Lessons Learned

Induction Heat Treat

3/13/17
PRI 16021-01

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MFPMEA for Induction Heat Treat Version 12/10/15
Recommendations for:
a. Product
b. Process
c. Equipment

(details in next pages)

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MFPMEA for Induction Heat Treat Version 12/10/15
Detailed description of Process Control (describe the best practice control for this failure mode)

a. Product:

1) Retain all cut samples. If Safety Characteristics apply, then follow PS Safety:
a. set-up samples -1 year
b. samples after program change 1 year
c. first piece after maintenance 1 year
d. 6 months of production samples (FCA approval required, for deviations)
d1. first piece samples of the week 1 year

2) 100% NDT automated inspection for shafts to detect soft spot or low surface hardness for safety shield
characteristic; or as alternative use lot release following inspection recommendations listed here.
3) Frequency of destructive testing: 1 per spindle, per 500 pieces or every shift if 500 not achieved in one shift
(deviations must be approved by FCA materials engineering), additional to set-up/1 st piece.
4) Hardness checks on diameters should be minimum 4 circumferential interface locations.
5) Reported hardness measurements must be an average of minimum 3 indents per required location.
6) Microstructure checks need to be in an etched and polished mount.
7) Microstructure checks required for assembly interface location(s). Locations shall be reviewed and agreed with
FCA Product, Materials and SQ Engineering.

Lessons Learned /Best Practices (Blue)

CQI9 & PS.50011 (Purple)
CQI9 (Orange)
PS.50011 (Green)

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MFPMEA for Induction Heat Treat Version 12/10/15
Detailed description of Process Control (describe the best practice control for this failure mode)
b. Process:

1) Induction Heat Treat Program:

a) identify the start / stop area of each scan speed location / zone as a critical characteristic in the control
plan. Lock PLC controls from unauthorized changes.
b) metallurgy lab specification / cut sheet to specify all inspection location(s) meet Start/Stop scanning
speed areas and satisfy print requirement for functional areas, each spindle. Cut sheets have to be
reviewed/approved with FCA Product, Materials and SQ Engineering.
c) Password protect non-operator functions.
2) Update Process Monitoring System with electronic record of inspections tied to start of production / set-up:
a. quench flow
b. quench concentration
c. coil maintenance, including visual inspection at start of each shift.
d. quench system (ring/nozzle/tank/filter)
e. coil signature
f. all metallurgy lab inspections
g. any other (detailed) machine maintenance
3) Add to Management Review Induction Heat Treat Program Audit.
4) Lot traceability tied to birth certificate / part identification.
5) Control of the energy or power for each part.
a. A signature monitor for each machine is preferred. A signature monitor gives the energy unit (voltage, kilowatt,
etc.) vs. time or distance (for scanning systems).
b. An energy monitor or equivalent is acceptable if approved by the authorized customer representative.
6) The heat treat supplier to have a coil management system. Coil refers to the heating coil and the quench
plenum.
a. Spare coils for each part shall be available on-site.
b. Coils shall conform to the approved original design.
c. Engineering change approval from the customer is required whenever the coil design is changed.
Lessons Learned /Best Practices (Blue)
CQI9 & PS.50011 (Purple)
CQI9 (Orange) 3/13/17 5
PS.50011 (Green)
MFPMEA for Induction Heat Treat Version 12/10/15
Detailed description of Process Control (describe the best practice control for this failure mode)

c. Equipment:

1) Use of flow meter and pressure sensor to detect acceptable flow at each induction coil.
2) Use stainless steel filter canisters / non-corrosive components on Induction line. Filtration system shall be
capable to filter quench media down to 100 micron size.
3) PM procedures to include the induction machine, quench rings & induction coils, verify cleanliness inside and
outside of components are clean and free of contaminants; per equipment manufacturer recommendations.

Lessons Learned /Best Practices (Blue)

CQI9 & PS.50011 (Purple)
CQI9 (Orange)
PS.50011 (Green)

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 Powertrain Mexico Strategy
Campaing
Kickoff Meeting
with tier 1

Campaing
Kickoff Meeting
with tier N

Follow-up call Follow-up call

Checklis review Checklis review

March April

3rd party Audit

CQ1-9 CQI-9 Implementation and/ or Audit recomended

MPFMEA Read across Implementation

Leasons learned

Compliance Audit

- At key tier 1 & tier N

At Tier 1
MPFMEA Compliance
CQI- 9 Compliance

At Tier N
FCA SQ Tier 1 MPFMEA Compliance
Responsability Responsability CQ1- 9 Compliance
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