To ensure top quality I have an extensive quality control system check and keep track on
all production lots made. All companies that make products to my specification have to comply to this quality level. The checks are done according to the TUV Quality Management System that was implemented to keep track records, to secure the TUV approvals and cover warranty issues. All products that are delivered to my warehouse are checked and tested to see if they are conform my specification.
However, in the last production lot, made by Weweler-Colaert NV, I had to reject 144 springs out of a batch of 200 units,
normally no rejections have to made because the quality control of the factory does not allow rejected springs to be shipped out.
 This should be
semi-eliptic, however, it looks like it was shaped by hand.. |
 Spring on test bench, it should be horizontal, not like a
moustache.. |
 Same spring,
but other side |
Our test bench is TÜV approved and measures within the strict
tolerances, so any errors are ruled out
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Irregularities in the shape of the main leaf caused by
incorrect setting of the leaf.
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Without force, the leaves touch, also the absence of the semi elliptical
shape is visible
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This bending is not normal and is rejected. There is a high
risk of failure and contact between the leaves when taken into use
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Again, a strange upward bending, however, it is a different
spring
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Overview of the multitude of incorrect shapes and other irregularities,
the markings show the extreme points.
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Here the poor painting of the springs is visible
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The shape of the leaf end and roundness of the eye is clearly
visible
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The roundness is visible, also the diameter is outside the tolerances
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The leaves should run in an identical semi-elliptical shape,
always with regular distances in order to prevent touching and
stress points along the leaf, clearly not the case with these
springs
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The second leaf is designed to wrap around the spring eye,
this is for safety,..
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..that is why it should wrap all the way down (left unit), not wide open like
the right unit.
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All details are specified in the master drawings, which I
supplied when I placed the order.
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.. More irregularities. The diameter is too large and will not
hold the bushes, so also a rejection.
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More non semi-elliptic shapes
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An other wrap-up not according to my specs.
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Large batches where rejected,..
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The result of the in-take quality control was appalling,
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The quality level is very low, considered that Weweler-Colaert
had a good reputation in making high quality products..
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..now this has been proven not the case!
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Also surface damages are precent
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Because it is the tension side, any damage will shortens the
life of the spring considerably
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The second leaf is not lining up with the main leaf, this
results in steel to steel contact with the chassis.
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Workers in the factory had problems assembling the springs, to
make things "easy" they ground-off the side of the eye
(!)
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More surface damaged caused by the cold-press used to re-shape
the leaves after the final quenching
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No semi-elliptical shape is present in this batch..
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All marked spots are not conform the drawings and specs.
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Not one spring looks like the other..
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Bending by hand? impossible; too hot, however, it looks like
it was.
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The main leaf in not lining-up with no.2,3 and 4
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