Truck Door Subsystem – Automotive client
Challenge: A truck was plagued by “slow glass” movement. Failure modes differed from passenger to driver side, front to back, and included uncommon slow “down” characteristics. The problem had resisted examination by individual subsystem teams.
Discovery: Under severe time pressure, ICG gathered all mechanical and electrical component door vendors plus assembly teams to perform a combined systems analysis and FMEA (Failure Modes & Effects Analysis). A variety of issues were at root cause: stamping and hemming processes between suppliers, excessive regulator loading on the glass, and, most important, a regulator design that permitted the spring to be installed in multiple ways which proved to be the “slow down” cause.