Among the 25 complaints regarding unexplained fracture failures, a significant number involved large-diameter wire rods with diameters greater than 11mm. This highlights a clear dimensional effect on material performance. Large-size wire rods typically exhibit a harder processing state, lower structural uniformity, and reduced sorbite content, leading to higher internal stress and brittleness. As a result, the stresses during drawing and winding for spring deformation are significantly increased, making it easier for the material to reach its tensile limit and fail. For larger specifications, cold deformation is possible depending on the overall material quality. However, as the size increases, the ability of the material to undergo cold plastic deformation decreases, and the sensitivity to fractures increases. Therefore, strict control during production is essential. Based on customer feedback, springs can be directly cold-drawn under 14mm in diameter, provided the microstructure and internal stress are properly managed. For sizes above 14mm, it is recommended that users consider annealing or heat forming to improve material properties. Additionally, surface defects such as severe cracks, bumps, and folds act as initiation points for failure, significantly increasing the likelihood of material fracture.
The analysis of complaint causes reveals underlying quality management issues. Repeated problems without effective solutions indicate weaknesses in the company’s management system. Quality experts suggest that 80% of quality issues stem from poor management practices. The company's overall quality performance reflects a lack of focus on user needs, unclear long-term quality strategies, insufficient leadership involvement in quality matters, and inadequate training for employees. A general lack of quality awareness and an overemphasis on production over quality also contribute to subpar product performance. Only through comprehensive quality management can the root causes of these issues be addressed. User complaints often point to common defects, which are not only linked to process equipment, control, and management but also to insufficient understanding of customer requirements. By improving both process and customer engagement, the company can make meaningful progress in quality improvement.
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