Before production of a new generation of cars is set to start, an automotive manufacturer is experiencing problems with modular retractable glass sunroofs: They rattle, creak and click. An error rate in excess of 70 percent per shift has everyone scratching their heads and wracking their brains. Production start and product launch are at risk.
S.QE designs an emergency program for the automotive company. Four key errors are identified after technical and statistical data analyses.
Developing a new measurement system on short notice reduces the error rate to under 5 percent. This also limits possible causes, which means that long-term design and process changes can be implemented. Special slow-motion images help locate concrete evidence for the physical process that is causing the sounds and redesign the geometry of the product.