D
David McGan
We have come up against a "Catch-22" situation that I frankly am at a loss to figure out. Chrysler requires a "complete annual layout inspection." For those familiar with die casting, it is naive at best to think that a casting die with 100,000 (or even 50,000) shots will conform 100% to all print dimensions. To correct some of these dimensions would require welding of the steel, which would severely accelerate further deterioration. To replace the cavity set prior to the one-year anniversary would result in scrapping a die that is producing fully functional parts.
Once we have performed this annual layout and find a dimension outside print tolerances, we can no longer knowingly ship parts made with this die. If Chrysler will not give us a deviation to ship, or will not waive the annual layout requirement (both of which have happened), our only alternative is to not ship parts. Yet, Chrylser tells us that we MUST ship parts.
If we send the die to the tool shop to have the discrepancies corrected, we still will miss shipments. If we produce a bank of parts to allow us time to correct the die, then we can't ship those parts, either.
I wonder if anyone at Chrysler really considered the potential ramifications of this requirement. Has anyone had any experience with dealing with this issue? (I would ask my registrar, but am reluctant to do so, for unstated obvious reasons).
In addition, it is only going to get worse, because effective January 1, 1999, Ford will also require annual layout.
Once we have performed this annual layout and find a dimension outside print tolerances, we can no longer knowingly ship parts made with this die. If Chrysler will not give us a deviation to ship, or will not waive the annual layout requirement (both of which have happened), our only alternative is to not ship parts. Yet, Chrylser tells us that we MUST ship parts.
If we send the die to the tool shop to have the discrepancies corrected, we still will miss shipments. If we produce a bank of parts to allow us time to correct the die, then we can't ship those parts, either.
I wonder if anyone at Chrysler really considered the potential ramifications of this requirement. Has anyone had any experience with dealing with this issue? (I would ask my registrar, but am reluctant to do so, for unstated obvious reasons).
In addition, it is only going to get worse, because effective January 1, 1999, Ford will also require annual layout.