The company faced repeated QC rejections due to components failing the Noise Analyzer test, with measured values ranging from 111 to 124 dB-far above the acceptable threshold of ≤100 ± 10 dB. Potential root causes included:

• Grinding wheel imbalance and vibration
• Assembly inconsistencies or heat treatment variations
• Inadequate lubricity leading to invisible burn marks
• Poor machine cleanliness and testing variability

These failures impacted batch approvals, production timelines, and customer satisfaction.