Abstract
Nowadays human safety and comfort are the most considerable parameters in designing and manufacturing of a vehicle, that is why every organization ensures the quality and reliability of components used in the vehicle. Leaf spring is also a component of vehicle which plays an important role in human safety and comfort. It acts as a structural member and an integral part of suspension system. It is important to eliminate the failures in designing and manufacturing process of leaf springs because of its importance in functionality and safety of vehicle. In this research, failure mode and effects analysis has been used to analyze and reduce the risks of 42 possible failures that can occur in automotive leaf spring. It starts from determining, classifying, and analyzing all potential failures and then rating them with the help numeric scores. The four numeric scores namely severity, occurrence, detection, and Risk Priority Number (RPN) are used to find the high potential failures of semi-elliptical leaf springs. In the end, actions are recommended for RPN greater than 250, to increase quality and reliably of product.
Highlights
History of leaf springs goes back to the Romans who decided that their chariots need suspension system when riding on irregular surfaces
Failure with Risk Priority Number (RPN) more than 250 are considered high priority failures according to Table 4 and actions are recommended for more reliable future design and manufacturing process
The second highest RPN is of less length for main leaf which can be controlled by periodic inspection of shearing machine and proper training of worker
Summary
History of leaf springs goes back to the Romans who decided that their chariots need suspension system when riding on irregular surfaces. There are many problems which a leaf spring manufacturing organization can face in designing and manufacturing process of a product. The increasing competition in the industry is forcing the manufacturers to adopt several quality improving tools. Failure mode and effects analysis (FMEA) is a tool for manufacturing organization to begin looking at their problems and correcting them while improving the quality and reliability of product. FMEA looks at all realistic potential problems and rate those problems with a numeric score
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