During the production of air spring assembly process, bead plate edge banding process around bead area of rubber flex member, scrap can sometimes occur. This can happen when bead plate does not have even shape of crimp around the circumference of bead plate and in one area bead misses crimp. The problem was addressed with A3 methodology for structured problem solving which enables detection of root cause for error leading into scrap. With help of analysis we identified two types of error, the first type is a consequence of predeceasing production step and the second type is caused by stretching the bead. We eliminated the first type with a change of work instruction on the predeceasing production step, while the second type was resolved by changing the crimping tooling for edge bending of bead plate. Adjustment of tooling resulted in changed profile of crimp and eliminated the problem with stretching the bead. With mentioned modifications we managed to completely eliminate above mentioned scrap.
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