Root Cause Analysis of a Braking System Issue: From Data Analysis to Root Cause Identification

This dissertation contains the results of a 6 month-long internship at Maserati S.p.A. , in the Proactive Quality department, as a member of the team chassis. More specifically it aims at explaining , in a clear and easily understandable way, the process of resolution of a quality problem affecting the braking system of some models of the group. The extent of the study starts with the identification of the problem and ends with the identification of the root cause originating it. Explaining in detail the steps undertaken throughout each single phase of the project, with the ultimate objective of identifying the root cause of the problem and proposing some countermeasures. In particular, at first a detailed description of the main components of an automotive braking system is provided, with specific focus on the description of friction material different types and characteristics. After a first smattering, covering the essential info which the reader is required to know in order to properly understand what explained further on, the data analysis of warranty data about the braking system is reported. Following the data analysis, and based on its results, the problem-solving approach adopted is explained, including the discussion of all the hypotheses formulated. Consequently, the planning, execution and results of benchmarking with competitors and laboratory tests to verify or discard each hypothesis. Eventually, the explanation of the root cause and the evaluation of various countermeasures and containment solutions.