researchonimprovementoftruckvibrationbasedonsystematic g8d...

12
Research Article Research on Improvement of Truck Vibration Based on Systematic G8D Method Hongfei Guo, 1,2 Minshi Chen , 2 Ru Zhang, 3 Jianke Li, 4 Congdong Li , 1,2 Ting Qu, 1,2 George Q. Huang, 1,2 Zhihui He, 1 and Yunhui Zeng 2 1 Institute of Internet of ings and Logistics Engineering, Jinan University, Zhuhai 519070, China 2 Institute of Intelligent Science and Engineering, Jinan University, Zhuhai 519070, China 3 Institute of Management Science and Engineering, Jinan University, Zhuhai 510970, China 4 School of Industrial Automation, Beijing Institute of Technology, Zhuhai 519088, China Correspondence should be addressed to Minshi Chen; [email protected] Received 5 March 2019; Accepted 15 May 2019; Published 16 June 2019 Academic Editor: Radoslaw Zimroz Copyright © 2019 Hongfei Guo et al. is is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited. In view of the common and difficult to solve vehicle vibration problem, taking a large truck manufacturing enterprise in China as an example, an improved model for solving truck vibration problem is established by using the G8D method, and the unbalanced excitation force of the wheel system is analysed. e coupling of the excitation frequency and the natural frequency of the system leads to the resonance phenomenon, as well as the inadequate damping function of the system, is the fundamental cause of the vibration problem. After verifying and implementing permanent correction measures at the same time at the three levels of components, devices, and the entire vehicle, the acceleration of the seat guide rails for the vibration performance of the truck reduces from the original state 1.04 m/s 2 to0.6m/s 2 , a decrease of 42.3%, which reaches the best level of mainstream cars in the country and is close to the optimal level of 0.5 m/s 2 among the same kinds of cars in Germany. erefore, the improved model can improve the sustainability of product manufacturing, provide industry guidance for solving the quality problem of truck vibration, and provide a sustainable guarantee for social public transport safety. 1. Introduction e vibration of the truck mainly refers to the vibration produced by the cab when the truck is running on the smooth road surface, which is the most common and dif- ficult quality problem in truck vibration [1]. is vibration will not only make the truck occupants feel uncomfortable but also affect their normal operation and even increase the risk of causing traffic accidents [2]. At the same time, the vibration problem is the quality problem which the customer repeatedly requests to correct, directly affects the customer to the product cognition, and negatively blocks the passage of the product manufacture sustainable development [3]. But, in the actual work, most of the researchers only analyze a certain vibration phenomenon and then propose a single solution, which is lack of systematic solutions. In this paper, G8D (also known as Global 8 Disciplines, TOPS 8D) is used to analyze the vibration problem sys- tematically [4]. First, temporary measures are taken to solve the problem temporarily, and then, permanent corrective measures are taken to solve the problem thoroughly in- volving the coordination of various departments in order to solve this problem thoroughly in system and regulation. An improved model of G8D is put forward to solve the problem of truck vibration in the system, and the permanent cor- rection measures are verified and put into practice in three levels of components, devices, and whole vehicles. e quality problem of truck vibration has been improved, which has reached the mainstream level in China and is close to the level of the same kind of car in Germany. erefore, the application of the improved model of the G8D system to solve the problem of truck vibration has stronger Hindawi Shock and Vibration Volume 2019, Article ID 1416340, 11 pages https://doi.org/10.1155/2019/1416340

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Page 1: ResearchonImprovementofTruckVibrationBasedonSystematic G8D ...downloads.hindawi.com/journals/sv/2019/1416340.pdf · ResearchArticle ResearchonImprovementofTruckVibrationBasedonSystematic

Research ArticleResearchon ImprovementofTruckVibrationBasedonSystematicG8D Method

Hongfei Guo12 Minshi Chen 2 Ru Zhang3 Jianke Li4 Congdong Li 12 Ting Qu12

George Q Huang12 Zhihui He1 and Yunhui Zeng2

1Institute of Internet of ings and Logistics Engineering Jinan University Zhuhai 519070 China2Institute of Intelligent Science and Engineering Jinan University Zhuhai 519070 China3Institute of Management Science and Engineering Jinan University Zhuhai 510970 China4School of Industrial Automation Beijing Institute of Technology Zhuhai 519088 China

Correspondence should be addressed to Minshi Chen minschanstu2016jnueducn

Received 5 March 2019 Accepted 15 May 2019 Published 16 June 2019

Academic Editor Radoslaw Zimroz

Copyright copy 2019 Hongfei Guo et al +is is an open access article distributed under the Creative Commons Attribution Licensewhich permits unrestricted use distribution and reproduction in any medium provided the original work is properly cited

In view of the common and difficult to solve vehicle vibration problem taking a large truck manufacturing enterprise inChina as an example an improved model for solving truck vibration problem is established by using the G8D method andthe unbalanced excitation force of the wheel system is analysed +e coupling of the excitation frequency and the naturalfrequency of the system leads to the resonance phenomenon as well as the inadequate damping function of the system isthe fundamental cause of the vibration problem After verifying and implementing permanent correction measures at thesame time at the three levels of components devices and the entire vehicle the acceleration of the seat guide rails for thevibration performance of the truck reduces from the original state 104 ms2 to 06 ms2 a decrease of 423 which reachesthe best level of mainstream cars in the country and is close to the optimal level of 05 ms2 among the same kinds of cars inGermany +erefore the improved model can improve the sustainability of product manufacturing provide industryguidance for solving the quality problem of truck vibration and provide a sustainable guarantee for social publictransport safety

1 Introduction

+e vibration of the truck mainly refers to the vibrationproduced by the cab when the truck is running on thesmooth road surface which is the most common and dif-ficult quality problem in truck vibration [1] +is vibrationwill not only make the truck occupants feel uncomfortablebut also affect their normal operation and even increase therisk of causing traffic accidents [2] At the same time thevibration problem is the quality problemwhich the customerrepeatedly requests to correct directly affects the customerto the product cognition and negatively blocks the passageof the product manufacture sustainable development [3]But in the actual work most of the researchers only analyzea certain vibration phenomenon and then propose a singlesolution which is lack of systematic solutions

In this paper G8D (also known as Global 8 DisciplinesTOPS 8D) is used to analyze the vibration problem sys-tematically [4] First temporary measures are taken to solvethe problem temporarily and then permanent correctivemeasures are taken to solve the problem thoroughly in-volving the coordination of various departments in order tosolve this problem thoroughly in system and regulation Animproved model of G8D is put forward to solve the problemof truck vibration in the system and the permanent cor-rection measures are verified and put into practice inthree levels of components devices and whole vehicles+e quality problem of truck vibration has been improvedwhich has reached the mainstream level in China and isclose to the level of the same kind of car in Germany+erefore the application of the improvedmodel of the G8Dsystem to solve the problem of truck vibration has stronger

HindawiShock and VibrationVolume 2019 Article ID 1416340 11 pageshttpsdoiorg10115520191416340

applicability and sustainability to the quality improvementof truck manufacturing industry [5]

2 Theory and Methodology

21 G8D +e G8D method is one of the most widely usedproblem-solving tools related to the prevention of repeatednonconformities in the manufacturing process and is oftenused for complaint management in the automotive industryFord Motor Company pioneered 8D problem solving inmid-1980 [6] for use by its suppliers to improve problemsolving +e G8D has been widely used in the automotiveindustry service or product problem solving [7] includingsupplier quality issues manufacturing process deviationdefect [8] maintenance customer complaints returns andother issues +e main area of current research is in in-dustrial process quality improvement [9] which facilitatesincreased productivity and timely handling of customercomplaints [10]

For the study of vehicle vibration problem most of theresearchers only analyze a certain vibration phenomenonand then propose a single solution which lacks systematicsolutions And the situation of recent research is shown inTable 1

+is paper introduces a set of improved models of G8Din solving truck vibration problem provides a generalprocess to effectively identify and solve the problem andprovides a method to identify the root cause and implementappropriate corrective action +is approach identifies thechanging needs of the system emphasizes teamwork in-creases management understanding of the problem itselfand the problem solution encourages direct and openproblem resolution and prevents the recurrence of the sameproblem and other similar problems Compared with thetraditional researchmethods it is more universal to solve thevehicle vibration problem systematically

22 Related eories on the Fundamental Causes of VehicleVibration

221 Exciting Force +e exciting force comes from severalaspects the imbalance of the wheel system the imbalance ofthe drive shaft system and the unsmoothness of the roadsurface

222 Ability of Vibration Isolation and Absorption +esystem has a front axle shock absorber and cab front and rearsuspension shock absorber [15] and the engine suspensionforms the vibration isolator of the vehicle system andprovides the system with the ability to reduce vibration

223 Resonance Phenomenon +e frame the suspensionspring of the front axle and the shock absorber of the frontaxle constitute a ldquomass-spring-dampingrdquo system [16] andthe powertrain with its front and rear suspensions forms theldquomass-spring-dampingrdquo vibration system [17] A mass-spring-damping vibration system [18] is formed betweenthe cab and the following suspension springs and dampers

Each of these systems has its own resonant frequency +efrequencies of these systems should not be the same or closeenough to form resonant coupling at the same time theseresonance frequencies should be as far away as possible fromthe excitation frequencies of the system such as the exci-tation frequency of the tire if the resonance of the system isinevitable If the exciting frequency of the tire coincides withthe resonance frequency of a certain system the vibrationabsorber of the system should reduce the vibration ampli-tude of the system as much as possible

3 Improvement Process of Truck Vibration

In view of the vibration problem existing in truckmanufacturing the G8D is used to establish an improvedmodel for solving the truck vibration problem In the ap-plication of the G8D step D1 ldquoestablishing a teamrdquo and stepD8 ldquosumming up and commendingrdquo are omitted because itsimplementation can be carried out by the enterprise man-agement department +erefore the improved model ofvibration problem is elaborated mainly from D2 to D7 andthe quality improvement tools in G8D are used to solve theproblem of vibration +e specific model is shown inFigure 1

31 Reaction to the Problem (D0) To prepare the applicationof G8D it is necessary to analyze the characteristics andobjectives of the problem Taking a large truck manufacturingenterprise in China as an example there may be someproblems of installation technology or improvement of somemanufacturing methods in the production process of local-ization of technology and drawings in Germany

Truck vibration has the following characteristics for thesame type of truck some vehicles have vibration problemsbut the rest of the vehicles do not have this problem whichshows that there is no problem in the design of vehicles+erefore it can be considered that the vibration of thevehicle is caused by themanufacture and installation of someparts and this kind of problem is very suitable to be solvedby G8D

+e G8D requires defining the objectives to be solved byusing this method one is to solve the vibration problem of thetruck the other is to confirm whether the vibration of the cabexists and the third is whether the existence of the problem isserious enough to affect the delivery of the vehicle

32 Description of the Problem (D2) +e first key step tosolve the truck vibration problem is to describe the truckvibration problem accurately including the accurate de-scription of the characteristics and manifestations of thevibration Based on the facts the paper states problems fromthe following aspects as in Table 2

321 5Whys +rough observation and test it is found thatthe acceleration of the seat guide rail near the vehicle speed(65 kmh) is the largest and the vibration is very serious inthe vertical direction of 210ms2 and in the longitudinal

2 Shock and Vibration

direction of 202ms2 calculated from formula (1) Fromformula (2) the vibration frequency is near 555Hz +iskind of vibration is produced only on the smooth roadsurface the speed maintains in the vibration speed and the

vibration is more serious which causes the passenger dis-comfort [19]

ajb 1113944n

11113944 Fia times VTFiajb

1113872 1113873 (1)

where ajb is the acceleration response of point j direction b(ms2) Fia is the load force of point i direction a (N) VTFiaja

is the vibration transfer function from point i direction a topoint j direction b (ms2N) +e formula means the vi-bration response is the load force of each driver point andeach direction produces the VTF from the driver point to theresponse point If the vibration acceleration of responsepoint is to be reduced the following three aspects need to becontrolled [20]

f num timesn

60 (2)

where num is the order and n is the speed Formula (2)indicates that each order frequency of the vibration signal isclosely related to the wheel speed

Table 1 Summary of research on vehicle vibration

Researchers Research object Cause of the problem Research methodsSim et al [11] Brake flutter deceleration suspension Uneven contact between brake disc and gasket Vibration path analysis

Yang and Zuo[12] Tyre self-excited vibration

+e difference between the component speed ofa vehiclersquos speed and the lateral direction of the

tire

Numerical simulationmethod

Liu et al [13] Whole vehicle vibration Insufficient stiffness of lower arm drive shaftand bushing of suspension Substructure power flow

Hao et al [14] Vehicle longitudinal low-frequencyvibration

Insufficient tire slip and half shaft torsionalstiffness 3-dof model

D0 response to the problem Analysis on manufacture and installation of truck parts

D1 establishment of the panelEstablish a study group on truck vibration

D2 description of the problem Describe the characteristics and forms of vibration

D3 development of immediate corrective actionDevelop urgent measures to address the vibration

problem

D4 analysis and identification of root causesAnalysis and confirmation of unbalanced exciting force

and coupling resonance

D5 development of permanent corrective actionReducing the amplitude of exciting force and increasing

system damping

D6 implementation of permanent corrective action

Is that theroot cause

Standard test

Evaluation ofthe feasibility of corrective

measures

Validity testVerification of permanent correction measures from

three levels

D7 prevention of problem recurrenceThe key problems and suggestions to solve vibration

are put forward

D8 summary and recognitionSummary of the systematic method and recognition of

relevant personnel

Invalid

Valid

No

Valid

Invalid

Valid

Yes

Invalid

Problem statement5Whys

Yes and No worksheet Truth factor assessment

Decision worksheet

Problem prevention list

5Whys

Figure 1 Improved model of G8D in systematically solving the problem of truck vibration

Table 2 Problem statement method

No Description of the problem

① Specific components of vibration(eg steering wheel seat cab)

② +e manifestation of vibration(eg torsional vibration reciprocating vibration)

③ Direction of vibration (longitudinaltransverse vertical etc)

④ Speed at which vibration occurs (engine speed)

⑤ Road conditions during vibration(smoothrough road surface uphill etc)

⑥ External environment (eg wind speed temperature)

⑦ Load condition during vibration(no load heavy load traction etc)

⑧ Changes in vehicle design and manufacture

Shock and Vibration 3

In order to find out the corresponding problems anddefine the root causes of vibration the five-question method(ldquorepeatedly ask whyrdquo) is adopted in this paper as in Figure 2

322 ldquoYes and Nordquo Worksheet +e Yes and No worksheetsdescribe the extent of the problem as in Table 3 and only thecorrect information is included in this table which is part ofthe observation phase as part of the problem resolutionprocess +e information in the Yes section of the worksheetdetermines the root of the problem and the No section helpsnarrow the scope of the problem

323 Truth Factor Assessment (1) Manifestation of VehicleVibration +e vehicle vibration is represented by the ver-tical transverse and longitudinal vibration of the steeringwheel [21] vibration of the gear vibration of the floor in thevertical direction vibration of the seat in the vertical andforward and backward directions and vibration of the leftand right rear mirrors in the cab

(2) Evaluation Method of Vehicle Vibration +e vi-bration of the vehicle is evaluated by measuring the vibrationacceleration of the seat guide rail in three directions with thehelp of data acquisition equipment In the absence of anytesting means it is also possible to evaluate the vibration of avehicle with the subjective evaluation method as well as theend-user and judge whether the vibration exists and itsseverity and acceptability from the point of view of a productconsumer to determine that it can be put on the market

(3) e True Cause Evaluation of Vehicle Vibration

(1) Quality problems of core components the pro-cessing of some rotating parts (such as transmissionshaft semishaft rim hub tyre and brake hub) doesnot meet the technical requirements and deviationresults in mass eccentricity when assembly does notmeet the technical requirements +ese eccentricmasses produce periodic exciting forces when thevehicle is running

(2) Tyre exciting force the periodic exciting forceproduced by the unbalanced wheels in the running ofa vehicle is transmitted to the frame through the leafspring and then to the cab

(3) Tire vibration mode there are two modes of tirevibration jumping mode and swinging mode +efirst is the run-out mode in which the vibrationphase of the left and right tires is the same that iswhen the left tire jumps to the top the right tirejumps to the top and when the left tire jumps to thebottom the tire on the right jumps to the top and thetire on the left jumps to the bottom +e tire on theright is also bouncing to the bottom +e second isthe swing mode in which the vibration phase of theleft and right tires is just the opposite that is whenthe left tire jumps to the top the right tire jumps tothe bottom and when the left tire jumps to thebottom and the tire on the right however leaps tothe top

(4) Cab and seat vibration the vibration problem dis-satisfied with by the end-user is often the cab and seatvibration [22] And the overwhelming majority ofthe unbearable vibration of the cab and seat is thatthe body is in the jumping mode [23] +e reason forthis vibration is that the exciting force produced bythe static and dynamic imbalances of the tire is in therun-out mode the front tire is in the run-out modeor the rear tire is in the run-out mode Another is thefront and rear tires are in the bounce mode +efrequency of the jumping mode may be consistentwith the mass of the frame and the rear axle platespring and the natural frequency of the spring sys-tem or with the mass of the frame and the front axleplate spring and the natural frequency of the springsystem which puts the frame into a resonant state atthe same frequency as the radial force on the tire+eresonance state of the frame is transferred to the cabthrough the cab suspension If the stiffness of the cabsuspension is not matched properly the excitationfrequency of the wheel system coincides with themass of the cab and the body suspension and thenatural frequency of the spring system and thenresonance occurs again

33 Development of Immediate Corrective Action (D3) Inthe case of vibration problems it is necessary to takeemergency response measures and choose ImmediateCorrective Action (ICA) to solve the vibration problemsprovisionally but the premise of the proposed measures isthat the existing design manufacturing and installationmethods and processes cannot be changed and no cost canbe increased +us the vehicles will be put into use so thatthe customers who purchase these vehicles will not beaffected by the vibration of the vehicles and damage thereputation of the quality of the vehicles +e criteria forselecting emergency response measures are shown inTable 4

Based on the above criteria immediate corrective actionsadopted include but are not limited to are as follows

(1) +e front right wheel and the rear right wheel tire arerotated 180 degrees before reinstallation

(2) Under the condition of keeping (1) the rear axle tiresare cross-suspensioned on the left and right sides

(3) Use a better cab suspension [24](4) Use a better front axle damper [25](5) Select tires brake drums and wheels with small

dynamic unbalances

34 Analysis and Identification of Root Causes (D4)

341 Describing Root Causes and Missing Points +emissing point is a point that is very close to the root causethat is it omits to analye what should have been the problemNo missing points were found in this particular vibrationproblem of the enterprise

4 Shock and Vibration

Based on the results of the problemmethod stated in D2the ldquoYes and Nordquo worksheet the ldquo5Whysrdquo and the truthfactor assessment the enterprise can tentatively determinethat the cause of the truck vibration is the unbalanced ex-citation force of the vehiclersquos wheel system the coupling ofthe excitation frequency and the natural frequency of the

system that leads to the resonance phenomenon and at thesame time the insufficient damping function of the systemas described in detail as follows

(1) Wheel systems (including tires hubs and rims)have significant manufacturing defects [26] suchas nonroundness of wheels and rims +e un-evenness of the inner and outer edges of the rim(that is the inner and outer edges are not in thesame plane) results in the imbalance of the tiresystem In the operation of the vehicle these un-balanced forces become the excitation force of thesystem vibration

(2) +e dynamic imbalance of the drive shaft system isone of the factors that cause the vibration of thesystem

1 Why is the cab vibratingBecause of the vibration of the frame the vibration is amplified by the body mount

2 Why does the body mount magnify the vibration The coupling of modal and excited frequencies of the cab results in resonance due to improper stiffness matching of the suspension

3 Why does the body mount match improperly

Poor control over suppliers lack of quality checks and inconsistent vehicle mount condition

4 Why is the frame vibrating at 65~70kmh

Because of the large unbalanced excitation force of the wheel system the excitation frequency is coupled with the rear bias frequency of the whole vehicle at this speed

5 Why is the unbalanced excitation force of the wheel system so large

Due to lack of quality control and inspection and roundness and flatness of rims wheels and brake hubsdo not meet the technical requirements

6 Why has not the cab vibration been damped off

Because the front and rear axle leaf springs dampers and cab suspension dampers do not work very well

7 Why damping shock absorbers donrsquot work well

Because vibration absorbers are accepted without quality inspection some dampers do not work

Figure 2 ldquo5Whysrdquo method to determine the root cause

Table 3 ldquoYes and Nordquo worksheet

Problem-solving worksheet does the truck have a vibration problem(1) Problem statement+e truck has longitudinal and vertical vibration in the cab at a speed of 65 kmh and 70 kmh in no-load condition(2) Problemdescription Yes No Access to

information

Problem

1 +e longitudinal and vertical vibration of a cab ofvehicle Steering wheel without vibration Measurement result

2 +e rear of the frame bounces in a verticaldirection Shift lever without vibration Measurement result

3 +e middle rear axle flutters along the verticaldirection Measurement result

Occurrenceplace

1 Cab Test data2 Frame of a vehicle Test data3 Middle rear axle Test data

Occurrence time 1 New car2 Vibration at speed 65sim70 kmh Other speed does not vibrate

Severity 1 In a severe state of discomforts Other speed does not exist same situation Live video recording

Table 4 Criteria for selecting emergency response measures

ICA Specific description

(1) Reduce exciting force Reduce the source ofvehicle vibration

(2) Enhance shock absorber Increase damping toattenuate vibration

(3) Avoid the resonancefrequency of the system

Avoid exciting frequencyas much as possible

Shock and Vibration 5

(3) Because the frequency of exciting force produced bythe wheel train in the 65sim70 kmh is about 55Hzthis resonance frequency obviously coincides withone of the frequencies of the above three vibrationsystems and produces resonance +e connection tothe cab through the system causes the cab to reso-nate Another reason is that the natural frequency ofthe cab itself is consistent with the excitation fre-quency resulting in resonance

(4) Shock absorbers for vehicles due to manufacturingquality inconsistencies [27] cause the component failto meet the technical requirements of providingsufficient damping during resonance [28] therebyreducing the resonance amplitude of the system +edamping force of the shock absorber of the front axleis not large enough [29] when the front axle resonatesthe amplitude of the resonance cannot be attenuatedto the design level the shock absorbers of the engineand the cab are unable to provide sufficient dampingbecause of inconsistent manufacturing quality

342 Confirming Description As shown in Figure 3 thevertical acceleration of the middle rear axle near 65 kmh islarge [30] up to 476ms2 magnified to 521ms2 from therear axle spring to the frame (at balance suspension) Fromthe frame to the cab the cab front suspension amplifies thevibration (178ms2 to 305ms2) and the cab rear suspen-sion attenuates the vibration (311ms2 to 205ms2)

+e cause of vibration can be determined as followswhen the vehicle speed is 65 kmh the unbalanced excitingforce produced by the rotating parts of themiddle rear axle isrelatively large [31] When passing through the rear axle leafspring it is coupled with the rear bias frequency of the wholevehicle so the acceleration on the frame is amplified [32]and the acceleration transferred from the frame to the cabthrough the front suspension of the cab is magnified It iscoupled with a certain order of the rigid body mode of thecab when it pass through suspension in the cab and theacceleration transmitted from the frame to the cab throughthe front suspension of the cab is magnified causing thetruck to vibrate

(1) Replace Cab Suspension +e cab of the vehicle wassuspended with an air spring and is now replaced with ahelical spring damper +e acceleration on both sides of cabsuspension near 65 kmh with different brands of shockabsorbers is listed as Table 5

Plan A the front suspension is replaced by the brandone spiral spring damper and the rear suspension isreplaced by the brand two spiral spring damperPlan B the front and rear suspensions are brand onespiral spring shock absorber

After replacing the cab suspension the vibration of thecab front suspension is no longer amplified the verticalacceleration of the cab is reduced from 210ms2 to 068ms2 and the longitudinal acceleration of the cab is reducedfrom 202ms2 to 056ms2 +e cab vibration is obviously

improved +ere is no significant difference in the isolationrate between the two types of spiral spring shock absorbers

(2) Replace the Dynamic Balance Brake Hub and DynamicBalance Tire +e acceleration comparison before and afterdynamic balancing is shown in Table 6

After dynamic balancing the vibration acceleration ofthe main seat guide rail decreased by 3036 in longitudinaldirection and 4559 in vertical direction +e vibrationacceleration at the left wheel of the rear axle is still large andbecomes the main excitation which may be caused by thepoor dynamic balance of the left rear axle tire and brake hubor the assembly error

+e manufacturing inconsistency of the wheel hub theuneven flatness of the inner and outer edges of the wheelrim and the uneven roundness of the rim can also beconfirmed by observation Overall the test results show thatthe brake hub and tire with dynamic balance have a greatattenuation effect on the vibration

35 Selection and Validation of Permanent Corrective Actionsfor Root Causes and Missing Points (D5) In order to de-termine the permanent corrective action (PCA) the prin-ciple is to reduce the amplitude of the exciting force separatethe modes of the system [14] and increase the damping forceof the system [33] +ere are six permanent measures listedin Table 7 If you have more than one vendor for these 6components you can use the decision table in Table 8 toselect a good vendor

According to the data in Table 8 the standard scoreexpected by supplier A is 52 and the standard score expectedby supplier B is 48 (the full score is 60) Meanwhile supplierB cannot meet the standard of ldquonot increasing the cost of theproductrdquo In the light of the above decisions vendor Ashould be selected

36 Implementation and Validation of Permanent CorrectiveAction (D6)

(1) Dynamic balance of transmission shaft put forwardcheck and carry out the technical requirementsabout the size and dynamic balance of transmissionshaft and have corresponding quality inspectionmechanism

(2) Dynamic balance of wheel hub put forward checkand carry out the technical requirements ofroundness dimension and dynamic balance of wheelhub and have corresponding quality inspectionmechanism

(3) Dynamic balance of wheel rim propose check andimplement the technical requirements of rim sizeroundness and dynamic balance and have thecorresponding quality inspection mechanism

(4) Dynamic balance of tire assembly put forwardcheck and implement the technical requirements ofstatic and dynamic balance of transfer tire assemblyand provide technical assistance to suppliers to

6 Shock and Vibration

Am

plitu

de (m

s2 ) 310

000

Am

plitu

de (m

s2 ) 320

000

Am

plitu

de (m

s2 ) 530

000

Am

plitu

de (m

s2 ) 480

000

Am

plitu

de

100

000

Am

plitu

de

100

000

Am

plitu

de

100

000

Am

plitu

de

100

000

F Spectrum Rear suspension body side of cab +ZSpectrum Front suspension body side of cab +ZF

F Spectrum Rear suspension frame side of cab +ZSpectrum Front suspension frame side of cab +ZF

F Spectrum Right side of balanced suspension +Z

F Spectrum Right side of middle axle +ZF Spectrum Right side of rear axle +ZF Spectrum Left side of middle axle +ZF Spectrum Left side of rear axle +Z

Spectrum Left side of balanced suspension +ZF

305

205

178

553

Hz000 1500

Hz000 1500

Hz000 1500

Hz000 1500

553

311

515

476319332431

577

521

577

Figure 3 Transmission of vibration acceleration

Table 5 Acceleration (ms2) on both sides of cab suspension near 65 kmh

Cab shockabsorber

Frontsuspensionbody side

Frontsuspensionframe side

Front suspensionvibration isolation rate

Rearsuspensionbody side

Rearsuspensionframe side

Rear suspensionvibration isolation rate

Original airspring 305 178 minus468 dB 205 311 362 dB

Ex-brand 1post-brand 2 139 237 463 dB 129 201 385 dB

Both are brandone 196 330 453 dB 161 255 399 dB

Notes Vibration isolation rate 20 log (active side vibration amplitudepassive side vibration amplitude)

Table 6 Acceleration comparison before and after dynamic balancing (ms2)

Measuring point position Before dynamic balancing After dynamic balancing Reduced percentageMain seat guide (longitudinal) 056 039 3036Main seat guide (vertical) 068 037 4559On the left wheel of the middle axle (vertical) 431 141 6729On the right wheel of the middle axle (vertical) 476 185 6113At the left wheel of the rear axle (vertical) 331 321 302At the right wheel of the rear axle (vertical) 319 215 3260

Shock and Vibration 7

purchase static and dynamic balance equipment oftire

(5) Provide the supplier with hardness and technicalrequirements for reinforced powertrain suspensionrubber and urge and assist them to achieve thesetechnical requirements and consistency of productcharacteristics it can be listed in Table 9

(i) +e technical requirements for the dampingcharacteristics of the hysteresis curve of the frontaxle damper are presented to the supplier

(ii) +e technical requirements for the dampingcharacteristics of the hysteresis curves of the

front and rear suspension dampers of the cab areproposed to the supplier

+e quality of these components must meet the qualityand technical requirements of the enterprise and there is asystematic mechanism to implement and verify the imple-mentation of the quality and technical requirements of thesecomponents

+ere are three levels of validation for these permanentcorrective measures

(1) Component level correct the dynamic balance of therotating parts of the vehicle drive shaft wheel hubrim and tire assembly [34] ensure the supplierrsquos

Table 7 Decision worksheet on permanent corrective measures

Decision worksheet 1Final result eliminate or reduce vibration in operation of this type of vehicle to the extent acceptable to the customerCriteria that must be met(a) Do not change existing design(b) Do not change the manufacturing process(c) No increase in product costExpected standard Importance (1ndash10 1 minimum 10 maximum)(1) Deviation quality and consistency of transmissionshaft 8

(2) Technical requirements for hub roundness andflatness and consistency 9

(3) Rims meet technical requirements roundness andconsistency 9

(4) Dynamic balance and consistency of tire assembly 9(5) Damping force of front axle shock absorber meetstechnical requirements and consistency 8

(6) Cab-suspensioning shock absorber meetstechnical requirements and consistency 9

Table 8 Vendor decision worksheet

Decision worksheet 2Vendor A Vendor B

Criteria that must be met Yesno Criteria that must be met Yesno

(a) Do not change existing design Yes (a) Do not change existing design Yes(b) Do not change the manufacturingprocess Yes (b) Do not change the manufacturing process Yes

(c) No increase in product cost Yes (c) No increase in product cost No

Expected standard Good or bad(1ndash10) Score Expected standard Good or bad

(1ndash10) Score

(1) Deviation quality and consistency oftransmission shaft Good 8 (1) Deviation quality and consistency of

transmission shaft Good 9

(2) Technical requirements for hubroundness and flatness and consistency Good 9 (2) Technical requirements for hub

roundness and flatness and consistency Good 8

(3) Rims meet technical requirementsroundness and consistency Good 8 (3) Rims meet technical requirements

roundness and consistency Good 8

(4) Dynamic balance and consistency oftire assembly Good 9 (4) Dynamic balance and consistency of

tire assembly Good 7

(5) Damping force of front axle shockabsorber meets technical requirementsand consistency

Good 9(5) Damping force of front axle shockabsorber meets technical requirements

and consistencyGood 8

(6) Cab-suspensioning shock absorbermeets technical requirements andconsistency

Good 9(6) Cab-suspensioning shock absorbermeets technical requirements and

consistencyGood 8

8 Shock and Vibration

parts meet the technical standards and check thedynamic balance

(2) Device level correct the cab damper and front axledamper ensure that the parts of the supplier meetthe technical standards and detect the stiffness anddamping of the damper [35]

(3) Whole car level load the car with the modified partsand carry out the road test to see the improvementeffect of the vibration performance of the whole car[20]

37 Prevent ProblemRecurrence (D7) +e ldquo5Whysrdquo methodis still used here to determine the root cause of the problemand the permanent measures that should be taken to preventthe recurrence of the problem According to the theory ofG8D it can be used to find out the problems about systemoperation process or policy Systemic problems arise fromfull references to previous organizations technical processespolicies and practices +ese past processes policies andpractices are often not applicable to the current situation andare not traceable

+e method proposed in this paper is very effective insolving the vibration problem systematically and makes thevibration problem be systematically tracked and controlledAccording to the above analysis and the actual situation thispaper puts forward some suggestions on the existing systemof the enterprise in order to prevent the recurrence of theproblem

(1) +e quality inspection mechanism of enterprisesneeds to be perfected +is is responsible for

formulating product quality inspection standardschecking the quality of parts provided by suppliersspot checking the qualified rate of products thesupplier shall provide quality product certificationaccording to the requirements of the enterprise if itdoes not meet the requirements it will not accept thesupply

(2) +e supplier quality evaluation system is yet to beestablished +e related personnel is responsible forsupplier quality review and supplier classificationmanagement In the case of unqualified productsenterprises need to have accurate technical means toprovide suppliers with accurate technical evidence ofnonconforming products and specific rectificationprograms for suppliers to rectify according to spe-cific technical objectives

(3) Technical support for supplier quality improvementis to be provided +e relevant departments are re-sponsible for technical guidance and help suppliersto improve quality suppliers and enterprises in thequality of a virtuous circle that is enterprises dotheir best to promote suppliers to improve qualityreward and punishment system for suppliers andlaunch mechanisms +e quality of suppliers isgradually improved due to technical feedback andassistance

(4) Supplier product quality feedback system is to beestablished Let the supplier define the technical andquality requirements of the enterprise and form aclosed loop between the quality of the product of thesupplier and the requirements of the enterprise +e

Table 9 Problem prevention worksheet

Problem prevention worksheetProgram objective to prevent vehicle vibration in terms of the manufacturing quality of components

Key step Nature Possible obstaclescauses of problemsP S P times S

(1) Deviation quality and consistency of transmissionshaft(2) Technical requirements for hub roundness andflatness and consistency(3) Rims meet technical requirements roundness andconsistency(4) Dynamic balance andconsistency of tire assembly(5) Damping force of front axleshock absorber meets technical requirements andconsistency(6) Cab-suspensioning shockabsorber meets technical requirements andconsistencyUse your experience to identifyyour plans and steps

+ese steps are complex havetight deadlines are new andhave an impact on other steps

Determine whichsteps

require yourattention

and resources most

Identify possible obstacles to completing these keysteps (people methods materials machinesmeasurements and environmental problems)

Notes questions such as the nature of the form need to be filled out later

Shock and Vibration 9

enterprise forms the complete system and themechanism causes the supplier and the enterprisemain engine factoryrsquos technical information to forma closed loop strengthens the system informationexchange between each other and forms the tech-nical accumulation for the past problem solving toprevent similar problems from happening in otherlocations or on other models

4 Discussion and Conclusions

By applying the G8D an improved model for solving thetruck vibration problem is established At the same timeaccording to the results of the statement problem methodthe Yes and No worksheet the 5Whys method and the truthfactor assessment the reason for determining the truckvibration is the unbalanced excitation force of the vehiclewheel system the resonance phenomenon caused by thecoupling of the excitation frequency with the natural fre-quency of the system and the insufficient damping functionof the system +erefore the corrective measures forchanging the wheel hub of cab suspension and dynamicbalance brake hub and dynamic balance tire are put forward+en the permanent correction measures are verified fromthree levels of components devices and whole vehicles byusing ldquodecision worksheetrdquo and ldquoproblem preventionworksheetrdquo to ensure the accuracy and feasibility of themodel and make recommendations for the existing systemof the enterprise to prevent recurrence of problems in thefuture

After the implementation of the abovementioned com-plete and improved model the acceleration of the seat rail ofthe truckrsquos vibration performance has been reduced from104ms2 to 06ms2 423 lower than that of the original carreaching the level of 06ms2 of the major domestic modelsand close to the level of 05ms2 of its German counterpartwhich prevents users from returning their cars For thecompany to reduce certain economic losses the sustainabilityof product manufacturing and enterprise economic benefitshave to be improved [36] +e practical implementation ofG8D can solve many technical problems but the wholeenterprise needs to pay attention to G8D training whichenables G8D become a sustainable solution to the problem ofenterprises +is is of great significance for solving the truckvibration problem and even the quality problem of the wholeautomobile manufacturing industry which is meaningful forthe sustainable construction of the industry Most impor-tantly it contributes to the sustainable guarantee of the publictraffic safety of the society [37]

Data Availability

+e numerical data used to support the findings of this studyare included within the article

Conflicts of Interest

+e authors declare that there are no conflicts of interestregarding the publication of this paper

Acknowledgments

+is research was funded by the Enterprise ManagementInnovation Project of the National Defense Science andTechnology Industry (grant no 13315502) FundamentalResearch Funds for the Central Universities (grant no21618412) Inner Mongolia Autonomous Region Scienceand Technology Innovation Guide Award Fund Project(grant no 103-413193) Scientific Research Project of HenanColleges and Universities in 2019 based on the research onmilitary science and technology innovation mechanism ofcolleges and universities from the perspective of civil-military integration (grant no 19A630037) Fund of Re-search on Enterprise Management Innovation Mode System(grant no 44860070) and Fund of Research on the En-terprise Management Mode and Countermeasures Based onthe Production Study and Research (grant no 44860071)

References

[1] S Zhang K Li G Wang and X Zhu ldquoSimulate design andexperimental analysis of commercial vehicle cab suspensionrdquoin Proceedings of the 19th Asia Pacific Automotive EngineeringConference amp SAE-hina Congress 2017 Selected Papers SAE-hina 2017 Lecture Notes in Electrical Engineering Edited by S(SAE-hina) Ed vol 486 pp 675ndash691 Springer ShanghaiChina October 2019

[2] L Morello L R Rossini G Pia and A Tonoli ldquoNoise vi-bration harshnessrdquo in e Automotive Body MechanicalEngineering Series pp 239ndash363 Springer DordrechtNetherlands 2011

[3] A Gupta A D Jayal M Chimienti and I S Jawahir ldquoA totallife-cycle approach towards developing product metrics forsustainable manufacturingrdquo in Glocalized Solutions for Sus-tainability in Manufacturing J Hesselbach and C HerrmannEds Springer Berlin Germany pp 240ndash245 2011

[4] A Zarghami and D Benbow ldquoIntroduction to 8D problemsolvingrdquo Journal for Quality amp Participation vol 40pp 23ndash28 2017

[5] S-O Shim K Park and S Choi ldquoInnovative productionscheduling with customer satisfaction based measurement forthe sustainability of manufacturing firmsrdquo Sustainabilityvol 9 no 12 p 2249 2017

[6] Ford Motor Company Training Group Training Manual forthe G8D Process Ford Motor Company Dearborn MI USA1999

[7] V Nicolae L M Ionescu N Belu and S L Elena ldquoIm-provement of the 8D analysis through a system based on theldquointernet of thingsrdquo concept applied in automotive industryrdquoin Proceedings of the CONAT 2016 International Congress ofAutomotive and Transport Engineering A Chiru and N IspasEds pp 635ndash642 Springer Brasov Romania October 2017

[8] T S M Kumar and B Adaveesh ldquoApplication of ldquo8Dmethodologyrdquo for the root cause analysis and reduction ofvalve spring rejection in a valve spring manufacturingcompany a case studyrdquo Indian Journal of Science andTechnology vol 10 no 11 pp 1ndash11 2017

[9] R Simmons ldquoBook review introduction to 8D problemsolving including practical applications and examplesrdquoQuality Management Journal vol 25 no 4 201 pages 2018

[10] C A Riesenberger and S D Sousa ldquo+e 8D methodology aneffective way to reduce recurrence of customer complaintsrdquo in

10 Shock and Vibration

Proceedings of the World Congress on Engineering vol 3London UK June-July 2010

[11] K S Sim J H Lee T W Park and M H Cho ldquoVibrationpath analysis and optimal design of the suspension for brakejudder reductionrdquo International Journal of AutomotiveTechnology vol 14 no 4 pp 587ndash594 2013

[12] X Yang and S Zuo ldquoParameters sensitivity analysis of self-excited vibration of tiresrdquo in Proceeding of the FISITA 2012World Automotive Congress Lecture Notes in Electrical En-gineering vol 201 pp 3ndash14 Springer Berlin Germany 2013

[13] Z Liu S Yuan S Xiao S Z Du Y Zhang and C Lu ldquoFullvehicle vibration and noise analysis based on substructurepower flowrdquo Shock and Vibration vol 2017 Article ID8725346 17 pages 2017

[14] D Hao C Zhao and Y Huang ldquoA reduced-order modelfor active suppression control of vehicle longitudinal low-frequency vibrationrdquo Shock and Vibration vol 2018Article ID 5731347 22 pages 2018

[15] Y Ren and L Zheng ldquoActive suspension control for wheel-drive electric vehicle based on vibration absorberrdquo in Pro-ceedings of the SAE-China Congress 2015 Selected PapersLecture Notes in Electrical Engineering vol 364 pp 75ndash86Springer Singapore 2016

[16] Y Taskin I Yuksek and N Yagiz ldquoVibration control ofvehicles with active tuned mass damperrdquo Journal ofVibroengineering vol 19 no 5 pp 3533ndash3541 2017

[17] Y M Han M H Nam S S Han H G Lee and S B ChoildquoVibration control evaluation of a commercial vehicle fea-turing MR seat damperrdquo Journal of Intelligent MaterialSystems and Structures vol 13 no 9 pp 575ndash579 2002

[18] H Sell T Ehrt and M Meszlig ldquoVibration-optimized com-ponents for chassis systemsrdquo ATZ Worldwide vol 110 no 2pp 26ndash31 2008

[19] A N +ite ldquoDevelopment of a refined quarter car model forthe analysis of discomfort due to vibrationrdquo Advances inAcoustics and Vibration vol 2012 Article ID 863061 7 pages2012

[20] Y Zhang H Wang Q Zhu Y Xu and L Wu ldquo+e iden-tification and countermeasure analysis of vehicle idle vibra-tionrdquo in Proceedings of the FISITA 2012 World AutomotiveCongress Lecture Notes in Electrical Engineering vol 201pp 443ndash455 Springer Berlin Germany 2013

[21] T Berberich P Gebhard S Bohlen O Danninger andM Lienkamp ldquoA new approach to the presentation of vi-bration phenomena in vehiclesrdquo in Proceedings of the FISITA2012 World Automotive Congress Lecture Notes in ElectricalEngineering vol 201 pp 591ndash598 Springer Berlin Germany2013

[22] N J Mansfield J Mackrill A N Rimell and S J MacMullldquoCombined effects of long-term sitting and whole-body vi-bration on discomfort onset for vehicle occupantsrdquo ISRNAutomotive Engineering vol 2014 Article ID 852607 8 pages2014

[23] J Park J Lee S Ahn and W Jeong ldquoReduced ride comfortcaused by beating idle vibrations in passenger vehiclesrdquo In-ternational Journal of Industrial Ergonomics vol 57 pp 74ndash79 2017

[24] A Jamali M Salehpour and N Nariman-zadeh ldquoRobustPareto active suspension design for vehicle vibration modelwith probabilistic uncertain parametersrdquo Multibody SystemDynamics vol 30 no 3 pp 265ndash285 2013

[25] X C Liang and J S Zhao ldquoResearch on recycling vibrationenergy of shock absorberrdquo International Journal of VehicleDesign vol 68 no 1ndash3 pp 201ndash220 2015

[26] S Zuo X Duan and Y Li ldquoStudy on dynamics of polygonalwear of automotive tire caused by self-excited vibrationrdquoMathematical Problems in Engineering vol 2014 Article ID653803 12 pages 2014

[27] J-J Bae and N Kang ldquoDesign optimization of a mecanumwheel to reduce vertical vibrations by the consideration ofequivalent stiffnessrdquo Shock and Vibration vol 2016 ArticleID 5892784 8 pages 2016

[28] A Pieper K Le Chau and J Kalberer ldquoOptimisation of rollvibration damping of a vehiclerdquo Auto Tech Review vol 4no 2 pp 36ndash41 2015

[29] G Pavic ldquoAnalysis of vibration reduction by damping usingsimple analytical modellingrdquo Shock and Vibration vol 2018Article ID 1098531 13 pages 2018

[30] M Heidari and H Homaei ldquoEstimation of accelerationamplitude of vehicle by back propagation neural networksrdquoAdvances in Acoustics and Vibration vol 2013 Article ID614025 7 pages 2013

[31] L-X Guo and L-P Zhang ldquoVehicle vibration analysis inchangeable speeds solved by pseudoexcitation methodrdquoMathematical Problems in Engineering vol 2010 Article ID802720 14 pages 2010

[32] B Sakhaei and M Durali ldquoVibration transfer path analysisand path ranking for NVH optimization of a vehicle interiorrdquoShock and Vibration vol 2014 Article ID 697450 5 pages2014

[33] D C Barton and J D Fieldhouse ldquoSuspension systems andcomponentsrdquo in Automotive Chassis Engineeringpp 111ndash214 Springer Cham Switzerland 2018

[34] K Jalics ldquoSimulation methods in the vehicle noise vibrationand harshness (NVH)rdquo in Vehicle and Automotive Engi-neering Lecture Notes in Mechanical Engineering K Jarmaiand B Bollo Eds pp 91ndash97 Springer Cham Switzerland2017

[35] X Xu F Yan Y Li W Chen and Y Cao ldquoRide comfortsimulation and abnormal vibration improvement of a com-mercial vehiclerdquo in Proceeding of the SAE-China Congress2015 Selected Papers Lecture Notes in Electrical Engineeringvol 364 pp 521ndash527 Springer Singapore January 2016

[36] D Dornfeld ldquoLeveraging manufacturing for a sustainablefuturerdquo in Glocalized Solutions for Sustainability inManufacturing J Hesselbach and C Herrmann EdsSpringer Berlin Germany pp 17ndash21 2011

[37] M A Gbededo and K Liyanage ldquoIdentification and align-ment of the social aspects of sustainable manufacturing withthe theory of motivationrdquo Sustainability vol 10 no 3 p 8522018

Shock and Vibration 11

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Page 2: ResearchonImprovementofTruckVibrationBasedonSystematic G8D ...downloads.hindawi.com/journals/sv/2019/1416340.pdf · ResearchArticle ResearchonImprovementofTruckVibrationBasedonSystematic

applicability and sustainability to the quality improvementof truck manufacturing industry [5]

2 Theory and Methodology

21 G8D +e G8D method is one of the most widely usedproblem-solving tools related to the prevention of repeatednonconformities in the manufacturing process and is oftenused for complaint management in the automotive industryFord Motor Company pioneered 8D problem solving inmid-1980 [6] for use by its suppliers to improve problemsolving +e G8D has been widely used in the automotiveindustry service or product problem solving [7] includingsupplier quality issues manufacturing process deviationdefect [8] maintenance customer complaints returns andother issues +e main area of current research is in in-dustrial process quality improvement [9] which facilitatesincreased productivity and timely handling of customercomplaints [10]

For the study of vehicle vibration problem most of theresearchers only analyze a certain vibration phenomenonand then propose a single solution which lacks systematicsolutions And the situation of recent research is shown inTable 1

+is paper introduces a set of improved models of G8Din solving truck vibration problem provides a generalprocess to effectively identify and solve the problem andprovides a method to identify the root cause and implementappropriate corrective action +is approach identifies thechanging needs of the system emphasizes teamwork in-creases management understanding of the problem itselfand the problem solution encourages direct and openproblem resolution and prevents the recurrence of the sameproblem and other similar problems Compared with thetraditional researchmethods it is more universal to solve thevehicle vibration problem systematically

22 Related eories on the Fundamental Causes of VehicleVibration

221 Exciting Force +e exciting force comes from severalaspects the imbalance of the wheel system the imbalance ofthe drive shaft system and the unsmoothness of the roadsurface

222 Ability of Vibration Isolation and Absorption +esystem has a front axle shock absorber and cab front and rearsuspension shock absorber [15] and the engine suspensionforms the vibration isolator of the vehicle system andprovides the system with the ability to reduce vibration

223 Resonance Phenomenon +e frame the suspensionspring of the front axle and the shock absorber of the frontaxle constitute a ldquomass-spring-dampingrdquo system [16] andthe powertrain with its front and rear suspensions forms theldquomass-spring-dampingrdquo vibration system [17] A mass-spring-damping vibration system [18] is formed betweenthe cab and the following suspension springs and dampers

Each of these systems has its own resonant frequency +efrequencies of these systems should not be the same or closeenough to form resonant coupling at the same time theseresonance frequencies should be as far away as possible fromthe excitation frequencies of the system such as the exci-tation frequency of the tire if the resonance of the system isinevitable If the exciting frequency of the tire coincides withthe resonance frequency of a certain system the vibrationabsorber of the system should reduce the vibration ampli-tude of the system as much as possible

3 Improvement Process of Truck Vibration

In view of the vibration problem existing in truckmanufacturing the G8D is used to establish an improvedmodel for solving the truck vibration problem In the ap-plication of the G8D step D1 ldquoestablishing a teamrdquo and stepD8 ldquosumming up and commendingrdquo are omitted because itsimplementation can be carried out by the enterprise man-agement department +erefore the improved model ofvibration problem is elaborated mainly from D2 to D7 andthe quality improvement tools in G8D are used to solve theproblem of vibration +e specific model is shown inFigure 1

31 Reaction to the Problem (D0) To prepare the applicationof G8D it is necessary to analyze the characteristics andobjectives of the problem Taking a large truck manufacturingenterprise in China as an example there may be someproblems of installation technology or improvement of somemanufacturing methods in the production process of local-ization of technology and drawings in Germany

Truck vibration has the following characteristics for thesame type of truck some vehicles have vibration problemsbut the rest of the vehicles do not have this problem whichshows that there is no problem in the design of vehicles+erefore it can be considered that the vibration of thevehicle is caused by themanufacture and installation of someparts and this kind of problem is very suitable to be solvedby G8D

+e G8D requires defining the objectives to be solved byusing this method one is to solve the vibration problem of thetruck the other is to confirm whether the vibration of the cabexists and the third is whether the existence of the problem isserious enough to affect the delivery of the vehicle

32 Description of the Problem (D2) +e first key step tosolve the truck vibration problem is to describe the truckvibration problem accurately including the accurate de-scription of the characteristics and manifestations of thevibration Based on the facts the paper states problems fromthe following aspects as in Table 2

321 5Whys +rough observation and test it is found thatthe acceleration of the seat guide rail near the vehicle speed(65 kmh) is the largest and the vibration is very serious inthe vertical direction of 210ms2 and in the longitudinal

2 Shock and Vibration

direction of 202ms2 calculated from formula (1) Fromformula (2) the vibration frequency is near 555Hz +iskind of vibration is produced only on the smooth roadsurface the speed maintains in the vibration speed and the

vibration is more serious which causes the passenger dis-comfort [19]

ajb 1113944n

11113944 Fia times VTFiajb

1113872 1113873 (1)

where ajb is the acceleration response of point j direction b(ms2) Fia is the load force of point i direction a (N) VTFiaja

is the vibration transfer function from point i direction a topoint j direction b (ms2N) +e formula means the vi-bration response is the load force of each driver point andeach direction produces the VTF from the driver point to theresponse point If the vibration acceleration of responsepoint is to be reduced the following three aspects need to becontrolled [20]

f num timesn

60 (2)

where num is the order and n is the speed Formula (2)indicates that each order frequency of the vibration signal isclosely related to the wheel speed

Table 1 Summary of research on vehicle vibration

Researchers Research object Cause of the problem Research methodsSim et al [11] Brake flutter deceleration suspension Uneven contact between brake disc and gasket Vibration path analysis

Yang and Zuo[12] Tyre self-excited vibration

+e difference between the component speed ofa vehiclersquos speed and the lateral direction of the

tire

Numerical simulationmethod

Liu et al [13] Whole vehicle vibration Insufficient stiffness of lower arm drive shaftand bushing of suspension Substructure power flow

Hao et al [14] Vehicle longitudinal low-frequencyvibration

Insufficient tire slip and half shaft torsionalstiffness 3-dof model

D0 response to the problem Analysis on manufacture and installation of truck parts

D1 establishment of the panelEstablish a study group on truck vibration

D2 description of the problem Describe the characteristics and forms of vibration

D3 development of immediate corrective actionDevelop urgent measures to address the vibration

problem

D4 analysis and identification of root causesAnalysis and confirmation of unbalanced exciting force

and coupling resonance

D5 development of permanent corrective actionReducing the amplitude of exciting force and increasing

system damping

D6 implementation of permanent corrective action

Is that theroot cause

Standard test

Evaluation ofthe feasibility of corrective

measures

Validity testVerification of permanent correction measures from

three levels

D7 prevention of problem recurrenceThe key problems and suggestions to solve vibration

are put forward

D8 summary and recognitionSummary of the systematic method and recognition of

relevant personnel

Invalid

Valid

No

Valid

Invalid

Valid

Yes

Invalid

Problem statement5Whys

Yes and No worksheet Truth factor assessment

Decision worksheet

Problem prevention list

5Whys

Figure 1 Improved model of G8D in systematically solving the problem of truck vibration

Table 2 Problem statement method

No Description of the problem

① Specific components of vibration(eg steering wheel seat cab)

② +e manifestation of vibration(eg torsional vibration reciprocating vibration)

③ Direction of vibration (longitudinaltransverse vertical etc)

④ Speed at which vibration occurs (engine speed)

⑤ Road conditions during vibration(smoothrough road surface uphill etc)

⑥ External environment (eg wind speed temperature)

⑦ Load condition during vibration(no load heavy load traction etc)

⑧ Changes in vehicle design and manufacture

Shock and Vibration 3

In order to find out the corresponding problems anddefine the root causes of vibration the five-question method(ldquorepeatedly ask whyrdquo) is adopted in this paper as in Figure 2

322 ldquoYes and Nordquo Worksheet +e Yes and No worksheetsdescribe the extent of the problem as in Table 3 and only thecorrect information is included in this table which is part ofthe observation phase as part of the problem resolutionprocess +e information in the Yes section of the worksheetdetermines the root of the problem and the No section helpsnarrow the scope of the problem

323 Truth Factor Assessment (1) Manifestation of VehicleVibration +e vehicle vibration is represented by the ver-tical transverse and longitudinal vibration of the steeringwheel [21] vibration of the gear vibration of the floor in thevertical direction vibration of the seat in the vertical andforward and backward directions and vibration of the leftand right rear mirrors in the cab

(2) Evaluation Method of Vehicle Vibration +e vi-bration of the vehicle is evaluated by measuring the vibrationacceleration of the seat guide rail in three directions with thehelp of data acquisition equipment In the absence of anytesting means it is also possible to evaluate the vibration of avehicle with the subjective evaluation method as well as theend-user and judge whether the vibration exists and itsseverity and acceptability from the point of view of a productconsumer to determine that it can be put on the market

(3) e True Cause Evaluation of Vehicle Vibration

(1) Quality problems of core components the pro-cessing of some rotating parts (such as transmissionshaft semishaft rim hub tyre and brake hub) doesnot meet the technical requirements and deviationresults in mass eccentricity when assembly does notmeet the technical requirements +ese eccentricmasses produce periodic exciting forces when thevehicle is running

(2) Tyre exciting force the periodic exciting forceproduced by the unbalanced wheels in the running ofa vehicle is transmitted to the frame through the leafspring and then to the cab

(3) Tire vibration mode there are two modes of tirevibration jumping mode and swinging mode +efirst is the run-out mode in which the vibrationphase of the left and right tires is the same that iswhen the left tire jumps to the top the right tirejumps to the top and when the left tire jumps to thebottom the tire on the right jumps to the top and thetire on the left jumps to the bottom +e tire on theright is also bouncing to the bottom +e second isthe swing mode in which the vibration phase of theleft and right tires is just the opposite that is whenthe left tire jumps to the top the right tire jumps tothe bottom and when the left tire jumps to thebottom and the tire on the right however leaps tothe top

(4) Cab and seat vibration the vibration problem dis-satisfied with by the end-user is often the cab and seatvibration [22] And the overwhelming majority ofthe unbearable vibration of the cab and seat is thatthe body is in the jumping mode [23] +e reason forthis vibration is that the exciting force produced bythe static and dynamic imbalances of the tire is in therun-out mode the front tire is in the run-out modeor the rear tire is in the run-out mode Another is thefront and rear tires are in the bounce mode +efrequency of the jumping mode may be consistentwith the mass of the frame and the rear axle platespring and the natural frequency of the spring sys-tem or with the mass of the frame and the front axleplate spring and the natural frequency of the springsystem which puts the frame into a resonant state atthe same frequency as the radial force on the tire+eresonance state of the frame is transferred to the cabthrough the cab suspension If the stiffness of the cabsuspension is not matched properly the excitationfrequency of the wheel system coincides with themass of the cab and the body suspension and thenatural frequency of the spring system and thenresonance occurs again

33 Development of Immediate Corrective Action (D3) Inthe case of vibration problems it is necessary to takeemergency response measures and choose ImmediateCorrective Action (ICA) to solve the vibration problemsprovisionally but the premise of the proposed measures isthat the existing design manufacturing and installationmethods and processes cannot be changed and no cost canbe increased +us the vehicles will be put into use so thatthe customers who purchase these vehicles will not beaffected by the vibration of the vehicles and damage thereputation of the quality of the vehicles +e criteria forselecting emergency response measures are shown inTable 4

Based on the above criteria immediate corrective actionsadopted include but are not limited to are as follows

(1) +e front right wheel and the rear right wheel tire arerotated 180 degrees before reinstallation

(2) Under the condition of keeping (1) the rear axle tiresare cross-suspensioned on the left and right sides

(3) Use a better cab suspension [24](4) Use a better front axle damper [25](5) Select tires brake drums and wheels with small

dynamic unbalances

34 Analysis and Identification of Root Causes (D4)

341 Describing Root Causes and Missing Points +emissing point is a point that is very close to the root causethat is it omits to analye what should have been the problemNo missing points were found in this particular vibrationproblem of the enterprise

4 Shock and Vibration

Based on the results of the problemmethod stated in D2the ldquoYes and Nordquo worksheet the ldquo5Whysrdquo and the truthfactor assessment the enterprise can tentatively determinethat the cause of the truck vibration is the unbalanced ex-citation force of the vehiclersquos wheel system the coupling ofthe excitation frequency and the natural frequency of the

system that leads to the resonance phenomenon and at thesame time the insufficient damping function of the systemas described in detail as follows

(1) Wheel systems (including tires hubs and rims)have significant manufacturing defects [26] suchas nonroundness of wheels and rims +e un-evenness of the inner and outer edges of the rim(that is the inner and outer edges are not in thesame plane) results in the imbalance of the tiresystem In the operation of the vehicle these un-balanced forces become the excitation force of thesystem vibration

(2) +e dynamic imbalance of the drive shaft system isone of the factors that cause the vibration of thesystem

1 Why is the cab vibratingBecause of the vibration of the frame the vibration is amplified by the body mount

2 Why does the body mount magnify the vibration The coupling of modal and excited frequencies of the cab results in resonance due to improper stiffness matching of the suspension

3 Why does the body mount match improperly

Poor control over suppliers lack of quality checks and inconsistent vehicle mount condition

4 Why is the frame vibrating at 65~70kmh

Because of the large unbalanced excitation force of the wheel system the excitation frequency is coupled with the rear bias frequency of the whole vehicle at this speed

5 Why is the unbalanced excitation force of the wheel system so large

Due to lack of quality control and inspection and roundness and flatness of rims wheels and brake hubsdo not meet the technical requirements

6 Why has not the cab vibration been damped off

Because the front and rear axle leaf springs dampers and cab suspension dampers do not work very well

7 Why damping shock absorbers donrsquot work well

Because vibration absorbers are accepted without quality inspection some dampers do not work

Figure 2 ldquo5Whysrdquo method to determine the root cause

Table 3 ldquoYes and Nordquo worksheet

Problem-solving worksheet does the truck have a vibration problem(1) Problem statement+e truck has longitudinal and vertical vibration in the cab at a speed of 65 kmh and 70 kmh in no-load condition(2) Problemdescription Yes No Access to

information

Problem

1 +e longitudinal and vertical vibration of a cab ofvehicle Steering wheel without vibration Measurement result

2 +e rear of the frame bounces in a verticaldirection Shift lever without vibration Measurement result

3 +e middle rear axle flutters along the verticaldirection Measurement result

Occurrenceplace

1 Cab Test data2 Frame of a vehicle Test data3 Middle rear axle Test data

Occurrence time 1 New car2 Vibration at speed 65sim70 kmh Other speed does not vibrate

Severity 1 In a severe state of discomforts Other speed does not exist same situation Live video recording

Table 4 Criteria for selecting emergency response measures

ICA Specific description

(1) Reduce exciting force Reduce the source ofvehicle vibration

(2) Enhance shock absorber Increase damping toattenuate vibration

(3) Avoid the resonancefrequency of the system

Avoid exciting frequencyas much as possible

Shock and Vibration 5

(3) Because the frequency of exciting force produced bythe wheel train in the 65sim70 kmh is about 55Hzthis resonance frequency obviously coincides withone of the frequencies of the above three vibrationsystems and produces resonance +e connection tothe cab through the system causes the cab to reso-nate Another reason is that the natural frequency ofthe cab itself is consistent with the excitation fre-quency resulting in resonance

(4) Shock absorbers for vehicles due to manufacturingquality inconsistencies [27] cause the component failto meet the technical requirements of providingsufficient damping during resonance [28] therebyreducing the resonance amplitude of the system +edamping force of the shock absorber of the front axleis not large enough [29] when the front axle resonatesthe amplitude of the resonance cannot be attenuatedto the design level the shock absorbers of the engineand the cab are unable to provide sufficient dampingbecause of inconsistent manufacturing quality

342 Confirming Description As shown in Figure 3 thevertical acceleration of the middle rear axle near 65 kmh islarge [30] up to 476ms2 magnified to 521ms2 from therear axle spring to the frame (at balance suspension) Fromthe frame to the cab the cab front suspension amplifies thevibration (178ms2 to 305ms2) and the cab rear suspen-sion attenuates the vibration (311ms2 to 205ms2)

+e cause of vibration can be determined as followswhen the vehicle speed is 65 kmh the unbalanced excitingforce produced by the rotating parts of themiddle rear axle isrelatively large [31] When passing through the rear axle leafspring it is coupled with the rear bias frequency of the wholevehicle so the acceleration on the frame is amplified [32]and the acceleration transferred from the frame to the cabthrough the front suspension of the cab is magnified It iscoupled with a certain order of the rigid body mode of thecab when it pass through suspension in the cab and theacceleration transmitted from the frame to the cab throughthe front suspension of the cab is magnified causing thetruck to vibrate

(1) Replace Cab Suspension +e cab of the vehicle wassuspended with an air spring and is now replaced with ahelical spring damper +e acceleration on both sides of cabsuspension near 65 kmh with different brands of shockabsorbers is listed as Table 5

Plan A the front suspension is replaced by the brandone spiral spring damper and the rear suspension isreplaced by the brand two spiral spring damperPlan B the front and rear suspensions are brand onespiral spring shock absorber

After replacing the cab suspension the vibration of thecab front suspension is no longer amplified the verticalacceleration of the cab is reduced from 210ms2 to 068ms2 and the longitudinal acceleration of the cab is reducedfrom 202ms2 to 056ms2 +e cab vibration is obviously

improved +ere is no significant difference in the isolationrate between the two types of spiral spring shock absorbers

(2) Replace the Dynamic Balance Brake Hub and DynamicBalance Tire +e acceleration comparison before and afterdynamic balancing is shown in Table 6

After dynamic balancing the vibration acceleration ofthe main seat guide rail decreased by 3036 in longitudinaldirection and 4559 in vertical direction +e vibrationacceleration at the left wheel of the rear axle is still large andbecomes the main excitation which may be caused by thepoor dynamic balance of the left rear axle tire and brake hubor the assembly error

+e manufacturing inconsistency of the wheel hub theuneven flatness of the inner and outer edges of the wheelrim and the uneven roundness of the rim can also beconfirmed by observation Overall the test results show thatthe brake hub and tire with dynamic balance have a greatattenuation effect on the vibration

35 Selection and Validation of Permanent Corrective Actionsfor Root Causes and Missing Points (D5) In order to de-termine the permanent corrective action (PCA) the prin-ciple is to reduce the amplitude of the exciting force separatethe modes of the system [14] and increase the damping forceof the system [33] +ere are six permanent measures listedin Table 7 If you have more than one vendor for these 6components you can use the decision table in Table 8 toselect a good vendor

According to the data in Table 8 the standard scoreexpected by supplier A is 52 and the standard score expectedby supplier B is 48 (the full score is 60) Meanwhile supplierB cannot meet the standard of ldquonot increasing the cost of theproductrdquo In the light of the above decisions vendor Ashould be selected

36 Implementation and Validation of Permanent CorrectiveAction (D6)

(1) Dynamic balance of transmission shaft put forwardcheck and carry out the technical requirementsabout the size and dynamic balance of transmissionshaft and have corresponding quality inspectionmechanism

(2) Dynamic balance of wheel hub put forward checkand carry out the technical requirements ofroundness dimension and dynamic balance of wheelhub and have corresponding quality inspectionmechanism

(3) Dynamic balance of wheel rim propose check andimplement the technical requirements of rim sizeroundness and dynamic balance and have thecorresponding quality inspection mechanism

(4) Dynamic balance of tire assembly put forwardcheck and implement the technical requirements ofstatic and dynamic balance of transfer tire assemblyand provide technical assistance to suppliers to

6 Shock and Vibration

Am

plitu

de (m

s2 ) 310

000

Am

plitu

de (m

s2 ) 320

000

Am

plitu

de (m

s2 ) 530

000

Am

plitu

de (m

s2 ) 480

000

Am

plitu

de

100

000

Am

plitu

de

100

000

Am

plitu

de

100

000

Am

plitu

de

100

000

F Spectrum Rear suspension body side of cab +ZSpectrum Front suspension body side of cab +ZF

F Spectrum Rear suspension frame side of cab +ZSpectrum Front suspension frame side of cab +ZF

F Spectrum Right side of balanced suspension +Z

F Spectrum Right side of middle axle +ZF Spectrum Right side of rear axle +ZF Spectrum Left side of middle axle +ZF Spectrum Left side of rear axle +Z

Spectrum Left side of balanced suspension +ZF

305

205

178

553

Hz000 1500

Hz000 1500

Hz000 1500

Hz000 1500

553

311

515

476319332431

577

521

577

Figure 3 Transmission of vibration acceleration

Table 5 Acceleration (ms2) on both sides of cab suspension near 65 kmh

Cab shockabsorber

Frontsuspensionbody side

Frontsuspensionframe side

Front suspensionvibration isolation rate

Rearsuspensionbody side

Rearsuspensionframe side

Rear suspensionvibration isolation rate

Original airspring 305 178 minus468 dB 205 311 362 dB

Ex-brand 1post-brand 2 139 237 463 dB 129 201 385 dB

Both are brandone 196 330 453 dB 161 255 399 dB

Notes Vibration isolation rate 20 log (active side vibration amplitudepassive side vibration amplitude)

Table 6 Acceleration comparison before and after dynamic balancing (ms2)

Measuring point position Before dynamic balancing After dynamic balancing Reduced percentageMain seat guide (longitudinal) 056 039 3036Main seat guide (vertical) 068 037 4559On the left wheel of the middle axle (vertical) 431 141 6729On the right wheel of the middle axle (vertical) 476 185 6113At the left wheel of the rear axle (vertical) 331 321 302At the right wheel of the rear axle (vertical) 319 215 3260

Shock and Vibration 7

purchase static and dynamic balance equipment oftire

(5) Provide the supplier with hardness and technicalrequirements for reinforced powertrain suspensionrubber and urge and assist them to achieve thesetechnical requirements and consistency of productcharacteristics it can be listed in Table 9

(i) +e technical requirements for the dampingcharacteristics of the hysteresis curve of the frontaxle damper are presented to the supplier

(ii) +e technical requirements for the dampingcharacteristics of the hysteresis curves of the

front and rear suspension dampers of the cab areproposed to the supplier

+e quality of these components must meet the qualityand technical requirements of the enterprise and there is asystematic mechanism to implement and verify the imple-mentation of the quality and technical requirements of thesecomponents

+ere are three levels of validation for these permanentcorrective measures

(1) Component level correct the dynamic balance of therotating parts of the vehicle drive shaft wheel hubrim and tire assembly [34] ensure the supplierrsquos

Table 7 Decision worksheet on permanent corrective measures

Decision worksheet 1Final result eliminate or reduce vibration in operation of this type of vehicle to the extent acceptable to the customerCriteria that must be met(a) Do not change existing design(b) Do not change the manufacturing process(c) No increase in product costExpected standard Importance (1ndash10 1 minimum 10 maximum)(1) Deviation quality and consistency of transmissionshaft 8

(2) Technical requirements for hub roundness andflatness and consistency 9

(3) Rims meet technical requirements roundness andconsistency 9

(4) Dynamic balance and consistency of tire assembly 9(5) Damping force of front axle shock absorber meetstechnical requirements and consistency 8

(6) Cab-suspensioning shock absorber meetstechnical requirements and consistency 9

Table 8 Vendor decision worksheet

Decision worksheet 2Vendor A Vendor B

Criteria that must be met Yesno Criteria that must be met Yesno

(a) Do not change existing design Yes (a) Do not change existing design Yes(b) Do not change the manufacturingprocess Yes (b) Do not change the manufacturing process Yes

(c) No increase in product cost Yes (c) No increase in product cost No

Expected standard Good or bad(1ndash10) Score Expected standard Good or bad

(1ndash10) Score

(1) Deviation quality and consistency oftransmission shaft Good 8 (1) Deviation quality and consistency of

transmission shaft Good 9

(2) Technical requirements for hubroundness and flatness and consistency Good 9 (2) Technical requirements for hub

roundness and flatness and consistency Good 8

(3) Rims meet technical requirementsroundness and consistency Good 8 (3) Rims meet technical requirements

roundness and consistency Good 8

(4) Dynamic balance and consistency oftire assembly Good 9 (4) Dynamic balance and consistency of

tire assembly Good 7

(5) Damping force of front axle shockabsorber meets technical requirementsand consistency

Good 9(5) Damping force of front axle shockabsorber meets technical requirements

and consistencyGood 8

(6) Cab-suspensioning shock absorbermeets technical requirements andconsistency

Good 9(6) Cab-suspensioning shock absorbermeets technical requirements and

consistencyGood 8

8 Shock and Vibration

parts meet the technical standards and check thedynamic balance

(2) Device level correct the cab damper and front axledamper ensure that the parts of the supplier meetthe technical standards and detect the stiffness anddamping of the damper [35]

(3) Whole car level load the car with the modified partsand carry out the road test to see the improvementeffect of the vibration performance of the whole car[20]

37 Prevent ProblemRecurrence (D7) +e ldquo5Whysrdquo methodis still used here to determine the root cause of the problemand the permanent measures that should be taken to preventthe recurrence of the problem According to the theory ofG8D it can be used to find out the problems about systemoperation process or policy Systemic problems arise fromfull references to previous organizations technical processespolicies and practices +ese past processes policies andpractices are often not applicable to the current situation andare not traceable

+e method proposed in this paper is very effective insolving the vibration problem systematically and makes thevibration problem be systematically tracked and controlledAccording to the above analysis and the actual situation thispaper puts forward some suggestions on the existing systemof the enterprise in order to prevent the recurrence of theproblem

(1) +e quality inspection mechanism of enterprisesneeds to be perfected +is is responsible for

formulating product quality inspection standardschecking the quality of parts provided by suppliersspot checking the qualified rate of products thesupplier shall provide quality product certificationaccording to the requirements of the enterprise if itdoes not meet the requirements it will not accept thesupply

(2) +e supplier quality evaluation system is yet to beestablished +e related personnel is responsible forsupplier quality review and supplier classificationmanagement In the case of unqualified productsenterprises need to have accurate technical means toprovide suppliers with accurate technical evidence ofnonconforming products and specific rectificationprograms for suppliers to rectify according to spe-cific technical objectives

(3) Technical support for supplier quality improvementis to be provided +e relevant departments are re-sponsible for technical guidance and help suppliersto improve quality suppliers and enterprises in thequality of a virtuous circle that is enterprises dotheir best to promote suppliers to improve qualityreward and punishment system for suppliers andlaunch mechanisms +e quality of suppliers isgradually improved due to technical feedback andassistance

(4) Supplier product quality feedback system is to beestablished Let the supplier define the technical andquality requirements of the enterprise and form aclosed loop between the quality of the product of thesupplier and the requirements of the enterprise +e

Table 9 Problem prevention worksheet

Problem prevention worksheetProgram objective to prevent vehicle vibration in terms of the manufacturing quality of components

Key step Nature Possible obstaclescauses of problemsP S P times S

(1) Deviation quality and consistency of transmissionshaft(2) Technical requirements for hub roundness andflatness and consistency(3) Rims meet technical requirements roundness andconsistency(4) Dynamic balance andconsistency of tire assembly(5) Damping force of front axleshock absorber meets technical requirements andconsistency(6) Cab-suspensioning shockabsorber meets technical requirements andconsistencyUse your experience to identifyyour plans and steps

+ese steps are complex havetight deadlines are new andhave an impact on other steps

Determine whichsteps

require yourattention

and resources most

Identify possible obstacles to completing these keysteps (people methods materials machinesmeasurements and environmental problems)

Notes questions such as the nature of the form need to be filled out later

Shock and Vibration 9

enterprise forms the complete system and themechanism causes the supplier and the enterprisemain engine factoryrsquos technical information to forma closed loop strengthens the system informationexchange between each other and forms the tech-nical accumulation for the past problem solving toprevent similar problems from happening in otherlocations or on other models

4 Discussion and Conclusions

By applying the G8D an improved model for solving thetruck vibration problem is established At the same timeaccording to the results of the statement problem methodthe Yes and No worksheet the 5Whys method and the truthfactor assessment the reason for determining the truckvibration is the unbalanced excitation force of the vehiclewheel system the resonance phenomenon caused by thecoupling of the excitation frequency with the natural fre-quency of the system and the insufficient damping functionof the system +erefore the corrective measures forchanging the wheel hub of cab suspension and dynamicbalance brake hub and dynamic balance tire are put forward+en the permanent correction measures are verified fromthree levels of components devices and whole vehicles byusing ldquodecision worksheetrdquo and ldquoproblem preventionworksheetrdquo to ensure the accuracy and feasibility of themodel and make recommendations for the existing systemof the enterprise to prevent recurrence of problems in thefuture

After the implementation of the abovementioned com-plete and improved model the acceleration of the seat rail ofthe truckrsquos vibration performance has been reduced from104ms2 to 06ms2 423 lower than that of the original carreaching the level of 06ms2 of the major domestic modelsand close to the level of 05ms2 of its German counterpartwhich prevents users from returning their cars For thecompany to reduce certain economic losses the sustainabilityof product manufacturing and enterprise economic benefitshave to be improved [36] +e practical implementation ofG8D can solve many technical problems but the wholeenterprise needs to pay attention to G8D training whichenables G8D become a sustainable solution to the problem ofenterprises +is is of great significance for solving the truckvibration problem and even the quality problem of the wholeautomobile manufacturing industry which is meaningful forthe sustainable construction of the industry Most impor-tantly it contributes to the sustainable guarantee of the publictraffic safety of the society [37]

Data Availability

+e numerical data used to support the findings of this studyare included within the article

Conflicts of Interest

+e authors declare that there are no conflicts of interestregarding the publication of this paper

Acknowledgments

+is research was funded by the Enterprise ManagementInnovation Project of the National Defense Science andTechnology Industry (grant no 13315502) FundamentalResearch Funds for the Central Universities (grant no21618412) Inner Mongolia Autonomous Region Scienceand Technology Innovation Guide Award Fund Project(grant no 103-413193) Scientific Research Project of HenanColleges and Universities in 2019 based on the research onmilitary science and technology innovation mechanism ofcolleges and universities from the perspective of civil-military integration (grant no 19A630037) Fund of Re-search on Enterprise Management Innovation Mode System(grant no 44860070) and Fund of Research on the En-terprise Management Mode and Countermeasures Based onthe Production Study and Research (grant no 44860071)

References

[1] S Zhang K Li G Wang and X Zhu ldquoSimulate design andexperimental analysis of commercial vehicle cab suspensionrdquoin Proceedings of the 19th Asia Pacific Automotive EngineeringConference amp SAE-hina Congress 2017 Selected Papers SAE-hina 2017 Lecture Notes in Electrical Engineering Edited by S(SAE-hina) Ed vol 486 pp 675ndash691 Springer ShanghaiChina October 2019

[2] L Morello L R Rossini G Pia and A Tonoli ldquoNoise vi-bration harshnessrdquo in e Automotive Body MechanicalEngineering Series pp 239ndash363 Springer DordrechtNetherlands 2011

[3] A Gupta A D Jayal M Chimienti and I S Jawahir ldquoA totallife-cycle approach towards developing product metrics forsustainable manufacturingrdquo in Glocalized Solutions for Sus-tainability in Manufacturing J Hesselbach and C HerrmannEds Springer Berlin Germany pp 240ndash245 2011

[4] A Zarghami and D Benbow ldquoIntroduction to 8D problemsolvingrdquo Journal for Quality amp Participation vol 40pp 23ndash28 2017

[5] S-O Shim K Park and S Choi ldquoInnovative productionscheduling with customer satisfaction based measurement forthe sustainability of manufacturing firmsrdquo Sustainabilityvol 9 no 12 p 2249 2017

[6] Ford Motor Company Training Group Training Manual forthe G8D Process Ford Motor Company Dearborn MI USA1999

[7] V Nicolae L M Ionescu N Belu and S L Elena ldquoIm-provement of the 8D analysis through a system based on theldquointernet of thingsrdquo concept applied in automotive industryrdquoin Proceedings of the CONAT 2016 International Congress ofAutomotive and Transport Engineering A Chiru and N IspasEds pp 635ndash642 Springer Brasov Romania October 2017

[8] T S M Kumar and B Adaveesh ldquoApplication of ldquo8Dmethodologyrdquo for the root cause analysis and reduction ofvalve spring rejection in a valve spring manufacturingcompany a case studyrdquo Indian Journal of Science andTechnology vol 10 no 11 pp 1ndash11 2017

[9] R Simmons ldquoBook review introduction to 8D problemsolving including practical applications and examplesrdquoQuality Management Journal vol 25 no 4 201 pages 2018

[10] C A Riesenberger and S D Sousa ldquo+e 8D methodology aneffective way to reduce recurrence of customer complaintsrdquo in

10 Shock and Vibration

Proceedings of the World Congress on Engineering vol 3London UK June-July 2010

[11] K S Sim J H Lee T W Park and M H Cho ldquoVibrationpath analysis and optimal design of the suspension for brakejudder reductionrdquo International Journal of AutomotiveTechnology vol 14 no 4 pp 587ndash594 2013

[12] X Yang and S Zuo ldquoParameters sensitivity analysis of self-excited vibration of tiresrdquo in Proceeding of the FISITA 2012World Automotive Congress Lecture Notes in Electrical En-gineering vol 201 pp 3ndash14 Springer Berlin Germany 2013

[13] Z Liu S Yuan S Xiao S Z Du Y Zhang and C Lu ldquoFullvehicle vibration and noise analysis based on substructurepower flowrdquo Shock and Vibration vol 2017 Article ID8725346 17 pages 2017

[14] D Hao C Zhao and Y Huang ldquoA reduced-order modelfor active suppression control of vehicle longitudinal low-frequency vibrationrdquo Shock and Vibration vol 2018Article ID 5731347 22 pages 2018

[15] Y Ren and L Zheng ldquoActive suspension control for wheel-drive electric vehicle based on vibration absorberrdquo in Pro-ceedings of the SAE-China Congress 2015 Selected PapersLecture Notes in Electrical Engineering vol 364 pp 75ndash86Springer Singapore 2016

[16] Y Taskin I Yuksek and N Yagiz ldquoVibration control ofvehicles with active tuned mass damperrdquo Journal ofVibroengineering vol 19 no 5 pp 3533ndash3541 2017

[17] Y M Han M H Nam S S Han H G Lee and S B ChoildquoVibration control evaluation of a commercial vehicle fea-turing MR seat damperrdquo Journal of Intelligent MaterialSystems and Structures vol 13 no 9 pp 575ndash579 2002

[18] H Sell T Ehrt and M Meszlig ldquoVibration-optimized com-ponents for chassis systemsrdquo ATZ Worldwide vol 110 no 2pp 26ndash31 2008

[19] A N +ite ldquoDevelopment of a refined quarter car model forthe analysis of discomfort due to vibrationrdquo Advances inAcoustics and Vibration vol 2012 Article ID 863061 7 pages2012

[20] Y Zhang H Wang Q Zhu Y Xu and L Wu ldquo+e iden-tification and countermeasure analysis of vehicle idle vibra-tionrdquo in Proceedings of the FISITA 2012 World AutomotiveCongress Lecture Notes in Electrical Engineering vol 201pp 443ndash455 Springer Berlin Germany 2013

[21] T Berberich P Gebhard S Bohlen O Danninger andM Lienkamp ldquoA new approach to the presentation of vi-bration phenomena in vehiclesrdquo in Proceedings of the FISITA2012 World Automotive Congress Lecture Notes in ElectricalEngineering vol 201 pp 591ndash598 Springer Berlin Germany2013

[22] N J Mansfield J Mackrill A N Rimell and S J MacMullldquoCombined effects of long-term sitting and whole-body vi-bration on discomfort onset for vehicle occupantsrdquo ISRNAutomotive Engineering vol 2014 Article ID 852607 8 pages2014

[23] J Park J Lee S Ahn and W Jeong ldquoReduced ride comfortcaused by beating idle vibrations in passenger vehiclesrdquo In-ternational Journal of Industrial Ergonomics vol 57 pp 74ndash79 2017

[24] A Jamali M Salehpour and N Nariman-zadeh ldquoRobustPareto active suspension design for vehicle vibration modelwith probabilistic uncertain parametersrdquo Multibody SystemDynamics vol 30 no 3 pp 265ndash285 2013

[25] X C Liang and J S Zhao ldquoResearch on recycling vibrationenergy of shock absorberrdquo International Journal of VehicleDesign vol 68 no 1ndash3 pp 201ndash220 2015

[26] S Zuo X Duan and Y Li ldquoStudy on dynamics of polygonalwear of automotive tire caused by self-excited vibrationrdquoMathematical Problems in Engineering vol 2014 Article ID653803 12 pages 2014

[27] J-J Bae and N Kang ldquoDesign optimization of a mecanumwheel to reduce vertical vibrations by the consideration ofequivalent stiffnessrdquo Shock and Vibration vol 2016 ArticleID 5892784 8 pages 2016

[28] A Pieper K Le Chau and J Kalberer ldquoOptimisation of rollvibration damping of a vehiclerdquo Auto Tech Review vol 4no 2 pp 36ndash41 2015

[29] G Pavic ldquoAnalysis of vibration reduction by damping usingsimple analytical modellingrdquo Shock and Vibration vol 2018Article ID 1098531 13 pages 2018

[30] M Heidari and H Homaei ldquoEstimation of accelerationamplitude of vehicle by back propagation neural networksrdquoAdvances in Acoustics and Vibration vol 2013 Article ID614025 7 pages 2013

[31] L-X Guo and L-P Zhang ldquoVehicle vibration analysis inchangeable speeds solved by pseudoexcitation methodrdquoMathematical Problems in Engineering vol 2010 Article ID802720 14 pages 2010

[32] B Sakhaei and M Durali ldquoVibration transfer path analysisand path ranking for NVH optimization of a vehicle interiorrdquoShock and Vibration vol 2014 Article ID 697450 5 pages2014

[33] D C Barton and J D Fieldhouse ldquoSuspension systems andcomponentsrdquo in Automotive Chassis Engineeringpp 111ndash214 Springer Cham Switzerland 2018

[34] K Jalics ldquoSimulation methods in the vehicle noise vibrationand harshness (NVH)rdquo in Vehicle and Automotive Engi-neering Lecture Notes in Mechanical Engineering K Jarmaiand B Bollo Eds pp 91ndash97 Springer Cham Switzerland2017

[35] X Xu F Yan Y Li W Chen and Y Cao ldquoRide comfortsimulation and abnormal vibration improvement of a com-mercial vehiclerdquo in Proceeding of the SAE-China Congress2015 Selected Papers Lecture Notes in Electrical Engineeringvol 364 pp 521ndash527 Springer Singapore January 2016

[36] D Dornfeld ldquoLeveraging manufacturing for a sustainablefuturerdquo in Glocalized Solutions for Sustainability inManufacturing J Hesselbach and C Herrmann EdsSpringer Berlin Germany pp 17ndash21 2011

[37] M A Gbededo and K Liyanage ldquoIdentification and align-ment of the social aspects of sustainable manufacturing withthe theory of motivationrdquo Sustainability vol 10 no 3 p 8522018

Shock and Vibration 11

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Page 3: ResearchonImprovementofTruckVibrationBasedonSystematic G8D ...downloads.hindawi.com/journals/sv/2019/1416340.pdf · ResearchArticle ResearchonImprovementofTruckVibrationBasedonSystematic

direction of 202ms2 calculated from formula (1) Fromformula (2) the vibration frequency is near 555Hz +iskind of vibration is produced only on the smooth roadsurface the speed maintains in the vibration speed and the

vibration is more serious which causes the passenger dis-comfort [19]

ajb 1113944n

11113944 Fia times VTFiajb

1113872 1113873 (1)

where ajb is the acceleration response of point j direction b(ms2) Fia is the load force of point i direction a (N) VTFiaja

is the vibration transfer function from point i direction a topoint j direction b (ms2N) +e formula means the vi-bration response is the load force of each driver point andeach direction produces the VTF from the driver point to theresponse point If the vibration acceleration of responsepoint is to be reduced the following three aspects need to becontrolled [20]

f num timesn

60 (2)

where num is the order and n is the speed Formula (2)indicates that each order frequency of the vibration signal isclosely related to the wheel speed

Table 1 Summary of research on vehicle vibration

Researchers Research object Cause of the problem Research methodsSim et al [11] Brake flutter deceleration suspension Uneven contact between brake disc and gasket Vibration path analysis

Yang and Zuo[12] Tyre self-excited vibration

+e difference between the component speed ofa vehiclersquos speed and the lateral direction of the

tire

Numerical simulationmethod

Liu et al [13] Whole vehicle vibration Insufficient stiffness of lower arm drive shaftand bushing of suspension Substructure power flow

Hao et al [14] Vehicle longitudinal low-frequencyvibration

Insufficient tire slip and half shaft torsionalstiffness 3-dof model

D0 response to the problem Analysis on manufacture and installation of truck parts

D1 establishment of the panelEstablish a study group on truck vibration

D2 description of the problem Describe the characteristics and forms of vibration

D3 development of immediate corrective actionDevelop urgent measures to address the vibration

problem

D4 analysis and identification of root causesAnalysis and confirmation of unbalanced exciting force

and coupling resonance

D5 development of permanent corrective actionReducing the amplitude of exciting force and increasing

system damping

D6 implementation of permanent corrective action

Is that theroot cause

Standard test

Evaluation ofthe feasibility of corrective

measures

Validity testVerification of permanent correction measures from

three levels

D7 prevention of problem recurrenceThe key problems and suggestions to solve vibration

are put forward

D8 summary and recognitionSummary of the systematic method and recognition of

relevant personnel

Invalid

Valid

No

Valid

Invalid

Valid

Yes

Invalid

Problem statement5Whys

Yes and No worksheet Truth factor assessment

Decision worksheet

Problem prevention list

5Whys

Figure 1 Improved model of G8D in systematically solving the problem of truck vibration

Table 2 Problem statement method

No Description of the problem

① Specific components of vibration(eg steering wheel seat cab)

② +e manifestation of vibration(eg torsional vibration reciprocating vibration)

③ Direction of vibration (longitudinaltransverse vertical etc)

④ Speed at which vibration occurs (engine speed)

⑤ Road conditions during vibration(smoothrough road surface uphill etc)

⑥ External environment (eg wind speed temperature)

⑦ Load condition during vibration(no load heavy load traction etc)

⑧ Changes in vehicle design and manufacture

Shock and Vibration 3

In order to find out the corresponding problems anddefine the root causes of vibration the five-question method(ldquorepeatedly ask whyrdquo) is adopted in this paper as in Figure 2

322 ldquoYes and Nordquo Worksheet +e Yes and No worksheetsdescribe the extent of the problem as in Table 3 and only thecorrect information is included in this table which is part ofthe observation phase as part of the problem resolutionprocess +e information in the Yes section of the worksheetdetermines the root of the problem and the No section helpsnarrow the scope of the problem

323 Truth Factor Assessment (1) Manifestation of VehicleVibration +e vehicle vibration is represented by the ver-tical transverse and longitudinal vibration of the steeringwheel [21] vibration of the gear vibration of the floor in thevertical direction vibration of the seat in the vertical andforward and backward directions and vibration of the leftand right rear mirrors in the cab

(2) Evaluation Method of Vehicle Vibration +e vi-bration of the vehicle is evaluated by measuring the vibrationacceleration of the seat guide rail in three directions with thehelp of data acquisition equipment In the absence of anytesting means it is also possible to evaluate the vibration of avehicle with the subjective evaluation method as well as theend-user and judge whether the vibration exists and itsseverity and acceptability from the point of view of a productconsumer to determine that it can be put on the market

(3) e True Cause Evaluation of Vehicle Vibration

(1) Quality problems of core components the pro-cessing of some rotating parts (such as transmissionshaft semishaft rim hub tyre and brake hub) doesnot meet the technical requirements and deviationresults in mass eccentricity when assembly does notmeet the technical requirements +ese eccentricmasses produce periodic exciting forces when thevehicle is running

(2) Tyre exciting force the periodic exciting forceproduced by the unbalanced wheels in the running ofa vehicle is transmitted to the frame through the leafspring and then to the cab

(3) Tire vibration mode there are two modes of tirevibration jumping mode and swinging mode +efirst is the run-out mode in which the vibrationphase of the left and right tires is the same that iswhen the left tire jumps to the top the right tirejumps to the top and when the left tire jumps to thebottom the tire on the right jumps to the top and thetire on the left jumps to the bottom +e tire on theright is also bouncing to the bottom +e second isthe swing mode in which the vibration phase of theleft and right tires is just the opposite that is whenthe left tire jumps to the top the right tire jumps tothe bottom and when the left tire jumps to thebottom and the tire on the right however leaps tothe top

(4) Cab and seat vibration the vibration problem dis-satisfied with by the end-user is often the cab and seatvibration [22] And the overwhelming majority ofthe unbearable vibration of the cab and seat is thatthe body is in the jumping mode [23] +e reason forthis vibration is that the exciting force produced bythe static and dynamic imbalances of the tire is in therun-out mode the front tire is in the run-out modeor the rear tire is in the run-out mode Another is thefront and rear tires are in the bounce mode +efrequency of the jumping mode may be consistentwith the mass of the frame and the rear axle platespring and the natural frequency of the spring sys-tem or with the mass of the frame and the front axleplate spring and the natural frequency of the springsystem which puts the frame into a resonant state atthe same frequency as the radial force on the tire+eresonance state of the frame is transferred to the cabthrough the cab suspension If the stiffness of the cabsuspension is not matched properly the excitationfrequency of the wheel system coincides with themass of the cab and the body suspension and thenatural frequency of the spring system and thenresonance occurs again

33 Development of Immediate Corrective Action (D3) Inthe case of vibration problems it is necessary to takeemergency response measures and choose ImmediateCorrective Action (ICA) to solve the vibration problemsprovisionally but the premise of the proposed measures isthat the existing design manufacturing and installationmethods and processes cannot be changed and no cost canbe increased +us the vehicles will be put into use so thatthe customers who purchase these vehicles will not beaffected by the vibration of the vehicles and damage thereputation of the quality of the vehicles +e criteria forselecting emergency response measures are shown inTable 4

Based on the above criteria immediate corrective actionsadopted include but are not limited to are as follows

(1) +e front right wheel and the rear right wheel tire arerotated 180 degrees before reinstallation

(2) Under the condition of keeping (1) the rear axle tiresare cross-suspensioned on the left and right sides

(3) Use a better cab suspension [24](4) Use a better front axle damper [25](5) Select tires brake drums and wheels with small

dynamic unbalances

34 Analysis and Identification of Root Causes (D4)

341 Describing Root Causes and Missing Points +emissing point is a point that is very close to the root causethat is it omits to analye what should have been the problemNo missing points were found in this particular vibrationproblem of the enterprise

4 Shock and Vibration

Based on the results of the problemmethod stated in D2the ldquoYes and Nordquo worksheet the ldquo5Whysrdquo and the truthfactor assessment the enterprise can tentatively determinethat the cause of the truck vibration is the unbalanced ex-citation force of the vehiclersquos wheel system the coupling ofthe excitation frequency and the natural frequency of the

system that leads to the resonance phenomenon and at thesame time the insufficient damping function of the systemas described in detail as follows

(1) Wheel systems (including tires hubs and rims)have significant manufacturing defects [26] suchas nonroundness of wheels and rims +e un-evenness of the inner and outer edges of the rim(that is the inner and outer edges are not in thesame plane) results in the imbalance of the tiresystem In the operation of the vehicle these un-balanced forces become the excitation force of thesystem vibration

(2) +e dynamic imbalance of the drive shaft system isone of the factors that cause the vibration of thesystem

1 Why is the cab vibratingBecause of the vibration of the frame the vibration is amplified by the body mount

2 Why does the body mount magnify the vibration The coupling of modal and excited frequencies of the cab results in resonance due to improper stiffness matching of the suspension

3 Why does the body mount match improperly

Poor control over suppliers lack of quality checks and inconsistent vehicle mount condition

4 Why is the frame vibrating at 65~70kmh

Because of the large unbalanced excitation force of the wheel system the excitation frequency is coupled with the rear bias frequency of the whole vehicle at this speed

5 Why is the unbalanced excitation force of the wheel system so large

Due to lack of quality control and inspection and roundness and flatness of rims wheels and brake hubsdo not meet the technical requirements

6 Why has not the cab vibration been damped off

Because the front and rear axle leaf springs dampers and cab suspension dampers do not work very well

7 Why damping shock absorbers donrsquot work well

Because vibration absorbers are accepted without quality inspection some dampers do not work

Figure 2 ldquo5Whysrdquo method to determine the root cause

Table 3 ldquoYes and Nordquo worksheet

Problem-solving worksheet does the truck have a vibration problem(1) Problem statement+e truck has longitudinal and vertical vibration in the cab at a speed of 65 kmh and 70 kmh in no-load condition(2) Problemdescription Yes No Access to

information

Problem

1 +e longitudinal and vertical vibration of a cab ofvehicle Steering wheel without vibration Measurement result

2 +e rear of the frame bounces in a verticaldirection Shift lever without vibration Measurement result

3 +e middle rear axle flutters along the verticaldirection Measurement result

Occurrenceplace

1 Cab Test data2 Frame of a vehicle Test data3 Middle rear axle Test data

Occurrence time 1 New car2 Vibration at speed 65sim70 kmh Other speed does not vibrate

Severity 1 In a severe state of discomforts Other speed does not exist same situation Live video recording

Table 4 Criteria for selecting emergency response measures

ICA Specific description

(1) Reduce exciting force Reduce the source ofvehicle vibration

(2) Enhance shock absorber Increase damping toattenuate vibration

(3) Avoid the resonancefrequency of the system

Avoid exciting frequencyas much as possible

Shock and Vibration 5

(3) Because the frequency of exciting force produced bythe wheel train in the 65sim70 kmh is about 55Hzthis resonance frequency obviously coincides withone of the frequencies of the above three vibrationsystems and produces resonance +e connection tothe cab through the system causes the cab to reso-nate Another reason is that the natural frequency ofthe cab itself is consistent with the excitation fre-quency resulting in resonance

(4) Shock absorbers for vehicles due to manufacturingquality inconsistencies [27] cause the component failto meet the technical requirements of providingsufficient damping during resonance [28] therebyreducing the resonance amplitude of the system +edamping force of the shock absorber of the front axleis not large enough [29] when the front axle resonatesthe amplitude of the resonance cannot be attenuatedto the design level the shock absorbers of the engineand the cab are unable to provide sufficient dampingbecause of inconsistent manufacturing quality

342 Confirming Description As shown in Figure 3 thevertical acceleration of the middle rear axle near 65 kmh islarge [30] up to 476ms2 magnified to 521ms2 from therear axle spring to the frame (at balance suspension) Fromthe frame to the cab the cab front suspension amplifies thevibration (178ms2 to 305ms2) and the cab rear suspen-sion attenuates the vibration (311ms2 to 205ms2)

+e cause of vibration can be determined as followswhen the vehicle speed is 65 kmh the unbalanced excitingforce produced by the rotating parts of themiddle rear axle isrelatively large [31] When passing through the rear axle leafspring it is coupled with the rear bias frequency of the wholevehicle so the acceleration on the frame is amplified [32]and the acceleration transferred from the frame to the cabthrough the front suspension of the cab is magnified It iscoupled with a certain order of the rigid body mode of thecab when it pass through suspension in the cab and theacceleration transmitted from the frame to the cab throughthe front suspension of the cab is magnified causing thetruck to vibrate

(1) Replace Cab Suspension +e cab of the vehicle wassuspended with an air spring and is now replaced with ahelical spring damper +e acceleration on both sides of cabsuspension near 65 kmh with different brands of shockabsorbers is listed as Table 5

Plan A the front suspension is replaced by the brandone spiral spring damper and the rear suspension isreplaced by the brand two spiral spring damperPlan B the front and rear suspensions are brand onespiral spring shock absorber

After replacing the cab suspension the vibration of thecab front suspension is no longer amplified the verticalacceleration of the cab is reduced from 210ms2 to 068ms2 and the longitudinal acceleration of the cab is reducedfrom 202ms2 to 056ms2 +e cab vibration is obviously

improved +ere is no significant difference in the isolationrate between the two types of spiral spring shock absorbers

(2) Replace the Dynamic Balance Brake Hub and DynamicBalance Tire +e acceleration comparison before and afterdynamic balancing is shown in Table 6

After dynamic balancing the vibration acceleration ofthe main seat guide rail decreased by 3036 in longitudinaldirection and 4559 in vertical direction +e vibrationacceleration at the left wheel of the rear axle is still large andbecomes the main excitation which may be caused by thepoor dynamic balance of the left rear axle tire and brake hubor the assembly error

+e manufacturing inconsistency of the wheel hub theuneven flatness of the inner and outer edges of the wheelrim and the uneven roundness of the rim can also beconfirmed by observation Overall the test results show thatthe brake hub and tire with dynamic balance have a greatattenuation effect on the vibration

35 Selection and Validation of Permanent Corrective Actionsfor Root Causes and Missing Points (D5) In order to de-termine the permanent corrective action (PCA) the prin-ciple is to reduce the amplitude of the exciting force separatethe modes of the system [14] and increase the damping forceof the system [33] +ere are six permanent measures listedin Table 7 If you have more than one vendor for these 6components you can use the decision table in Table 8 toselect a good vendor

According to the data in Table 8 the standard scoreexpected by supplier A is 52 and the standard score expectedby supplier B is 48 (the full score is 60) Meanwhile supplierB cannot meet the standard of ldquonot increasing the cost of theproductrdquo In the light of the above decisions vendor Ashould be selected

36 Implementation and Validation of Permanent CorrectiveAction (D6)

(1) Dynamic balance of transmission shaft put forwardcheck and carry out the technical requirementsabout the size and dynamic balance of transmissionshaft and have corresponding quality inspectionmechanism

(2) Dynamic balance of wheel hub put forward checkand carry out the technical requirements ofroundness dimension and dynamic balance of wheelhub and have corresponding quality inspectionmechanism

(3) Dynamic balance of wheel rim propose check andimplement the technical requirements of rim sizeroundness and dynamic balance and have thecorresponding quality inspection mechanism

(4) Dynamic balance of tire assembly put forwardcheck and implement the technical requirements ofstatic and dynamic balance of transfer tire assemblyand provide technical assistance to suppliers to

6 Shock and Vibration

Am

plitu

de (m

s2 ) 310

000

Am

plitu

de (m

s2 ) 320

000

Am

plitu

de (m

s2 ) 530

000

Am

plitu

de (m

s2 ) 480

000

Am

plitu

de

100

000

Am

plitu

de

100

000

Am

plitu

de

100

000

Am

plitu

de

100

000

F Spectrum Rear suspension body side of cab +ZSpectrum Front suspension body side of cab +ZF

F Spectrum Rear suspension frame side of cab +ZSpectrum Front suspension frame side of cab +ZF

F Spectrum Right side of balanced suspension +Z

F Spectrum Right side of middle axle +ZF Spectrum Right side of rear axle +ZF Spectrum Left side of middle axle +ZF Spectrum Left side of rear axle +Z

Spectrum Left side of balanced suspension +ZF

305

205

178

553

Hz000 1500

Hz000 1500

Hz000 1500

Hz000 1500

553

311

515

476319332431

577

521

577

Figure 3 Transmission of vibration acceleration

Table 5 Acceleration (ms2) on both sides of cab suspension near 65 kmh

Cab shockabsorber

Frontsuspensionbody side

Frontsuspensionframe side

Front suspensionvibration isolation rate

Rearsuspensionbody side

Rearsuspensionframe side

Rear suspensionvibration isolation rate

Original airspring 305 178 minus468 dB 205 311 362 dB

Ex-brand 1post-brand 2 139 237 463 dB 129 201 385 dB

Both are brandone 196 330 453 dB 161 255 399 dB

Notes Vibration isolation rate 20 log (active side vibration amplitudepassive side vibration amplitude)

Table 6 Acceleration comparison before and after dynamic balancing (ms2)

Measuring point position Before dynamic balancing After dynamic balancing Reduced percentageMain seat guide (longitudinal) 056 039 3036Main seat guide (vertical) 068 037 4559On the left wheel of the middle axle (vertical) 431 141 6729On the right wheel of the middle axle (vertical) 476 185 6113At the left wheel of the rear axle (vertical) 331 321 302At the right wheel of the rear axle (vertical) 319 215 3260

Shock and Vibration 7

purchase static and dynamic balance equipment oftire

(5) Provide the supplier with hardness and technicalrequirements for reinforced powertrain suspensionrubber and urge and assist them to achieve thesetechnical requirements and consistency of productcharacteristics it can be listed in Table 9

(i) +e technical requirements for the dampingcharacteristics of the hysteresis curve of the frontaxle damper are presented to the supplier

(ii) +e technical requirements for the dampingcharacteristics of the hysteresis curves of the

front and rear suspension dampers of the cab areproposed to the supplier

+e quality of these components must meet the qualityand technical requirements of the enterprise and there is asystematic mechanism to implement and verify the imple-mentation of the quality and technical requirements of thesecomponents

+ere are three levels of validation for these permanentcorrective measures

(1) Component level correct the dynamic balance of therotating parts of the vehicle drive shaft wheel hubrim and tire assembly [34] ensure the supplierrsquos

Table 7 Decision worksheet on permanent corrective measures

Decision worksheet 1Final result eliminate or reduce vibration in operation of this type of vehicle to the extent acceptable to the customerCriteria that must be met(a) Do not change existing design(b) Do not change the manufacturing process(c) No increase in product costExpected standard Importance (1ndash10 1 minimum 10 maximum)(1) Deviation quality and consistency of transmissionshaft 8

(2) Technical requirements for hub roundness andflatness and consistency 9

(3) Rims meet technical requirements roundness andconsistency 9

(4) Dynamic balance and consistency of tire assembly 9(5) Damping force of front axle shock absorber meetstechnical requirements and consistency 8

(6) Cab-suspensioning shock absorber meetstechnical requirements and consistency 9

Table 8 Vendor decision worksheet

Decision worksheet 2Vendor A Vendor B

Criteria that must be met Yesno Criteria that must be met Yesno

(a) Do not change existing design Yes (a) Do not change existing design Yes(b) Do not change the manufacturingprocess Yes (b) Do not change the manufacturing process Yes

(c) No increase in product cost Yes (c) No increase in product cost No

Expected standard Good or bad(1ndash10) Score Expected standard Good or bad

(1ndash10) Score

(1) Deviation quality and consistency oftransmission shaft Good 8 (1) Deviation quality and consistency of

transmission shaft Good 9

(2) Technical requirements for hubroundness and flatness and consistency Good 9 (2) Technical requirements for hub

roundness and flatness and consistency Good 8

(3) Rims meet technical requirementsroundness and consistency Good 8 (3) Rims meet technical requirements

roundness and consistency Good 8

(4) Dynamic balance and consistency oftire assembly Good 9 (4) Dynamic balance and consistency of

tire assembly Good 7

(5) Damping force of front axle shockabsorber meets technical requirementsand consistency

Good 9(5) Damping force of front axle shockabsorber meets technical requirements

and consistencyGood 8

(6) Cab-suspensioning shock absorbermeets technical requirements andconsistency

Good 9(6) Cab-suspensioning shock absorbermeets technical requirements and

consistencyGood 8

8 Shock and Vibration

parts meet the technical standards and check thedynamic balance

(2) Device level correct the cab damper and front axledamper ensure that the parts of the supplier meetthe technical standards and detect the stiffness anddamping of the damper [35]

(3) Whole car level load the car with the modified partsand carry out the road test to see the improvementeffect of the vibration performance of the whole car[20]

37 Prevent ProblemRecurrence (D7) +e ldquo5Whysrdquo methodis still used here to determine the root cause of the problemand the permanent measures that should be taken to preventthe recurrence of the problem According to the theory ofG8D it can be used to find out the problems about systemoperation process or policy Systemic problems arise fromfull references to previous organizations technical processespolicies and practices +ese past processes policies andpractices are often not applicable to the current situation andare not traceable

+e method proposed in this paper is very effective insolving the vibration problem systematically and makes thevibration problem be systematically tracked and controlledAccording to the above analysis and the actual situation thispaper puts forward some suggestions on the existing systemof the enterprise in order to prevent the recurrence of theproblem

(1) +e quality inspection mechanism of enterprisesneeds to be perfected +is is responsible for

formulating product quality inspection standardschecking the quality of parts provided by suppliersspot checking the qualified rate of products thesupplier shall provide quality product certificationaccording to the requirements of the enterprise if itdoes not meet the requirements it will not accept thesupply

(2) +e supplier quality evaluation system is yet to beestablished +e related personnel is responsible forsupplier quality review and supplier classificationmanagement In the case of unqualified productsenterprises need to have accurate technical means toprovide suppliers with accurate technical evidence ofnonconforming products and specific rectificationprograms for suppliers to rectify according to spe-cific technical objectives

(3) Technical support for supplier quality improvementis to be provided +e relevant departments are re-sponsible for technical guidance and help suppliersto improve quality suppliers and enterprises in thequality of a virtuous circle that is enterprises dotheir best to promote suppliers to improve qualityreward and punishment system for suppliers andlaunch mechanisms +e quality of suppliers isgradually improved due to technical feedback andassistance

(4) Supplier product quality feedback system is to beestablished Let the supplier define the technical andquality requirements of the enterprise and form aclosed loop between the quality of the product of thesupplier and the requirements of the enterprise +e

Table 9 Problem prevention worksheet

Problem prevention worksheetProgram objective to prevent vehicle vibration in terms of the manufacturing quality of components

Key step Nature Possible obstaclescauses of problemsP S P times S

(1) Deviation quality and consistency of transmissionshaft(2) Technical requirements for hub roundness andflatness and consistency(3) Rims meet technical requirements roundness andconsistency(4) Dynamic balance andconsistency of tire assembly(5) Damping force of front axleshock absorber meets technical requirements andconsistency(6) Cab-suspensioning shockabsorber meets technical requirements andconsistencyUse your experience to identifyyour plans and steps

+ese steps are complex havetight deadlines are new andhave an impact on other steps

Determine whichsteps

require yourattention

and resources most

Identify possible obstacles to completing these keysteps (people methods materials machinesmeasurements and environmental problems)

Notes questions such as the nature of the form need to be filled out later

Shock and Vibration 9

enterprise forms the complete system and themechanism causes the supplier and the enterprisemain engine factoryrsquos technical information to forma closed loop strengthens the system informationexchange between each other and forms the tech-nical accumulation for the past problem solving toprevent similar problems from happening in otherlocations or on other models

4 Discussion and Conclusions

By applying the G8D an improved model for solving thetruck vibration problem is established At the same timeaccording to the results of the statement problem methodthe Yes and No worksheet the 5Whys method and the truthfactor assessment the reason for determining the truckvibration is the unbalanced excitation force of the vehiclewheel system the resonance phenomenon caused by thecoupling of the excitation frequency with the natural fre-quency of the system and the insufficient damping functionof the system +erefore the corrective measures forchanging the wheel hub of cab suspension and dynamicbalance brake hub and dynamic balance tire are put forward+en the permanent correction measures are verified fromthree levels of components devices and whole vehicles byusing ldquodecision worksheetrdquo and ldquoproblem preventionworksheetrdquo to ensure the accuracy and feasibility of themodel and make recommendations for the existing systemof the enterprise to prevent recurrence of problems in thefuture

After the implementation of the abovementioned com-plete and improved model the acceleration of the seat rail ofthe truckrsquos vibration performance has been reduced from104ms2 to 06ms2 423 lower than that of the original carreaching the level of 06ms2 of the major domestic modelsand close to the level of 05ms2 of its German counterpartwhich prevents users from returning their cars For thecompany to reduce certain economic losses the sustainabilityof product manufacturing and enterprise economic benefitshave to be improved [36] +e practical implementation ofG8D can solve many technical problems but the wholeenterprise needs to pay attention to G8D training whichenables G8D become a sustainable solution to the problem ofenterprises +is is of great significance for solving the truckvibration problem and even the quality problem of the wholeautomobile manufacturing industry which is meaningful forthe sustainable construction of the industry Most impor-tantly it contributes to the sustainable guarantee of the publictraffic safety of the society [37]

Data Availability

+e numerical data used to support the findings of this studyare included within the article

Conflicts of Interest

+e authors declare that there are no conflicts of interestregarding the publication of this paper

Acknowledgments

+is research was funded by the Enterprise ManagementInnovation Project of the National Defense Science andTechnology Industry (grant no 13315502) FundamentalResearch Funds for the Central Universities (grant no21618412) Inner Mongolia Autonomous Region Scienceand Technology Innovation Guide Award Fund Project(grant no 103-413193) Scientific Research Project of HenanColleges and Universities in 2019 based on the research onmilitary science and technology innovation mechanism ofcolleges and universities from the perspective of civil-military integration (grant no 19A630037) Fund of Re-search on Enterprise Management Innovation Mode System(grant no 44860070) and Fund of Research on the En-terprise Management Mode and Countermeasures Based onthe Production Study and Research (grant no 44860071)

References

[1] S Zhang K Li G Wang and X Zhu ldquoSimulate design andexperimental analysis of commercial vehicle cab suspensionrdquoin Proceedings of the 19th Asia Pacific Automotive EngineeringConference amp SAE-hina Congress 2017 Selected Papers SAE-hina 2017 Lecture Notes in Electrical Engineering Edited by S(SAE-hina) Ed vol 486 pp 675ndash691 Springer ShanghaiChina October 2019

[2] L Morello L R Rossini G Pia and A Tonoli ldquoNoise vi-bration harshnessrdquo in e Automotive Body MechanicalEngineering Series pp 239ndash363 Springer DordrechtNetherlands 2011

[3] A Gupta A D Jayal M Chimienti and I S Jawahir ldquoA totallife-cycle approach towards developing product metrics forsustainable manufacturingrdquo in Glocalized Solutions for Sus-tainability in Manufacturing J Hesselbach and C HerrmannEds Springer Berlin Germany pp 240ndash245 2011

[4] A Zarghami and D Benbow ldquoIntroduction to 8D problemsolvingrdquo Journal for Quality amp Participation vol 40pp 23ndash28 2017

[5] S-O Shim K Park and S Choi ldquoInnovative productionscheduling with customer satisfaction based measurement forthe sustainability of manufacturing firmsrdquo Sustainabilityvol 9 no 12 p 2249 2017

[6] Ford Motor Company Training Group Training Manual forthe G8D Process Ford Motor Company Dearborn MI USA1999

[7] V Nicolae L M Ionescu N Belu and S L Elena ldquoIm-provement of the 8D analysis through a system based on theldquointernet of thingsrdquo concept applied in automotive industryrdquoin Proceedings of the CONAT 2016 International Congress ofAutomotive and Transport Engineering A Chiru and N IspasEds pp 635ndash642 Springer Brasov Romania October 2017

[8] T S M Kumar and B Adaveesh ldquoApplication of ldquo8Dmethodologyrdquo for the root cause analysis and reduction ofvalve spring rejection in a valve spring manufacturingcompany a case studyrdquo Indian Journal of Science andTechnology vol 10 no 11 pp 1ndash11 2017

[9] R Simmons ldquoBook review introduction to 8D problemsolving including practical applications and examplesrdquoQuality Management Journal vol 25 no 4 201 pages 2018

[10] C A Riesenberger and S D Sousa ldquo+e 8D methodology aneffective way to reduce recurrence of customer complaintsrdquo in

10 Shock and Vibration

Proceedings of the World Congress on Engineering vol 3London UK June-July 2010

[11] K S Sim J H Lee T W Park and M H Cho ldquoVibrationpath analysis and optimal design of the suspension for brakejudder reductionrdquo International Journal of AutomotiveTechnology vol 14 no 4 pp 587ndash594 2013

[12] X Yang and S Zuo ldquoParameters sensitivity analysis of self-excited vibration of tiresrdquo in Proceeding of the FISITA 2012World Automotive Congress Lecture Notes in Electrical En-gineering vol 201 pp 3ndash14 Springer Berlin Germany 2013

[13] Z Liu S Yuan S Xiao S Z Du Y Zhang and C Lu ldquoFullvehicle vibration and noise analysis based on substructurepower flowrdquo Shock and Vibration vol 2017 Article ID8725346 17 pages 2017

[14] D Hao C Zhao and Y Huang ldquoA reduced-order modelfor active suppression control of vehicle longitudinal low-frequency vibrationrdquo Shock and Vibration vol 2018Article ID 5731347 22 pages 2018

[15] Y Ren and L Zheng ldquoActive suspension control for wheel-drive electric vehicle based on vibration absorberrdquo in Pro-ceedings of the SAE-China Congress 2015 Selected PapersLecture Notes in Electrical Engineering vol 364 pp 75ndash86Springer Singapore 2016

[16] Y Taskin I Yuksek and N Yagiz ldquoVibration control ofvehicles with active tuned mass damperrdquo Journal ofVibroengineering vol 19 no 5 pp 3533ndash3541 2017

[17] Y M Han M H Nam S S Han H G Lee and S B ChoildquoVibration control evaluation of a commercial vehicle fea-turing MR seat damperrdquo Journal of Intelligent MaterialSystems and Structures vol 13 no 9 pp 575ndash579 2002

[18] H Sell T Ehrt and M Meszlig ldquoVibration-optimized com-ponents for chassis systemsrdquo ATZ Worldwide vol 110 no 2pp 26ndash31 2008

[19] A N +ite ldquoDevelopment of a refined quarter car model forthe analysis of discomfort due to vibrationrdquo Advances inAcoustics and Vibration vol 2012 Article ID 863061 7 pages2012

[20] Y Zhang H Wang Q Zhu Y Xu and L Wu ldquo+e iden-tification and countermeasure analysis of vehicle idle vibra-tionrdquo in Proceedings of the FISITA 2012 World AutomotiveCongress Lecture Notes in Electrical Engineering vol 201pp 443ndash455 Springer Berlin Germany 2013

[21] T Berberich P Gebhard S Bohlen O Danninger andM Lienkamp ldquoA new approach to the presentation of vi-bration phenomena in vehiclesrdquo in Proceedings of the FISITA2012 World Automotive Congress Lecture Notes in ElectricalEngineering vol 201 pp 591ndash598 Springer Berlin Germany2013

[22] N J Mansfield J Mackrill A N Rimell and S J MacMullldquoCombined effects of long-term sitting and whole-body vi-bration on discomfort onset for vehicle occupantsrdquo ISRNAutomotive Engineering vol 2014 Article ID 852607 8 pages2014

[23] J Park J Lee S Ahn and W Jeong ldquoReduced ride comfortcaused by beating idle vibrations in passenger vehiclesrdquo In-ternational Journal of Industrial Ergonomics vol 57 pp 74ndash79 2017

[24] A Jamali M Salehpour and N Nariman-zadeh ldquoRobustPareto active suspension design for vehicle vibration modelwith probabilistic uncertain parametersrdquo Multibody SystemDynamics vol 30 no 3 pp 265ndash285 2013

[25] X C Liang and J S Zhao ldquoResearch on recycling vibrationenergy of shock absorberrdquo International Journal of VehicleDesign vol 68 no 1ndash3 pp 201ndash220 2015

[26] S Zuo X Duan and Y Li ldquoStudy on dynamics of polygonalwear of automotive tire caused by self-excited vibrationrdquoMathematical Problems in Engineering vol 2014 Article ID653803 12 pages 2014

[27] J-J Bae and N Kang ldquoDesign optimization of a mecanumwheel to reduce vertical vibrations by the consideration ofequivalent stiffnessrdquo Shock and Vibration vol 2016 ArticleID 5892784 8 pages 2016

[28] A Pieper K Le Chau and J Kalberer ldquoOptimisation of rollvibration damping of a vehiclerdquo Auto Tech Review vol 4no 2 pp 36ndash41 2015

[29] G Pavic ldquoAnalysis of vibration reduction by damping usingsimple analytical modellingrdquo Shock and Vibration vol 2018Article ID 1098531 13 pages 2018

[30] M Heidari and H Homaei ldquoEstimation of accelerationamplitude of vehicle by back propagation neural networksrdquoAdvances in Acoustics and Vibration vol 2013 Article ID614025 7 pages 2013

[31] L-X Guo and L-P Zhang ldquoVehicle vibration analysis inchangeable speeds solved by pseudoexcitation methodrdquoMathematical Problems in Engineering vol 2010 Article ID802720 14 pages 2010

[32] B Sakhaei and M Durali ldquoVibration transfer path analysisand path ranking for NVH optimization of a vehicle interiorrdquoShock and Vibration vol 2014 Article ID 697450 5 pages2014

[33] D C Barton and J D Fieldhouse ldquoSuspension systems andcomponentsrdquo in Automotive Chassis Engineeringpp 111ndash214 Springer Cham Switzerland 2018

[34] K Jalics ldquoSimulation methods in the vehicle noise vibrationand harshness (NVH)rdquo in Vehicle and Automotive Engi-neering Lecture Notes in Mechanical Engineering K Jarmaiand B Bollo Eds pp 91ndash97 Springer Cham Switzerland2017

[35] X Xu F Yan Y Li W Chen and Y Cao ldquoRide comfortsimulation and abnormal vibration improvement of a com-mercial vehiclerdquo in Proceeding of the SAE-China Congress2015 Selected Papers Lecture Notes in Electrical Engineeringvol 364 pp 521ndash527 Springer Singapore January 2016

[36] D Dornfeld ldquoLeveraging manufacturing for a sustainablefuturerdquo in Glocalized Solutions for Sustainability inManufacturing J Hesselbach and C Herrmann EdsSpringer Berlin Germany pp 17ndash21 2011

[37] M A Gbededo and K Liyanage ldquoIdentification and align-ment of the social aspects of sustainable manufacturing withthe theory of motivationrdquo Sustainability vol 10 no 3 p 8522018

Shock and Vibration 11

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Page 4: ResearchonImprovementofTruckVibrationBasedonSystematic G8D ...downloads.hindawi.com/journals/sv/2019/1416340.pdf · ResearchArticle ResearchonImprovementofTruckVibrationBasedonSystematic

In order to find out the corresponding problems anddefine the root causes of vibration the five-question method(ldquorepeatedly ask whyrdquo) is adopted in this paper as in Figure 2

322 ldquoYes and Nordquo Worksheet +e Yes and No worksheetsdescribe the extent of the problem as in Table 3 and only thecorrect information is included in this table which is part ofthe observation phase as part of the problem resolutionprocess +e information in the Yes section of the worksheetdetermines the root of the problem and the No section helpsnarrow the scope of the problem

323 Truth Factor Assessment (1) Manifestation of VehicleVibration +e vehicle vibration is represented by the ver-tical transverse and longitudinal vibration of the steeringwheel [21] vibration of the gear vibration of the floor in thevertical direction vibration of the seat in the vertical andforward and backward directions and vibration of the leftand right rear mirrors in the cab

(2) Evaluation Method of Vehicle Vibration +e vi-bration of the vehicle is evaluated by measuring the vibrationacceleration of the seat guide rail in three directions with thehelp of data acquisition equipment In the absence of anytesting means it is also possible to evaluate the vibration of avehicle with the subjective evaluation method as well as theend-user and judge whether the vibration exists and itsseverity and acceptability from the point of view of a productconsumer to determine that it can be put on the market

(3) e True Cause Evaluation of Vehicle Vibration

(1) Quality problems of core components the pro-cessing of some rotating parts (such as transmissionshaft semishaft rim hub tyre and brake hub) doesnot meet the technical requirements and deviationresults in mass eccentricity when assembly does notmeet the technical requirements +ese eccentricmasses produce periodic exciting forces when thevehicle is running

(2) Tyre exciting force the periodic exciting forceproduced by the unbalanced wheels in the running ofa vehicle is transmitted to the frame through the leafspring and then to the cab

(3) Tire vibration mode there are two modes of tirevibration jumping mode and swinging mode +efirst is the run-out mode in which the vibrationphase of the left and right tires is the same that iswhen the left tire jumps to the top the right tirejumps to the top and when the left tire jumps to thebottom the tire on the right jumps to the top and thetire on the left jumps to the bottom +e tire on theright is also bouncing to the bottom +e second isthe swing mode in which the vibration phase of theleft and right tires is just the opposite that is whenthe left tire jumps to the top the right tire jumps tothe bottom and when the left tire jumps to thebottom and the tire on the right however leaps tothe top

(4) Cab and seat vibration the vibration problem dis-satisfied with by the end-user is often the cab and seatvibration [22] And the overwhelming majority ofthe unbearable vibration of the cab and seat is thatthe body is in the jumping mode [23] +e reason forthis vibration is that the exciting force produced bythe static and dynamic imbalances of the tire is in therun-out mode the front tire is in the run-out modeor the rear tire is in the run-out mode Another is thefront and rear tires are in the bounce mode +efrequency of the jumping mode may be consistentwith the mass of the frame and the rear axle platespring and the natural frequency of the spring sys-tem or with the mass of the frame and the front axleplate spring and the natural frequency of the springsystem which puts the frame into a resonant state atthe same frequency as the radial force on the tire+eresonance state of the frame is transferred to the cabthrough the cab suspension If the stiffness of the cabsuspension is not matched properly the excitationfrequency of the wheel system coincides with themass of the cab and the body suspension and thenatural frequency of the spring system and thenresonance occurs again

33 Development of Immediate Corrective Action (D3) Inthe case of vibration problems it is necessary to takeemergency response measures and choose ImmediateCorrective Action (ICA) to solve the vibration problemsprovisionally but the premise of the proposed measures isthat the existing design manufacturing and installationmethods and processes cannot be changed and no cost canbe increased +us the vehicles will be put into use so thatthe customers who purchase these vehicles will not beaffected by the vibration of the vehicles and damage thereputation of the quality of the vehicles +e criteria forselecting emergency response measures are shown inTable 4

Based on the above criteria immediate corrective actionsadopted include but are not limited to are as follows

(1) +e front right wheel and the rear right wheel tire arerotated 180 degrees before reinstallation

(2) Under the condition of keeping (1) the rear axle tiresare cross-suspensioned on the left and right sides

(3) Use a better cab suspension [24](4) Use a better front axle damper [25](5) Select tires brake drums and wheels with small

dynamic unbalances

34 Analysis and Identification of Root Causes (D4)

341 Describing Root Causes and Missing Points +emissing point is a point that is very close to the root causethat is it omits to analye what should have been the problemNo missing points were found in this particular vibrationproblem of the enterprise

4 Shock and Vibration

Based on the results of the problemmethod stated in D2the ldquoYes and Nordquo worksheet the ldquo5Whysrdquo and the truthfactor assessment the enterprise can tentatively determinethat the cause of the truck vibration is the unbalanced ex-citation force of the vehiclersquos wheel system the coupling ofthe excitation frequency and the natural frequency of the

system that leads to the resonance phenomenon and at thesame time the insufficient damping function of the systemas described in detail as follows

(1) Wheel systems (including tires hubs and rims)have significant manufacturing defects [26] suchas nonroundness of wheels and rims +e un-evenness of the inner and outer edges of the rim(that is the inner and outer edges are not in thesame plane) results in the imbalance of the tiresystem In the operation of the vehicle these un-balanced forces become the excitation force of thesystem vibration

(2) +e dynamic imbalance of the drive shaft system isone of the factors that cause the vibration of thesystem

1 Why is the cab vibratingBecause of the vibration of the frame the vibration is amplified by the body mount

2 Why does the body mount magnify the vibration The coupling of modal and excited frequencies of the cab results in resonance due to improper stiffness matching of the suspension

3 Why does the body mount match improperly

Poor control over suppliers lack of quality checks and inconsistent vehicle mount condition

4 Why is the frame vibrating at 65~70kmh

Because of the large unbalanced excitation force of the wheel system the excitation frequency is coupled with the rear bias frequency of the whole vehicle at this speed

5 Why is the unbalanced excitation force of the wheel system so large

Due to lack of quality control and inspection and roundness and flatness of rims wheels and brake hubsdo not meet the technical requirements

6 Why has not the cab vibration been damped off

Because the front and rear axle leaf springs dampers and cab suspension dampers do not work very well

7 Why damping shock absorbers donrsquot work well

Because vibration absorbers are accepted without quality inspection some dampers do not work

Figure 2 ldquo5Whysrdquo method to determine the root cause

Table 3 ldquoYes and Nordquo worksheet

Problem-solving worksheet does the truck have a vibration problem(1) Problem statement+e truck has longitudinal and vertical vibration in the cab at a speed of 65 kmh and 70 kmh in no-load condition(2) Problemdescription Yes No Access to

information

Problem

1 +e longitudinal and vertical vibration of a cab ofvehicle Steering wheel without vibration Measurement result

2 +e rear of the frame bounces in a verticaldirection Shift lever without vibration Measurement result

3 +e middle rear axle flutters along the verticaldirection Measurement result

Occurrenceplace

1 Cab Test data2 Frame of a vehicle Test data3 Middle rear axle Test data

Occurrence time 1 New car2 Vibration at speed 65sim70 kmh Other speed does not vibrate

Severity 1 In a severe state of discomforts Other speed does not exist same situation Live video recording

Table 4 Criteria for selecting emergency response measures

ICA Specific description

(1) Reduce exciting force Reduce the source ofvehicle vibration

(2) Enhance shock absorber Increase damping toattenuate vibration

(3) Avoid the resonancefrequency of the system

Avoid exciting frequencyas much as possible

Shock and Vibration 5

(3) Because the frequency of exciting force produced bythe wheel train in the 65sim70 kmh is about 55Hzthis resonance frequency obviously coincides withone of the frequencies of the above three vibrationsystems and produces resonance +e connection tothe cab through the system causes the cab to reso-nate Another reason is that the natural frequency ofthe cab itself is consistent with the excitation fre-quency resulting in resonance

(4) Shock absorbers for vehicles due to manufacturingquality inconsistencies [27] cause the component failto meet the technical requirements of providingsufficient damping during resonance [28] therebyreducing the resonance amplitude of the system +edamping force of the shock absorber of the front axleis not large enough [29] when the front axle resonatesthe amplitude of the resonance cannot be attenuatedto the design level the shock absorbers of the engineand the cab are unable to provide sufficient dampingbecause of inconsistent manufacturing quality

342 Confirming Description As shown in Figure 3 thevertical acceleration of the middle rear axle near 65 kmh islarge [30] up to 476ms2 magnified to 521ms2 from therear axle spring to the frame (at balance suspension) Fromthe frame to the cab the cab front suspension amplifies thevibration (178ms2 to 305ms2) and the cab rear suspen-sion attenuates the vibration (311ms2 to 205ms2)

+e cause of vibration can be determined as followswhen the vehicle speed is 65 kmh the unbalanced excitingforce produced by the rotating parts of themiddle rear axle isrelatively large [31] When passing through the rear axle leafspring it is coupled with the rear bias frequency of the wholevehicle so the acceleration on the frame is amplified [32]and the acceleration transferred from the frame to the cabthrough the front suspension of the cab is magnified It iscoupled with a certain order of the rigid body mode of thecab when it pass through suspension in the cab and theacceleration transmitted from the frame to the cab throughthe front suspension of the cab is magnified causing thetruck to vibrate

(1) Replace Cab Suspension +e cab of the vehicle wassuspended with an air spring and is now replaced with ahelical spring damper +e acceleration on both sides of cabsuspension near 65 kmh with different brands of shockabsorbers is listed as Table 5

Plan A the front suspension is replaced by the brandone spiral spring damper and the rear suspension isreplaced by the brand two spiral spring damperPlan B the front and rear suspensions are brand onespiral spring shock absorber

After replacing the cab suspension the vibration of thecab front suspension is no longer amplified the verticalacceleration of the cab is reduced from 210ms2 to 068ms2 and the longitudinal acceleration of the cab is reducedfrom 202ms2 to 056ms2 +e cab vibration is obviously

improved +ere is no significant difference in the isolationrate between the two types of spiral spring shock absorbers

(2) Replace the Dynamic Balance Brake Hub and DynamicBalance Tire +e acceleration comparison before and afterdynamic balancing is shown in Table 6

After dynamic balancing the vibration acceleration ofthe main seat guide rail decreased by 3036 in longitudinaldirection and 4559 in vertical direction +e vibrationacceleration at the left wheel of the rear axle is still large andbecomes the main excitation which may be caused by thepoor dynamic balance of the left rear axle tire and brake hubor the assembly error

+e manufacturing inconsistency of the wheel hub theuneven flatness of the inner and outer edges of the wheelrim and the uneven roundness of the rim can also beconfirmed by observation Overall the test results show thatthe brake hub and tire with dynamic balance have a greatattenuation effect on the vibration

35 Selection and Validation of Permanent Corrective Actionsfor Root Causes and Missing Points (D5) In order to de-termine the permanent corrective action (PCA) the prin-ciple is to reduce the amplitude of the exciting force separatethe modes of the system [14] and increase the damping forceof the system [33] +ere are six permanent measures listedin Table 7 If you have more than one vendor for these 6components you can use the decision table in Table 8 toselect a good vendor

According to the data in Table 8 the standard scoreexpected by supplier A is 52 and the standard score expectedby supplier B is 48 (the full score is 60) Meanwhile supplierB cannot meet the standard of ldquonot increasing the cost of theproductrdquo In the light of the above decisions vendor Ashould be selected

36 Implementation and Validation of Permanent CorrectiveAction (D6)

(1) Dynamic balance of transmission shaft put forwardcheck and carry out the technical requirementsabout the size and dynamic balance of transmissionshaft and have corresponding quality inspectionmechanism

(2) Dynamic balance of wheel hub put forward checkand carry out the technical requirements ofroundness dimension and dynamic balance of wheelhub and have corresponding quality inspectionmechanism

(3) Dynamic balance of wheel rim propose check andimplement the technical requirements of rim sizeroundness and dynamic balance and have thecorresponding quality inspection mechanism

(4) Dynamic balance of tire assembly put forwardcheck and implement the technical requirements ofstatic and dynamic balance of transfer tire assemblyand provide technical assistance to suppliers to

6 Shock and Vibration

Am

plitu

de (m

s2 ) 310

000

Am

plitu

de (m

s2 ) 320

000

Am

plitu

de (m

s2 ) 530

000

Am

plitu

de (m

s2 ) 480

000

Am

plitu

de

100

000

Am

plitu

de

100

000

Am

plitu

de

100

000

Am

plitu

de

100

000

F Spectrum Rear suspension body side of cab +ZSpectrum Front suspension body side of cab +ZF

F Spectrum Rear suspension frame side of cab +ZSpectrum Front suspension frame side of cab +ZF

F Spectrum Right side of balanced suspension +Z

F Spectrum Right side of middle axle +ZF Spectrum Right side of rear axle +ZF Spectrum Left side of middle axle +ZF Spectrum Left side of rear axle +Z

Spectrum Left side of balanced suspension +ZF

305

205

178

553

Hz000 1500

Hz000 1500

Hz000 1500

Hz000 1500

553

311

515

476319332431

577

521

577

Figure 3 Transmission of vibration acceleration

Table 5 Acceleration (ms2) on both sides of cab suspension near 65 kmh

Cab shockabsorber

Frontsuspensionbody side

Frontsuspensionframe side

Front suspensionvibration isolation rate

Rearsuspensionbody side

Rearsuspensionframe side

Rear suspensionvibration isolation rate

Original airspring 305 178 minus468 dB 205 311 362 dB

Ex-brand 1post-brand 2 139 237 463 dB 129 201 385 dB

Both are brandone 196 330 453 dB 161 255 399 dB

Notes Vibration isolation rate 20 log (active side vibration amplitudepassive side vibration amplitude)

Table 6 Acceleration comparison before and after dynamic balancing (ms2)

Measuring point position Before dynamic balancing After dynamic balancing Reduced percentageMain seat guide (longitudinal) 056 039 3036Main seat guide (vertical) 068 037 4559On the left wheel of the middle axle (vertical) 431 141 6729On the right wheel of the middle axle (vertical) 476 185 6113At the left wheel of the rear axle (vertical) 331 321 302At the right wheel of the rear axle (vertical) 319 215 3260

Shock and Vibration 7

purchase static and dynamic balance equipment oftire

(5) Provide the supplier with hardness and technicalrequirements for reinforced powertrain suspensionrubber and urge and assist them to achieve thesetechnical requirements and consistency of productcharacteristics it can be listed in Table 9

(i) +e technical requirements for the dampingcharacteristics of the hysteresis curve of the frontaxle damper are presented to the supplier

(ii) +e technical requirements for the dampingcharacteristics of the hysteresis curves of the

front and rear suspension dampers of the cab areproposed to the supplier

+e quality of these components must meet the qualityand technical requirements of the enterprise and there is asystematic mechanism to implement and verify the imple-mentation of the quality and technical requirements of thesecomponents

+ere are three levels of validation for these permanentcorrective measures

(1) Component level correct the dynamic balance of therotating parts of the vehicle drive shaft wheel hubrim and tire assembly [34] ensure the supplierrsquos

Table 7 Decision worksheet on permanent corrective measures

Decision worksheet 1Final result eliminate or reduce vibration in operation of this type of vehicle to the extent acceptable to the customerCriteria that must be met(a) Do not change existing design(b) Do not change the manufacturing process(c) No increase in product costExpected standard Importance (1ndash10 1 minimum 10 maximum)(1) Deviation quality and consistency of transmissionshaft 8

(2) Technical requirements for hub roundness andflatness and consistency 9

(3) Rims meet technical requirements roundness andconsistency 9

(4) Dynamic balance and consistency of tire assembly 9(5) Damping force of front axle shock absorber meetstechnical requirements and consistency 8

(6) Cab-suspensioning shock absorber meetstechnical requirements and consistency 9

Table 8 Vendor decision worksheet

Decision worksheet 2Vendor A Vendor B

Criteria that must be met Yesno Criteria that must be met Yesno

(a) Do not change existing design Yes (a) Do not change existing design Yes(b) Do not change the manufacturingprocess Yes (b) Do not change the manufacturing process Yes

(c) No increase in product cost Yes (c) No increase in product cost No

Expected standard Good or bad(1ndash10) Score Expected standard Good or bad

(1ndash10) Score

(1) Deviation quality and consistency oftransmission shaft Good 8 (1) Deviation quality and consistency of

transmission shaft Good 9

(2) Technical requirements for hubroundness and flatness and consistency Good 9 (2) Technical requirements for hub

roundness and flatness and consistency Good 8

(3) Rims meet technical requirementsroundness and consistency Good 8 (3) Rims meet technical requirements

roundness and consistency Good 8

(4) Dynamic balance and consistency oftire assembly Good 9 (4) Dynamic balance and consistency of

tire assembly Good 7

(5) Damping force of front axle shockabsorber meets technical requirementsand consistency

Good 9(5) Damping force of front axle shockabsorber meets technical requirements

and consistencyGood 8

(6) Cab-suspensioning shock absorbermeets technical requirements andconsistency

Good 9(6) Cab-suspensioning shock absorbermeets technical requirements and

consistencyGood 8

8 Shock and Vibration

parts meet the technical standards and check thedynamic balance

(2) Device level correct the cab damper and front axledamper ensure that the parts of the supplier meetthe technical standards and detect the stiffness anddamping of the damper [35]

(3) Whole car level load the car with the modified partsand carry out the road test to see the improvementeffect of the vibration performance of the whole car[20]

37 Prevent ProblemRecurrence (D7) +e ldquo5Whysrdquo methodis still used here to determine the root cause of the problemand the permanent measures that should be taken to preventthe recurrence of the problem According to the theory ofG8D it can be used to find out the problems about systemoperation process or policy Systemic problems arise fromfull references to previous organizations technical processespolicies and practices +ese past processes policies andpractices are often not applicable to the current situation andare not traceable

+e method proposed in this paper is very effective insolving the vibration problem systematically and makes thevibration problem be systematically tracked and controlledAccording to the above analysis and the actual situation thispaper puts forward some suggestions on the existing systemof the enterprise in order to prevent the recurrence of theproblem

(1) +e quality inspection mechanism of enterprisesneeds to be perfected +is is responsible for

formulating product quality inspection standardschecking the quality of parts provided by suppliersspot checking the qualified rate of products thesupplier shall provide quality product certificationaccording to the requirements of the enterprise if itdoes not meet the requirements it will not accept thesupply

(2) +e supplier quality evaluation system is yet to beestablished +e related personnel is responsible forsupplier quality review and supplier classificationmanagement In the case of unqualified productsenterprises need to have accurate technical means toprovide suppliers with accurate technical evidence ofnonconforming products and specific rectificationprograms for suppliers to rectify according to spe-cific technical objectives

(3) Technical support for supplier quality improvementis to be provided +e relevant departments are re-sponsible for technical guidance and help suppliersto improve quality suppliers and enterprises in thequality of a virtuous circle that is enterprises dotheir best to promote suppliers to improve qualityreward and punishment system for suppliers andlaunch mechanisms +e quality of suppliers isgradually improved due to technical feedback andassistance

(4) Supplier product quality feedback system is to beestablished Let the supplier define the technical andquality requirements of the enterprise and form aclosed loop between the quality of the product of thesupplier and the requirements of the enterprise +e

Table 9 Problem prevention worksheet

Problem prevention worksheetProgram objective to prevent vehicle vibration in terms of the manufacturing quality of components

Key step Nature Possible obstaclescauses of problemsP S P times S

(1) Deviation quality and consistency of transmissionshaft(2) Technical requirements for hub roundness andflatness and consistency(3) Rims meet technical requirements roundness andconsistency(4) Dynamic balance andconsistency of tire assembly(5) Damping force of front axleshock absorber meets technical requirements andconsistency(6) Cab-suspensioning shockabsorber meets technical requirements andconsistencyUse your experience to identifyyour plans and steps

+ese steps are complex havetight deadlines are new andhave an impact on other steps

Determine whichsteps

require yourattention

and resources most

Identify possible obstacles to completing these keysteps (people methods materials machinesmeasurements and environmental problems)

Notes questions such as the nature of the form need to be filled out later

Shock and Vibration 9

enterprise forms the complete system and themechanism causes the supplier and the enterprisemain engine factoryrsquos technical information to forma closed loop strengthens the system informationexchange between each other and forms the tech-nical accumulation for the past problem solving toprevent similar problems from happening in otherlocations or on other models

4 Discussion and Conclusions

By applying the G8D an improved model for solving thetruck vibration problem is established At the same timeaccording to the results of the statement problem methodthe Yes and No worksheet the 5Whys method and the truthfactor assessment the reason for determining the truckvibration is the unbalanced excitation force of the vehiclewheel system the resonance phenomenon caused by thecoupling of the excitation frequency with the natural fre-quency of the system and the insufficient damping functionof the system +erefore the corrective measures forchanging the wheel hub of cab suspension and dynamicbalance brake hub and dynamic balance tire are put forward+en the permanent correction measures are verified fromthree levels of components devices and whole vehicles byusing ldquodecision worksheetrdquo and ldquoproblem preventionworksheetrdquo to ensure the accuracy and feasibility of themodel and make recommendations for the existing systemof the enterprise to prevent recurrence of problems in thefuture

After the implementation of the abovementioned com-plete and improved model the acceleration of the seat rail ofthe truckrsquos vibration performance has been reduced from104ms2 to 06ms2 423 lower than that of the original carreaching the level of 06ms2 of the major domestic modelsand close to the level of 05ms2 of its German counterpartwhich prevents users from returning their cars For thecompany to reduce certain economic losses the sustainabilityof product manufacturing and enterprise economic benefitshave to be improved [36] +e practical implementation ofG8D can solve many technical problems but the wholeenterprise needs to pay attention to G8D training whichenables G8D become a sustainable solution to the problem ofenterprises +is is of great significance for solving the truckvibration problem and even the quality problem of the wholeautomobile manufacturing industry which is meaningful forthe sustainable construction of the industry Most impor-tantly it contributes to the sustainable guarantee of the publictraffic safety of the society [37]

Data Availability

+e numerical data used to support the findings of this studyare included within the article

Conflicts of Interest

+e authors declare that there are no conflicts of interestregarding the publication of this paper

Acknowledgments

+is research was funded by the Enterprise ManagementInnovation Project of the National Defense Science andTechnology Industry (grant no 13315502) FundamentalResearch Funds for the Central Universities (grant no21618412) Inner Mongolia Autonomous Region Scienceand Technology Innovation Guide Award Fund Project(grant no 103-413193) Scientific Research Project of HenanColleges and Universities in 2019 based on the research onmilitary science and technology innovation mechanism ofcolleges and universities from the perspective of civil-military integration (grant no 19A630037) Fund of Re-search on Enterprise Management Innovation Mode System(grant no 44860070) and Fund of Research on the En-terprise Management Mode and Countermeasures Based onthe Production Study and Research (grant no 44860071)

References

[1] S Zhang K Li G Wang and X Zhu ldquoSimulate design andexperimental analysis of commercial vehicle cab suspensionrdquoin Proceedings of the 19th Asia Pacific Automotive EngineeringConference amp SAE-hina Congress 2017 Selected Papers SAE-hina 2017 Lecture Notes in Electrical Engineering Edited by S(SAE-hina) Ed vol 486 pp 675ndash691 Springer ShanghaiChina October 2019

[2] L Morello L R Rossini G Pia and A Tonoli ldquoNoise vi-bration harshnessrdquo in e Automotive Body MechanicalEngineering Series pp 239ndash363 Springer DordrechtNetherlands 2011

[3] A Gupta A D Jayal M Chimienti and I S Jawahir ldquoA totallife-cycle approach towards developing product metrics forsustainable manufacturingrdquo in Glocalized Solutions for Sus-tainability in Manufacturing J Hesselbach and C HerrmannEds Springer Berlin Germany pp 240ndash245 2011

[4] A Zarghami and D Benbow ldquoIntroduction to 8D problemsolvingrdquo Journal for Quality amp Participation vol 40pp 23ndash28 2017

[5] S-O Shim K Park and S Choi ldquoInnovative productionscheduling with customer satisfaction based measurement forthe sustainability of manufacturing firmsrdquo Sustainabilityvol 9 no 12 p 2249 2017

[6] Ford Motor Company Training Group Training Manual forthe G8D Process Ford Motor Company Dearborn MI USA1999

[7] V Nicolae L M Ionescu N Belu and S L Elena ldquoIm-provement of the 8D analysis through a system based on theldquointernet of thingsrdquo concept applied in automotive industryrdquoin Proceedings of the CONAT 2016 International Congress ofAutomotive and Transport Engineering A Chiru and N IspasEds pp 635ndash642 Springer Brasov Romania October 2017

[8] T S M Kumar and B Adaveesh ldquoApplication of ldquo8Dmethodologyrdquo for the root cause analysis and reduction ofvalve spring rejection in a valve spring manufacturingcompany a case studyrdquo Indian Journal of Science andTechnology vol 10 no 11 pp 1ndash11 2017

[9] R Simmons ldquoBook review introduction to 8D problemsolving including practical applications and examplesrdquoQuality Management Journal vol 25 no 4 201 pages 2018

[10] C A Riesenberger and S D Sousa ldquo+e 8D methodology aneffective way to reduce recurrence of customer complaintsrdquo in

10 Shock and Vibration

Proceedings of the World Congress on Engineering vol 3London UK June-July 2010

[11] K S Sim J H Lee T W Park and M H Cho ldquoVibrationpath analysis and optimal design of the suspension for brakejudder reductionrdquo International Journal of AutomotiveTechnology vol 14 no 4 pp 587ndash594 2013

[12] X Yang and S Zuo ldquoParameters sensitivity analysis of self-excited vibration of tiresrdquo in Proceeding of the FISITA 2012World Automotive Congress Lecture Notes in Electrical En-gineering vol 201 pp 3ndash14 Springer Berlin Germany 2013

[13] Z Liu S Yuan S Xiao S Z Du Y Zhang and C Lu ldquoFullvehicle vibration and noise analysis based on substructurepower flowrdquo Shock and Vibration vol 2017 Article ID8725346 17 pages 2017

[14] D Hao C Zhao and Y Huang ldquoA reduced-order modelfor active suppression control of vehicle longitudinal low-frequency vibrationrdquo Shock and Vibration vol 2018Article ID 5731347 22 pages 2018

[15] Y Ren and L Zheng ldquoActive suspension control for wheel-drive electric vehicle based on vibration absorberrdquo in Pro-ceedings of the SAE-China Congress 2015 Selected PapersLecture Notes in Electrical Engineering vol 364 pp 75ndash86Springer Singapore 2016

[16] Y Taskin I Yuksek and N Yagiz ldquoVibration control ofvehicles with active tuned mass damperrdquo Journal ofVibroengineering vol 19 no 5 pp 3533ndash3541 2017

[17] Y M Han M H Nam S S Han H G Lee and S B ChoildquoVibration control evaluation of a commercial vehicle fea-turing MR seat damperrdquo Journal of Intelligent MaterialSystems and Structures vol 13 no 9 pp 575ndash579 2002

[18] H Sell T Ehrt and M Meszlig ldquoVibration-optimized com-ponents for chassis systemsrdquo ATZ Worldwide vol 110 no 2pp 26ndash31 2008

[19] A N +ite ldquoDevelopment of a refined quarter car model forthe analysis of discomfort due to vibrationrdquo Advances inAcoustics and Vibration vol 2012 Article ID 863061 7 pages2012

[20] Y Zhang H Wang Q Zhu Y Xu and L Wu ldquo+e iden-tification and countermeasure analysis of vehicle idle vibra-tionrdquo in Proceedings of the FISITA 2012 World AutomotiveCongress Lecture Notes in Electrical Engineering vol 201pp 443ndash455 Springer Berlin Germany 2013

[21] T Berberich P Gebhard S Bohlen O Danninger andM Lienkamp ldquoA new approach to the presentation of vi-bration phenomena in vehiclesrdquo in Proceedings of the FISITA2012 World Automotive Congress Lecture Notes in ElectricalEngineering vol 201 pp 591ndash598 Springer Berlin Germany2013

[22] N J Mansfield J Mackrill A N Rimell and S J MacMullldquoCombined effects of long-term sitting and whole-body vi-bration on discomfort onset for vehicle occupantsrdquo ISRNAutomotive Engineering vol 2014 Article ID 852607 8 pages2014

[23] J Park J Lee S Ahn and W Jeong ldquoReduced ride comfortcaused by beating idle vibrations in passenger vehiclesrdquo In-ternational Journal of Industrial Ergonomics vol 57 pp 74ndash79 2017

[24] A Jamali M Salehpour and N Nariman-zadeh ldquoRobustPareto active suspension design for vehicle vibration modelwith probabilistic uncertain parametersrdquo Multibody SystemDynamics vol 30 no 3 pp 265ndash285 2013

[25] X C Liang and J S Zhao ldquoResearch on recycling vibrationenergy of shock absorberrdquo International Journal of VehicleDesign vol 68 no 1ndash3 pp 201ndash220 2015

[26] S Zuo X Duan and Y Li ldquoStudy on dynamics of polygonalwear of automotive tire caused by self-excited vibrationrdquoMathematical Problems in Engineering vol 2014 Article ID653803 12 pages 2014

[27] J-J Bae and N Kang ldquoDesign optimization of a mecanumwheel to reduce vertical vibrations by the consideration ofequivalent stiffnessrdquo Shock and Vibration vol 2016 ArticleID 5892784 8 pages 2016

[28] A Pieper K Le Chau and J Kalberer ldquoOptimisation of rollvibration damping of a vehiclerdquo Auto Tech Review vol 4no 2 pp 36ndash41 2015

[29] G Pavic ldquoAnalysis of vibration reduction by damping usingsimple analytical modellingrdquo Shock and Vibration vol 2018Article ID 1098531 13 pages 2018

[30] M Heidari and H Homaei ldquoEstimation of accelerationamplitude of vehicle by back propagation neural networksrdquoAdvances in Acoustics and Vibration vol 2013 Article ID614025 7 pages 2013

[31] L-X Guo and L-P Zhang ldquoVehicle vibration analysis inchangeable speeds solved by pseudoexcitation methodrdquoMathematical Problems in Engineering vol 2010 Article ID802720 14 pages 2010

[32] B Sakhaei and M Durali ldquoVibration transfer path analysisand path ranking for NVH optimization of a vehicle interiorrdquoShock and Vibration vol 2014 Article ID 697450 5 pages2014

[33] D C Barton and J D Fieldhouse ldquoSuspension systems andcomponentsrdquo in Automotive Chassis Engineeringpp 111ndash214 Springer Cham Switzerland 2018

[34] K Jalics ldquoSimulation methods in the vehicle noise vibrationand harshness (NVH)rdquo in Vehicle and Automotive Engi-neering Lecture Notes in Mechanical Engineering K Jarmaiand B Bollo Eds pp 91ndash97 Springer Cham Switzerland2017

[35] X Xu F Yan Y Li W Chen and Y Cao ldquoRide comfortsimulation and abnormal vibration improvement of a com-mercial vehiclerdquo in Proceeding of the SAE-China Congress2015 Selected Papers Lecture Notes in Electrical Engineeringvol 364 pp 521ndash527 Springer Singapore January 2016

[36] D Dornfeld ldquoLeveraging manufacturing for a sustainablefuturerdquo in Glocalized Solutions for Sustainability inManufacturing J Hesselbach and C Herrmann EdsSpringer Berlin Germany pp 17ndash21 2011

[37] M A Gbededo and K Liyanage ldquoIdentification and align-ment of the social aspects of sustainable manufacturing withthe theory of motivationrdquo Sustainability vol 10 no 3 p 8522018

Shock and Vibration 11

International Journal of

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Hindawiwwwhindawicom Volume 2018

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Shock and Vibration

Hindawiwwwhindawicom Volume 2018

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Advances inOptoElectronics

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Hindawi Publishing Corporation httpwwwhindawicom Volume 2013Hindawiwwwhindawicom

The Scientific World Journal

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Hindawiwwwhindawicom Volume 2018

Modelling ampSimulationin EngineeringHindawiwwwhindawicom Volume 2018

Hindawiwwwhindawicom Volume 2018

Chemical EngineeringInternational Journal of Antennas and

Propagation

International Journal of

Hindawiwwwhindawicom Volume 2018

Hindawiwwwhindawicom Volume 2018

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International Journal of

Hindawi

wwwhindawicom Volume 2018

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Multimedia

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Page 5: ResearchonImprovementofTruckVibrationBasedonSystematic G8D ...downloads.hindawi.com/journals/sv/2019/1416340.pdf · ResearchArticle ResearchonImprovementofTruckVibrationBasedonSystematic

Based on the results of the problemmethod stated in D2the ldquoYes and Nordquo worksheet the ldquo5Whysrdquo and the truthfactor assessment the enterprise can tentatively determinethat the cause of the truck vibration is the unbalanced ex-citation force of the vehiclersquos wheel system the coupling ofthe excitation frequency and the natural frequency of the

system that leads to the resonance phenomenon and at thesame time the insufficient damping function of the systemas described in detail as follows

(1) Wheel systems (including tires hubs and rims)have significant manufacturing defects [26] suchas nonroundness of wheels and rims +e un-evenness of the inner and outer edges of the rim(that is the inner and outer edges are not in thesame plane) results in the imbalance of the tiresystem In the operation of the vehicle these un-balanced forces become the excitation force of thesystem vibration

(2) +e dynamic imbalance of the drive shaft system isone of the factors that cause the vibration of thesystem

1 Why is the cab vibratingBecause of the vibration of the frame the vibration is amplified by the body mount

2 Why does the body mount magnify the vibration The coupling of modal and excited frequencies of the cab results in resonance due to improper stiffness matching of the suspension

3 Why does the body mount match improperly

Poor control over suppliers lack of quality checks and inconsistent vehicle mount condition

4 Why is the frame vibrating at 65~70kmh

Because of the large unbalanced excitation force of the wheel system the excitation frequency is coupled with the rear bias frequency of the whole vehicle at this speed

5 Why is the unbalanced excitation force of the wheel system so large

Due to lack of quality control and inspection and roundness and flatness of rims wheels and brake hubsdo not meet the technical requirements

6 Why has not the cab vibration been damped off

Because the front and rear axle leaf springs dampers and cab suspension dampers do not work very well

7 Why damping shock absorbers donrsquot work well

Because vibration absorbers are accepted without quality inspection some dampers do not work

Figure 2 ldquo5Whysrdquo method to determine the root cause

Table 3 ldquoYes and Nordquo worksheet

Problem-solving worksheet does the truck have a vibration problem(1) Problem statement+e truck has longitudinal and vertical vibration in the cab at a speed of 65 kmh and 70 kmh in no-load condition(2) Problemdescription Yes No Access to

information

Problem

1 +e longitudinal and vertical vibration of a cab ofvehicle Steering wheel without vibration Measurement result

2 +e rear of the frame bounces in a verticaldirection Shift lever without vibration Measurement result

3 +e middle rear axle flutters along the verticaldirection Measurement result

Occurrenceplace

1 Cab Test data2 Frame of a vehicle Test data3 Middle rear axle Test data

Occurrence time 1 New car2 Vibration at speed 65sim70 kmh Other speed does not vibrate

Severity 1 In a severe state of discomforts Other speed does not exist same situation Live video recording

Table 4 Criteria for selecting emergency response measures

ICA Specific description

(1) Reduce exciting force Reduce the source ofvehicle vibration

(2) Enhance shock absorber Increase damping toattenuate vibration

(3) Avoid the resonancefrequency of the system

Avoid exciting frequencyas much as possible

Shock and Vibration 5

(3) Because the frequency of exciting force produced bythe wheel train in the 65sim70 kmh is about 55Hzthis resonance frequency obviously coincides withone of the frequencies of the above three vibrationsystems and produces resonance +e connection tothe cab through the system causes the cab to reso-nate Another reason is that the natural frequency ofthe cab itself is consistent with the excitation fre-quency resulting in resonance

(4) Shock absorbers for vehicles due to manufacturingquality inconsistencies [27] cause the component failto meet the technical requirements of providingsufficient damping during resonance [28] therebyreducing the resonance amplitude of the system +edamping force of the shock absorber of the front axleis not large enough [29] when the front axle resonatesthe amplitude of the resonance cannot be attenuatedto the design level the shock absorbers of the engineand the cab are unable to provide sufficient dampingbecause of inconsistent manufacturing quality

342 Confirming Description As shown in Figure 3 thevertical acceleration of the middle rear axle near 65 kmh islarge [30] up to 476ms2 magnified to 521ms2 from therear axle spring to the frame (at balance suspension) Fromthe frame to the cab the cab front suspension amplifies thevibration (178ms2 to 305ms2) and the cab rear suspen-sion attenuates the vibration (311ms2 to 205ms2)

+e cause of vibration can be determined as followswhen the vehicle speed is 65 kmh the unbalanced excitingforce produced by the rotating parts of themiddle rear axle isrelatively large [31] When passing through the rear axle leafspring it is coupled with the rear bias frequency of the wholevehicle so the acceleration on the frame is amplified [32]and the acceleration transferred from the frame to the cabthrough the front suspension of the cab is magnified It iscoupled with a certain order of the rigid body mode of thecab when it pass through suspension in the cab and theacceleration transmitted from the frame to the cab throughthe front suspension of the cab is magnified causing thetruck to vibrate

(1) Replace Cab Suspension +e cab of the vehicle wassuspended with an air spring and is now replaced with ahelical spring damper +e acceleration on both sides of cabsuspension near 65 kmh with different brands of shockabsorbers is listed as Table 5

Plan A the front suspension is replaced by the brandone spiral spring damper and the rear suspension isreplaced by the brand two spiral spring damperPlan B the front and rear suspensions are brand onespiral spring shock absorber

After replacing the cab suspension the vibration of thecab front suspension is no longer amplified the verticalacceleration of the cab is reduced from 210ms2 to 068ms2 and the longitudinal acceleration of the cab is reducedfrom 202ms2 to 056ms2 +e cab vibration is obviously

improved +ere is no significant difference in the isolationrate between the two types of spiral spring shock absorbers

(2) Replace the Dynamic Balance Brake Hub and DynamicBalance Tire +e acceleration comparison before and afterdynamic balancing is shown in Table 6

After dynamic balancing the vibration acceleration ofthe main seat guide rail decreased by 3036 in longitudinaldirection and 4559 in vertical direction +e vibrationacceleration at the left wheel of the rear axle is still large andbecomes the main excitation which may be caused by thepoor dynamic balance of the left rear axle tire and brake hubor the assembly error

+e manufacturing inconsistency of the wheel hub theuneven flatness of the inner and outer edges of the wheelrim and the uneven roundness of the rim can also beconfirmed by observation Overall the test results show thatthe brake hub and tire with dynamic balance have a greatattenuation effect on the vibration

35 Selection and Validation of Permanent Corrective Actionsfor Root Causes and Missing Points (D5) In order to de-termine the permanent corrective action (PCA) the prin-ciple is to reduce the amplitude of the exciting force separatethe modes of the system [14] and increase the damping forceof the system [33] +ere are six permanent measures listedin Table 7 If you have more than one vendor for these 6components you can use the decision table in Table 8 toselect a good vendor

According to the data in Table 8 the standard scoreexpected by supplier A is 52 and the standard score expectedby supplier B is 48 (the full score is 60) Meanwhile supplierB cannot meet the standard of ldquonot increasing the cost of theproductrdquo In the light of the above decisions vendor Ashould be selected

36 Implementation and Validation of Permanent CorrectiveAction (D6)

(1) Dynamic balance of transmission shaft put forwardcheck and carry out the technical requirementsabout the size and dynamic balance of transmissionshaft and have corresponding quality inspectionmechanism

(2) Dynamic balance of wheel hub put forward checkand carry out the technical requirements ofroundness dimension and dynamic balance of wheelhub and have corresponding quality inspectionmechanism

(3) Dynamic balance of wheel rim propose check andimplement the technical requirements of rim sizeroundness and dynamic balance and have thecorresponding quality inspection mechanism

(4) Dynamic balance of tire assembly put forwardcheck and implement the technical requirements ofstatic and dynamic balance of transfer tire assemblyand provide technical assistance to suppliers to

6 Shock and Vibration

Am

plitu

de (m

s2 ) 310

000

Am

plitu

de (m

s2 ) 320

000

Am

plitu

de (m

s2 ) 530

000

Am

plitu

de (m

s2 ) 480

000

Am

plitu

de

100

000

Am

plitu

de

100

000

Am

plitu

de

100

000

Am

plitu

de

100

000

F Spectrum Rear suspension body side of cab +ZSpectrum Front suspension body side of cab +ZF

F Spectrum Rear suspension frame side of cab +ZSpectrum Front suspension frame side of cab +ZF

F Spectrum Right side of balanced suspension +Z

F Spectrum Right side of middle axle +ZF Spectrum Right side of rear axle +ZF Spectrum Left side of middle axle +ZF Spectrum Left side of rear axle +Z

Spectrum Left side of balanced suspension +ZF

305

205

178

553

Hz000 1500

Hz000 1500

Hz000 1500

Hz000 1500

553

311

515

476319332431

577

521

577

Figure 3 Transmission of vibration acceleration

Table 5 Acceleration (ms2) on both sides of cab suspension near 65 kmh

Cab shockabsorber

Frontsuspensionbody side

Frontsuspensionframe side

Front suspensionvibration isolation rate

Rearsuspensionbody side

Rearsuspensionframe side

Rear suspensionvibration isolation rate

Original airspring 305 178 minus468 dB 205 311 362 dB

Ex-brand 1post-brand 2 139 237 463 dB 129 201 385 dB

Both are brandone 196 330 453 dB 161 255 399 dB

Notes Vibration isolation rate 20 log (active side vibration amplitudepassive side vibration amplitude)

Table 6 Acceleration comparison before and after dynamic balancing (ms2)

Measuring point position Before dynamic balancing After dynamic balancing Reduced percentageMain seat guide (longitudinal) 056 039 3036Main seat guide (vertical) 068 037 4559On the left wheel of the middle axle (vertical) 431 141 6729On the right wheel of the middle axle (vertical) 476 185 6113At the left wheel of the rear axle (vertical) 331 321 302At the right wheel of the rear axle (vertical) 319 215 3260

Shock and Vibration 7

purchase static and dynamic balance equipment oftire

(5) Provide the supplier with hardness and technicalrequirements for reinforced powertrain suspensionrubber and urge and assist them to achieve thesetechnical requirements and consistency of productcharacteristics it can be listed in Table 9

(i) +e technical requirements for the dampingcharacteristics of the hysteresis curve of the frontaxle damper are presented to the supplier

(ii) +e technical requirements for the dampingcharacteristics of the hysteresis curves of the

front and rear suspension dampers of the cab areproposed to the supplier

+e quality of these components must meet the qualityand technical requirements of the enterprise and there is asystematic mechanism to implement and verify the imple-mentation of the quality and technical requirements of thesecomponents

+ere are three levels of validation for these permanentcorrective measures

(1) Component level correct the dynamic balance of therotating parts of the vehicle drive shaft wheel hubrim and tire assembly [34] ensure the supplierrsquos

Table 7 Decision worksheet on permanent corrective measures

Decision worksheet 1Final result eliminate or reduce vibration in operation of this type of vehicle to the extent acceptable to the customerCriteria that must be met(a) Do not change existing design(b) Do not change the manufacturing process(c) No increase in product costExpected standard Importance (1ndash10 1 minimum 10 maximum)(1) Deviation quality and consistency of transmissionshaft 8

(2) Technical requirements for hub roundness andflatness and consistency 9

(3) Rims meet technical requirements roundness andconsistency 9

(4) Dynamic balance and consistency of tire assembly 9(5) Damping force of front axle shock absorber meetstechnical requirements and consistency 8

(6) Cab-suspensioning shock absorber meetstechnical requirements and consistency 9

Table 8 Vendor decision worksheet

Decision worksheet 2Vendor A Vendor B

Criteria that must be met Yesno Criteria that must be met Yesno

(a) Do not change existing design Yes (a) Do not change existing design Yes(b) Do not change the manufacturingprocess Yes (b) Do not change the manufacturing process Yes

(c) No increase in product cost Yes (c) No increase in product cost No

Expected standard Good or bad(1ndash10) Score Expected standard Good or bad

(1ndash10) Score

(1) Deviation quality and consistency oftransmission shaft Good 8 (1) Deviation quality and consistency of

transmission shaft Good 9

(2) Technical requirements for hubroundness and flatness and consistency Good 9 (2) Technical requirements for hub

roundness and flatness and consistency Good 8

(3) Rims meet technical requirementsroundness and consistency Good 8 (3) Rims meet technical requirements

roundness and consistency Good 8

(4) Dynamic balance and consistency oftire assembly Good 9 (4) Dynamic balance and consistency of

tire assembly Good 7

(5) Damping force of front axle shockabsorber meets technical requirementsand consistency

Good 9(5) Damping force of front axle shockabsorber meets technical requirements

and consistencyGood 8

(6) Cab-suspensioning shock absorbermeets technical requirements andconsistency

Good 9(6) Cab-suspensioning shock absorbermeets technical requirements and

consistencyGood 8

8 Shock and Vibration

parts meet the technical standards and check thedynamic balance

(2) Device level correct the cab damper and front axledamper ensure that the parts of the supplier meetthe technical standards and detect the stiffness anddamping of the damper [35]

(3) Whole car level load the car with the modified partsand carry out the road test to see the improvementeffect of the vibration performance of the whole car[20]

37 Prevent ProblemRecurrence (D7) +e ldquo5Whysrdquo methodis still used here to determine the root cause of the problemand the permanent measures that should be taken to preventthe recurrence of the problem According to the theory ofG8D it can be used to find out the problems about systemoperation process or policy Systemic problems arise fromfull references to previous organizations technical processespolicies and practices +ese past processes policies andpractices are often not applicable to the current situation andare not traceable

+e method proposed in this paper is very effective insolving the vibration problem systematically and makes thevibration problem be systematically tracked and controlledAccording to the above analysis and the actual situation thispaper puts forward some suggestions on the existing systemof the enterprise in order to prevent the recurrence of theproblem

(1) +e quality inspection mechanism of enterprisesneeds to be perfected +is is responsible for

formulating product quality inspection standardschecking the quality of parts provided by suppliersspot checking the qualified rate of products thesupplier shall provide quality product certificationaccording to the requirements of the enterprise if itdoes not meet the requirements it will not accept thesupply

(2) +e supplier quality evaluation system is yet to beestablished +e related personnel is responsible forsupplier quality review and supplier classificationmanagement In the case of unqualified productsenterprises need to have accurate technical means toprovide suppliers with accurate technical evidence ofnonconforming products and specific rectificationprograms for suppliers to rectify according to spe-cific technical objectives

(3) Technical support for supplier quality improvementis to be provided +e relevant departments are re-sponsible for technical guidance and help suppliersto improve quality suppliers and enterprises in thequality of a virtuous circle that is enterprises dotheir best to promote suppliers to improve qualityreward and punishment system for suppliers andlaunch mechanisms +e quality of suppliers isgradually improved due to technical feedback andassistance

(4) Supplier product quality feedback system is to beestablished Let the supplier define the technical andquality requirements of the enterprise and form aclosed loop between the quality of the product of thesupplier and the requirements of the enterprise +e

Table 9 Problem prevention worksheet

Problem prevention worksheetProgram objective to prevent vehicle vibration in terms of the manufacturing quality of components

Key step Nature Possible obstaclescauses of problemsP S P times S

(1) Deviation quality and consistency of transmissionshaft(2) Technical requirements for hub roundness andflatness and consistency(3) Rims meet technical requirements roundness andconsistency(4) Dynamic balance andconsistency of tire assembly(5) Damping force of front axleshock absorber meets technical requirements andconsistency(6) Cab-suspensioning shockabsorber meets technical requirements andconsistencyUse your experience to identifyyour plans and steps

+ese steps are complex havetight deadlines are new andhave an impact on other steps

Determine whichsteps

require yourattention

and resources most

Identify possible obstacles to completing these keysteps (people methods materials machinesmeasurements and environmental problems)

Notes questions such as the nature of the form need to be filled out later

Shock and Vibration 9

enterprise forms the complete system and themechanism causes the supplier and the enterprisemain engine factoryrsquos technical information to forma closed loop strengthens the system informationexchange between each other and forms the tech-nical accumulation for the past problem solving toprevent similar problems from happening in otherlocations or on other models

4 Discussion and Conclusions

By applying the G8D an improved model for solving thetruck vibration problem is established At the same timeaccording to the results of the statement problem methodthe Yes and No worksheet the 5Whys method and the truthfactor assessment the reason for determining the truckvibration is the unbalanced excitation force of the vehiclewheel system the resonance phenomenon caused by thecoupling of the excitation frequency with the natural fre-quency of the system and the insufficient damping functionof the system +erefore the corrective measures forchanging the wheel hub of cab suspension and dynamicbalance brake hub and dynamic balance tire are put forward+en the permanent correction measures are verified fromthree levels of components devices and whole vehicles byusing ldquodecision worksheetrdquo and ldquoproblem preventionworksheetrdquo to ensure the accuracy and feasibility of themodel and make recommendations for the existing systemof the enterprise to prevent recurrence of problems in thefuture

After the implementation of the abovementioned com-plete and improved model the acceleration of the seat rail ofthe truckrsquos vibration performance has been reduced from104ms2 to 06ms2 423 lower than that of the original carreaching the level of 06ms2 of the major domestic modelsand close to the level of 05ms2 of its German counterpartwhich prevents users from returning their cars For thecompany to reduce certain economic losses the sustainabilityof product manufacturing and enterprise economic benefitshave to be improved [36] +e practical implementation ofG8D can solve many technical problems but the wholeenterprise needs to pay attention to G8D training whichenables G8D become a sustainable solution to the problem ofenterprises +is is of great significance for solving the truckvibration problem and even the quality problem of the wholeautomobile manufacturing industry which is meaningful forthe sustainable construction of the industry Most impor-tantly it contributes to the sustainable guarantee of the publictraffic safety of the society [37]

Data Availability

+e numerical data used to support the findings of this studyare included within the article

Conflicts of Interest

+e authors declare that there are no conflicts of interestregarding the publication of this paper

Acknowledgments

+is research was funded by the Enterprise ManagementInnovation Project of the National Defense Science andTechnology Industry (grant no 13315502) FundamentalResearch Funds for the Central Universities (grant no21618412) Inner Mongolia Autonomous Region Scienceand Technology Innovation Guide Award Fund Project(grant no 103-413193) Scientific Research Project of HenanColleges and Universities in 2019 based on the research onmilitary science and technology innovation mechanism ofcolleges and universities from the perspective of civil-military integration (grant no 19A630037) Fund of Re-search on Enterprise Management Innovation Mode System(grant no 44860070) and Fund of Research on the En-terprise Management Mode and Countermeasures Based onthe Production Study and Research (grant no 44860071)

References

[1] S Zhang K Li G Wang and X Zhu ldquoSimulate design andexperimental analysis of commercial vehicle cab suspensionrdquoin Proceedings of the 19th Asia Pacific Automotive EngineeringConference amp SAE-hina Congress 2017 Selected Papers SAE-hina 2017 Lecture Notes in Electrical Engineering Edited by S(SAE-hina) Ed vol 486 pp 675ndash691 Springer ShanghaiChina October 2019

[2] L Morello L R Rossini G Pia and A Tonoli ldquoNoise vi-bration harshnessrdquo in e Automotive Body MechanicalEngineering Series pp 239ndash363 Springer DordrechtNetherlands 2011

[3] A Gupta A D Jayal M Chimienti and I S Jawahir ldquoA totallife-cycle approach towards developing product metrics forsustainable manufacturingrdquo in Glocalized Solutions for Sus-tainability in Manufacturing J Hesselbach and C HerrmannEds Springer Berlin Germany pp 240ndash245 2011

[4] A Zarghami and D Benbow ldquoIntroduction to 8D problemsolvingrdquo Journal for Quality amp Participation vol 40pp 23ndash28 2017

[5] S-O Shim K Park and S Choi ldquoInnovative productionscheduling with customer satisfaction based measurement forthe sustainability of manufacturing firmsrdquo Sustainabilityvol 9 no 12 p 2249 2017

[6] Ford Motor Company Training Group Training Manual forthe G8D Process Ford Motor Company Dearborn MI USA1999

[7] V Nicolae L M Ionescu N Belu and S L Elena ldquoIm-provement of the 8D analysis through a system based on theldquointernet of thingsrdquo concept applied in automotive industryrdquoin Proceedings of the CONAT 2016 International Congress ofAutomotive and Transport Engineering A Chiru and N IspasEds pp 635ndash642 Springer Brasov Romania October 2017

[8] T S M Kumar and B Adaveesh ldquoApplication of ldquo8Dmethodologyrdquo for the root cause analysis and reduction ofvalve spring rejection in a valve spring manufacturingcompany a case studyrdquo Indian Journal of Science andTechnology vol 10 no 11 pp 1ndash11 2017

[9] R Simmons ldquoBook review introduction to 8D problemsolving including practical applications and examplesrdquoQuality Management Journal vol 25 no 4 201 pages 2018

[10] C A Riesenberger and S D Sousa ldquo+e 8D methodology aneffective way to reduce recurrence of customer complaintsrdquo in

10 Shock and Vibration

Proceedings of the World Congress on Engineering vol 3London UK June-July 2010

[11] K S Sim J H Lee T W Park and M H Cho ldquoVibrationpath analysis and optimal design of the suspension for brakejudder reductionrdquo International Journal of AutomotiveTechnology vol 14 no 4 pp 587ndash594 2013

[12] X Yang and S Zuo ldquoParameters sensitivity analysis of self-excited vibration of tiresrdquo in Proceeding of the FISITA 2012World Automotive Congress Lecture Notes in Electrical En-gineering vol 201 pp 3ndash14 Springer Berlin Germany 2013

[13] Z Liu S Yuan S Xiao S Z Du Y Zhang and C Lu ldquoFullvehicle vibration and noise analysis based on substructurepower flowrdquo Shock and Vibration vol 2017 Article ID8725346 17 pages 2017

[14] D Hao C Zhao and Y Huang ldquoA reduced-order modelfor active suppression control of vehicle longitudinal low-frequency vibrationrdquo Shock and Vibration vol 2018Article ID 5731347 22 pages 2018

[15] Y Ren and L Zheng ldquoActive suspension control for wheel-drive electric vehicle based on vibration absorberrdquo in Pro-ceedings of the SAE-China Congress 2015 Selected PapersLecture Notes in Electrical Engineering vol 364 pp 75ndash86Springer Singapore 2016

[16] Y Taskin I Yuksek and N Yagiz ldquoVibration control ofvehicles with active tuned mass damperrdquo Journal ofVibroengineering vol 19 no 5 pp 3533ndash3541 2017

[17] Y M Han M H Nam S S Han H G Lee and S B ChoildquoVibration control evaluation of a commercial vehicle fea-turing MR seat damperrdquo Journal of Intelligent MaterialSystems and Structures vol 13 no 9 pp 575ndash579 2002

[18] H Sell T Ehrt and M Meszlig ldquoVibration-optimized com-ponents for chassis systemsrdquo ATZ Worldwide vol 110 no 2pp 26ndash31 2008

[19] A N +ite ldquoDevelopment of a refined quarter car model forthe analysis of discomfort due to vibrationrdquo Advances inAcoustics and Vibration vol 2012 Article ID 863061 7 pages2012

[20] Y Zhang H Wang Q Zhu Y Xu and L Wu ldquo+e iden-tification and countermeasure analysis of vehicle idle vibra-tionrdquo in Proceedings of the FISITA 2012 World AutomotiveCongress Lecture Notes in Electrical Engineering vol 201pp 443ndash455 Springer Berlin Germany 2013

[21] T Berberich P Gebhard S Bohlen O Danninger andM Lienkamp ldquoA new approach to the presentation of vi-bration phenomena in vehiclesrdquo in Proceedings of the FISITA2012 World Automotive Congress Lecture Notes in ElectricalEngineering vol 201 pp 591ndash598 Springer Berlin Germany2013

[22] N J Mansfield J Mackrill A N Rimell and S J MacMullldquoCombined effects of long-term sitting and whole-body vi-bration on discomfort onset for vehicle occupantsrdquo ISRNAutomotive Engineering vol 2014 Article ID 852607 8 pages2014

[23] J Park J Lee S Ahn and W Jeong ldquoReduced ride comfortcaused by beating idle vibrations in passenger vehiclesrdquo In-ternational Journal of Industrial Ergonomics vol 57 pp 74ndash79 2017

[24] A Jamali M Salehpour and N Nariman-zadeh ldquoRobustPareto active suspension design for vehicle vibration modelwith probabilistic uncertain parametersrdquo Multibody SystemDynamics vol 30 no 3 pp 265ndash285 2013

[25] X C Liang and J S Zhao ldquoResearch on recycling vibrationenergy of shock absorberrdquo International Journal of VehicleDesign vol 68 no 1ndash3 pp 201ndash220 2015

[26] S Zuo X Duan and Y Li ldquoStudy on dynamics of polygonalwear of automotive tire caused by self-excited vibrationrdquoMathematical Problems in Engineering vol 2014 Article ID653803 12 pages 2014

[27] J-J Bae and N Kang ldquoDesign optimization of a mecanumwheel to reduce vertical vibrations by the consideration ofequivalent stiffnessrdquo Shock and Vibration vol 2016 ArticleID 5892784 8 pages 2016

[28] A Pieper K Le Chau and J Kalberer ldquoOptimisation of rollvibration damping of a vehiclerdquo Auto Tech Review vol 4no 2 pp 36ndash41 2015

[29] G Pavic ldquoAnalysis of vibration reduction by damping usingsimple analytical modellingrdquo Shock and Vibration vol 2018Article ID 1098531 13 pages 2018

[30] M Heidari and H Homaei ldquoEstimation of accelerationamplitude of vehicle by back propagation neural networksrdquoAdvances in Acoustics and Vibration vol 2013 Article ID614025 7 pages 2013

[31] L-X Guo and L-P Zhang ldquoVehicle vibration analysis inchangeable speeds solved by pseudoexcitation methodrdquoMathematical Problems in Engineering vol 2010 Article ID802720 14 pages 2010

[32] B Sakhaei and M Durali ldquoVibration transfer path analysisand path ranking for NVH optimization of a vehicle interiorrdquoShock and Vibration vol 2014 Article ID 697450 5 pages2014

[33] D C Barton and J D Fieldhouse ldquoSuspension systems andcomponentsrdquo in Automotive Chassis Engineeringpp 111ndash214 Springer Cham Switzerland 2018

[34] K Jalics ldquoSimulation methods in the vehicle noise vibrationand harshness (NVH)rdquo in Vehicle and Automotive Engi-neering Lecture Notes in Mechanical Engineering K Jarmaiand B Bollo Eds pp 91ndash97 Springer Cham Switzerland2017

[35] X Xu F Yan Y Li W Chen and Y Cao ldquoRide comfortsimulation and abnormal vibration improvement of a com-mercial vehiclerdquo in Proceeding of the SAE-China Congress2015 Selected Papers Lecture Notes in Electrical Engineeringvol 364 pp 521ndash527 Springer Singapore January 2016

[36] D Dornfeld ldquoLeveraging manufacturing for a sustainablefuturerdquo in Glocalized Solutions for Sustainability inManufacturing J Hesselbach and C Herrmann EdsSpringer Berlin Germany pp 17ndash21 2011

[37] M A Gbededo and K Liyanage ldquoIdentification and align-ment of the social aspects of sustainable manufacturing withthe theory of motivationrdquo Sustainability vol 10 no 3 p 8522018

Shock and Vibration 11

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Shock and Vibration

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Hindawi Publishing Corporation httpwwwhindawicom Volume 2013Hindawiwwwhindawicom

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RotatingMachinery

Hindawiwwwhindawicom Volume 2018

Modelling ampSimulationin EngineeringHindawiwwwhindawicom Volume 2018

Hindawiwwwhindawicom Volume 2018

Chemical EngineeringInternational Journal of Antennas and

Propagation

International Journal of

Hindawiwwwhindawicom Volume 2018

Hindawiwwwhindawicom Volume 2018

Navigation and Observation

International Journal of

Hindawi

wwwhindawicom Volume 2018

Advances in

Multimedia

Submit your manuscripts atwwwhindawicom

Page 6: ResearchonImprovementofTruckVibrationBasedonSystematic G8D ...downloads.hindawi.com/journals/sv/2019/1416340.pdf · ResearchArticle ResearchonImprovementofTruckVibrationBasedonSystematic

(3) Because the frequency of exciting force produced bythe wheel train in the 65sim70 kmh is about 55Hzthis resonance frequency obviously coincides withone of the frequencies of the above three vibrationsystems and produces resonance +e connection tothe cab through the system causes the cab to reso-nate Another reason is that the natural frequency ofthe cab itself is consistent with the excitation fre-quency resulting in resonance

(4) Shock absorbers for vehicles due to manufacturingquality inconsistencies [27] cause the component failto meet the technical requirements of providingsufficient damping during resonance [28] therebyreducing the resonance amplitude of the system +edamping force of the shock absorber of the front axleis not large enough [29] when the front axle resonatesthe amplitude of the resonance cannot be attenuatedto the design level the shock absorbers of the engineand the cab are unable to provide sufficient dampingbecause of inconsistent manufacturing quality

342 Confirming Description As shown in Figure 3 thevertical acceleration of the middle rear axle near 65 kmh islarge [30] up to 476ms2 magnified to 521ms2 from therear axle spring to the frame (at balance suspension) Fromthe frame to the cab the cab front suspension amplifies thevibration (178ms2 to 305ms2) and the cab rear suspen-sion attenuates the vibration (311ms2 to 205ms2)

+e cause of vibration can be determined as followswhen the vehicle speed is 65 kmh the unbalanced excitingforce produced by the rotating parts of themiddle rear axle isrelatively large [31] When passing through the rear axle leafspring it is coupled with the rear bias frequency of the wholevehicle so the acceleration on the frame is amplified [32]and the acceleration transferred from the frame to the cabthrough the front suspension of the cab is magnified It iscoupled with a certain order of the rigid body mode of thecab when it pass through suspension in the cab and theacceleration transmitted from the frame to the cab throughthe front suspension of the cab is magnified causing thetruck to vibrate

(1) Replace Cab Suspension +e cab of the vehicle wassuspended with an air spring and is now replaced with ahelical spring damper +e acceleration on both sides of cabsuspension near 65 kmh with different brands of shockabsorbers is listed as Table 5

Plan A the front suspension is replaced by the brandone spiral spring damper and the rear suspension isreplaced by the brand two spiral spring damperPlan B the front and rear suspensions are brand onespiral spring shock absorber

After replacing the cab suspension the vibration of thecab front suspension is no longer amplified the verticalacceleration of the cab is reduced from 210ms2 to 068ms2 and the longitudinal acceleration of the cab is reducedfrom 202ms2 to 056ms2 +e cab vibration is obviously

improved +ere is no significant difference in the isolationrate between the two types of spiral spring shock absorbers

(2) Replace the Dynamic Balance Brake Hub and DynamicBalance Tire +e acceleration comparison before and afterdynamic balancing is shown in Table 6

After dynamic balancing the vibration acceleration ofthe main seat guide rail decreased by 3036 in longitudinaldirection and 4559 in vertical direction +e vibrationacceleration at the left wheel of the rear axle is still large andbecomes the main excitation which may be caused by thepoor dynamic balance of the left rear axle tire and brake hubor the assembly error

+e manufacturing inconsistency of the wheel hub theuneven flatness of the inner and outer edges of the wheelrim and the uneven roundness of the rim can also beconfirmed by observation Overall the test results show thatthe brake hub and tire with dynamic balance have a greatattenuation effect on the vibration

35 Selection and Validation of Permanent Corrective Actionsfor Root Causes and Missing Points (D5) In order to de-termine the permanent corrective action (PCA) the prin-ciple is to reduce the amplitude of the exciting force separatethe modes of the system [14] and increase the damping forceof the system [33] +ere are six permanent measures listedin Table 7 If you have more than one vendor for these 6components you can use the decision table in Table 8 toselect a good vendor

According to the data in Table 8 the standard scoreexpected by supplier A is 52 and the standard score expectedby supplier B is 48 (the full score is 60) Meanwhile supplierB cannot meet the standard of ldquonot increasing the cost of theproductrdquo In the light of the above decisions vendor Ashould be selected

36 Implementation and Validation of Permanent CorrectiveAction (D6)

(1) Dynamic balance of transmission shaft put forwardcheck and carry out the technical requirementsabout the size and dynamic balance of transmissionshaft and have corresponding quality inspectionmechanism

(2) Dynamic balance of wheel hub put forward checkand carry out the technical requirements ofroundness dimension and dynamic balance of wheelhub and have corresponding quality inspectionmechanism

(3) Dynamic balance of wheel rim propose check andimplement the technical requirements of rim sizeroundness and dynamic balance and have thecorresponding quality inspection mechanism

(4) Dynamic balance of tire assembly put forwardcheck and implement the technical requirements ofstatic and dynamic balance of transfer tire assemblyand provide technical assistance to suppliers to

6 Shock and Vibration

Am

plitu

de (m

s2 ) 310

000

Am

plitu

de (m

s2 ) 320

000

Am

plitu

de (m

s2 ) 530

000

Am

plitu

de (m

s2 ) 480

000

Am

plitu

de

100

000

Am

plitu

de

100

000

Am

plitu

de

100

000

Am

plitu

de

100

000

F Spectrum Rear suspension body side of cab +ZSpectrum Front suspension body side of cab +ZF

F Spectrum Rear suspension frame side of cab +ZSpectrum Front suspension frame side of cab +ZF

F Spectrum Right side of balanced suspension +Z

F Spectrum Right side of middle axle +ZF Spectrum Right side of rear axle +ZF Spectrum Left side of middle axle +ZF Spectrum Left side of rear axle +Z

Spectrum Left side of balanced suspension +ZF

305

205

178

553

Hz000 1500

Hz000 1500

Hz000 1500

Hz000 1500

553

311

515

476319332431

577

521

577

Figure 3 Transmission of vibration acceleration

Table 5 Acceleration (ms2) on both sides of cab suspension near 65 kmh

Cab shockabsorber

Frontsuspensionbody side

Frontsuspensionframe side

Front suspensionvibration isolation rate

Rearsuspensionbody side

Rearsuspensionframe side

Rear suspensionvibration isolation rate

Original airspring 305 178 minus468 dB 205 311 362 dB

Ex-brand 1post-brand 2 139 237 463 dB 129 201 385 dB

Both are brandone 196 330 453 dB 161 255 399 dB

Notes Vibration isolation rate 20 log (active side vibration amplitudepassive side vibration amplitude)

Table 6 Acceleration comparison before and after dynamic balancing (ms2)

Measuring point position Before dynamic balancing After dynamic balancing Reduced percentageMain seat guide (longitudinal) 056 039 3036Main seat guide (vertical) 068 037 4559On the left wheel of the middle axle (vertical) 431 141 6729On the right wheel of the middle axle (vertical) 476 185 6113At the left wheel of the rear axle (vertical) 331 321 302At the right wheel of the rear axle (vertical) 319 215 3260

Shock and Vibration 7

purchase static and dynamic balance equipment oftire

(5) Provide the supplier with hardness and technicalrequirements for reinforced powertrain suspensionrubber and urge and assist them to achieve thesetechnical requirements and consistency of productcharacteristics it can be listed in Table 9

(i) +e technical requirements for the dampingcharacteristics of the hysteresis curve of the frontaxle damper are presented to the supplier

(ii) +e technical requirements for the dampingcharacteristics of the hysteresis curves of the

front and rear suspension dampers of the cab areproposed to the supplier

+e quality of these components must meet the qualityand technical requirements of the enterprise and there is asystematic mechanism to implement and verify the imple-mentation of the quality and technical requirements of thesecomponents

+ere are three levels of validation for these permanentcorrective measures

(1) Component level correct the dynamic balance of therotating parts of the vehicle drive shaft wheel hubrim and tire assembly [34] ensure the supplierrsquos

Table 7 Decision worksheet on permanent corrective measures

Decision worksheet 1Final result eliminate or reduce vibration in operation of this type of vehicle to the extent acceptable to the customerCriteria that must be met(a) Do not change existing design(b) Do not change the manufacturing process(c) No increase in product costExpected standard Importance (1ndash10 1 minimum 10 maximum)(1) Deviation quality and consistency of transmissionshaft 8

(2) Technical requirements for hub roundness andflatness and consistency 9

(3) Rims meet technical requirements roundness andconsistency 9

(4) Dynamic balance and consistency of tire assembly 9(5) Damping force of front axle shock absorber meetstechnical requirements and consistency 8

(6) Cab-suspensioning shock absorber meetstechnical requirements and consistency 9

Table 8 Vendor decision worksheet

Decision worksheet 2Vendor A Vendor B

Criteria that must be met Yesno Criteria that must be met Yesno

(a) Do not change existing design Yes (a) Do not change existing design Yes(b) Do not change the manufacturingprocess Yes (b) Do not change the manufacturing process Yes

(c) No increase in product cost Yes (c) No increase in product cost No

Expected standard Good or bad(1ndash10) Score Expected standard Good or bad

(1ndash10) Score

(1) Deviation quality and consistency oftransmission shaft Good 8 (1) Deviation quality and consistency of

transmission shaft Good 9

(2) Technical requirements for hubroundness and flatness and consistency Good 9 (2) Technical requirements for hub

roundness and flatness and consistency Good 8

(3) Rims meet technical requirementsroundness and consistency Good 8 (3) Rims meet technical requirements

roundness and consistency Good 8

(4) Dynamic balance and consistency oftire assembly Good 9 (4) Dynamic balance and consistency of

tire assembly Good 7

(5) Damping force of front axle shockabsorber meets technical requirementsand consistency

Good 9(5) Damping force of front axle shockabsorber meets technical requirements

and consistencyGood 8

(6) Cab-suspensioning shock absorbermeets technical requirements andconsistency

Good 9(6) Cab-suspensioning shock absorbermeets technical requirements and

consistencyGood 8

8 Shock and Vibration

parts meet the technical standards and check thedynamic balance

(2) Device level correct the cab damper and front axledamper ensure that the parts of the supplier meetthe technical standards and detect the stiffness anddamping of the damper [35]

(3) Whole car level load the car with the modified partsand carry out the road test to see the improvementeffect of the vibration performance of the whole car[20]

37 Prevent ProblemRecurrence (D7) +e ldquo5Whysrdquo methodis still used here to determine the root cause of the problemand the permanent measures that should be taken to preventthe recurrence of the problem According to the theory ofG8D it can be used to find out the problems about systemoperation process or policy Systemic problems arise fromfull references to previous organizations technical processespolicies and practices +ese past processes policies andpractices are often not applicable to the current situation andare not traceable

+e method proposed in this paper is very effective insolving the vibration problem systematically and makes thevibration problem be systematically tracked and controlledAccording to the above analysis and the actual situation thispaper puts forward some suggestions on the existing systemof the enterprise in order to prevent the recurrence of theproblem

(1) +e quality inspection mechanism of enterprisesneeds to be perfected +is is responsible for

formulating product quality inspection standardschecking the quality of parts provided by suppliersspot checking the qualified rate of products thesupplier shall provide quality product certificationaccording to the requirements of the enterprise if itdoes not meet the requirements it will not accept thesupply

(2) +e supplier quality evaluation system is yet to beestablished +e related personnel is responsible forsupplier quality review and supplier classificationmanagement In the case of unqualified productsenterprises need to have accurate technical means toprovide suppliers with accurate technical evidence ofnonconforming products and specific rectificationprograms for suppliers to rectify according to spe-cific technical objectives

(3) Technical support for supplier quality improvementis to be provided +e relevant departments are re-sponsible for technical guidance and help suppliersto improve quality suppliers and enterprises in thequality of a virtuous circle that is enterprises dotheir best to promote suppliers to improve qualityreward and punishment system for suppliers andlaunch mechanisms +e quality of suppliers isgradually improved due to technical feedback andassistance

(4) Supplier product quality feedback system is to beestablished Let the supplier define the technical andquality requirements of the enterprise and form aclosed loop between the quality of the product of thesupplier and the requirements of the enterprise +e

Table 9 Problem prevention worksheet

Problem prevention worksheetProgram objective to prevent vehicle vibration in terms of the manufacturing quality of components

Key step Nature Possible obstaclescauses of problemsP S P times S

(1) Deviation quality and consistency of transmissionshaft(2) Technical requirements for hub roundness andflatness and consistency(3) Rims meet technical requirements roundness andconsistency(4) Dynamic balance andconsistency of tire assembly(5) Damping force of front axleshock absorber meets technical requirements andconsistency(6) Cab-suspensioning shockabsorber meets technical requirements andconsistencyUse your experience to identifyyour plans and steps

+ese steps are complex havetight deadlines are new andhave an impact on other steps

Determine whichsteps

require yourattention

and resources most

Identify possible obstacles to completing these keysteps (people methods materials machinesmeasurements and environmental problems)

Notes questions such as the nature of the form need to be filled out later

Shock and Vibration 9

enterprise forms the complete system and themechanism causes the supplier and the enterprisemain engine factoryrsquos technical information to forma closed loop strengthens the system informationexchange between each other and forms the tech-nical accumulation for the past problem solving toprevent similar problems from happening in otherlocations or on other models

4 Discussion and Conclusions

By applying the G8D an improved model for solving thetruck vibration problem is established At the same timeaccording to the results of the statement problem methodthe Yes and No worksheet the 5Whys method and the truthfactor assessment the reason for determining the truckvibration is the unbalanced excitation force of the vehiclewheel system the resonance phenomenon caused by thecoupling of the excitation frequency with the natural fre-quency of the system and the insufficient damping functionof the system +erefore the corrective measures forchanging the wheel hub of cab suspension and dynamicbalance brake hub and dynamic balance tire are put forward+en the permanent correction measures are verified fromthree levels of components devices and whole vehicles byusing ldquodecision worksheetrdquo and ldquoproblem preventionworksheetrdquo to ensure the accuracy and feasibility of themodel and make recommendations for the existing systemof the enterprise to prevent recurrence of problems in thefuture

After the implementation of the abovementioned com-plete and improved model the acceleration of the seat rail ofthe truckrsquos vibration performance has been reduced from104ms2 to 06ms2 423 lower than that of the original carreaching the level of 06ms2 of the major domestic modelsand close to the level of 05ms2 of its German counterpartwhich prevents users from returning their cars For thecompany to reduce certain economic losses the sustainabilityof product manufacturing and enterprise economic benefitshave to be improved [36] +e practical implementation ofG8D can solve many technical problems but the wholeenterprise needs to pay attention to G8D training whichenables G8D become a sustainable solution to the problem ofenterprises +is is of great significance for solving the truckvibration problem and even the quality problem of the wholeautomobile manufacturing industry which is meaningful forthe sustainable construction of the industry Most impor-tantly it contributes to the sustainable guarantee of the publictraffic safety of the society [37]

Data Availability

+e numerical data used to support the findings of this studyare included within the article

Conflicts of Interest

+e authors declare that there are no conflicts of interestregarding the publication of this paper

Acknowledgments

+is research was funded by the Enterprise ManagementInnovation Project of the National Defense Science andTechnology Industry (grant no 13315502) FundamentalResearch Funds for the Central Universities (grant no21618412) Inner Mongolia Autonomous Region Scienceand Technology Innovation Guide Award Fund Project(grant no 103-413193) Scientific Research Project of HenanColleges and Universities in 2019 based on the research onmilitary science and technology innovation mechanism ofcolleges and universities from the perspective of civil-military integration (grant no 19A630037) Fund of Re-search on Enterprise Management Innovation Mode System(grant no 44860070) and Fund of Research on the En-terprise Management Mode and Countermeasures Based onthe Production Study and Research (grant no 44860071)

References

[1] S Zhang K Li G Wang and X Zhu ldquoSimulate design andexperimental analysis of commercial vehicle cab suspensionrdquoin Proceedings of the 19th Asia Pacific Automotive EngineeringConference amp SAE-hina Congress 2017 Selected Papers SAE-hina 2017 Lecture Notes in Electrical Engineering Edited by S(SAE-hina) Ed vol 486 pp 675ndash691 Springer ShanghaiChina October 2019

[2] L Morello L R Rossini G Pia and A Tonoli ldquoNoise vi-bration harshnessrdquo in e Automotive Body MechanicalEngineering Series pp 239ndash363 Springer DordrechtNetherlands 2011

[3] A Gupta A D Jayal M Chimienti and I S Jawahir ldquoA totallife-cycle approach towards developing product metrics forsustainable manufacturingrdquo in Glocalized Solutions for Sus-tainability in Manufacturing J Hesselbach and C HerrmannEds Springer Berlin Germany pp 240ndash245 2011

[4] A Zarghami and D Benbow ldquoIntroduction to 8D problemsolvingrdquo Journal for Quality amp Participation vol 40pp 23ndash28 2017

[5] S-O Shim K Park and S Choi ldquoInnovative productionscheduling with customer satisfaction based measurement forthe sustainability of manufacturing firmsrdquo Sustainabilityvol 9 no 12 p 2249 2017

[6] Ford Motor Company Training Group Training Manual forthe G8D Process Ford Motor Company Dearborn MI USA1999

[7] V Nicolae L M Ionescu N Belu and S L Elena ldquoIm-provement of the 8D analysis through a system based on theldquointernet of thingsrdquo concept applied in automotive industryrdquoin Proceedings of the CONAT 2016 International Congress ofAutomotive and Transport Engineering A Chiru and N IspasEds pp 635ndash642 Springer Brasov Romania October 2017

[8] T S M Kumar and B Adaveesh ldquoApplication of ldquo8Dmethodologyrdquo for the root cause analysis and reduction ofvalve spring rejection in a valve spring manufacturingcompany a case studyrdquo Indian Journal of Science andTechnology vol 10 no 11 pp 1ndash11 2017

[9] R Simmons ldquoBook review introduction to 8D problemsolving including practical applications and examplesrdquoQuality Management Journal vol 25 no 4 201 pages 2018

[10] C A Riesenberger and S D Sousa ldquo+e 8D methodology aneffective way to reduce recurrence of customer complaintsrdquo in

10 Shock and Vibration

Proceedings of the World Congress on Engineering vol 3London UK June-July 2010

[11] K S Sim J H Lee T W Park and M H Cho ldquoVibrationpath analysis and optimal design of the suspension for brakejudder reductionrdquo International Journal of AutomotiveTechnology vol 14 no 4 pp 587ndash594 2013

[12] X Yang and S Zuo ldquoParameters sensitivity analysis of self-excited vibration of tiresrdquo in Proceeding of the FISITA 2012World Automotive Congress Lecture Notes in Electrical En-gineering vol 201 pp 3ndash14 Springer Berlin Germany 2013

[13] Z Liu S Yuan S Xiao S Z Du Y Zhang and C Lu ldquoFullvehicle vibration and noise analysis based on substructurepower flowrdquo Shock and Vibration vol 2017 Article ID8725346 17 pages 2017

[14] D Hao C Zhao and Y Huang ldquoA reduced-order modelfor active suppression control of vehicle longitudinal low-frequency vibrationrdquo Shock and Vibration vol 2018Article ID 5731347 22 pages 2018

[15] Y Ren and L Zheng ldquoActive suspension control for wheel-drive electric vehicle based on vibration absorberrdquo in Pro-ceedings of the SAE-China Congress 2015 Selected PapersLecture Notes in Electrical Engineering vol 364 pp 75ndash86Springer Singapore 2016

[16] Y Taskin I Yuksek and N Yagiz ldquoVibration control ofvehicles with active tuned mass damperrdquo Journal ofVibroengineering vol 19 no 5 pp 3533ndash3541 2017

[17] Y M Han M H Nam S S Han H G Lee and S B ChoildquoVibration control evaluation of a commercial vehicle fea-turing MR seat damperrdquo Journal of Intelligent MaterialSystems and Structures vol 13 no 9 pp 575ndash579 2002

[18] H Sell T Ehrt and M Meszlig ldquoVibration-optimized com-ponents for chassis systemsrdquo ATZ Worldwide vol 110 no 2pp 26ndash31 2008

[19] A N +ite ldquoDevelopment of a refined quarter car model forthe analysis of discomfort due to vibrationrdquo Advances inAcoustics and Vibration vol 2012 Article ID 863061 7 pages2012

[20] Y Zhang H Wang Q Zhu Y Xu and L Wu ldquo+e iden-tification and countermeasure analysis of vehicle idle vibra-tionrdquo in Proceedings of the FISITA 2012 World AutomotiveCongress Lecture Notes in Electrical Engineering vol 201pp 443ndash455 Springer Berlin Germany 2013

[21] T Berberich P Gebhard S Bohlen O Danninger andM Lienkamp ldquoA new approach to the presentation of vi-bration phenomena in vehiclesrdquo in Proceedings of the FISITA2012 World Automotive Congress Lecture Notes in ElectricalEngineering vol 201 pp 591ndash598 Springer Berlin Germany2013

[22] N J Mansfield J Mackrill A N Rimell and S J MacMullldquoCombined effects of long-term sitting and whole-body vi-bration on discomfort onset for vehicle occupantsrdquo ISRNAutomotive Engineering vol 2014 Article ID 852607 8 pages2014

[23] J Park J Lee S Ahn and W Jeong ldquoReduced ride comfortcaused by beating idle vibrations in passenger vehiclesrdquo In-ternational Journal of Industrial Ergonomics vol 57 pp 74ndash79 2017

[24] A Jamali M Salehpour and N Nariman-zadeh ldquoRobustPareto active suspension design for vehicle vibration modelwith probabilistic uncertain parametersrdquo Multibody SystemDynamics vol 30 no 3 pp 265ndash285 2013

[25] X C Liang and J S Zhao ldquoResearch on recycling vibrationenergy of shock absorberrdquo International Journal of VehicleDesign vol 68 no 1ndash3 pp 201ndash220 2015

[26] S Zuo X Duan and Y Li ldquoStudy on dynamics of polygonalwear of automotive tire caused by self-excited vibrationrdquoMathematical Problems in Engineering vol 2014 Article ID653803 12 pages 2014

[27] J-J Bae and N Kang ldquoDesign optimization of a mecanumwheel to reduce vertical vibrations by the consideration ofequivalent stiffnessrdquo Shock and Vibration vol 2016 ArticleID 5892784 8 pages 2016

[28] A Pieper K Le Chau and J Kalberer ldquoOptimisation of rollvibration damping of a vehiclerdquo Auto Tech Review vol 4no 2 pp 36ndash41 2015

[29] G Pavic ldquoAnalysis of vibration reduction by damping usingsimple analytical modellingrdquo Shock and Vibration vol 2018Article ID 1098531 13 pages 2018

[30] M Heidari and H Homaei ldquoEstimation of accelerationamplitude of vehicle by back propagation neural networksrdquoAdvances in Acoustics and Vibration vol 2013 Article ID614025 7 pages 2013

[31] L-X Guo and L-P Zhang ldquoVehicle vibration analysis inchangeable speeds solved by pseudoexcitation methodrdquoMathematical Problems in Engineering vol 2010 Article ID802720 14 pages 2010

[32] B Sakhaei and M Durali ldquoVibration transfer path analysisand path ranking for NVH optimization of a vehicle interiorrdquoShock and Vibration vol 2014 Article ID 697450 5 pages2014

[33] D C Barton and J D Fieldhouse ldquoSuspension systems andcomponentsrdquo in Automotive Chassis Engineeringpp 111ndash214 Springer Cham Switzerland 2018

[34] K Jalics ldquoSimulation methods in the vehicle noise vibrationand harshness (NVH)rdquo in Vehicle and Automotive Engi-neering Lecture Notes in Mechanical Engineering K Jarmaiand B Bollo Eds pp 91ndash97 Springer Cham Switzerland2017

[35] X Xu F Yan Y Li W Chen and Y Cao ldquoRide comfortsimulation and abnormal vibration improvement of a com-mercial vehiclerdquo in Proceeding of the SAE-China Congress2015 Selected Papers Lecture Notes in Electrical Engineeringvol 364 pp 521ndash527 Springer Singapore January 2016

[36] D Dornfeld ldquoLeveraging manufacturing for a sustainablefuturerdquo in Glocalized Solutions for Sustainability inManufacturing J Hesselbach and C Herrmann EdsSpringer Berlin Germany pp 17ndash21 2011

[37] M A Gbededo and K Liyanage ldquoIdentification and align-ment of the social aspects of sustainable manufacturing withthe theory of motivationrdquo Sustainability vol 10 no 3 p 8522018

Shock and Vibration 11

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Page 7: ResearchonImprovementofTruckVibrationBasedonSystematic G8D ...downloads.hindawi.com/journals/sv/2019/1416340.pdf · ResearchArticle ResearchonImprovementofTruckVibrationBasedonSystematic

Am

plitu

de (m

s2 ) 310

000

Am

plitu

de (m

s2 ) 320

000

Am

plitu

de (m

s2 ) 530

000

Am

plitu

de (m

s2 ) 480

000

Am

plitu

de

100

000

Am

plitu

de

100

000

Am

plitu

de

100

000

Am

plitu

de

100

000

F Spectrum Rear suspension body side of cab +ZSpectrum Front suspension body side of cab +ZF

F Spectrum Rear suspension frame side of cab +ZSpectrum Front suspension frame side of cab +ZF

F Spectrum Right side of balanced suspension +Z

F Spectrum Right side of middle axle +ZF Spectrum Right side of rear axle +ZF Spectrum Left side of middle axle +ZF Spectrum Left side of rear axle +Z

Spectrum Left side of balanced suspension +ZF

305

205

178

553

Hz000 1500

Hz000 1500

Hz000 1500

Hz000 1500

553

311

515

476319332431

577

521

577

Figure 3 Transmission of vibration acceleration

Table 5 Acceleration (ms2) on both sides of cab suspension near 65 kmh

Cab shockabsorber

Frontsuspensionbody side

Frontsuspensionframe side

Front suspensionvibration isolation rate

Rearsuspensionbody side

Rearsuspensionframe side

Rear suspensionvibration isolation rate

Original airspring 305 178 minus468 dB 205 311 362 dB

Ex-brand 1post-brand 2 139 237 463 dB 129 201 385 dB

Both are brandone 196 330 453 dB 161 255 399 dB

Notes Vibration isolation rate 20 log (active side vibration amplitudepassive side vibration amplitude)

Table 6 Acceleration comparison before and after dynamic balancing (ms2)

Measuring point position Before dynamic balancing After dynamic balancing Reduced percentageMain seat guide (longitudinal) 056 039 3036Main seat guide (vertical) 068 037 4559On the left wheel of the middle axle (vertical) 431 141 6729On the right wheel of the middle axle (vertical) 476 185 6113At the left wheel of the rear axle (vertical) 331 321 302At the right wheel of the rear axle (vertical) 319 215 3260

Shock and Vibration 7

purchase static and dynamic balance equipment oftire

(5) Provide the supplier with hardness and technicalrequirements for reinforced powertrain suspensionrubber and urge and assist them to achieve thesetechnical requirements and consistency of productcharacteristics it can be listed in Table 9

(i) +e technical requirements for the dampingcharacteristics of the hysteresis curve of the frontaxle damper are presented to the supplier

(ii) +e technical requirements for the dampingcharacteristics of the hysteresis curves of the

front and rear suspension dampers of the cab areproposed to the supplier

+e quality of these components must meet the qualityand technical requirements of the enterprise and there is asystematic mechanism to implement and verify the imple-mentation of the quality and technical requirements of thesecomponents

+ere are three levels of validation for these permanentcorrective measures

(1) Component level correct the dynamic balance of therotating parts of the vehicle drive shaft wheel hubrim and tire assembly [34] ensure the supplierrsquos

Table 7 Decision worksheet on permanent corrective measures

Decision worksheet 1Final result eliminate or reduce vibration in operation of this type of vehicle to the extent acceptable to the customerCriteria that must be met(a) Do not change existing design(b) Do not change the manufacturing process(c) No increase in product costExpected standard Importance (1ndash10 1 minimum 10 maximum)(1) Deviation quality and consistency of transmissionshaft 8

(2) Technical requirements for hub roundness andflatness and consistency 9

(3) Rims meet technical requirements roundness andconsistency 9

(4) Dynamic balance and consistency of tire assembly 9(5) Damping force of front axle shock absorber meetstechnical requirements and consistency 8

(6) Cab-suspensioning shock absorber meetstechnical requirements and consistency 9

Table 8 Vendor decision worksheet

Decision worksheet 2Vendor A Vendor B

Criteria that must be met Yesno Criteria that must be met Yesno

(a) Do not change existing design Yes (a) Do not change existing design Yes(b) Do not change the manufacturingprocess Yes (b) Do not change the manufacturing process Yes

(c) No increase in product cost Yes (c) No increase in product cost No

Expected standard Good or bad(1ndash10) Score Expected standard Good or bad

(1ndash10) Score

(1) Deviation quality and consistency oftransmission shaft Good 8 (1) Deviation quality and consistency of

transmission shaft Good 9

(2) Technical requirements for hubroundness and flatness and consistency Good 9 (2) Technical requirements for hub

roundness and flatness and consistency Good 8

(3) Rims meet technical requirementsroundness and consistency Good 8 (3) Rims meet technical requirements

roundness and consistency Good 8

(4) Dynamic balance and consistency oftire assembly Good 9 (4) Dynamic balance and consistency of

tire assembly Good 7

(5) Damping force of front axle shockabsorber meets technical requirementsand consistency

Good 9(5) Damping force of front axle shockabsorber meets technical requirements

and consistencyGood 8

(6) Cab-suspensioning shock absorbermeets technical requirements andconsistency

Good 9(6) Cab-suspensioning shock absorbermeets technical requirements and

consistencyGood 8

8 Shock and Vibration

parts meet the technical standards and check thedynamic balance

(2) Device level correct the cab damper and front axledamper ensure that the parts of the supplier meetthe technical standards and detect the stiffness anddamping of the damper [35]

(3) Whole car level load the car with the modified partsand carry out the road test to see the improvementeffect of the vibration performance of the whole car[20]

37 Prevent ProblemRecurrence (D7) +e ldquo5Whysrdquo methodis still used here to determine the root cause of the problemand the permanent measures that should be taken to preventthe recurrence of the problem According to the theory ofG8D it can be used to find out the problems about systemoperation process or policy Systemic problems arise fromfull references to previous organizations technical processespolicies and practices +ese past processes policies andpractices are often not applicable to the current situation andare not traceable

+e method proposed in this paper is very effective insolving the vibration problem systematically and makes thevibration problem be systematically tracked and controlledAccording to the above analysis and the actual situation thispaper puts forward some suggestions on the existing systemof the enterprise in order to prevent the recurrence of theproblem

(1) +e quality inspection mechanism of enterprisesneeds to be perfected +is is responsible for

formulating product quality inspection standardschecking the quality of parts provided by suppliersspot checking the qualified rate of products thesupplier shall provide quality product certificationaccording to the requirements of the enterprise if itdoes not meet the requirements it will not accept thesupply

(2) +e supplier quality evaluation system is yet to beestablished +e related personnel is responsible forsupplier quality review and supplier classificationmanagement In the case of unqualified productsenterprises need to have accurate technical means toprovide suppliers with accurate technical evidence ofnonconforming products and specific rectificationprograms for suppliers to rectify according to spe-cific technical objectives

(3) Technical support for supplier quality improvementis to be provided +e relevant departments are re-sponsible for technical guidance and help suppliersto improve quality suppliers and enterprises in thequality of a virtuous circle that is enterprises dotheir best to promote suppliers to improve qualityreward and punishment system for suppliers andlaunch mechanisms +e quality of suppliers isgradually improved due to technical feedback andassistance

(4) Supplier product quality feedback system is to beestablished Let the supplier define the technical andquality requirements of the enterprise and form aclosed loop between the quality of the product of thesupplier and the requirements of the enterprise +e

Table 9 Problem prevention worksheet

Problem prevention worksheetProgram objective to prevent vehicle vibration in terms of the manufacturing quality of components

Key step Nature Possible obstaclescauses of problemsP S P times S

(1) Deviation quality and consistency of transmissionshaft(2) Technical requirements for hub roundness andflatness and consistency(3) Rims meet technical requirements roundness andconsistency(4) Dynamic balance andconsistency of tire assembly(5) Damping force of front axleshock absorber meets technical requirements andconsistency(6) Cab-suspensioning shockabsorber meets technical requirements andconsistencyUse your experience to identifyyour plans and steps

+ese steps are complex havetight deadlines are new andhave an impact on other steps

Determine whichsteps

require yourattention

and resources most

Identify possible obstacles to completing these keysteps (people methods materials machinesmeasurements and environmental problems)

Notes questions such as the nature of the form need to be filled out later

Shock and Vibration 9

enterprise forms the complete system and themechanism causes the supplier and the enterprisemain engine factoryrsquos technical information to forma closed loop strengthens the system informationexchange between each other and forms the tech-nical accumulation for the past problem solving toprevent similar problems from happening in otherlocations or on other models

4 Discussion and Conclusions

By applying the G8D an improved model for solving thetruck vibration problem is established At the same timeaccording to the results of the statement problem methodthe Yes and No worksheet the 5Whys method and the truthfactor assessment the reason for determining the truckvibration is the unbalanced excitation force of the vehiclewheel system the resonance phenomenon caused by thecoupling of the excitation frequency with the natural fre-quency of the system and the insufficient damping functionof the system +erefore the corrective measures forchanging the wheel hub of cab suspension and dynamicbalance brake hub and dynamic balance tire are put forward+en the permanent correction measures are verified fromthree levels of components devices and whole vehicles byusing ldquodecision worksheetrdquo and ldquoproblem preventionworksheetrdquo to ensure the accuracy and feasibility of themodel and make recommendations for the existing systemof the enterprise to prevent recurrence of problems in thefuture

After the implementation of the abovementioned com-plete and improved model the acceleration of the seat rail ofthe truckrsquos vibration performance has been reduced from104ms2 to 06ms2 423 lower than that of the original carreaching the level of 06ms2 of the major domestic modelsand close to the level of 05ms2 of its German counterpartwhich prevents users from returning their cars For thecompany to reduce certain economic losses the sustainabilityof product manufacturing and enterprise economic benefitshave to be improved [36] +e practical implementation ofG8D can solve many technical problems but the wholeenterprise needs to pay attention to G8D training whichenables G8D become a sustainable solution to the problem ofenterprises +is is of great significance for solving the truckvibration problem and even the quality problem of the wholeautomobile manufacturing industry which is meaningful forthe sustainable construction of the industry Most impor-tantly it contributes to the sustainable guarantee of the publictraffic safety of the society [37]

Data Availability

+e numerical data used to support the findings of this studyare included within the article

Conflicts of Interest

+e authors declare that there are no conflicts of interestregarding the publication of this paper

Acknowledgments

+is research was funded by the Enterprise ManagementInnovation Project of the National Defense Science andTechnology Industry (grant no 13315502) FundamentalResearch Funds for the Central Universities (grant no21618412) Inner Mongolia Autonomous Region Scienceand Technology Innovation Guide Award Fund Project(grant no 103-413193) Scientific Research Project of HenanColleges and Universities in 2019 based on the research onmilitary science and technology innovation mechanism ofcolleges and universities from the perspective of civil-military integration (grant no 19A630037) Fund of Re-search on Enterprise Management Innovation Mode System(grant no 44860070) and Fund of Research on the En-terprise Management Mode and Countermeasures Based onthe Production Study and Research (grant no 44860071)

References

[1] S Zhang K Li G Wang and X Zhu ldquoSimulate design andexperimental analysis of commercial vehicle cab suspensionrdquoin Proceedings of the 19th Asia Pacific Automotive EngineeringConference amp SAE-hina Congress 2017 Selected Papers SAE-hina 2017 Lecture Notes in Electrical Engineering Edited by S(SAE-hina) Ed vol 486 pp 675ndash691 Springer ShanghaiChina October 2019

[2] L Morello L R Rossini G Pia and A Tonoli ldquoNoise vi-bration harshnessrdquo in e Automotive Body MechanicalEngineering Series pp 239ndash363 Springer DordrechtNetherlands 2011

[3] A Gupta A D Jayal M Chimienti and I S Jawahir ldquoA totallife-cycle approach towards developing product metrics forsustainable manufacturingrdquo in Glocalized Solutions for Sus-tainability in Manufacturing J Hesselbach and C HerrmannEds Springer Berlin Germany pp 240ndash245 2011

[4] A Zarghami and D Benbow ldquoIntroduction to 8D problemsolvingrdquo Journal for Quality amp Participation vol 40pp 23ndash28 2017

[5] S-O Shim K Park and S Choi ldquoInnovative productionscheduling with customer satisfaction based measurement forthe sustainability of manufacturing firmsrdquo Sustainabilityvol 9 no 12 p 2249 2017

[6] Ford Motor Company Training Group Training Manual forthe G8D Process Ford Motor Company Dearborn MI USA1999

[7] V Nicolae L M Ionescu N Belu and S L Elena ldquoIm-provement of the 8D analysis through a system based on theldquointernet of thingsrdquo concept applied in automotive industryrdquoin Proceedings of the CONAT 2016 International Congress ofAutomotive and Transport Engineering A Chiru and N IspasEds pp 635ndash642 Springer Brasov Romania October 2017

[8] T S M Kumar and B Adaveesh ldquoApplication of ldquo8Dmethodologyrdquo for the root cause analysis and reduction ofvalve spring rejection in a valve spring manufacturingcompany a case studyrdquo Indian Journal of Science andTechnology vol 10 no 11 pp 1ndash11 2017

[9] R Simmons ldquoBook review introduction to 8D problemsolving including practical applications and examplesrdquoQuality Management Journal vol 25 no 4 201 pages 2018

[10] C A Riesenberger and S D Sousa ldquo+e 8D methodology aneffective way to reduce recurrence of customer complaintsrdquo in

10 Shock and Vibration

Proceedings of the World Congress on Engineering vol 3London UK June-July 2010

[11] K S Sim J H Lee T W Park and M H Cho ldquoVibrationpath analysis and optimal design of the suspension for brakejudder reductionrdquo International Journal of AutomotiveTechnology vol 14 no 4 pp 587ndash594 2013

[12] X Yang and S Zuo ldquoParameters sensitivity analysis of self-excited vibration of tiresrdquo in Proceeding of the FISITA 2012World Automotive Congress Lecture Notes in Electrical En-gineering vol 201 pp 3ndash14 Springer Berlin Germany 2013

[13] Z Liu S Yuan S Xiao S Z Du Y Zhang and C Lu ldquoFullvehicle vibration and noise analysis based on substructurepower flowrdquo Shock and Vibration vol 2017 Article ID8725346 17 pages 2017

[14] D Hao C Zhao and Y Huang ldquoA reduced-order modelfor active suppression control of vehicle longitudinal low-frequency vibrationrdquo Shock and Vibration vol 2018Article ID 5731347 22 pages 2018

[15] Y Ren and L Zheng ldquoActive suspension control for wheel-drive electric vehicle based on vibration absorberrdquo in Pro-ceedings of the SAE-China Congress 2015 Selected PapersLecture Notes in Electrical Engineering vol 364 pp 75ndash86Springer Singapore 2016

[16] Y Taskin I Yuksek and N Yagiz ldquoVibration control ofvehicles with active tuned mass damperrdquo Journal ofVibroengineering vol 19 no 5 pp 3533ndash3541 2017

[17] Y M Han M H Nam S S Han H G Lee and S B ChoildquoVibration control evaluation of a commercial vehicle fea-turing MR seat damperrdquo Journal of Intelligent MaterialSystems and Structures vol 13 no 9 pp 575ndash579 2002

[18] H Sell T Ehrt and M Meszlig ldquoVibration-optimized com-ponents for chassis systemsrdquo ATZ Worldwide vol 110 no 2pp 26ndash31 2008

[19] A N +ite ldquoDevelopment of a refined quarter car model forthe analysis of discomfort due to vibrationrdquo Advances inAcoustics and Vibration vol 2012 Article ID 863061 7 pages2012

[20] Y Zhang H Wang Q Zhu Y Xu and L Wu ldquo+e iden-tification and countermeasure analysis of vehicle idle vibra-tionrdquo in Proceedings of the FISITA 2012 World AutomotiveCongress Lecture Notes in Electrical Engineering vol 201pp 443ndash455 Springer Berlin Germany 2013

[21] T Berberich P Gebhard S Bohlen O Danninger andM Lienkamp ldquoA new approach to the presentation of vi-bration phenomena in vehiclesrdquo in Proceedings of the FISITA2012 World Automotive Congress Lecture Notes in ElectricalEngineering vol 201 pp 591ndash598 Springer Berlin Germany2013

[22] N J Mansfield J Mackrill A N Rimell and S J MacMullldquoCombined effects of long-term sitting and whole-body vi-bration on discomfort onset for vehicle occupantsrdquo ISRNAutomotive Engineering vol 2014 Article ID 852607 8 pages2014

[23] J Park J Lee S Ahn and W Jeong ldquoReduced ride comfortcaused by beating idle vibrations in passenger vehiclesrdquo In-ternational Journal of Industrial Ergonomics vol 57 pp 74ndash79 2017

[24] A Jamali M Salehpour and N Nariman-zadeh ldquoRobustPareto active suspension design for vehicle vibration modelwith probabilistic uncertain parametersrdquo Multibody SystemDynamics vol 30 no 3 pp 265ndash285 2013

[25] X C Liang and J S Zhao ldquoResearch on recycling vibrationenergy of shock absorberrdquo International Journal of VehicleDesign vol 68 no 1ndash3 pp 201ndash220 2015

[26] S Zuo X Duan and Y Li ldquoStudy on dynamics of polygonalwear of automotive tire caused by self-excited vibrationrdquoMathematical Problems in Engineering vol 2014 Article ID653803 12 pages 2014

[27] J-J Bae and N Kang ldquoDesign optimization of a mecanumwheel to reduce vertical vibrations by the consideration ofequivalent stiffnessrdquo Shock and Vibration vol 2016 ArticleID 5892784 8 pages 2016

[28] A Pieper K Le Chau and J Kalberer ldquoOptimisation of rollvibration damping of a vehiclerdquo Auto Tech Review vol 4no 2 pp 36ndash41 2015

[29] G Pavic ldquoAnalysis of vibration reduction by damping usingsimple analytical modellingrdquo Shock and Vibration vol 2018Article ID 1098531 13 pages 2018

[30] M Heidari and H Homaei ldquoEstimation of accelerationamplitude of vehicle by back propagation neural networksrdquoAdvances in Acoustics and Vibration vol 2013 Article ID614025 7 pages 2013

[31] L-X Guo and L-P Zhang ldquoVehicle vibration analysis inchangeable speeds solved by pseudoexcitation methodrdquoMathematical Problems in Engineering vol 2010 Article ID802720 14 pages 2010

[32] B Sakhaei and M Durali ldquoVibration transfer path analysisand path ranking for NVH optimization of a vehicle interiorrdquoShock and Vibration vol 2014 Article ID 697450 5 pages2014

[33] D C Barton and J D Fieldhouse ldquoSuspension systems andcomponentsrdquo in Automotive Chassis Engineeringpp 111ndash214 Springer Cham Switzerland 2018

[34] K Jalics ldquoSimulation methods in the vehicle noise vibrationand harshness (NVH)rdquo in Vehicle and Automotive Engi-neering Lecture Notes in Mechanical Engineering K Jarmaiand B Bollo Eds pp 91ndash97 Springer Cham Switzerland2017

[35] X Xu F Yan Y Li W Chen and Y Cao ldquoRide comfortsimulation and abnormal vibration improvement of a com-mercial vehiclerdquo in Proceeding of the SAE-China Congress2015 Selected Papers Lecture Notes in Electrical Engineeringvol 364 pp 521ndash527 Springer Singapore January 2016

[36] D Dornfeld ldquoLeveraging manufacturing for a sustainablefuturerdquo in Glocalized Solutions for Sustainability inManufacturing J Hesselbach and C Herrmann EdsSpringer Berlin Germany pp 17ndash21 2011

[37] M A Gbededo and K Liyanage ldquoIdentification and align-ment of the social aspects of sustainable manufacturing withthe theory of motivationrdquo Sustainability vol 10 no 3 p 8522018

Shock and Vibration 11

International Journal of

AerospaceEngineeringHindawiwwwhindawicom Volume 2018

RoboticsJournal of

Hindawiwwwhindawicom Volume 2018

Hindawiwwwhindawicom Volume 2018

Active and Passive Electronic Components

VLSI Design

Hindawiwwwhindawicom Volume 2018

Hindawiwwwhindawicom Volume 2018

Shock and Vibration

Hindawiwwwhindawicom Volume 2018

Civil EngineeringAdvances in

Acoustics and VibrationAdvances in

Hindawiwwwhindawicom Volume 2018

Hindawiwwwhindawicom Volume 2018

Electrical and Computer Engineering

Journal of

Advances inOptoElectronics

Hindawiwwwhindawicom

Volume 2018

Hindawi Publishing Corporation httpwwwhindawicom Volume 2013Hindawiwwwhindawicom

The Scientific World Journal

Volume 2018

Control Scienceand Engineering

Journal of

Hindawiwwwhindawicom Volume 2018

Hindawiwwwhindawicom

Journal ofEngineeringVolume 2018

SensorsJournal of

Hindawiwwwhindawicom Volume 2018

International Journal of

RotatingMachinery

Hindawiwwwhindawicom Volume 2018

Modelling ampSimulationin EngineeringHindawiwwwhindawicom Volume 2018

Hindawiwwwhindawicom Volume 2018

Chemical EngineeringInternational Journal of Antennas and

Propagation

International Journal of

Hindawiwwwhindawicom Volume 2018

Hindawiwwwhindawicom Volume 2018

Navigation and Observation

International Journal of

Hindawi

wwwhindawicom Volume 2018

Advances in

Multimedia

Submit your manuscripts atwwwhindawicom

Page 8: ResearchonImprovementofTruckVibrationBasedonSystematic G8D ...downloads.hindawi.com/journals/sv/2019/1416340.pdf · ResearchArticle ResearchonImprovementofTruckVibrationBasedonSystematic

purchase static and dynamic balance equipment oftire

(5) Provide the supplier with hardness and technicalrequirements for reinforced powertrain suspensionrubber and urge and assist them to achieve thesetechnical requirements and consistency of productcharacteristics it can be listed in Table 9

(i) +e technical requirements for the dampingcharacteristics of the hysteresis curve of the frontaxle damper are presented to the supplier

(ii) +e technical requirements for the dampingcharacteristics of the hysteresis curves of the

front and rear suspension dampers of the cab areproposed to the supplier

+e quality of these components must meet the qualityand technical requirements of the enterprise and there is asystematic mechanism to implement and verify the imple-mentation of the quality and technical requirements of thesecomponents

+ere are three levels of validation for these permanentcorrective measures

(1) Component level correct the dynamic balance of therotating parts of the vehicle drive shaft wheel hubrim and tire assembly [34] ensure the supplierrsquos

Table 7 Decision worksheet on permanent corrective measures

Decision worksheet 1Final result eliminate or reduce vibration in operation of this type of vehicle to the extent acceptable to the customerCriteria that must be met(a) Do not change existing design(b) Do not change the manufacturing process(c) No increase in product costExpected standard Importance (1ndash10 1 minimum 10 maximum)(1) Deviation quality and consistency of transmissionshaft 8

(2) Technical requirements for hub roundness andflatness and consistency 9

(3) Rims meet technical requirements roundness andconsistency 9

(4) Dynamic balance and consistency of tire assembly 9(5) Damping force of front axle shock absorber meetstechnical requirements and consistency 8

(6) Cab-suspensioning shock absorber meetstechnical requirements and consistency 9

Table 8 Vendor decision worksheet

Decision worksheet 2Vendor A Vendor B

Criteria that must be met Yesno Criteria that must be met Yesno

(a) Do not change existing design Yes (a) Do not change existing design Yes(b) Do not change the manufacturingprocess Yes (b) Do not change the manufacturing process Yes

(c) No increase in product cost Yes (c) No increase in product cost No

Expected standard Good or bad(1ndash10) Score Expected standard Good or bad

(1ndash10) Score

(1) Deviation quality and consistency oftransmission shaft Good 8 (1) Deviation quality and consistency of

transmission shaft Good 9

(2) Technical requirements for hubroundness and flatness and consistency Good 9 (2) Technical requirements for hub

roundness and flatness and consistency Good 8

(3) Rims meet technical requirementsroundness and consistency Good 8 (3) Rims meet technical requirements

roundness and consistency Good 8

(4) Dynamic balance and consistency oftire assembly Good 9 (4) Dynamic balance and consistency of

tire assembly Good 7

(5) Damping force of front axle shockabsorber meets technical requirementsand consistency

Good 9(5) Damping force of front axle shockabsorber meets technical requirements

and consistencyGood 8

(6) Cab-suspensioning shock absorbermeets technical requirements andconsistency

Good 9(6) Cab-suspensioning shock absorbermeets technical requirements and

consistencyGood 8

8 Shock and Vibration

parts meet the technical standards and check thedynamic balance

(2) Device level correct the cab damper and front axledamper ensure that the parts of the supplier meetthe technical standards and detect the stiffness anddamping of the damper [35]

(3) Whole car level load the car with the modified partsand carry out the road test to see the improvementeffect of the vibration performance of the whole car[20]

37 Prevent ProblemRecurrence (D7) +e ldquo5Whysrdquo methodis still used here to determine the root cause of the problemand the permanent measures that should be taken to preventthe recurrence of the problem According to the theory ofG8D it can be used to find out the problems about systemoperation process or policy Systemic problems arise fromfull references to previous organizations technical processespolicies and practices +ese past processes policies andpractices are often not applicable to the current situation andare not traceable

+e method proposed in this paper is very effective insolving the vibration problem systematically and makes thevibration problem be systematically tracked and controlledAccording to the above analysis and the actual situation thispaper puts forward some suggestions on the existing systemof the enterprise in order to prevent the recurrence of theproblem

(1) +e quality inspection mechanism of enterprisesneeds to be perfected +is is responsible for

formulating product quality inspection standardschecking the quality of parts provided by suppliersspot checking the qualified rate of products thesupplier shall provide quality product certificationaccording to the requirements of the enterprise if itdoes not meet the requirements it will not accept thesupply

(2) +e supplier quality evaluation system is yet to beestablished +e related personnel is responsible forsupplier quality review and supplier classificationmanagement In the case of unqualified productsenterprises need to have accurate technical means toprovide suppliers with accurate technical evidence ofnonconforming products and specific rectificationprograms for suppliers to rectify according to spe-cific technical objectives

(3) Technical support for supplier quality improvementis to be provided +e relevant departments are re-sponsible for technical guidance and help suppliersto improve quality suppliers and enterprises in thequality of a virtuous circle that is enterprises dotheir best to promote suppliers to improve qualityreward and punishment system for suppliers andlaunch mechanisms +e quality of suppliers isgradually improved due to technical feedback andassistance

(4) Supplier product quality feedback system is to beestablished Let the supplier define the technical andquality requirements of the enterprise and form aclosed loop between the quality of the product of thesupplier and the requirements of the enterprise +e

Table 9 Problem prevention worksheet

Problem prevention worksheetProgram objective to prevent vehicle vibration in terms of the manufacturing quality of components

Key step Nature Possible obstaclescauses of problemsP S P times S

(1) Deviation quality and consistency of transmissionshaft(2) Technical requirements for hub roundness andflatness and consistency(3) Rims meet technical requirements roundness andconsistency(4) Dynamic balance andconsistency of tire assembly(5) Damping force of front axleshock absorber meets technical requirements andconsistency(6) Cab-suspensioning shockabsorber meets technical requirements andconsistencyUse your experience to identifyyour plans and steps

+ese steps are complex havetight deadlines are new andhave an impact on other steps

Determine whichsteps

require yourattention

and resources most

Identify possible obstacles to completing these keysteps (people methods materials machinesmeasurements and environmental problems)

Notes questions such as the nature of the form need to be filled out later

Shock and Vibration 9

enterprise forms the complete system and themechanism causes the supplier and the enterprisemain engine factoryrsquos technical information to forma closed loop strengthens the system informationexchange between each other and forms the tech-nical accumulation for the past problem solving toprevent similar problems from happening in otherlocations or on other models

4 Discussion and Conclusions

By applying the G8D an improved model for solving thetruck vibration problem is established At the same timeaccording to the results of the statement problem methodthe Yes and No worksheet the 5Whys method and the truthfactor assessment the reason for determining the truckvibration is the unbalanced excitation force of the vehiclewheel system the resonance phenomenon caused by thecoupling of the excitation frequency with the natural fre-quency of the system and the insufficient damping functionof the system +erefore the corrective measures forchanging the wheel hub of cab suspension and dynamicbalance brake hub and dynamic balance tire are put forward+en the permanent correction measures are verified fromthree levels of components devices and whole vehicles byusing ldquodecision worksheetrdquo and ldquoproblem preventionworksheetrdquo to ensure the accuracy and feasibility of themodel and make recommendations for the existing systemof the enterprise to prevent recurrence of problems in thefuture

After the implementation of the abovementioned com-plete and improved model the acceleration of the seat rail ofthe truckrsquos vibration performance has been reduced from104ms2 to 06ms2 423 lower than that of the original carreaching the level of 06ms2 of the major domestic modelsand close to the level of 05ms2 of its German counterpartwhich prevents users from returning their cars For thecompany to reduce certain economic losses the sustainabilityof product manufacturing and enterprise economic benefitshave to be improved [36] +e practical implementation ofG8D can solve many technical problems but the wholeenterprise needs to pay attention to G8D training whichenables G8D become a sustainable solution to the problem ofenterprises +is is of great significance for solving the truckvibration problem and even the quality problem of the wholeautomobile manufacturing industry which is meaningful forthe sustainable construction of the industry Most impor-tantly it contributes to the sustainable guarantee of the publictraffic safety of the society [37]

Data Availability

+e numerical data used to support the findings of this studyare included within the article

Conflicts of Interest

+e authors declare that there are no conflicts of interestregarding the publication of this paper

Acknowledgments

+is research was funded by the Enterprise ManagementInnovation Project of the National Defense Science andTechnology Industry (grant no 13315502) FundamentalResearch Funds for the Central Universities (grant no21618412) Inner Mongolia Autonomous Region Scienceand Technology Innovation Guide Award Fund Project(grant no 103-413193) Scientific Research Project of HenanColleges and Universities in 2019 based on the research onmilitary science and technology innovation mechanism ofcolleges and universities from the perspective of civil-military integration (grant no 19A630037) Fund of Re-search on Enterprise Management Innovation Mode System(grant no 44860070) and Fund of Research on the En-terprise Management Mode and Countermeasures Based onthe Production Study and Research (grant no 44860071)

References

[1] S Zhang K Li G Wang and X Zhu ldquoSimulate design andexperimental analysis of commercial vehicle cab suspensionrdquoin Proceedings of the 19th Asia Pacific Automotive EngineeringConference amp SAE-hina Congress 2017 Selected Papers SAE-hina 2017 Lecture Notes in Electrical Engineering Edited by S(SAE-hina) Ed vol 486 pp 675ndash691 Springer ShanghaiChina October 2019

[2] L Morello L R Rossini G Pia and A Tonoli ldquoNoise vi-bration harshnessrdquo in e Automotive Body MechanicalEngineering Series pp 239ndash363 Springer DordrechtNetherlands 2011

[3] A Gupta A D Jayal M Chimienti and I S Jawahir ldquoA totallife-cycle approach towards developing product metrics forsustainable manufacturingrdquo in Glocalized Solutions for Sus-tainability in Manufacturing J Hesselbach and C HerrmannEds Springer Berlin Germany pp 240ndash245 2011

[4] A Zarghami and D Benbow ldquoIntroduction to 8D problemsolvingrdquo Journal for Quality amp Participation vol 40pp 23ndash28 2017

[5] S-O Shim K Park and S Choi ldquoInnovative productionscheduling with customer satisfaction based measurement forthe sustainability of manufacturing firmsrdquo Sustainabilityvol 9 no 12 p 2249 2017

[6] Ford Motor Company Training Group Training Manual forthe G8D Process Ford Motor Company Dearborn MI USA1999

[7] V Nicolae L M Ionescu N Belu and S L Elena ldquoIm-provement of the 8D analysis through a system based on theldquointernet of thingsrdquo concept applied in automotive industryrdquoin Proceedings of the CONAT 2016 International Congress ofAutomotive and Transport Engineering A Chiru and N IspasEds pp 635ndash642 Springer Brasov Romania October 2017

[8] T S M Kumar and B Adaveesh ldquoApplication of ldquo8Dmethodologyrdquo for the root cause analysis and reduction ofvalve spring rejection in a valve spring manufacturingcompany a case studyrdquo Indian Journal of Science andTechnology vol 10 no 11 pp 1ndash11 2017

[9] R Simmons ldquoBook review introduction to 8D problemsolving including practical applications and examplesrdquoQuality Management Journal vol 25 no 4 201 pages 2018

[10] C A Riesenberger and S D Sousa ldquo+e 8D methodology aneffective way to reduce recurrence of customer complaintsrdquo in

10 Shock and Vibration

Proceedings of the World Congress on Engineering vol 3London UK June-July 2010

[11] K S Sim J H Lee T W Park and M H Cho ldquoVibrationpath analysis and optimal design of the suspension for brakejudder reductionrdquo International Journal of AutomotiveTechnology vol 14 no 4 pp 587ndash594 2013

[12] X Yang and S Zuo ldquoParameters sensitivity analysis of self-excited vibration of tiresrdquo in Proceeding of the FISITA 2012World Automotive Congress Lecture Notes in Electrical En-gineering vol 201 pp 3ndash14 Springer Berlin Germany 2013

[13] Z Liu S Yuan S Xiao S Z Du Y Zhang and C Lu ldquoFullvehicle vibration and noise analysis based on substructurepower flowrdquo Shock and Vibration vol 2017 Article ID8725346 17 pages 2017

[14] D Hao C Zhao and Y Huang ldquoA reduced-order modelfor active suppression control of vehicle longitudinal low-frequency vibrationrdquo Shock and Vibration vol 2018Article ID 5731347 22 pages 2018

[15] Y Ren and L Zheng ldquoActive suspension control for wheel-drive electric vehicle based on vibration absorberrdquo in Pro-ceedings of the SAE-China Congress 2015 Selected PapersLecture Notes in Electrical Engineering vol 364 pp 75ndash86Springer Singapore 2016

[16] Y Taskin I Yuksek and N Yagiz ldquoVibration control ofvehicles with active tuned mass damperrdquo Journal ofVibroengineering vol 19 no 5 pp 3533ndash3541 2017

[17] Y M Han M H Nam S S Han H G Lee and S B ChoildquoVibration control evaluation of a commercial vehicle fea-turing MR seat damperrdquo Journal of Intelligent MaterialSystems and Structures vol 13 no 9 pp 575ndash579 2002

[18] H Sell T Ehrt and M Meszlig ldquoVibration-optimized com-ponents for chassis systemsrdquo ATZ Worldwide vol 110 no 2pp 26ndash31 2008

[19] A N +ite ldquoDevelopment of a refined quarter car model forthe analysis of discomfort due to vibrationrdquo Advances inAcoustics and Vibration vol 2012 Article ID 863061 7 pages2012

[20] Y Zhang H Wang Q Zhu Y Xu and L Wu ldquo+e iden-tification and countermeasure analysis of vehicle idle vibra-tionrdquo in Proceedings of the FISITA 2012 World AutomotiveCongress Lecture Notes in Electrical Engineering vol 201pp 443ndash455 Springer Berlin Germany 2013

[21] T Berberich P Gebhard S Bohlen O Danninger andM Lienkamp ldquoA new approach to the presentation of vi-bration phenomena in vehiclesrdquo in Proceedings of the FISITA2012 World Automotive Congress Lecture Notes in ElectricalEngineering vol 201 pp 591ndash598 Springer Berlin Germany2013

[22] N J Mansfield J Mackrill A N Rimell and S J MacMullldquoCombined effects of long-term sitting and whole-body vi-bration on discomfort onset for vehicle occupantsrdquo ISRNAutomotive Engineering vol 2014 Article ID 852607 8 pages2014

[23] J Park J Lee S Ahn and W Jeong ldquoReduced ride comfortcaused by beating idle vibrations in passenger vehiclesrdquo In-ternational Journal of Industrial Ergonomics vol 57 pp 74ndash79 2017

[24] A Jamali M Salehpour and N Nariman-zadeh ldquoRobustPareto active suspension design for vehicle vibration modelwith probabilistic uncertain parametersrdquo Multibody SystemDynamics vol 30 no 3 pp 265ndash285 2013

[25] X C Liang and J S Zhao ldquoResearch on recycling vibrationenergy of shock absorberrdquo International Journal of VehicleDesign vol 68 no 1ndash3 pp 201ndash220 2015

[26] S Zuo X Duan and Y Li ldquoStudy on dynamics of polygonalwear of automotive tire caused by self-excited vibrationrdquoMathematical Problems in Engineering vol 2014 Article ID653803 12 pages 2014

[27] J-J Bae and N Kang ldquoDesign optimization of a mecanumwheel to reduce vertical vibrations by the consideration ofequivalent stiffnessrdquo Shock and Vibration vol 2016 ArticleID 5892784 8 pages 2016

[28] A Pieper K Le Chau and J Kalberer ldquoOptimisation of rollvibration damping of a vehiclerdquo Auto Tech Review vol 4no 2 pp 36ndash41 2015

[29] G Pavic ldquoAnalysis of vibration reduction by damping usingsimple analytical modellingrdquo Shock and Vibration vol 2018Article ID 1098531 13 pages 2018

[30] M Heidari and H Homaei ldquoEstimation of accelerationamplitude of vehicle by back propagation neural networksrdquoAdvances in Acoustics and Vibration vol 2013 Article ID614025 7 pages 2013

[31] L-X Guo and L-P Zhang ldquoVehicle vibration analysis inchangeable speeds solved by pseudoexcitation methodrdquoMathematical Problems in Engineering vol 2010 Article ID802720 14 pages 2010

[32] B Sakhaei and M Durali ldquoVibration transfer path analysisand path ranking for NVH optimization of a vehicle interiorrdquoShock and Vibration vol 2014 Article ID 697450 5 pages2014

[33] D C Barton and J D Fieldhouse ldquoSuspension systems andcomponentsrdquo in Automotive Chassis Engineeringpp 111ndash214 Springer Cham Switzerland 2018

[34] K Jalics ldquoSimulation methods in the vehicle noise vibrationand harshness (NVH)rdquo in Vehicle and Automotive Engi-neering Lecture Notes in Mechanical Engineering K Jarmaiand B Bollo Eds pp 91ndash97 Springer Cham Switzerland2017

[35] X Xu F Yan Y Li W Chen and Y Cao ldquoRide comfortsimulation and abnormal vibration improvement of a com-mercial vehiclerdquo in Proceeding of the SAE-China Congress2015 Selected Papers Lecture Notes in Electrical Engineeringvol 364 pp 521ndash527 Springer Singapore January 2016

[36] D Dornfeld ldquoLeveraging manufacturing for a sustainablefuturerdquo in Glocalized Solutions for Sustainability inManufacturing J Hesselbach and C Herrmann EdsSpringer Berlin Germany pp 17ndash21 2011

[37] M A Gbededo and K Liyanage ldquoIdentification and align-ment of the social aspects of sustainable manufacturing withthe theory of motivationrdquo Sustainability vol 10 no 3 p 8522018

Shock and Vibration 11

International Journal of

AerospaceEngineeringHindawiwwwhindawicom Volume 2018

RoboticsJournal of

Hindawiwwwhindawicom Volume 2018

Hindawiwwwhindawicom Volume 2018

Active and Passive Electronic Components

VLSI Design

Hindawiwwwhindawicom Volume 2018

Hindawiwwwhindawicom Volume 2018

Shock and Vibration

Hindawiwwwhindawicom Volume 2018

Civil EngineeringAdvances in

Acoustics and VibrationAdvances in

Hindawiwwwhindawicom Volume 2018

Hindawiwwwhindawicom Volume 2018

Electrical and Computer Engineering

Journal of

Advances inOptoElectronics

Hindawiwwwhindawicom

Volume 2018

Hindawi Publishing Corporation httpwwwhindawicom Volume 2013Hindawiwwwhindawicom

The Scientific World Journal

Volume 2018

Control Scienceand Engineering

Journal of

Hindawiwwwhindawicom Volume 2018

Hindawiwwwhindawicom

Journal ofEngineeringVolume 2018

SensorsJournal of

Hindawiwwwhindawicom Volume 2018

International Journal of

RotatingMachinery

Hindawiwwwhindawicom Volume 2018

Modelling ampSimulationin EngineeringHindawiwwwhindawicom Volume 2018

Hindawiwwwhindawicom Volume 2018

Chemical EngineeringInternational Journal of Antennas and

Propagation

International Journal of

Hindawiwwwhindawicom Volume 2018

Hindawiwwwhindawicom Volume 2018

Navigation and Observation

International Journal of

Hindawi

wwwhindawicom Volume 2018

Advances in

Multimedia

Submit your manuscripts atwwwhindawicom

Page 9: ResearchonImprovementofTruckVibrationBasedonSystematic G8D ...downloads.hindawi.com/journals/sv/2019/1416340.pdf · ResearchArticle ResearchonImprovementofTruckVibrationBasedonSystematic

parts meet the technical standards and check thedynamic balance

(2) Device level correct the cab damper and front axledamper ensure that the parts of the supplier meetthe technical standards and detect the stiffness anddamping of the damper [35]

(3) Whole car level load the car with the modified partsand carry out the road test to see the improvementeffect of the vibration performance of the whole car[20]

37 Prevent ProblemRecurrence (D7) +e ldquo5Whysrdquo methodis still used here to determine the root cause of the problemand the permanent measures that should be taken to preventthe recurrence of the problem According to the theory ofG8D it can be used to find out the problems about systemoperation process or policy Systemic problems arise fromfull references to previous organizations technical processespolicies and practices +ese past processes policies andpractices are often not applicable to the current situation andare not traceable

+e method proposed in this paper is very effective insolving the vibration problem systematically and makes thevibration problem be systematically tracked and controlledAccording to the above analysis and the actual situation thispaper puts forward some suggestions on the existing systemof the enterprise in order to prevent the recurrence of theproblem

(1) +e quality inspection mechanism of enterprisesneeds to be perfected +is is responsible for

formulating product quality inspection standardschecking the quality of parts provided by suppliersspot checking the qualified rate of products thesupplier shall provide quality product certificationaccording to the requirements of the enterprise if itdoes not meet the requirements it will not accept thesupply

(2) +e supplier quality evaluation system is yet to beestablished +e related personnel is responsible forsupplier quality review and supplier classificationmanagement In the case of unqualified productsenterprises need to have accurate technical means toprovide suppliers with accurate technical evidence ofnonconforming products and specific rectificationprograms for suppliers to rectify according to spe-cific technical objectives

(3) Technical support for supplier quality improvementis to be provided +e relevant departments are re-sponsible for technical guidance and help suppliersto improve quality suppliers and enterprises in thequality of a virtuous circle that is enterprises dotheir best to promote suppliers to improve qualityreward and punishment system for suppliers andlaunch mechanisms +e quality of suppliers isgradually improved due to technical feedback andassistance

(4) Supplier product quality feedback system is to beestablished Let the supplier define the technical andquality requirements of the enterprise and form aclosed loop between the quality of the product of thesupplier and the requirements of the enterprise +e

Table 9 Problem prevention worksheet

Problem prevention worksheetProgram objective to prevent vehicle vibration in terms of the manufacturing quality of components

Key step Nature Possible obstaclescauses of problemsP S P times S

(1) Deviation quality and consistency of transmissionshaft(2) Technical requirements for hub roundness andflatness and consistency(3) Rims meet technical requirements roundness andconsistency(4) Dynamic balance andconsistency of tire assembly(5) Damping force of front axleshock absorber meets technical requirements andconsistency(6) Cab-suspensioning shockabsorber meets technical requirements andconsistencyUse your experience to identifyyour plans and steps

+ese steps are complex havetight deadlines are new andhave an impact on other steps

Determine whichsteps

require yourattention

and resources most

Identify possible obstacles to completing these keysteps (people methods materials machinesmeasurements and environmental problems)

Notes questions such as the nature of the form need to be filled out later

Shock and Vibration 9

enterprise forms the complete system and themechanism causes the supplier and the enterprisemain engine factoryrsquos technical information to forma closed loop strengthens the system informationexchange between each other and forms the tech-nical accumulation for the past problem solving toprevent similar problems from happening in otherlocations or on other models

4 Discussion and Conclusions

By applying the G8D an improved model for solving thetruck vibration problem is established At the same timeaccording to the results of the statement problem methodthe Yes and No worksheet the 5Whys method and the truthfactor assessment the reason for determining the truckvibration is the unbalanced excitation force of the vehiclewheel system the resonance phenomenon caused by thecoupling of the excitation frequency with the natural fre-quency of the system and the insufficient damping functionof the system +erefore the corrective measures forchanging the wheel hub of cab suspension and dynamicbalance brake hub and dynamic balance tire are put forward+en the permanent correction measures are verified fromthree levels of components devices and whole vehicles byusing ldquodecision worksheetrdquo and ldquoproblem preventionworksheetrdquo to ensure the accuracy and feasibility of themodel and make recommendations for the existing systemof the enterprise to prevent recurrence of problems in thefuture

After the implementation of the abovementioned com-plete and improved model the acceleration of the seat rail ofthe truckrsquos vibration performance has been reduced from104ms2 to 06ms2 423 lower than that of the original carreaching the level of 06ms2 of the major domestic modelsand close to the level of 05ms2 of its German counterpartwhich prevents users from returning their cars For thecompany to reduce certain economic losses the sustainabilityof product manufacturing and enterprise economic benefitshave to be improved [36] +e practical implementation ofG8D can solve many technical problems but the wholeenterprise needs to pay attention to G8D training whichenables G8D become a sustainable solution to the problem ofenterprises +is is of great significance for solving the truckvibration problem and even the quality problem of the wholeautomobile manufacturing industry which is meaningful forthe sustainable construction of the industry Most impor-tantly it contributes to the sustainable guarantee of the publictraffic safety of the society [37]

Data Availability

+e numerical data used to support the findings of this studyare included within the article

Conflicts of Interest

+e authors declare that there are no conflicts of interestregarding the publication of this paper

Acknowledgments

+is research was funded by the Enterprise ManagementInnovation Project of the National Defense Science andTechnology Industry (grant no 13315502) FundamentalResearch Funds for the Central Universities (grant no21618412) Inner Mongolia Autonomous Region Scienceand Technology Innovation Guide Award Fund Project(grant no 103-413193) Scientific Research Project of HenanColleges and Universities in 2019 based on the research onmilitary science and technology innovation mechanism ofcolleges and universities from the perspective of civil-military integration (grant no 19A630037) Fund of Re-search on Enterprise Management Innovation Mode System(grant no 44860070) and Fund of Research on the En-terprise Management Mode and Countermeasures Based onthe Production Study and Research (grant no 44860071)

References

[1] S Zhang K Li G Wang and X Zhu ldquoSimulate design andexperimental analysis of commercial vehicle cab suspensionrdquoin Proceedings of the 19th Asia Pacific Automotive EngineeringConference amp SAE-hina Congress 2017 Selected Papers SAE-hina 2017 Lecture Notes in Electrical Engineering Edited by S(SAE-hina) Ed vol 486 pp 675ndash691 Springer ShanghaiChina October 2019

[2] L Morello L R Rossini G Pia and A Tonoli ldquoNoise vi-bration harshnessrdquo in e Automotive Body MechanicalEngineering Series pp 239ndash363 Springer DordrechtNetherlands 2011

[3] A Gupta A D Jayal M Chimienti and I S Jawahir ldquoA totallife-cycle approach towards developing product metrics forsustainable manufacturingrdquo in Glocalized Solutions for Sus-tainability in Manufacturing J Hesselbach and C HerrmannEds Springer Berlin Germany pp 240ndash245 2011

[4] A Zarghami and D Benbow ldquoIntroduction to 8D problemsolvingrdquo Journal for Quality amp Participation vol 40pp 23ndash28 2017

[5] S-O Shim K Park and S Choi ldquoInnovative productionscheduling with customer satisfaction based measurement forthe sustainability of manufacturing firmsrdquo Sustainabilityvol 9 no 12 p 2249 2017

[6] Ford Motor Company Training Group Training Manual forthe G8D Process Ford Motor Company Dearborn MI USA1999

[7] V Nicolae L M Ionescu N Belu and S L Elena ldquoIm-provement of the 8D analysis through a system based on theldquointernet of thingsrdquo concept applied in automotive industryrdquoin Proceedings of the CONAT 2016 International Congress ofAutomotive and Transport Engineering A Chiru and N IspasEds pp 635ndash642 Springer Brasov Romania October 2017

[8] T S M Kumar and B Adaveesh ldquoApplication of ldquo8Dmethodologyrdquo for the root cause analysis and reduction ofvalve spring rejection in a valve spring manufacturingcompany a case studyrdquo Indian Journal of Science andTechnology vol 10 no 11 pp 1ndash11 2017

[9] R Simmons ldquoBook review introduction to 8D problemsolving including practical applications and examplesrdquoQuality Management Journal vol 25 no 4 201 pages 2018

[10] C A Riesenberger and S D Sousa ldquo+e 8D methodology aneffective way to reduce recurrence of customer complaintsrdquo in

10 Shock and Vibration

Proceedings of the World Congress on Engineering vol 3London UK June-July 2010

[11] K S Sim J H Lee T W Park and M H Cho ldquoVibrationpath analysis and optimal design of the suspension for brakejudder reductionrdquo International Journal of AutomotiveTechnology vol 14 no 4 pp 587ndash594 2013

[12] X Yang and S Zuo ldquoParameters sensitivity analysis of self-excited vibration of tiresrdquo in Proceeding of the FISITA 2012World Automotive Congress Lecture Notes in Electrical En-gineering vol 201 pp 3ndash14 Springer Berlin Germany 2013

[13] Z Liu S Yuan S Xiao S Z Du Y Zhang and C Lu ldquoFullvehicle vibration and noise analysis based on substructurepower flowrdquo Shock and Vibration vol 2017 Article ID8725346 17 pages 2017

[14] D Hao C Zhao and Y Huang ldquoA reduced-order modelfor active suppression control of vehicle longitudinal low-frequency vibrationrdquo Shock and Vibration vol 2018Article ID 5731347 22 pages 2018

[15] Y Ren and L Zheng ldquoActive suspension control for wheel-drive electric vehicle based on vibration absorberrdquo in Pro-ceedings of the SAE-China Congress 2015 Selected PapersLecture Notes in Electrical Engineering vol 364 pp 75ndash86Springer Singapore 2016

[16] Y Taskin I Yuksek and N Yagiz ldquoVibration control ofvehicles with active tuned mass damperrdquo Journal ofVibroengineering vol 19 no 5 pp 3533ndash3541 2017

[17] Y M Han M H Nam S S Han H G Lee and S B ChoildquoVibration control evaluation of a commercial vehicle fea-turing MR seat damperrdquo Journal of Intelligent MaterialSystems and Structures vol 13 no 9 pp 575ndash579 2002

[18] H Sell T Ehrt and M Meszlig ldquoVibration-optimized com-ponents for chassis systemsrdquo ATZ Worldwide vol 110 no 2pp 26ndash31 2008

[19] A N +ite ldquoDevelopment of a refined quarter car model forthe analysis of discomfort due to vibrationrdquo Advances inAcoustics and Vibration vol 2012 Article ID 863061 7 pages2012

[20] Y Zhang H Wang Q Zhu Y Xu and L Wu ldquo+e iden-tification and countermeasure analysis of vehicle idle vibra-tionrdquo in Proceedings of the FISITA 2012 World AutomotiveCongress Lecture Notes in Electrical Engineering vol 201pp 443ndash455 Springer Berlin Germany 2013

[21] T Berberich P Gebhard S Bohlen O Danninger andM Lienkamp ldquoA new approach to the presentation of vi-bration phenomena in vehiclesrdquo in Proceedings of the FISITA2012 World Automotive Congress Lecture Notes in ElectricalEngineering vol 201 pp 591ndash598 Springer Berlin Germany2013

[22] N J Mansfield J Mackrill A N Rimell and S J MacMullldquoCombined effects of long-term sitting and whole-body vi-bration on discomfort onset for vehicle occupantsrdquo ISRNAutomotive Engineering vol 2014 Article ID 852607 8 pages2014

[23] J Park J Lee S Ahn and W Jeong ldquoReduced ride comfortcaused by beating idle vibrations in passenger vehiclesrdquo In-ternational Journal of Industrial Ergonomics vol 57 pp 74ndash79 2017

[24] A Jamali M Salehpour and N Nariman-zadeh ldquoRobustPareto active suspension design for vehicle vibration modelwith probabilistic uncertain parametersrdquo Multibody SystemDynamics vol 30 no 3 pp 265ndash285 2013

[25] X C Liang and J S Zhao ldquoResearch on recycling vibrationenergy of shock absorberrdquo International Journal of VehicleDesign vol 68 no 1ndash3 pp 201ndash220 2015

[26] S Zuo X Duan and Y Li ldquoStudy on dynamics of polygonalwear of automotive tire caused by self-excited vibrationrdquoMathematical Problems in Engineering vol 2014 Article ID653803 12 pages 2014

[27] J-J Bae and N Kang ldquoDesign optimization of a mecanumwheel to reduce vertical vibrations by the consideration ofequivalent stiffnessrdquo Shock and Vibration vol 2016 ArticleID 5892784 8 pages 2016

[28] A Pieper K Le Chau and J Kalberer ldquoOptimisation of rollvibration damping of a vehiclerdquo Auto Tech Review vol 4no 2 pp 36ndash41 2015

[29] G Pavic ldquoAnalysis of vibration reduction by damping usingsimple analytical modellingrdquo Shock and Vibration vol 2018Article ID 1098531 13 pages 2018

[30] M Heidari and H Homaei ldquoEstimation of accelerationamplitude of vehicle by back propagation neural networksrdquoAdvances in Acoustics and Vibration vol 2013 Article ID614025 7 pages 2013

[31] L-X Guo and L-P Zhang ldquoVehicle vibration analysis inchangeable speeds solved by pseudoexcitation methodrdquoMathematical Problems in Engineering vol 2010 Article ID802720 14 pages 2010

[32] B Sakhaei and M Durali ldquoVibration transfer path analysisand path ranking for NVH optimization of a vehicle interiorrdquoShock and Vibration vol 2014 Article ID 697450 5 pages2014

[33] D C Barton and J D Fieldhouse ldquoSuspension systems andcomponentsrdquo in Automotive Chassis Engineeringpp 111ndash214 Springer Cham Switzerland 2018

[34] K Jalics ldquoSimulation methods in the vehicle noise vibrationand harshness (NVH)rdquo in Vehicle and Automotive Engi-neering Lecture Notes in Mechanical Engineering K Jarmaiand B Bollo Eds pp 91ndash97 Springer Cham Switzerland2017

[35] X Xu F Yan Y Li W Chen and Y Cao ldquoRide comfortsimulation and abnormal vibration improvement of a com-mercial vehiclerdquo in Proceeding of the SAE-China Congress2015 Selected Papers Lecture Notes in Electrical Engineeringvol 364 pp 521ndash527 Springer Singapore January 2016

[36] D Dornfeld ldquoLeveraging manufacturing for a sustainablefuturerdquo in Glocalized Solutions for Sustainability inManufacturing J Hesselbach and C Herrmann EdsSpringer Berlin Germany pp 17ndash21 2011

[37] M A Gbededo and K Liyanage ldquoIdentification and align-ment of the social aspects of sustainable manufacturing withthe theory of motivationrdquo Sustainability vol 10 no 3 p 8522018

Shock and Vibration 11

International Journal of

AerospaceEngineeringHindawiwwwhindawicom Volume 2018

RoboticsJournal of

Hindawiwwwhindawicom Volume 2018

Hindawiwwwhindawicom Volume 2018

Active and Passive Electronic Components

VLSI Design

Hindawiwwwhindawicom Volume 2018

Hindawiwwwhindawicom Volume 2018

Shock and Vibration

Hindawiwwwhindawicom Volume 2018

Civil EngineeringAdvances in

Acoustics and VibrationAdvances in

Hindawiwwwhindawicom Volume 2018

Hindawiwwwhindawicom Volume 2018

Electrical and Computer Engineering

Journal of

Advances inOptoElectronics

Hindawiwwwhindawicom

Volume 2018

Hindawi Publishing Corporation httpwwwhindawicom Volume 2013Hindawiwwwhindawicom

The Scientific World Journal

Volume 2018

Control Scienceand Engineering

Journal of

Hindawiwwwhindawicom Volume 2018

Hindawiwwwhindawicom

Journal ofEngineeringVolume 2018

SensorsJournal of

Hindawiwwwhindawicom Volume 2018

International Journal of

RotatingMachinery

Hindawiwwwhindawicom Volume 2018

Modelling ampSimulationin EngineeringHindawiwwwhindawicom Volume 2018

Hindawiwwwhindawicom Volume 2018

Chemical EngineeringInternational Journal of Antennas and

Propagation

International Journal of

Hindawiwwwhindawicom Volume 2018

Hindawiwwwhindawicom Volume 2018

Navigation and Observation

International Journal of

Hindawi

wwwhindawicom Volume 2018

Advances in

Multimedia

Submit your manuscripts atwwwhindawicom

Page 10: ResearchonImprovementofTruckVibrationBasedonSystematic G8D ...downloads.hindawi.com/journals/sv/2019/1416340.pdf · ResearchArticle ResearchonImprovementofTruckVibrationBasedonSystematic

enterprise forms the complete system and themechanism causes the supplier and the enterprisemain engine factoryrsquos technical information to forma closed loop strengthens the system informationexchange between each other and forms the tech-nical accumulation for the past problem solving toprevent similar problems from happening in otherlocations or on other models

4 Discussion and Conclusions

By applying the G8D an improved model for solving thetruck vibration problem is established At the same timeaccording to the results of the statement problem methodthe Yes and No worksheet the 5Whys method and the truthfactor assessment the reason for determining the truckvibration is the unbalanced excitation force of the vehiclewheel system the resonance phenomenon caused by thecoupling of the excitation frequency with the natural fre-quency of the system and the insufficient damping functionof the system +erefore the corrective measures forchanging the wheel hub of cab suspension and dynamicbalance brake hub and dynamic balance tire are put forward+en the permanent correction measures are verified fromthree levels of components devices and whole vehicles byusing ldquodecision worksheetrdquo and ldquoproblem preventionworksheetrdquo to ensure the accuracy and feasibility of themodel and make recommendations for the existing systemof the enterprise to prevent recurrence of problems in thefuture

After the implementation of the abovementioned com-plete and improved model the acceleration of the seat rail ofthe truckrsquos vibration performance has been reduced from104ms2 to 06ms2 423 lower than that of the original carreaching the level of 06ms2 of the major domestic modelsand close to the level of 05ms2 of its German counterpartwhich prevents users from returning their cars For thecompany to reduce certain economic losses the sustainabilityof product manufacturing and enterprise economic benefitshave to be improved [36] +e practical implementation ofG8D can solve many technical problems but the wholeenterprise needs to pay attention to G8D training whichenables G8D become a sustainable solution to the problem ofenterprises +is is of great significance for solving the truckvibration problem and even the quality problem of the wholeautomobile manufacturing industry which is meaningful forthe sustainable construction of the industry Most impor-tantly it contributes to the sustainable guarantee of the publictraffic safety of the society [37]

Data Availability

+e numerical data used to support the findings of this studyare included within the article

Conflicts of Interest

+e authors declare that there are no conflicts of interestregarding the publication of this paper

Acknowledgments

+is research was funded by the Enterprise ManagementInnovation Project of the National Defense Science andTechnology Industry (grant no 13315502) FundamentalResearch Funds for the Central Universities (grant no21618412) Inner Mongolia Autonomous Region Scienceand Technology Innovation Guide Award Fund Project(grant no 103-413193) Scientific Research Project of HenanColleges and Universities in 2019 based on the research onmilitary science and technology innovation mechanism ofcolleges and universities from the perspective of civil-military integration (grant no 19A630037) Fund of Re-search on Enterprise Management Innovation Mode System(grant no 44860070) and Fund of Research on the En-terprise Management Mode and Countermeasures Based onthe Production Study and Research (grant no 44860071)

References

[1] S Zhang K Li G Wang and X Zhu ldquoSimulate design andexperimental analysis of commercial vehicle cab suspensionrdquoin Proceedings of the 19th Asia Pacific Automotive EngineeringConference amp SAE-hina Congress 2017 Selected Papers SAE-hina 2017 Lecture Notes in Electrical Engineering Edited by S(SAE-hina) Ed vol 486 pp 675ndash691 Springer ShanghaiChina October 2019

[2] L Morello L R Rossini G Pia and A Tonoli ldquoNoise vi-bration harshnessrdquo in e Automotive Body MechanicalEngineering Series pp 239ndash363 Springer DordrechtNetherlands 2011

[3] A Gupta A D Jayal M Chimienti and I S Jawahir ldquoA totallife-cycle approach towards developing product metrics forsustainable manufacturingrdquo in Glocalized Solutions for Sus-tainability in Manufacturing J Hesselbach and C HerrmannEds Springer Berlin Germany pp 240ndash245 2011

[4] A Zarghami and D Benbow ldquoIntroduction to 8D problemsolvingrdquo Journal for Quality amp Participation vol 40pp 23ndash28 2017

[5] S-O Shim K Park and S Choi ldquoInnovative productionscheduling with customer satisfaction based measurement forthe sustainability of manufacturing firmsrdquo Sustainabilityvol 9 no 12 p 2249 2017

[6] Ford Motor Company Training Group Training Manual forthe G8D Process Ford Motor Company Dearborn MI USA1999

[7] V Nicolae L M Ionescu N Belu and S L Elena ldquoIm-provement of the 8D analysis through a system based on theldquointernet of thingsrdquo concept applied in automotive industryrdquoin Proceedings of the CONAT 2016 International Congress ofAutomotive and Transport Engineering A Chiru and N IspasEds pp 635ndash642 Springer Brasov Romania October 2017

[8] T S M Kumar and B Adaveesh ldquoApplication of ldquo8Dmethodologyrdquo for the root cause analysis and reduction ofvalve spring rejection in a valve spring manufacturingcompany a case studyrdquo Indian Journal of Science andTechnology vol 10 no 11 pp 1ndash11 2017

[9] R Simmons ldquoBook review introduction to 8D problemsolving including practical applications and examplesrdquoQuality Management Journal vol 25 no 4 201 pages 2018

[10] C A Riesenberger and S D Sousa ldquo+e 8D methodology aneffective way to reduce recurrence of customer complaintsrdquo in

10 Shock and Vibration

Proceedings of the World Congress on Engineering vol 3London UK June-July 2010

[11] K S Sim J H Lee T W Park and M H Cho ldquoVibrationpath analysis and optimal design of the suspension for brakejudder reductionrdquo International Journal of AutomotiveTechnology vol 14 no 4 pp 587ndash594 2013

[12] X Yang and S Zuo ldquoParameters sensitivity analysis of self-excited vibration of tiresrdquo in Proceeding of the FISITA 2012World Automotive Congress Lecture Notes in Electrical En-gineering vol 201 pp 3ndash14 Springer Berlin Germany 2013

[13] Z Liu S Yuan S Xiao S Z Du Y Zhang and C Lu ldquoFullvehicle vibration and noise analysis based on substructurepower flowrdquo Shock and Vibration vol 2017 Article ID8725346 17 pages 2017

[14] D Hao C Zhao and Y Huang ldquoA reduced-order modelfor active suppression control of vehicle longitudinal low-frequency vibrationrdquo Shock and Vibration vol 2018Article ID 5731347 22 pages 2018

[15] Y Ren and L Zheng ldquoActive suspension control for wheel-drive electric vehicle based on vibration absorberrdquo in Pro-ceedings of the SAE-China Congress 2015 Selected PapersLecture Notes in Electrical Engineering vol 364 pp 75ndash86Springer Singapore 2016

[16] Y Taskin I Yuksek and N Yagiz ldquoVibration control ofvehicles with active tuned mass damperrdquo Journal ofVibroengineering vol 19 no 5 pp 3533ndash3541 2017

[17] Y M Han M H Nam S S Han H G Lee and S B ChoildquoVibration control evaluation of a commercial vehicle fea-turing MR seat damperrdquo Journal of Intelligent MaterialSystems and Structures vol 13 no 9 pp 575ndash579 2002

[18] H Sell T Ehrt and M Meszlig ldquoVibration-optimized com-ponents for chassis systemsrdquo ATZ Worldwide vol 110 no 2pp 26ndash31 2008

[19] A N +ite ldquoDevelopment of a refined quarter car model forthe analysis of discomfort due to vibrationrdquo Advances inAcoustics and Vibration vol 2012 Article ID 863061 7 pages2012

[20] Y Zhang H Wang Q Zhu Y Xu and L Wu ldquo+e iden-tification and countermeasure analysis of vehicle idle vibra-tionrdquo in Proceedings of the FISITA 2012 World AutomotiveCongress Lecture Notes in Electrical Engineering vol 201pp 443ndash455 Springer Berlin Germany 2013

[21] T Berberich P Gebhard S Bohlen O Danninger andM Lienkamp ldquoA new approach to the presentation of vi-bration phenomena in vehiclesrdquo in Proceedings of the FISITA2012 World Automotive Congress Lecture Notes in ElectricalEngineering vol 201 pp 591ndash598 Springer Berlin Germany2013

[22] N J Mansfield J Mackrill A N Rimell and S J MacMullldquoCombined effects of long-term sitting and whole-body vi-bration on discomfort onset for vehicle occupantsrdquo ISRNAutomotive Engineering vol 2014 Article ID 852607 8 pages2014

[23] J Park J Lee S Ahn and W Jeong ldquoReduced ride comfortcaused by beating idle vibrations in passenger vehiclesrdquo In-ternational Journal of Industrial Ergonomics vol 57 pp 74ndash79 2017

[24] A Jamali M Salehpour and N Nariman-zadeh ldquoRobustPareto active suspension design for vehicle vibration modelwith probabilistic uncertain parametersrdquo Multibody SystemDynamics vol 30 no 3 pp 265ndash285 2013

[25] X C Liang and J S Zhao ldquoResearch on recycling vibrationenergy of shock absorberrdquo International Journal of VehicleDesign vol 68 no 1ndash3 pp 201ndash220 2015

[26] S Zuo X Duan and Y Li ldquoStudy on dynamics of polygonalwear of automotive tire caused by self-excited vibrationrdquoMathematical Problems in Engineering vol 2014 Article ID653803 12 pages 2014

[27] J-J Bae and N Kang ldquoDesign optimization of a mecanumwheel to reduce vertical vibrations by the consideration ofequivalent stiffnessrdquo Shock and Vibration vol 2016 ArticleID 5892784 8 pages 2016

[28] A Pieper K Le Chau and J Kalberer ldquoOptimisation of rollvibration damping of a vehiclerdquo Auto Tech Review vol 4no 2 pp 36ndash41 2015

[29] G Pavic ldquoAnalysis of vibration reduction by damping usingsimple analytical modellingrdquo Shock and Vibration vol 2018Article ID 1098531 13 pages 2018

[30] M Heidari and H Homaei ldquoEstimation of accelerationamplitude of vehicle by back propagation neural networksrdquoAdvances in Acoustics and Vibration vol 2013 Article ID614025 7 pages 2013

[31] L-X Guo and L-P Zhang ldquoVehicle vibration analysis inchangeable speeds solved by pseudoexcitation methodrdquoMathematical Problems in Engineering vol 2010 Article ID802720 14 pages 2010

[32] B Sakhaei and M Durali ldquoVibration transfer path analysisand path ranking for NVH optimization of a vehicle interiorrdquoShock and Vibration vol 2014 Article ID 697450 5 pages2014

[33] D C Barton and J D Fieldhouse ldquoSuspension systems andcomponentsrdquo in Automotive Chassis Engineeringpp 111ndash214 Springer Cham Switzerland 2018

[34] K Jalics ldquoSimulation methods in the vehicle noise vibrationand harshness (NVH)rdquo in Vehicle and Automotive Engi-neering Lecture Notes in Mechanical Engineering K Jarmaiand B Bollo Eds pp 91ndash97 Springer Cham Switzerland2017

[35] X Xu F Yan Y Li W Chen and Y Cao ldquoRide comfortsimulation and abnormal vibration improvement of a com-mercial vehiclerdquo in Proceeding of the SAE-China Congress2015 Selected Papers Lecture Notes in Electrical Engineeringvol 364 pp 521ndash527 Springer Singapore January 2016

[36] D Dornfeld ldquoLeveraging manufacturing for a sustainablefuturerdquo in Glocalized Solutions for Sustainability inManufacturing J Hesselbach and C Herrmann EdsSpringer Berlin Germany pp 17ndash21 2011

[37] M A Gbededo and K Liyanage ldquoIdentification and align-ment of the social aspects of sustainable manufacturing withthe theory of motivationrdquo Sustainability vol 10 no 3 p 8522018

Shock and Vibration 11

International Journal of

AerospaceEngineeringHindawiwwwhindawicom Volume 2018

RoboticsJournal of

Hindawiwwwhindawicom Volume 2018

Hindawiwwwhindawicom Volume 2018

Active and Passive Electronic Components

VLSI Design

Hindawiwwwhindawicom Volume 2018

Hindawiwwwhindawicom Volume 2018

Shock and Vibration

Hindawiwwwhindawicom Volume 2018

Civil EngineeringAdvances in

Acoustics and VibrationAdvances in

Hindawiwwwhindawicom Volume 2018

Hindawiwwwhindawicom Volume 2018

Electrical and Computer Engineering

Journal of

Advances inOptoElectronics

Hindawiwwwhindawicom

Volume 2018

Hindawi Publishing Corporation httpwwwhindawicom Volume 2013Hindawiwwwhindawicom

The Scientific World Journal

Volume 2018

Control Scienceand Engineering

Journal of

Hindawiwwwhindawicom Volume 2018

Hindawiwwwhindawicom

Journal ofEngineeringVolume 2018

SensorsJournal of

Hindawiwwwhindawicom Volume 2018

International Journal of

RotatingMachinery

Hindawiwwwhindawicom Volume 2018

Modelling ampSimulationin EngineeringHindawiwwwhindawicom Volume 2018

Hindawiwwwhindawicom Volume 2018

Chemical EngineeringInternational Journal of Antennas and

Propagation

International Journal of

Hindawiwwwhindawicom Volume 2018

Hindawiwwwhindawicom Volume 2018

Navigation and Observation

International Journal of

Hindawi

wwwhindawicom Volume 2018

Advances in

Multimedia

Submit your manuscripts atwwwhindawicom

Page 11: ResearchonImprovementofTruckVibrationBasedonSystematic G8D ...downloads.hindawi.com/journals/sv/2019/1416340.pdf · ResearchArticle ResearchonImprovementofTruckVibrationBasedonSystematic

Proceedings of the World Congress on Engineering vol 3London UK June-July 2010

[11] K S Sim J H Lee T W Park and M H Cho ldquoVibrationpath analysis and optimal design of the suspension for brakejudder reductionrdquo International Journal of AutomotiveTechnology vol 14 no 4 pp 587ndash594 2013

[12] X Yang and S Zuo ldquoParameters sensitivity analysis of self-excited vibration of tiresrdquo in Proceeding of the FISITA 2012World Automotive Congress Lecture Notes in Electrical En-gineering vol 201 pp 3ndash14 Springer Berlin Germany 2013

[13] Z Liu S Yuan S Xiao S Z Du Y Zhang and C Lu ldquoFullvehicle vibration and noise analysis based on substructurepower flowrdquo Shock and Vibration vol 2017 Article ID8725346 17 pages 2017

[14] D Hao C Zhao and Y Huang ldquoA reduced-order modelfor active suppression control of vehicle longitudinal low-frequency vibrationrdquo Shock and Vibration vol 2018Article ID 5731347 22 pages 2018

[15] Y Ren and L Zheng ldquoActive suspension control for wheel-drive electric vehicle based on vibration absorberrdquo in Pro-ceedings of the SAE-China Congress 2015 Selected PapersLecture Notes in Electrical Engineering vol 364 pp 75ndash86Springer Singapore 2016

[16] Y Taskin I Yuksek and N Yagiz ldquoVibration control ofvehicles with active tuned mass damperrdquo Journal ofVibroengineering vol 19 no 5 pp 3533ndash3541 2017

[17] Y M Han M H Nam S S Han H G Lee and S B ChoildquoVibration control evaluation of a commercial vehicle fea-turing MR seat damperrdquo Journal of Intelligent MaterialSystems and Structures vol 13 no 9 pp 575ndash579 2002

[18] H Sell T Ehrt and M Meszlig ldquoVibration-optimized com-ponents for chassis systemsrdquo ATZ Worldwide vol 110 no 2pp 26ndash31 2008

[19] A N +ite ldquoDevelopment of a refined quarter car model forthe analysis of discomfort due to vibrationrdquo Advances inAcoustics and Vibration vol 2012 Article ID 863061 7 pages2012

[20] Y Zhang H Wang Q Zhu Y Xu and L Wu ldquo+e iden-tification and countermeasure analysis of vehicle idle vibra-tionrdquo in Proceedings of the FISITA 2012 World AutomotiveCongress Lecture Notes in Electrical Engineering vol 201pp 443ndash455 Springer Berlin Germany 2013

[21] T Berberich P Gebhard S Bohlen O Danninger andM Lienkamp ldquoA new approach to the presentation of vi-bration phenomena in vehiclesrdquo in Proceedings of the FISITA2012 World Automotive Congress Lecture Notes in ElectricalEngineering vol 201 pp 591ndash598 Springer Berlin Germany2013

[22] N J Mansfield J Mackrill A N Rimell and S J MacMullldquoCombined effects of long-term sitting and whole-body vi-bration on discomfort onset for vehicle occupantsrdquo ISRNAutomotive Engineering vol 2014 Article ID 852607 8 pages2014

[23] J Park J Lee S Ahn and W Jeong ldquoReduced ride comfortcaused by beating idle vibrations in passenger vehiclesrdquo In-ternational Journal of Industrial Ergonomics vol 57 pp 74ndash79 2017

[24] A Jamali M Salehpour and N Nariman-zadeh ldquoRobustPareto active suspension design for vehicle vibration modelwith probabilistic uncertain parametersrdquo Multibody SystemDynamics vol 30 no 3 pp 265ndash285 2013

[25] X C Liang and J S Zhao ldquoResearch on recycling vibrationenergy of shock absorberrdquo International Journal of VehicleDesign vol 68 no 1ndash3 pp 201ndash220 2015

[26] S Zuo X Duan and Y Li ldquoStudy on dynamics of polygonalwear of automotive tire caused by self-excited vibrationrdquoMathematical Problems in Engineering vol 2014 Article ID653803 12 pages 2014

[27] J-J Bae and N Kang ldquoDesign optimization of a mecanumwheel to reduce vertical vibrations by the consideration ofequivalent stiffnessrdquo Shock and Vibration vol 2016 ArticleID 5892784 8 pages 2016

[28] A Pieper K Le Chau and J Kalberer ldquoOptimisation of rollvibration damping of a vehiclerdquo Auto Tech Review vol 4no 2 pp 36ndash41 2015

[29] G Pavic ldquoAnalysis of vibration reduction by damping usingsimple analytical modellingrdquo Shock and Vibration vol 2018Article ID 1098531 13 pages 2018

[30] M Heidari and H Homaei ldquoEstimation of accelerationamplitude of vehicle by back propagation neural networksrdquoAdvances in Acoustics and Vibration vol 2013 Article ID614025 7 pages 2013

[31] L-X Guo and L-P Zhang ldquoVehicle vibration analysis inchangeable speeds solved by pseudoexcitation methodrdquoMathematical Problems in Engineering vol 2010 Article ID802720 14 pages 2010

[32] B Sakhaei and M Durali ldquoVibration transfer path analysisand path ranking for NVH optimization of a vehicle interiorrdquoShock and Vibration vol 2014 Article ID 697450 5 pages2014

[33] D C Barton and J D Fieldhouse ldquoSuspension systems andcomponentsrdquo in Automotive Chassis Engineeringpp 111ndash214 Springer Cham Switzerland 2018

[34] K Jalics ldquoSimulation methods in the vehicle noise vibrationand harshness (NVH)rdquo in Vehicle and Automotive Engi-neering Lecture Notes in Mechanical Engineering K Jarmaiand B Bollo Eds pp 91ndash97 Springer Cham Switzerland2017

[35] X Xu F Yan Y Li W Chen and Y Cao ldquoRide comfortsimulation and abnormal vibration improvement of a com-mercial vehiclerdquo in Proceeding of the SAE-China Congress2015 Selected Papers Lecture Notes in Electrical Engineeringvol 364 pp 521ndash527 Springer Singapore January 2016

[36] D Dornfeld ldquoLeveraging manufacturing for a sustainablefuturerdquo in Glocalized Solutions for Sustainability inManufacturing J Hesselbach and C Herrmann EdsSpringer Berlin Germany pp 17ndash21 2011

[37] M A Gbededo and K Liyanage ldquoIdentification and align-ment of the social aspects of sustainable manufacturing withthe theory of motivationrdquo Sustainability vol 10 no 3 p 8522018

Shock and Vibration 11

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Civil EngineeringAdvances in

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Hindawiwwwhindawicom Volume 2018

Electrical and Computer Engineering

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Hindawi Publishing Corporation httpwwwhindawicom Volume 2013Hindawiwwwhindawicom

The Scientific World Journal

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Control Scienceand Engineering

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Hindawiwwwhindawicom

Journal ofEngineeringVolume 2018

SensorsJournal of

Hindawiwwwhindawicom Volume 2018

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RotatingMachinery

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Modelling ampSimulationin EngineeringHindawiwwwhindawicom Volume 2018

Hindawiwwwhindawicom Volume 2018

Chemical EngineeringInternational Journal of Antennas and

Propagation

International Journal of

Hindawiwwwhindawicom Volume 2018

Hindawiwwwhindawicom Volume 2018

Navigation and Observation

International Journal of

Hindawi

wwwhindawicom Volume 2018

Advances in

Multimedia

Submit your manuscripts atwwwhindawicom

Page 12: ResearchonImprovementofTruckVibrationBasedonSystematic G8D ...downloads.hindawi.com/journals/sv/2019/1416340.pdf · ResearchArticle ResearchonImprovementofTruckVibrationBasedonSystematic

International Journal of

AerospaceEngineeringHindawiwwwhindawicom Volume 2018

RoboticsJournal of

Hindawiwwwhindawicom Volume 2018

Hindawiwwwhindawicom Volume 2018

Active and Passive Electronic Components

VLSI Design

Hindawiwwwhindawicom Volume 2018

Hindawiwwwhindawicom Volume 2018

Shock and Vibration

Hindawiwwwhindawicom Volume 2018

Civil EngineeringAdvances in

Acoustics and VibrationAdvances in

Hindawiwwwhindawicom Volume 2018

Hindawiwwwhindawicom Volume 2018

Electrical and Computer Engineering

Journal of

Advances inOptoElectronics

Hindawiwwwhindawicom

Volume 2018

Hindawi Publishing Corporation httpwwwhindawicom Volume 2013Hindawiwwwhindawicom

The Scientific World Journal

Volume 2018

Control Scienceand Engineering

Journal of

Hindawiwwwhindawicom Volume 2018

Hindawiwwwhindawicom

Journal ofEngineeringVolume 2018

SensorsJournal of

Hindawiwwwhindawicom Volume 2018

International Journal of

RotatingMachinery

Hindawiwwwhindawicom Volume 2018

Modelling ampSimulationin EngineeringHindawiwwwhindawicom Volume 2018

Hindawiwwwhindawicom Volume 2018

Chemical EngineeringInternational Journal of Antennas and

Propagation

International Journal of

Hindawiwwwhindawicom Volume 2018

Hindawiwwwhindawicom Volume 2018

Navigation and Observation

International Journal of

Hindawi

wwwhindawicom Volume 2018

Advances in

Multimedia

Submit your manuscripts atwwwhindawicom