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All of us in the manufacturing industry understand the importance of quality testing. For the customer, quality testing means assurance that the product performs properly—assurance that the tank will not leak, that the pump casting does not have imperfections, resulting in a leak. For the manufacturer, bad parts delivered to the customer mean lost revenue, or even lost business. That's why it is important to have a system in place to identify and deal with substandard parts. But what if the manufacturer is failing good parts? The consequences are far more subtle, but nonetheless impactful for both the manufacturer and the customer. Costs rise as production must be increased to compensate for the lost parts, costs that are often passed on to the customer. Such was the case with one of our clients, a consumer goods manufacturer. They were leak testing the water-tightness of a dishwasher component, an unpressurized water vessel, using a bubble test. The vessel was filled with air and submerged, and escaping bubbles signaled leaks in the ultrasonic weld seam, resulting in a fail. However, the customer had not been taking into account the fact that the difference between the size of an air molecule (the medium used in the application) and a water molecule (the medium that the part was specified to contain) means that air can escape through openings that water can't. By using an antiquated technology that was still in place only because of years of use, the company was rejecting a high percentage of potentially good parts that leaked air, but would not necessarily have leaked water. We helped this customer by first identifying the problem in their current application, and then designing a new custom solution. Could your leak test or other application be failing good parts? Although quality isn't the issue, the wasted time and materials could be leaching money from your profits and limiting your company's ability to compete. It may be time to update. Don't keep doing it the way you're doing it because it's the way you've always done it.
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About Us: Turner Machine Company is a custom automation solutions provider with an emphasis in leak testing, fluid dispensing, robotic automation, engineering services and Low Cost Regions Sourcing. For more information, visit the company website at: www.turnermc.com.
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