This is the 3rd post in continuation of the 2 posts i made on linkedin earlier
you can review the first 2 posts here
The Road to Reliability: Overcoming Challenges in Differential Manufacturing
When Challenges Struck: Our Journey to Fixing the Axle Shaft Issue and Rebuilding Trust
Let's Continue
As we navigated the complex world of differential manufacturing, we knew that new challenges will emerge, testing our resolve and commitment to quality. Next challenge came in the form of a peculiar and pressing problem with brake shoes—a problem that wasn’t of our making but demanded our immediate attention.
We had been steadily producing and refining our differentials when feedback from customers brought an issue to light. Two concerns were raised, one more troubling than the other.
The first complaint was about brake shoes wearing out faster than expected. While concerning, this was something we could tackle with relative ease. The second, however, was alarming. Customers reported that, after a few days of use, the brake shoe would stick to the brake drum when brakes were applied. The shoe wouldn't release, forcing drivers to unknowingly drive with the brakes engaged. The result? Increased strain on the vehicle and, in some cases, complete breakdowns.
When we inspected the returned components, the mystery deepened. A thin, steel-like layer had developed on the brake lining. Under the high temperatures generated during braking, this layer caused the lining to stick to the inner wall of the brake drum. It was a serious issue, and we knew we had to act quickly.
We immediately launched an investigation, following a structured elimination process. Here’s how we approached it:
We started by ruling out the obvious. Testing confirmed that the brake spring and its assembly were in perfect working order. This left us with three potential culprits: the drum material, drum design, and brake shoe lining.
Spectro analysis of the brake drum material showed that it met all required standards. With this confirmed, we were left to focus on the drum design and the brake shoe lining material. Both seemed likely contributors to the problem.
We decided to address both simultaneously. On one side, we refined the machining process for the drum’s inner wall, ensuring a smoother finish that would reduce friction and heat. On the other, we opted for a new brake shoe lining with a higher coefficient of friction, designed to withstand higher temperatures without degradation.
When the revised drum design and improved brake shoe lining were tested together, the results were clear—the problem was resolved. The steel-like layer no longer formed, and the brake shoes performed flawlessly without sticking. This marked a significant milestone in our journey.
Throughout this process, one principle guided us: never let a problem pass to the customer. The moment we identified the issue, we paused production. While this approach may seem drastic, we believe it is essential to prevent the escalation of a problem within the market. For us, ensuring customer trust and safety always takes precedence over temporary delays in production.
With the issue resolved, we resumed production, confident that we had addressed a significant challenge and emerged stronger from the experience.
This incident was more than just a technical challenge; it was a lesson in accountability and perseverance. Every obstacle we face reinforces our belief that quality and trust go hand in hand. And as we continue to innovate, we remain steadfast in our commitment to delivering excellence.
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