CMI-07072022-A

Updated: 07/7/2022
STATUS: Open
ESCALATION:
BACKGROUND
• JEP (Jamestown Engine Plant) has received 35 BIS (Before In Service) reports of ECM’s (Electronic Control Modules) with No Communication;
• 1 reported by DTNA Cleveland
• RMEP (Rocky Mount Engine Plant) has received 15 BIS reports of ECM’s with No Communication;
• 9 reported by DTNA (4 at DTNA Santiago, 2 at DTNA Mount Holly, 2 at DTNA Cleveland, and 1 at FCCC Gaffney)
• There have been no failure reports from units at the supplier or at Cummins plants
• Cummins is investigating 1 reported failure from the field
FAULT CODE/FAIL MODE
• Engine will not start and ECM will not communicate
• ECM has no communication and may cause the engine to stop running
CURRENT STATE
• Total suspect ECM’s for all Cummins locations = 15,122
• No suspect ECM’s were shipped to Cummins MDC locations
• The supplier (Vitesco) does not have new ECM’s from the suspect population at their facility
• Suspect quantity of ECM’s for DTNA:
• RMEP = 1590 total (787 - Kontane, 729 - Santiago, 63 - TBB High Point, and 11 - Portland)
• JEP = 254 total (137 - Kontane, 79 - Saltillo, 27 - Santiago, and 11 - Portland
ROOT CAUSE AND GOAL STATEMENT
• Selective Solder Fixture had a screw loose. Screw was contacting the Lytic cap and applying excess force into the PCB (Printed Circuit Board).
Vitesco can detect a direct short of capacitor ground post to V-Batt layer. However, when the capacitor post ground is pressed into the dielectric
layer, there is no short to detect. Some scrubbing or movement of PCB & capacitor wears through the dielectric layer into the V-Batt layer resulting
in high current draw and heat leading to L2002 reflow and ECM No communication.
Cummins Confidential
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Updated: 07/7/2022
STATUS: Open
ESCALATION:
Completed
• Selective Solder Screw maintenance log shows repair on 06/03/2022 at the Supplier
• This date was determined through the failure investigation of an ECM that was returned to the supplier on June 27th; the supplier notified
Cummins on June 28th with this information
• To date Vitesco has analyzed 5 ECM’s returned from OEM’s
• SCAR issued to the Supplier
• RMEP is building with clean date ECM’s
• JEP is building with clean date ECM’s
Location of loose/raised screw
in Selective Solder fixture
Damaged Lytic Cap
Cummins Confidential
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Dielectric
Over layer 5
V-batt-fltr
Layer 6
Ground
Layer 5
Ground
V-batt-fltr
Layer 6
Ground
3
PC Board layers
Capacitor
Bulkhead
4
Updated: 07/7/2022
STATUS: Open
ESCALATION:
NEXT STEPS
Agree on next steps for engines still at customer locations and past customer locations
Vitesco
• Complete analysis of a module manufactured May 10th
• No visible dents, will cross-section to confirm no issues
• Complete cross sections (3)
• (1) Current module (manufactured June 28th) to confirm no issues
• (2) Module manufactured May 10th to confirm no issues
• (3) Suspect module to understand proximity to trace
• Information and pictures available July 7th for all 3 cross sections
• Complete combined environment testing (shaker and temperature, 1 shaker table with 3 nests)
• Publish results of testing using different levels of a loose screw
• Understand different failure rates between Heavy Duty and Midrange, is it related to vibration, heat, etc..
• Revisit the use of x-ray or scans to see if the defect can be identified
• Re-creating defect
• Does part pass Vitesco testing but starts to look physically different
• Define screening method for ECM’s already in trucks
• Perform Risk Assessment for ECM’s already in trucks
Cummins Electronics
• Working on CT imaging in the Fuel Systems lab
• Understand if dent is visible
• Understand if compressive residual stress can be measured
Cummins Confidential
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