Part #

Defect

BX769097

BX769097

723487-1

723487-1

723487-1

723487-1

723487-1

723487-1

822536-12

822536-12

822536-12

822536-12

725436-1

725436-1

725436-1

C722589-12

815239-3

815239-3

765722-10

765722-10

765722-10

765722-10

4503225

757255

744278-1

733782-10

733782-10

MD755941

MD1700002

Linear Indications

Through W

all

Undercut ULL

Wall Thickness .050-.055 ULL

Hole Missing B/P Loc View E

Did Not Clean Up Surf -A-

Dimple

Packaging Foam on Part

Linear Indications

Dimensional

Did Not Clean Up Suf -E-

Thru-W

all Void B/P Loc View M

Core Blow

Did Not Clean Up

Void

Lack of Cast Mat'l

Porosity on Machined Surface

Thru-W

all on Cast Surface

Void

Groove Cuts

Linear Indications

Did Not Clean Up

Wall Thickness .-25-.045 ULL

Positive Caast Material

Dimensional

Burr

Nodule and Sand

Core Blows

Did Not Clean Up

December-05 Field

HS

DSQR

November-05 Field

HS

DSQR

October-05 Field

HS

DSQR

September-05 Field

HS

DSQR

CUSTOMER: Hamilton Sundstrand

Joe's Machining Elephant Chart of Customer Escapes

Where the defect

was caught?

Field

HS

DSQR Metric requirement

Year to date totals

DSQR

August-05 Field

HS

DSQR

July-05 Field

HS

DSQR

June-05 Field

HS

DSQR

May-05 Field

HS

DSQR

April-05 Field

HS

DSQR

March-05 Field

HS 3 3 4 5 6 3 3 6

DSQR

February-05 Field 1 1 1 1 1 1 1

HS

DSQR

January-05 Field

HS

DSQR 3 3 3 3 2 2 2

Field 1 1 1 1 1 1 1

HS 3 3 3 5 6 3 3 6

DSQR 3 3 3 3 2 2 2

Field 2

HS 2 1 17 12 3 2 2 1 4 8 4 1 2 31 3 2 1 1 1 1 1 1 49 1 10 7 7 7 3

DSQR

Field 2

HS 5 3 20 19 6 4 4 3 6 10 6 3 4 33 5 4 3 3 3 3 3 3 52 4 20 7 7 7 3

DSQR

2003 TOTAL

2004 TOTAL

2005 TOTAL

Tracking Months

Ascending

upward

Metric requirement