Analysis and Prevention of Automotive Component Failure: A Case Study

This paper presents a case study on troubleshooting and resolving an issue with the High Illumination (HI) beam in the headlights of two car models. The investigation found that manufacturers’ combination switches caused the problem. The process involves carefully selecting a project, analyzing prospective results, setting clear objectives, researching the issue, verifying actions, implementing standardized methods, and scheduling future operations. Process improvement requires all of these phases to be completed. The organized problem-solving method adopted for this study has these steps involved. Under the leadership of the Production Unit (PU) manager, six investigators from several departments found that an improperly sized hole in the HI plate fitting caused the contact pressure to increase. They trained operators at the supplier’s end and swiftly distributed quality management notifications. A comprehensive study of process assessments, symptom observations, and hypothesis testing confirmed the phenomenon’s underlying cause. To fix the problem, the HI plate fitting aperture was increased by one millimeter. Since there have been no issues since adopting this procedure, validation testing has shown that it works well. To avoid this issue, we implemented and standardized results to ensure consistency across all components. This case study shows how to usea methodical approach and quality assurance techniques to find and fix auto component faults. The study signifies that comprehensive maintenance, quick problem resolution, and detailed cause investigation are necessary to ensure the longevity and satisfaction of automotive components.