Eastgate Engineering – Incorrect Threads

Steyr Motors ordered 127 x CDZ9-129 anodes. Invoice 41732. On fitting the anodes, they found that they did not fit the threads.
They returned the 127 anodes. JL tested them and found inconsistencies. Some were too loose, some too tight and other OK. We had 1085 of these threads machined in May, and the inconsistencies are evident throughout the entire batch (our PO 14456 with Eastgate Engineering).

JL apologised offered to credit Steyr for the entire order. Steyr replied that they will be going back to the original equipment manufacturer and they want a full refund.

Eastgate explanation 20OCT17:
Hi Jody
Just replying to your email sent to me with an update regarding these anodes. We have gone through these and have found that there was a malfunction of some kind in this run of parts due to human error. Unfortunately this was not picked up in the process and at QC of parts on completion. To this end Eastgate takes responsibility (limited to replacement or rework of faulty parts) we will remake the faulty parts that are undersized and rework the oversized parts as per our policies. We have some Zinc bar here from previous owners of Eastgate but will be in contact to purchase further bar to rework the balance. We have done a full investigation into the issue and attached is the quality sheet which was done at run of job which is lacking and a big part of the issue which has been addressed in our factory.
We value our reputation for quality and in the 7 years I have been at Eastgate I have never seen this happen on Zinc bar as once job is set Zinc is one of the few jobs we can run on lights out machining and with these types of low profit jobs we do regularly run after hours with no issues. Attached is a copy of the in house quality sheet and also an extract from our contract policy’s we do encourage our customers to do a quality check on their parts on receipt of goods as at the end of the day we are dealing with humans and machines both of which have breakdowns at times. We have a great in house QC process that has been inspected and approved by some multinational companies we make parts for and this occurrence is extremely rare as we generally always pick up on any issue before it gets to our customer.

Below is an extract from investigation of quality issue in house.

Again apologies for the inconvenience with this order and as stated above we will replace the parts at our cost.

Results of investigation into quality issue.
1. Upon investigation of machine no faults could be found, it was determined that it had to be a human error of either wrong tool tip in toolholder or tool cutter tip not installed into holder firmly causing inconsistent machining.
2. QC sheet was not adequately completed this has been addressed in the factory.
3. Suggested new no go gauges for these type of jobs to be sourced for quick checking of parts on machine.

Thanks and Regards
Craig Williams / Manager

20OCT17: BL forwarded the explanation to Steyr and also indicated that our internal failure was not to check any of the threads prior to disptach. This has been discussed in our factory for future orders from Eastgate and other companies. Awaiting reply from Steyr whether we get second chance.

27JUL18: CAR Re-opened. We ended up re-supplying more CDZ9-129 to Steyr. Again, the anode threads did not fit in the genuine Steyr plugs (but they fit our plugs). They bottomed out before screwing all the way in, as the threads were too long. Problem with about 10% of anodes. The whole batch returned to Eastgate, who will check each anode and fix the ones that are too long. Then send the correct anodes to Steyr and the remainder back to us for our stock.

11MAY18: Recently commenced discussions with Steyr. No orders received since the incident.
27JUL18: CAR Re-Opened. Replaced incorrect anodes. Second time in 2 jobs that we have had trouble with these anodes. Not sure whether Steyr will continue to purchase from us. Eastgate staff told to manually check each anode prior to dspatch to us. CAA staff trained to check all threads when good arrive.
05SEP19: Eastgate pricing has gone through the roof, so we will no longer use them regardless of this quality issue. LS found an alternative supplier IFS.

Verification –Leave open until JUL19 (1 year).See if similar issues re-occur.
Reported by –BL
Closed by –BL
Date closed –September 5, 2019