Mustang Rear Stabilizer Bar Bushing Squawk. Project Leader: Rod Watts Project Champion: Jeff Check Commodity Manager: Brent White Process Owner: Mike Wroblewski Organization: Chassis / Vehicle Engineering Project Location: Flat Rock Assembly Plant Project Completion Date: Feb 28 th , 2013. - PowerPoint PPT Presentation
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6-PANEL6-PANEL
6 Panel Team Leader Corporate 6-PANEL Template version 3.3.ppt
Originated: March 12, 2002 Updated: April 29, 2009
STANDARD REPORTING METHODSTANDARD REPORTING METHOD FOR PROBLEM SOLVING FOR PROBLEM SOLVING
DEFINE VOICE OF THE CUSTOMERDEFINE VOICE OF THE CUSTOMER
DDDD MMMM AAAA IIII CCCC RRRR
VOICE OF THE CUSTOMER: From initial concern notice verbatim “CUSTOMER STATES SQUEAKING NOISE REAR OF CAR OVER BIG BUMPS”CTQ STATEMENT (Customer Requirement): No audible bushing noises for life of the stabilizer bar assembly.
DEFECT DEFINITION for Y (Objective Metric): Audible squawk inside of vehicle from rear stabar bushings.
COST OF POOR QUALITY: Cost TBD, collected from containment, replacement, disposition, repair.Average cost to date $106 per repair.PROBLEM STATEMENT, SCOPE, AND GOAL Squawk noise in vehicle from rear stabilizer bar link bushing. Issue effecting all parts built since May 2013 change. Goal is to reduce stabar bushing noise in vehicle to zero.
Flat Rock Assembly PlantFlat Rock Assembly PlantSuspensionSuspensionChassisChassis
2013 S197 Mustang Rear Stabilizer Bar Assembly2013 S197 Mustang Rear Stabilizer Bar Assembly CR33-5A771-A BAR ASY RR STABCR33-5A771-A BAR ASY RR STAB
6-PANEL6-PANEL
Originated: March 12, 2002, Updated: April 29, 2009Corporate 6-PANEL Template version 3.3.ppt
CONTAINMENT (state reasoning if not required): Testing shows noise present at low temperature for all bushings. Above data is for bushings using normal soapy water installation at MSSC.
High Force Bushing(WOW) Temperature
-20 deg F-20 deg F -10 deg F 0 deg F 10 deg F 20 deg F 30 deg F 40 deg F 50 deg F
Noise Noise Noise Noise No Noise No Noise No Noise No Noise
-10 deg F-10 deg F 0 deg F 10 deg F 20 deg F 30 deg F 40 deg F 50 deg F
Noise Noise Noise Noise No Noise No Noise No Noise
0 deg F0 deg F 10 deg F 20 deg F 30 deg F 40 deg F 50 deg F Noise Noise Noise No Noise No Noise No Noise
High force bushings are from material lot 8/22/12 01235157. Average rotational force on 6 parts was 20.60 lbf.
Low Force Bushing (BOB) Temperature
-20 deg F-20 deg F -10 deg F 0 deg F 10 deg F 20 deg F 30 deg F 40 deg F 50 deg F
Noise Noise No Noise No Noise No Noise No Noise No Noise No Noise
-10 deg F-10 deg F 0 deg F 10 deg F 20 deg F 30 deg F 40 deg F 50 deg F
Noise Noise No Noise No Noise No Noise No Noise No Noise
0 deg F0 deg F 10 deg F 20 deg F 30 deg F 40 deg F 50 deg F No Noise No Noise No Noise No Noise No Noise No Noise
Low force bushings are from material lot 12/12/12 01347031. Average rotational force on 6 parts was 7.27 lbf.
6-PANEL6-PANEL
Originated: March 12, 2002, Updated: April 29, 2009Corporate 6-PANEL Template version 3.3.ppt
Theoretical Bushing Rotational Forces and Friction Simulation: Link bushings were sent to Axel Products in Ann Arbor, MI for rubber property analyses. This friction and hyperelastic
data was utilized in Ansys as a basis for simulating the expected link rotational forces.
Theoretical Bushing Rotational Forces and Friction Simulation: The theoretical force values of 10.1 lbs (45.0N) for 22mm and 11.3lbs (50.66N) for 24mm were lower than what was
measured at MSSC and FRAP. The difference shows us that there is another factor causing of higher efforts apart from simple geometry and the material variation.
6-PANEL6-PANEL
Originated: March 12, 2002, Updated: April 29, 2009Corporate 6-PANEL Template version 3.3.ppt
Images below show rotational force testing. Noise testing is performed the same but part is pulled by hand rather than by the force
instrument.Wax State of Cure1st Pass = Wax in MB (Current ZD022S Material) High = 360 Seconds3rd Pass = Wax in Final (Trial EX2332 Material) Low = 270 Seconds
LubricantsSoapy Water - (4oz soap - 3L water) Applied by dipping the bushing end of the link into the lubricant.
NYE 880 Gel - (straight) Applied to bushing ID with a brush.Napthetic Oil - (straight) Applied to bushing ID by finger.
PreparationApply lubricant to bushing ID. Install bar into bushing ID. Let parts sit 24 hours prior to testing.
Testing (after 24hr rest)
*Rotate parts 30o and record force using handheld force instrument.
Assemble link with bushing/ bar into test fixture.Place fixture into chamber. Soak in chamber with liquid nitrogen at correct temperature for 10 minutes.Remove after soak and place fixture into vise.
Immediately rotate and evaluate for noise. Rotation is to be one back and forth movement of 30o each direction. Specify whether the link or can is rotating around the bar.
Repeat rotation every 10oF as part warms, evaluate for noise and specify whether the link or the can is rotating around the bar. Record results.
Install Lubricant: Soapy Water Temperature / Noise Test Results Specify whether link or can is rotating around the bar. Also specify at what temperature.Wax State of Cure Rotational Force (lbf.) -40 F -30 F -20 F -10 F 0 F
1st Pass Add Low 5.80 Squeak Squeak None None None Link rotating around bar. (All temperatures)1st Pass Add High 6.20 Squeak Squeak Squeak None None Link rotating around bar. (All temperatures)3rd Pass Add Low 4.60 Squeak None None None None Link rotating around bar. (All temperatures)3rd Pass Add High 4.40 None None None None None Link rotating around bar. (All temperatures)
Install Lubricant: NYE 880 Gel Temperature / Noise Test Results Specify whether link or can is rotating around the bar. Also specify at what temperature.Wax State of Cure Rotational Force (lbf.) -40 F -30 F -20 F -10 F 0 F
1st Pass Add Low 2.00 None None None None None Link rotating around bar. (All temperatures)1st Pass Add High 1.80 None None None None None Link rotating around bar. (All temperatures)3rd Pass Add Low 1.80 None None None None None Link rotating around bar. (All temperatures)3rd Pass Add High 2.00 None None None None None Link rotating around bar. (All temperatures)
Install Lubricant: Napthetic Oil Temperature / Noise Test Results Specify whether link or can is rotating around the bar. Also specify at what temperature.Wax State of Cure Rotational Force (lbf.) -40 F -30 F -20 F -10 F 0 F
1st Pass Add Low 7.20 None None None None None Link rotating around bar. (All temperatures)1st Pass Add High 6.80 None None None None None Link rotating around bar. (All temperatures)3rd Pass Add Low 5.60 None None None None None Link rotating around bar. (All temperatures)3rd Pass Add High 5.80 None None None None None Link rotating around bar. (All temperatures)
6-PANEL6-PANEL
Originated: March 12, 2002, Updated: April 29, 2009Corporate 6-PANEL Template version 3.3.ppt
REPLICATION (who else across Ford Motor Company could benefit?): Key Actions Is this Replicable? If Yes, Where? Responsibility
Note: Recommend initiating Global Corporate Learning E Tracker and complete Prevent Action Health Chart to assure replication AND corporate memory is
updated and critical x’s are replicated in current and future models. http://www.etracker.ford.com/apps/AddIssues/AddIssue.asp?ProjectID=GCORPLRN
UPDATES TO CORPORATE KNOWLEDGE BASE (what core documents or processes require update?): Core Book Change Made Owner Agree? Document/ E Tracker # Completed
Requirements (SDS/VDS: Trustmark, GAP, Spec.) Foundation FMEAs CETP GPDS MDS LQOS Warranty Savings Checklist Other (Specify):List available at web link: http://www.quality.ford.com/warranty/html/gcl_pr.htm
Replicate: Who else at Ford can benefit from the project findings?
What has been done to update the corporate knowledge?
(Six months later…) Is the improvement sustained?
Corrective and Preventive ActionsCorrective and Preventive Actions
By signing this document, I agree that the project has been completed and that the design requirements / process standards have been implemented as declared above.
Checklist for Warranty Savings Opportunities: YESYES
YEYESS
NNOO
1. Are warranty costs associated with the issue? If no, do not continue w/checklist
2. Has causal part driving the issue been identified? If no, return to checklist when causal part identified3. Does the QB/Function responsible for the part have the causal part on their top spend list and/or IFR list? (For contacts, see Quarterback Functional Matrix link on 6-Panel website)
If causal part not on QB’s lists, do not continue w/checklist Name of Quality QB rep contacted: 4. Has the QB/Function reviewed the warranty spend reduction tools for additional warranty reduction opportunities?5. Has the QB/Function identified potential warranty reduction opportunities through the warranty spend reduction tools?6. Has the QB/Function engaged FCSD to support delivery of the identified warranty reduction opportunities?7. Has the QB/Function identified savings and developed action plans for implementation of the opportunities?8. Have the opportunities been implemented and can warranty spend savings be booked in project’s 6-panel?9. If the causal part is supplied by outside resource, has the QB/Function engaged the supplier in the spike recovery process?
YESYES
6-panelUnXchecklistv2.ppt02/27/2009
NOTE: When causal part is determined to be on QB top spend pareto, problem solver is required to ensure follow up with QB/Function for closure on the identified warranty savings opportunities.