Automotive diesel pumps made by a major automotive supplier break and fail when in use, with the risk approaching 100 percent. The company tries to locate the causes using internal resources and the help of four renowned institutes. The result: €140 million in damages without the cause having been found.
S.QE uses forensics and a subsequent confirmation by statistical DOE to locate the cause. The company had changed the milling direction on
a sealing surface to solve a small technical problem that arose when manufacturing the pump casing. The changed surface profile around the seal led to erosion followed by tearing and finally the complete failure of the pumps. Adapting the milling procedure reduces the error rate by 100 percent, saving about €120 million.