Creation of a preventive and predictive maintenance system on automatic test benches for Stellantis transmissions

Present work goal is the know-how acquisition of structure and operation of an NVH test bench for Stellantis transmissions, with the aim of building its Quality Maintenance system by applying the 7 Steps of Quality Control Pillar (WCM). Throughout the study, two main benches' chronic loss factors are detected and faced: - Bearings overheating on "primary shaft" group; - Tripods joint unscrewing and elastic joint breakage on "secondary shafts" group. In both cases the Advanced Kaizen tool is implemented to analyse the issues, to verify the system according to the State of Art, and finally to make proposals of alternative layouts, in order to eradicate the loss factors. After the Opening Chapter, the first Chapter is devoted to the presentation of Stellantis plant (Mirafiori Meccanica in Turin), the transmission C5.14 produced there and the stage activity run from March to September 2021 link to the project; the following two Chapters contain information about the test bench and the theory of WCM applied in the study. In Chapters 5 is depicted the application of the 7 QC Steps to the case study and in Chapter 6 are set out the two Advanced Kaizen's development. Final Chapter contains the results of the analysis, together with the impact quantification of the corrective actions implemented at Mirafiori Meccanica: it is proposed a focus over the beneficial effect on the Quality KPIs, which are affected by the excessive noise level recorded during the NVH test and caused by the two chronic loss factors attacked. It is shown the stable decrease of fake scrap after the issues resolution and, regarding the improvements which have yet to be realized, is proposed a road map for future works towards a further test benches' enhancement.