Last updated:
04-02-2010

Recall of recent production

Due to quality problems with springs made by Weweler-Colaert NV in Belgium

To ensure top quality we have an extensive quality control system check and keep track on all production lots made. All companies that make products for us to our specification have to comply to this quality level, drawings specification are supplied and combined into a written production agreement which is signed by both parties to ensure a proper legal basis. All this and the quality checks are described in the TUV Quality Management System that was implemented to keep track records, to secure the TUV approvals and cover warranty issues. Subsequently all products that are delivered to our warehouse are checked and tested upon arrival to see if they are conform the agreed specifications.

Weweler-Colaert NV agreed, in writing, to make for us these products and this resulted in a production and delivery of springs early 2009, however, we found that a large part of the production was not conform the specifications. Normally no rejections have to be made because the ISO quality control system of the factory does not allow rejected/non conform springs to pass the inspection and/or to be shipped out so it was surprising to us, when we made our intake inspection, to see that there where so many bad springs delivered.

To ensure that we have made the correct assessment of the quality of these products we have called in an external consultant engineer who did a full inspection of all springs. 
Results: The majority of all springs show on more then 4 points major differences outside the tolerances.

The steel was analyzed at an external, approved, laboratory to establish both metallurgical composition and hardness.
Results: Steel composition: OK - Hardness: NOT OK. 

The results of the inspection of both the engineer and the lab matched our own data and their conclusion confirms our findings;
The conclusion: All springs are rejected!

The pictures below are taken from this production lot made by:

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
	Irregularities in the shape of the main leaf caused by incorrect setting of the leaf.	Without force, the leaves touch, also the absence of the semi elliptical shape is visible	This bending is not normal and is rejected. There is a high risk of failure and contact between the leaves when taken into use
Again, a strange upward bending, however, it is a different spring	Overview of the multitude of incorrect shapes and other irregularities, the markings show the extreme points.	Here the poor painting of the springs is visible	The shape of the leaf end and roundness of the eye is clearly visible
The roundness is visible, also the diameter is outside the tolerances		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
The second leaf is designed to wrap around the spring eye, this is for safety,..	..that is why it should wrap all the way down (left unit), not wide open like the right unit.	All details are specified in the master drawings, which I supplied when I placed the order.	.. More irregularities. The diameter is too large and will not hold the bushes, so also a rejection.
More non semi-elliptic shapes	No comment...	An other wrap-up not according to my specs.
Large batches where rejected,..	The result of the in-take quality control was appalling,	The quality level is very low, considered that Weweler-Colaert had a good reputation in making high quality products..	..now this has been proven not the case!
Also surface damages are precent	.. no comment ..	Because it is the tension side, any damage will shorten the life of the spring considerably	Cutting by hand?
The second leaf is not lining up with the main leaf, this results in steel to steel contact with the chassis.	Workers in the factory had problems assembling the springs, to make things "easy" they ground-off the side of the eye (!)	More surface damaged caused by the cold-press used to re-shape the leaves after the final quenching	.....
No semi-elliptical shape is present in this batch..	All marked spots are not conform the drawings and specs.	Not one spring looks like the other..	Bending by hand? impossible; too hot, however, it looks like it was.
The main leaf in not lining-up with no.2,3 and 4	Spring eye diameter has the shape of a cone, it should resemble a cylinder...	More cones..	...

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