it leaks when it rains. And speaking of the dealer, I have never had worse customer service. I called to complain about the car really shortly after I got it, and the dealer told me "well, I tried to steer you away from it." Meaning that they knew they were selling me a complete piece of crap!!!! I have tried to take it to some of those "buy one of our cars and we'll pay off your car" sales that dealers always have and I have consistently been laughed at by every dealer because Kias are such auto industry jokes. Well, thanks for letting me rant and rave. I didn't' even know that I was this annoyed about that car until now!
Melissa Leeper
Harrisburg, PA

 

 

 

 


WHEN THE GERMANS CANNOT "CONTROL" A SIMPLE, FUNDAMENTAL MANUFACTURING PROCESS YOU KNOW THE WORLD HAS CHANGED
.

Mercedes: Manufacturing Management Issue.


Peter writes: I bought a Mercedes SL 500 in September 2003 [August 2003 build]. Terrible rattles over uneven roads [this is a big issue as most small A & B roads in the UK are uneven!]. It's been in for repair for 2 days and again for 3 more days. As one accelerates even gently the car sounds as though its bending or tearing apart under duress.. a disconcerting creaking noise, and in addition so many rattles from seat, roof, and rear compartments it's hard to tell where they are coming from. The noise from the drive train also sounds rough!! as though it has no oil in it. This is my 6th Mercedes and the only one that sounds like a bigfiat punto.

I noticed a rather nasty smell that I thought was the catalytic converter - as they can stink a bit when new. However I did notice that it was worse when one had opened up the engine some and was therefore hot! Now I keep reading about the hot weather in Texas and the effect heat has on the leather in this car causing a smell like cat's pee. -

Anybody else had rattling noises on the Glass Roof? Please let me know as i would like to decide do I sell this car and buy something else or do I just have a one off Lemon! In the UK we regrettably do not have the 'Lemon Law' and Mercedes feel it is beneath them to talk to customers even if it is a Safety issue. I really wish Chrysler had not bought MB as the cars are now just overpriced ~ $126,000 Ford look-a-likes! or are my expectations too high?



Porsche: Manufacturing Management Issue.

[] Porsche 5400 911 Carrera (993), 91 1 Turbo (933) Voltage peaks may deploy airbag Germany
[] Porsche 9600 Boxster Problems with ignition lock Germany
[] Porsche 2900 911 Carrera 4 Faulty fuel gauge U.S.A
[] Porsche 2400 Carrera Defective trunk lock U.S.A
[] Porsche 11000 Carrera Defective cruise control mechanism U.S.A
[] Porsche 26000 Passanger cars Failure of rear seat belts to meet US standards U.S.A
[] Porsche Passenger cars Problems with steering mechanism U.S.A

Porsche: Manufacturing Management Issue.

[] Porsche 53400 Porsche 924 S, 944 Defective fuel line U.S.A
[] Porsche Porsche 928 S4 Possible loss of speed while overtaking due to fault in transmission U.S.A
[] Porsche 3800 Porsche 944 Problems with suspension U.S.A
[] Porsche 10.637 Cayenne sport-utility vehicles 2003 Wiring defect U.S.A
[] Porsche 19175 Cayenne Turbo 2003/04 Problems with rear seat belt U.S.A
[] Porsche 25000 Passanger cars Defective fuel line WORLD WIDE

[] Porsche 54000 Porsche 911 (91-92 models) Too much play on the steering shaft WORLD WIDE
[] 2004-2005. Porsche recalls 18,600 Carreras worldwide


Porsche: Manufacturing Management Issue.

Porsche is recalling some 18,600 of its iconic 911 Carrera model line worldwide to fix problems with welding joints in their exhaust systems.The vehicles affected are from its sportier 911 Carrera S and its all-wheel drive 911 Carrera 4S derivatives that were built between April 2004 and October 2005, the company said in a statement on Wednesday. In a worst-case scenario, the defective welding joints can lead to the loss of the tail pipe.




Labor Contracts that Hinder Automation:


It's simply illogical in 2005 for any manufacturing plant to work under a labor contract that has clauses or labor requirements that can hinder the success of automation.

For example, the weld job descriptions in many global plants that use robots are typically based on "manual weld practices". Both unions and management would do well to review both their blue collar, engineering and management robot weld job descriptions.

Here's a mouthful for weld automation management reality.

The majority of robot weld issues are simply "PEOPLE management issues".

 

 



Volkswagen : Manufacturing Management Issue.

Due to a lack of management manufacturing expertise,
Volkswagen recalled 28,000 Golf and Audi A3 cars that were manufactured in Brazil to inspect a possible problem with welding on the front suspension. Volkswagen is the largest automaker in Brazil. The auto defect could lead to a weld on one of the fixtures to become loose because the front suspension is incomplete.

 




Doing it right the first time has always
been the quickest way.


Of course when it comes to welded
parts, with the high daily production demands of an auto / truck plant, the plant focus is typically placed on weld productivity rather than on the weld quality. This incorrect management focus can have a tremendous negative impact on the a shop floor welding culture.

All managers should recognize the following fundamental fact, and hammer it home to all plant welding personnel.


Once a manager understands the fundamentals of management and weld process controls as discussed in my CD self teaching / training resources, It's easy to state that it takes less time to produce a robot welded part that does not require weld rework, than it does to weld a part that ends up in the scrap or rework pallet.

 

 


Volkswagen : Manufacturing Management Issue
.

[] 2006 Volkswagen Passat 2.0T Select Different Vehicle

Component: Steering: Linkages: Tie Rod Assembly
Defect Summary: ON CERTAIN PASSENGER VEHICLES, THE LEFT AND RIGHT TIE ROD SECURING NUT MAY BE INSUFFICIENTLY TORQUED.


[] 2006 Volkswagen Passat 2.0T Select Different Vehicle

Component: Steering: Linkages: Tie Rod Assembly

Defect Summary: ON CERTAIN PASSENGER VEHICLES, THE LEFT AND RIGHT TIE ROD SECURING NUT MAY BE INSUFFICIENTLY TORQUED.


Volkswagen : Manufacturing Management Issue.

[] Volkswagen recalled 4,218 Golf models.September 21, 2000 Volkswagen recalled 4,218 Golf models in the U.S. because of possible welding defect in the control arm of the car's front suspension system, which could lead to loss of vehicle control.

[] VW 40000 Audi 100 Defective brake line U.K. 1/1984
[] VW 28000 Minibuses Defective fuel line U.K. 0/1988
[] VW Audi 80 Coupe and convertible Faulty screws Germany 2/1992
[] VW 60000 Audi TT Enhancement of ESP stability programme needed Germany 2/2000
[] VW Convertible Purportedly impaired drivability due to improper carpet mats in pedal area. Real reason:the roofs of some convertibles could not be opened and closed properly Germany 0/1993
[] VW 40000 Golf Vento, Corrado, Passat (92-94 models) Modification of the cooling system Germany 11/1995

Volkswagen : Manufacturing Management Issue.

[] VW Golf, Jetta Check on brake lines Germany 0/1990
[] VW 1,9m Golf, Jetta Defective heating system Germany 3/1995
[] VW 43000 Passat Faulty trailer hitch Germany 4/1999
[] VW Vans and buses Defective steering shaft Germany 6/1994
[] VW 350000 VW, Audi Hairline cracks in brake line Germany 8/1985
[] VW 900000 Audi 80, A4, A6, A8 (95/96 models) Airbag malfunction - airbag triggered unintentionally when occupants enter and leave the vehicle EUROPE 10/1996
[] VW 120000 Golf, Vento Possibility of short circuits due to defective electrical cables EUROPE 0/1993
[] VW 10800 Cars Improvement of transmission and computer system cabling JAPAN 5/1995


Volkswagen : Manufacturing Management Issue.

[] VW 41000 Golf Defective clutch JAPAN 0/1988
[] VW 41000 Golf Material fatigue in wall between engine and passenger compartment JAPAN 0/1988
[] VW Golf, Jetta, Corrado Possible damage to heat exchanger JAPAN 12/1992
[] VW 43900 Golf, Polo, Audi A3 Defects in different hoses and cables JAPAN 8/2000, GAS HOSE?
[] VW 14000 Golf, Scirocco Defective accelerator pedal and tanks JAPAN 1/1985
[] VW 180000 Passenger cars Problems with electrical window openers, cables in battery area, engine electronics JAPAN 10/1998
[] VW 47000 Polo 1.6 Defective brakes JAPAN 5/2000
[] VW 22000 Santana, Audi Problems with electronic components for stabilising idling JAPAN 0/1987
[] VW 11400 1993 Eurovan Potential fuel-leakage problem U.S.A 2/2000
[] VW 35000 Audi Passenger cars, of which 5,000 turbos Faulty gaskets in injection system U.S.A 0/1989
[] VW 1600 Audi 80, 90, Quattro Replacement of bolt in steering linkage U.S.A 0/1990

Volkswagen : Manufacturing Management Issue.

[] VW 27900 Audi A4 Plastic ignition switch housing can fracture at the return spring anchor point causing windshield wipers and headlights to become inoperative U.S.A 10/2000
[] VW 250000 Audi Passenger cars Defective automatic transmission U.S.A 1/1987
[] VW 152000 AudiPassanger cars Replacement of lubricant in drive train with improved synthetic oil U.S.A 1/1993
[] VW 57200 AudiPassanger cars, of which 5,000 turbos Problems with fuel filler neck and rear brakes U.S.A 0/1987
[] VW 110 Bentley Arnage Defective fuel feed U.S.A 3/2000
[] VW 16000 Camper Front door tends to fly open U.S.A 0/1984
[] VW 18000 Camper Defective tailgate lock U.S.A 3/1986
[] VW 7000 Corrado Possible loosening of fuel pump due to deformation of fuel filter U.S.A 6/1991
[] VW 4200 Golf Control arm could gradually loosen because of inadequate weld U.S.A 9/2000

Volkswagen : Manufacturing Management Issue.

[] VW 77000 Golf GTI Leaky fuel tank U.S.A 1/1986
[] VW 324000 Golf, Jetta and New Beetle Malfunctioning heated exhaust gas oxygen sensor U.S.A 1/2002
[] VW 130000 Golf, New Beetle, Bora, Audi A3, Skoda Fault in the braking system U.S.A 3/2002
[] VW 1700 Jetta, Golf Flaws in brake system U.S.A 0/1988
[] VW 153000 Jetta, Golf Worn brake tubes may impair brake effectiveness U.S.A 10/1998
[] VW 290000 Passenger and busses Defective fuel pump and some defective fuel filters U.S.A 5/1987
[] VW 311047 Passat Fuel may leak U.S.A 3/2002
[] VW 2400 Passat 4 Motion Faulty fuel gauge U.S.A 5/2000
[] VW 10450 1996 Passat Electrical problem U.S.A 10/2002
[] VW 269151 VW New Beetle 1998 The brake lamp switch may malfunction U.S.A 7/2003

Volkswagen : Manufacturing Management Issue.

[] VW 15.115 New Beetle 2004 The tire information label is incorrect U.S.A 12/2003
[] VW 172.866 A6, S6, Allroad Quatro 1998-2004 (Audi) Defective cable U.S.A 3/2004
[] VW 20900 Passenger cars Problems with the doors BRAZIL 6/2000
[] VW 10000 Audi 100/20, of which 10, 000 cars only in Europe Unknown WORLD WIDE 0/1989
[] VW 5000 Audi 80 Fuel line check WORLD WIDE 0/1988

[] VW 3800 Audi 80 Sharp edges on dashboard where passenger airbag is released can damage the airbag WORLD WIDE 2/1995
[] VW Audi 80, A4, A6, A8 Airbag defects WORLD WIDE 0/1997
[] VW Audi A3, A4, A6 Problems with safety belts WORLD WIDE 0/1997
[] VW Audi A4 Passenger airbag incorrectly folded WORLD WIDE 3/1995
[] VW 2600 Audi A4,A6, S6,A8 Failure of electric child security device WORLD WIDE 8/1995

Volkswagen : Manufacturing Management Issue.

[] VW 93000 Golf III, Vento Sliding safety catch for fixing roof rack can be incorrectly positioned WORLD WIDE 8/1995
[] VW 950000 Golf Jetta, Passat, Corrado (88-89 models) Faulty cooling systems WORLD WIDE 6/1996
[] VW Golf Variant, Vento Abrasion of rear-door electric window lifter cables WORLD WIDE 6/1996
[] VW 18000 Golf, Jetta Danger of failure of screws holding engine subframe WORLD WIDE 12/1990
[] VW 428000 Passat, Audi Premature wear of track rod ends of front axle WORLD WIDE 8/1999
[] VW 560000 Passat, Audi A4, Audi A6, Audi A8 Some tie rod seals may not seal properly WORLD WIDE 3/2001
[] VW 25.000 Touareg off-roader Fault in hand brake WORLD WIDE 3/2004
[] VW 870.000 Passat 1996-99, Audi A4, A8 1994-99, Audi A6 1997-99 Problems with the front axle WORLD WIDE 4/2004
[] VW 28000 Golf, A3 Potential problems with welding on the front suspension South-America / USA 9/2000
[] VW 51400 Audi A6 Quattro Faulty fuel gauge USA / Canada 6/2000
[] VW 10100 Beetle Electric cables may fray USA / Canada 5/1998
[] VW 89000 Golf Defective tank USA / Canada 3/1986



2005: ED'S COMMENT
. At one time in the annals of manufacturing history < 1960s to 1980s, German tradesmen were a site to behold. If you hired a German machinist or welder you knew they were as good as they could be. I guess in this new automated age of Six Sigma, ISO influenced, bean counter driven manufacturing environment, management and engineers have forgotten the importance of manufacturing skills and the process expertise that was an integral part of those skils. Today we have complex automation and management and engineers who simply lack the ability to control the automated processes. When it comes to manufacturing quality in 2005 we now have third world countries that can now compete with German tradesmen.




Motor Vehicle Recalls

BMW recalls 350 model year 2004 X5 models due to front drive train fasteners.

Recall Data From GE Insurance Solutions

BMW: Manufacturing Management Issue.


BMW 2000 Passenger cars Fault in distributor JAPAN 0/1989
BMW 8800 Passenger cars Defective transmission JAPAN 0/1987
BMW 1200 Passenger cars Problems with backrests of front seats JAPAN 0/1988
BMW 5000 Series 3 Possibly defective battery cable JAPAN 4/1992
BMW 34860 2000 BMW X5 The brake pedal arm may loosen U.S.A 7/2002
BMW 22345 2001 BMW 7-Series, 3-Series, X5-Series and Z8-Series Failure of the fan motor causes the electrical circuitry of the fan control unit to overload and fail, causing the fan to stop operating U.S.A 8/2001
BMW 2,438 2001 BMW M3 On certain passenger vehicles, two screws that secure the parking brake cable mounting bracket to the backing plate on one or both sides of the vehicle were not tightened properly U.S.A 10/2001
BMW 22000 2011 3-series, 7-series, Z8, X5 Faulty radiator cooling fan switch U.S.A 8/2001
BMW 1900 315I, 335I Inner rim flange of the wheels may be damaged U.S.A 11/2000
BMW 2635 2002-2003 Z4 & X5 Safety belt can detach U.S.A 2/2003

BMW Manufacturing Management Issues.

BMW 17000 M3 Spontaneous inflation of lateral airbag possible U.S.A 11/1999
BMW 3200 M5 Machine used to mount and inflate the tires on the wheels may have damaged the sidewall, damaged area could weaken to the point where a sudden loss of air from the tire could occur U.S.A 1/2001
BMW 1100 Motorcycle F650 GS Rear brake caliper support could bend, leading to contact between brake hose connecting piece on rear caliper and swing arm, brake fluid may leak, loosing braking capability U.S.A 4/2001
BMW 410 Motorcycle F650GS, F650GS Dakar Defective fuel tank could leak during refueling, possible resulting in a fire U.S.A 9/2000
BMW 2300 Motorcycle K1200RS Snap ring on the thermostatic element in the oil thermostat housing may not have been properly installed U.S.A 9/2000
BMW 1600 Motorcycle R1200C Backrest can detach from it amount U.S.A 10/2000

BMW 1600 Passenger cars Problems with brake system U.S.A 0/1984
BMW 97000 Passenger cars Defective brake lights U.S.A 3/1987


BMW: Manufacturing Management Issue.


BMW 57000 Passenger cars Failure to comply with some criteria of US safety laws U.S.A 9/1994
BMW 4672 Series 2,3 and 5 The front strut could separate from the upper mount U.S.A 3/2002
BMW 12000 Series 3 (85/86 models) Defective safety element in steering gear U.S.A 5/1985
BMW 17700 Series 3, 5 and 7 Defective stop light U.S.A 2/2000
BMW 190 X5 Steering problems U.S.A 1/2000
BMW 490 X5 Safety belt lower outboard anchorage bolt on the front seats may not have been secured properly U.S.A 9/2000
BMW 20500 1999 BMW 3231, 3281 Air bag deployment problems U.S.A 8/2002
BMW 84000 2000-02 BMW X 5 Defective front brakes U.S.A 3/2003
BMW 2003 325i, 325Ci and M3 The window lifting anti-pinching device might not function properly U.S.A 5/2003
BMW 5.470 BMW 745i & 745Li 2002-3 Problems with the engine U.S.A 9/2003
BMW Motorcycle R1100s Handlebar can twist out of position AUSTRALIA 12/2000

BMW: Manufacturing Management Issue.

BMW 8000 Motorcycles Problems with brake line WORLD WIDE 3/1991
BMW 25000 Motorcycles Checks and replacement of brake linings WORLD WIDE 3/1992
BMW 7000 Motorcycles K 1200 RS Faulty sealing between tank and fuel pump WORLD WIDE 11/1998
BMW 5600 Motorcycles R 1100 GS Possible loosening of journal of rear-wheel bearing WORLD WIDE 6/1994
BMW 2,4m Passenger cars Faulty radiator cap WORLD WIDE 10/1998
BMW 280000 Series 3 Safety problems with airbag and brakes WORLD WIDE 5/1999
BMW 1,2m Series 3,5 and 7 Defective cooling system WORLD WIDE 0/1997
BMW 22000 X5 Steering defect WORLD WIDE 2/2001
BMW 520i, 525i Danger of complete failure of electrical system due to fuse deterioration in main power unit UK / Germany 1/1993
BMW 740 i Fuel vapour seepage possible through the fuel line USA



Infiniti QX4 Frame CX Cracks.

Hello Ed,

I found you site while looking for a sub frame weld issues for my parents 1998 Infiniti QX4. The dealer has recently told us that my parents truck is not safe to drive because of a crack in the sub frame that even the body shop doesn’t want to weld because it is on a critical location and its beyond repair (maybe a sales pitch, but I haven’t looked at it myself yet) The dealer has quoted my parents $10,000 to replace the entire sub frame with a used one! Being that the truck is a unibody, explains the amount of labour. The truck has approx 100.000 miles, and for this to be happening already seems un-acceptable. Have you heard of any cases of people who fought the dealer for poor initial quality control on welds(maybe its not a weld, but your site has me wondering)? Or something to that affect? I’ve tried looking for similar cases on the internet, but none so far, maybe people don’t post them, or ours is a real lemon. There is rust holes everywhere on this truck, all over the tail gate, the roof, driver door, under the window trim, etc.

My parents are pretty upset about the matter, as some of the family still needs to use the truck for lugging furniture and what have you around. We cannot even sell it, because it would not pass safety…only if they caught it, but my parents would not be able to live with themselves if that were the case. The only thing this rig is good for now is a field truck because its not even worth 10k in decent shape!

Thanks for reading, and great site by the way.

Eds Answer:

There are two things you can do.

[1] The frame is easily repaired. Remove the crack and surrounding defective welds with grinding and add a 6 mm hgh strength steel reinforcement plate attached with 70S-3 or 7018 welds. Toltal labor 2 to 3 hours. Costs approx $300.

[2] Sue the car company for providing a defective frame and sue the dealer for being a lying scumbag...





WELD PROCESS CONTROL EDUCATION DOES NOT START ON THE SHOP FLOOR, IT STARTS IN THE MANUFACTURING MANAGEMENT AND ENGINEERS OFFICES.



IF THE FRONT OFFICE AND SHOP FLOOR DOES NOT HAVE THE SAME REQUIRED PROCESS CONTROL EXPERTISE, HOW THE HELL DO MANAGERS EXPECT TO CONSISTENTLY ATTAIN OPTIMUM, UNIFORM WELD QUALITY AND PRODUCTIVITY?

To respond to the high tech automaton challenge of the next decade, it would be beneficial if the "technical caliber" of engineers and mangers responsible for the automations could be taken up a notch.

You will find that most shop floor workers will increase their respect for management and engineers when they see them rolling up their sleeves and striving to learn about the core processes and equipment that are critical to their company. With MIG welding, It can come from simply reading my self teaching MIG process control training books and CDs.

 


 

 


TAKE A LOOK AT THE WHEEL WELDS.

 

Company: Acuride Corporation.

Models: Accuride Wheel Rim, (not this picture).


Number Involved: 5,719
Dates of Manufacture: January - March 2000.

Defect: Due to a lack of management manufacturing expertise certain 22.5 x 8.25 15 tubeless demountable rims, Part No. 32051, contain an incomplete weld in the mounting ring. Under certain circumstances, this could develop into a crack on the mounting ring. Over time, the crack could propagate, resulting in mounting ring failure and causing the rim to separate from the vehicle. Loss of vehicle control could occur. Owners who do not receive the free remedy should contact Accuride Customer Service at 1-812-962-5027.

 

 

A CRITICAL ROLL OVER BAR TRUCK WELD
MADE IN NORTH AMERICA 2005



 

KME TRUCKS AND WELD QUALITY:

By Louis Marro 03-2007:

I was recently called to assist an F.D. with a problem that could have been fatal.

An acting Engineer was raising the cab on a 1998 KME Renegade when a weld on the right side cab tilt hinge (pivot) failed as the cab was about 3/4 of the way up. The guy raising the cab was standing on the officer's side when the weld failed and the cab came crashing down towards him. Luckily he wasn't injured.

KME uses safety fuses (as they called them) on their cab tilt cylinder's so they stopped the cylinders from dropping, however because the attaching point came loose, the right rear side of the cab dropped as that's where all the weight was.

KME did say that they have seen this type of failure once before and stated that REGULAR maintenance and SAFETY inspections are a must.

These 2 pictures show the failed aluminum welds, the cab shifted (18" towards the fireman) as the cab came back down.


04-2007: Note from Ed . The KME truck manufacturing management are aware of the bad weld problem and their recommendation is maintenance should keep their eye on this. This again is manufacturing management without accountability. Preventive maintenance cannot be responsible or even aware of a potential weld failure. These aluminum welds with complete lack of weld fussion are simply bad weld practices and bad weld management.



2009: SKI DOO MANAGEMENT'S INABILITY TO CONTROL IT'S WELD QUALITY. Cracks may be developing in the welded joints of the drive axle assembly and may lead to a complete breakage of the component. This may cause the track of the vehicle to suddenly lock. If this occurs riders may be ejected off the vehicle or loose control and collide with bystanders, a fixed object or other vehicles potentially resulting in serious injuries or death.


 

IF YOU WANT TO SEE REAL WHEEL WELD AND
MANAGEMENT ISSUES CLICK HERE .


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