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Reproducing mal-functioning parts using same materials

An understanding of why the product does not break while functioning is helpful. If you know specifically what in the formulation makes the part not break when rotating then you can focus on that ingredient. Perhaps the original formulation development notes can shed some light. Why talc is used? Is it added to reinforce or physically strengthen the material or for some other property like opacity or just to cut costs?

Do you actually make the part or just buy it and use it in an assembly? If you purchase the part already made, I would suggest putting the quality testing/inspection on the seller/supplier. Enlist them to help discover what happened and why the product no longer functions. Focusing on how to prevent failure in the future rather than whose fault it is also helps resolve issues.

Reproducing a mistake can help determine what caused it. If you make the part, you can easily verify if it is the material by reproducing mal-functioning parts using all the same materials and process variables. I would also make some with the previous materials which created non-malfunctioning parts or at least different batches of the materials if retains are unavailable to verify those materials still produce good parts. This should eliminate the process or process variables like the shift or climate or time of year, etc., some operators have their own comfort settings they use instead of those specified which can often produce good parts unless combined with another variable. When this product is usually produced? Historically has it been produced only in January or only in August when it is dryer or colder or damper in the plant? Is the product only made on specific equipment? If so you might try to produce it on another machine.
Once you determine what caused the problem it will be easier to select a test or quality inspection method to screen parts going forward.

If I saw your part I'd go down a checklist:
  • Is the break point random or consistent?
  • If consistent is it weld line related? Or vent related?
  • If part of an assembly, does the mating part affect it somehow? Inserts can cause cracks in mating parts.
  • Failure during rotation: Does the load change or is it erratic or continuous?

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