Originally posted by Sweet Pea 50
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Man, I could list parts all day long that have, and have had, a high failure rate because inferior quality and even worse quality control.
In a metallurgical lab you perform at least 10 quality checks a night per each line producing parts plus a percentage check of any parts brought in from other facilities. This involves microscopic evaluation of the entire part under a microscope, as well as cutting it into sections and examining it like that. It involves strength testing, stress testing and a whole host of other tests done not only daily but on every shift that operates. Granted, this can't guarantee that every single part sent out will last as long as it is supposed to but it does cut failure rate into the single digits percentages.
Now, for example, the Chinese manufacturing facility I worked closely with produced a key steering housing for a Dodge Durango or a Ram truck, I forget which. Regardless, they had three QC people working, per shift, in a facility that ran something like 50 lines of production. All day, all night. 9 people doing quality checks for something like 75000 parts per day. Plus they only performed 5 microscopic evaluation per WEEK.
They had a QC rating of something like 52% when they gained our contract. TRW spent untold millions of dollars reworking parts that should have been copacetic when they came through the door. However, and this is the absolute fcked up part, Dodge and Ford and Chevrolet all deemed all of this to be more cost effective than putting this on the American labor force. I mean, to them, a few deaths in relation to faulty parts, and the class action suit that could arise, are worth the risk and are less of a threat to a profit margin than using American labor. It's truly pathetic.
No automaker is immune to it, all of them have lapses. Toyota had a multitude of airbag issues and problems with parts used in the brake system. Honda has had mass steering pump issues because of faulty parts. However, Japanese QC is without a doubt the most stringent on the planet and it's not even close. It's absolutely top notch and it's part of the reason I will never ever buy a new American car off of a lot.
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