Quality in Gear Manufacture: A Case Study

The result of a Teaching Company Scheme between the University of Newcastle‐upon‐Tyne and Eaton Ltd (axle division), Newton Aycliffe, is presented. The programme was devel‐.pb oped to address quality problems encountered in the manufacture of the main driving gears in truck axles. There had been quality‐related rejections of gearsets in the plant and by customers. The nature of the problems was essentially unknown; it was generally termed “distortion” and was thought to be related to the heat treatment process. The approach to quality appraisal in two areas of the plant is described and a description of the production environment is outlined. The use of quality procedures and reporting systems for quantitative analysis is developed. Among the major findings are: the need for communication; the important role of simple quality systems; the need to identify material quality and process‐induced variables.