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Application:

Customers (Automotive OEM and tier two suppliers) were having intermittent fuel rail leakage. Rails were 100% tested and all passed standard leak test inspection. However, one per 100,000 rails would leak once in the field, causing the potential for injury.

 

Challenge:

Why was this problem intermittent?  Using 50% of the manufacturing tolerances, very defined disciplines and 100% leak test inspection, parts would still fail in the field.  Promess was contacted as a last resort. Customers actually purchased our lab for a day to use our Electro-Mechanical Assembly Press (EMAP) for differential monitoring to see if we could detect the problem during the assembly process.

Promess assisted in a 200-part run for 12 hours. Upon completion, we could detect 100% of failed components (reason for failure is confidential) using differential monitoring techniques in the assembly process, even though they passed the pressure test (see graph above).