the beginning of the us automotive industry -...
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The Beginning of the US Automotive Industry Henry Ford – Plowing New Ground
• Major Inventions – Quadricycle – Assembly Line – Rouge Factory Complex
• Regulations Evolving – Workforce – Vehicle
• Standards Evolving – Engineering Specifications – Manufacturing Processes – Quality Control
The US Automotive Industry Constant Evolution
• Major Inventions – Types of Vehicles – Major Systems – Components
• Regulations Evolving – US Government State and Federal – Global Government
• Standards Evolving – Vehicle Life Cycle Development – Engineering Specifications – Manufacturing Processes – Quality Control
ISO TS 16949 Quality Management System Managing the Complexities
• What is the standard? – Managed by the International Automotive Task Force (IATF) – Integral into the Automotive Industry Action Group (AIAG) – Integral into the Project Management Institute (PMI)
• Why use the standard? – Quality focus throughout the entire product lifecycle – Mandated by major global OEMs for their suppliers
• How to use the standard? – Document your product lifecycle development process – Ensure all ISO TS 16949 elements are addressed in processes – Compliance to your documented process – Certified by a 3rd party auditor for compliance
TS 16949 Quality Management System Tools, techniques and methodologies
Defining the Overall Vehicle Objectives 1. Application Analysis 2. Key Product Characteristics (KPCs) 3. Features and MSRP Pricing Defining the Vehicle 4. Total Vehicle Diagram 5. Bill of Materials (BOM) Potential Failure Modes 6. Design FMEA Fishbone Diagram 7. Design Failure Mode and Effects Analysis 8. ISO 26262 Automotive Safety Integrity Design Validation 9. Vehicle Builds 10. Design Controls Protocol 11. Design, Verification, Plan and Report
Manufacturing Validation 12. Supplier Evaluation and Selection 13. Manufacture Process 14. Manufacture Fishbone Diagram 15. Manufacture Process Failure Mode & Effects Analysis 16. Manufacture Control Plan 17. Manufacture Production Part Approval Process (PPAP) Assembly Validation 18. Plant Layout 19. Assembly Process 20. Assembly Fishbone Diagram 21. Assembly Process Failure Mode & Effects Analysis 22. Assembly Control Plan 23. Assembly Production Part Approval Process (PPAP) Continuous Improvement
TS 16949 Quality Management System What other types of programs have we used it on?
• Standard applies to more than the global automotive industry – Off Road Vehicles, Military, Mining, Forestry, etc.
• Effectively manages the complete lifecycle of complex products – Quality Assurance, Regulatory Mandates, Safety elements
• Applicable to many different products in multiple industries – Food, Medical, Plastic Resins, Consumer Products, etc.
• Technical documentation package – Baseline and updated with any changes made to the product
• Can be effectively used on many different types of programs – New product development programs – Refreshed product development programs – Root cause analysis – Value Added Engineering (VAE)
2003 Ford Mustang GT Street Legal Muscle Car Case Study
• Targeted Customers • Classic muscle car enthusiast
• Customer Requirements • Extreme looking car show participants • Unique muscle car technology
• 100% Displacement With CNG • 45% / 21% (2014/2017) reduction in fuel costs • 25% reduction in emissions
• Additional Benefits to Program • Horsepower and torque are the same using CNG • Both dual fuel systems utilize Methanol injection • Demonstration vehicle of the technology • Research and Development for other programs
Video Skid Marks
2003 Ford Mustang GT Program Vehicle Specifications
Feature Specification Ford Stock Engine V8 4.6 Liter Port Inject Transmission Tremec 5 Speed Manual Alternator 130 Amps Gross Vehicle Weight 3,379 Pounds Miles per Gallon 12 Miles Gasoline Fuel Tank 15.7 Gallons
Suspension Edelbrock Adjustable Control Arms
Brakes Roush Drill Slotted 2 Piece Rotors Wheels and Tires 17” 245/45 ZR17 Rear Axle Ratio 3.73 Posi Traction Cargo Space 10.9 Cubic Feet Ground Clearance 4”
2003 Ford Mustang GT Program Engine Specifications
Feature Specification
Configuration V8 4.6 liter SOHC
Bore and Stroke 3.60” x 3.60”
Cylinder Head Cast Iron
Engine Block Cast Iron
Firing Order 1, 3, 7, 2, 6, 5, 4, 8
Compression Ratio 9.36 : 1
Injection Port Injection
Aspiration Anderson Motorsports Mass Air Flow
Valvetrain Trick Flow Camshafts
Coolant Capacity 14.6 Quarts
Oil Capacity 6 Quarts With Filter
Governed Speed 6,000 RPM
2003 Ford Mustang GT Program Transmission Specifications
Gear 1st 2nd 3rd 4th 5th R
Ratio 3.27 1.97 1.34 1.00 0.68 3.00
Feature Specification
Transmission Tremec TKO 500
Type 5 Speed Manual
Weight 105 Pounds
Input Shaft 10 Spline
Torque Capacity 500 Foot Pounds
Shafts Tapered Roller Bearing on All Shafts
Gearsets Made From Grade Steel ASTM 4615
Clutch McLeod Street Extreme
Shift Control Dual Electronic Speedometer Pick-Ups
2003 Ford Mustang GT Program Overall Program Timing
Feasibility Prototype Validation Production Improvement
Plan & Define Program
Product Design & Verification
Process Validation
Assessment & Corrective Action
Process Design & Verification
Product Design & Development
Process Design & Development
Product & Process Validation
Planning
Feedback, Assessment & Corrective Action
Production
Weeks 4 8 12 16
2003 Ford Mustang GT Program Application Sheet – page (1 of 4)
Address
Title Phone
1 Types Other
Model Usage
216 miles Other
Model Other
Model Other
Model Other
Model Other
Model Other
Model Other
Model Other
Model Other
Model Other
Yes
Retail Model Volume Pressure Temp Fill Rate
Model Volume Pressure Temp Fill Rate
Model Volume Pressure Temp Fill Rate
Model Volume Pressure Temp Fill Rate
Yes
Retail Model Volume Pressure Temp Fill Rate
Model Volume Pressure Temp Fill Rate
DivisionsResearch and development and sales and marketing demonstrator of technologyCompany Objective
Fleet Vehicles How Many
2003
Rear Wheel Drive
Suspension Progressive rate lowering
Vehicle Make
Fuel Types
Manufacturer
Manufacturer
Fuel Types
Manufacturer
Manufacturer
Wheels 18" Manufacturer
Tires Kumho ASX 275/35R18
Front Axle
Fuel Types
Gasoline/E85 Fuel Categories Fuel Types
Gasoline/E85 Fill
Diesel
Propane Fill
Fuel Categories
Customer InformationCompany Name Website
Manufacturer
Fuel Categories
Key Contact Name Daryl Patrishkoff Chief Engineer
Base Vehicle Key InformationVehicle Year Mustang GT
248-505-7426 Email [email protected]
Performance Alt Fuels
Diesel Fill
Manufacturer
Vehicle Location(s) Metro Detroit Area
Ford
5 speed manual Manufacturer Tremec
n/a
Type All Season
BBK
Base Vehicle Fuel Types Usage and Fuel Accessibility
R&D, sales and marketing demonstrator
Manufacturer
Cobra
TKO 500
V8 4.6 Liter SOHC Manufacturer Vortech V2 supercharger 10-12 PSI boost
With Alt Fuel Range 90 miles
Manufacturer Ford
Daily Mile Run n/a Primary Fuel Range
Manufacturer Ford
Ford
Transmission
Engine
Transfer Case Ford
Fuel Types
n/a
Rear Axle 3.73 Posi Traction Ford
Methanol
Methanol Fill
Replica Chrome
Fuel TypesFuel Categories
Manufacturer
Manufacturer
Propane
Fuel Categories
Drivetrain
LNG
LNG Fill
Fuel Categories
CNG
CNG Fill
2003 Ford Mustang GT Program Application Sheet – page (2 of 4)
Dedicated Other
Mixed Other
Dual Fuel Other
Bi-Fuel Yes Gasoline CNG Other
Tri-Fuel Other
Gas/E85 Yes Volume 18 gallon Pressure Temp Other
Diesel Volume Pressure Temp Other
LNG Volume Pressure Temp Other
CNG Yes Volume 7.8 DGE Pressure 3600 PSI Temp Other
Methanol Volume Pressure Temp Other
Propane Volume Pressure Temp Other
Yes 2nd Fuel Yes 3rd Fuel Other
Yes 2nd Fuel Yes 3rd Fuel Other
Yes 2nd Fuel Yes 3rd Fuel Other
Yes 2nd Fuel Yes 3rd Fuel Other
Yes 2nd Fuel Yes 3rd Fuel Other
Yes 2nd Fuel Yes 3rd Fuel Other
Torque
Idle
Maintain existing 515 HP in all fuel modes
Maintain existing 413 lbs of torque in all fuel modes
Reduction in emissions estimated at 25% in alternative fuel mode
Automatic seamless transition between all fuel modes
Normal Driving
Fuel Types
Primary Fuel
Primary Fuel
Inspection protocols routine definition
Comply with all FMVSS Safety Standards
Primary Fuel
Reduction of maintenance intervals and costs
Emissions
Vehicle Operational Conditions
100%
Fuel TypesFuel
Configuration
Aggressive Driving
Shut Down
Start Up
Primary Fuel
Primary Fuel
Primary Fuel
Proposed ApplicationFuel Types
Tank Type
Maintain standard 12 Miles per gallon in all fuel modesCustomer Desired Key Product Characteristics (KPC) of Alternative Fuel Application
Fuel Types
Horsepower
Reduction of fuel costs by applying alternative fuel appropriately
Return on Investment (ROI)
Total Fuel Costs
ROI approved by customer, variable interest levels based on opinion and vehicle usage
Drivability
Engine Calibration Models
Maintenance
Safety
Automatic seamless transition between all fuel modes
Inspection
Fuel Types
Type 3
Tank Type
Standard
Fuel On-Board Vehicle Storage
Tank Type
Tank Type
Tank Type
Tank Type
Miles per Gallon
2003 Ford Mustang GT Program Application Sheet – page (3 of 4)
Yes Yes No Other
Yes Yes No Other
Yes Yes No Other
Yes Yes No Other
Yes Yes No Other
Yes Yes Yes Other
Yes Yes Yes Other
Yes Yes Yes Other
Yes Yes Yes Other
Yes Yes No Other
Yes Yes Yes Other
Yes Yes Yes Other
Yes Yes Yes Other
Yes Yes Yes Spec
Yes Yes Yes Spec
Yes Yes Yes Spec
Yes Yes Yes Spec
Yes Yes Yes Spec
Yes Yes Yes Spec
Yes Yes Yes Spec
Yes Yes Yes Spec
Yes Yes Yes Spec
Yes Yes Yes Spec
Yes Yes Yes Spec
3006 No 100 lbs Spec
n/a Spec
183.2" Yes Spec
73.1" Yes Spec
53.1" Yes Spec
101.3" Yes Spec
4" Yes Spec
8° Yes Spec
8° Yes Spec
8° Yes Spec
12 Yes Spec
465 Yes Spec
Car Yes Spec
10.9 cu ft No 10.9 cu ft Spec
EPA Classification Maintain Current Maximum Changed Expect 25% reduction in dual fuel mode
Maximum Changed
Range
Maximum Changed
Fuel Sensors MAP
Crash Worthiness
Post Crash Design Intent
Other Govt Regulations
Design Intent
Manual
Engine Compartment
Crash Tested
Design Intent
Leak Testing Protocol
FMVSS 101
FMVSS 101Fuel Type
CertificationLeak Testing
Altitude Range
Crash Tested
Driver Controls Fuel Control Shutdown System
Driver Information
Ram Air Powered
Crash Tested
Maintain Current Maximum Changed
Brake over Angle Maintain Current
Maintain Current Tested
Fuel Tank(s) Shutoff Leak Testing Certification
Fuel Tank(s) Shutoff
Engine Cooling Maintain Current
Fuel Lines Leak Testing
Fuel System Integrity
Safety
Crash Avoidance Design Intent Crash Tested
Tank Compartment Venting
Vehicle Operation
Ambient Temperature Range Maintain Current Tested
Upgrade
Engine Exhaust Maintain Current Upgrade
Chassis Maintain Current Upgrade
Suspension Maintain Current Upgrade
Structure Maintain Current Upgrade
Acceleration Maintain Current Upgrade
Vehicle Dimensions
Gross Vehicle Weight Maintain Current Maximum Changed
Brakes Maintain Current Upgrade
Transmission Maintain Current Upgrade
Overall Length Maintain Current Maximum Changed
Electrical Maintain Current Upgrade
Maximum Towing Capacity
Maximum Changed
Overall Width Maintain Current Maximum Changed
Overall Height Maintain Current Maximum Changed
Departure Angle Maintain Current
Miles per Gallon Maintain Current Maximum Changed
Wheelbase Maintain Current Maximum Changed
Ground Clearance Maintain Current
Maintain Current
Design Intent
FMVSS 304
Fuel Level
Automatic
LNG Sniff
FMVSS 301
Crash Tested
Certification
Ambient to 700° F
Dynamic Testing Protocol
Dynamic Testing Protocol
Stored in truck box
FMVSS 304
FMVSS 304
Dynamic Testing Protocol
Dynamic Testing Protocol
-20° F to 160° F
Sea Level to 10,000 feet
193°F to 205°F
Dynamic Testing Protocol
Trunk Maximum ChangedMaintain Current
Maximum Changed
Approach Angle Maintain Current Maximum Changed
Dynamic Testing Protocol
Dynamic Testing Protocol
CNG tanks in trunk
2003 Ford Mustang GT Program Application Sheet – page (4 of 4)
Yes Yes No Spec
Yes Yes Yes Spec
No No No Spec
No No No Spec
Yes Yes Yes Spec
Yes Yes Yes Spec
No No No Spec
No No No Spec
Yes Yes Yes Spec
Yes Yes Yes Spec
No No No Spec
No No No Spec
Yes Yes Yes Spec
Yes Yes Yes Spec
No No No Spec
No No No Spec
Yes Yes Yes Spec
Yes Yes Yes Spec
No No No Spec
No No No Spec
Yes Yes Yes Spec
Yes Yes Yes Spec
No No No Spec
No No No Spec
Yes Yes Yes Spec
Validation Testing
Instrument Tested
Drive Evaluation Dual Fuel Driver Evaluation Instrument Tested
Drive Evaluation Dedicated
Dynamic Dual Fuel Drive Evaluation
Drive Evaluation Bi-Fuel Driver Evaluation
Dyno Tested
Instrument Tested
Drive Evaluation Dyno Tested
FMVSS Compliance
Driver Evaluation
Drive Evaluation Dyno Tested
Torque Bi-Fuel Drive Evaluation Dyno Tested
Drive Evaluation
Torque Dual Fuel
Drive Evaluation Dyno Tested
Horsepower Bi-Fuel Drive Evaluation
Horsepower Dedicated
Driver Evaluation Instrument Tested
Dynamic Dedicated
Dynamic Mixed
Drive Evaluation Instrument Tested
Drive Evaluation Instrument Tested
Instrument Tested
Instrument Tested
Drive Evaluation Mixed
Torque Mixed Drive Evaluation Dyno Tested
MPG Mixed Course Tested
Torque Dedicated Drive Evaluation Dyno Tested
Emissions Dual Fuel Sniff Tested Dyno Tested
Emissions Bi-Fuel
Horsepower Dual Fuel
Dyno Tested
Dyno Tested
MPG Bi-Fuel
Dyno Tested
Emissions Dedicated
Emissions Mixed
Dyno Tested
Course Tested
Course Tested
Dyno Tested
Dyno Tested
Dynamic Bi-Fuel Drive Evaluation
Sniff Tested
Sniff Tested
Horsepower Mixed
Sniff Tested
MPG Dual Fuel Course Tested
MPG Dedicated 12 Miles per Gallon
Crash Tested
Dyno Tested
Design Intent
Dyno Tested
413 foot pounds
Dynamic Testing Protocol
12 Miles per Gallon
470 Horsepower at rear wheels
470 Horsepower at rear wheels
Dynamic Testing Protocol
Dynamic Testing Protocol
Expect 25% to 35% reduction in dual fuel mode
Dynamic Testing Protocol
413 foot pounds
2003 Ford Mustang GT Program Key Product Characteristics (KPCs)
Number1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
T1
T2
T3
T4
T5
T6
T7
A
B
C
D
E
F
G
H
Engineering Specification12 Miles Per Gallon in all fuel modes
515 HP in all fuel modesNo loss of horsepower
Quality documentation package
Globally accepted documentation
Project Management Institute (PMI)
CNG fuel tank and plumbing regulations
25% reduction in dual fuel modes
Engine Calibration Model characteristics
Engine Calibration Model characteristics
Globally accepted documentation
Safe vehicle operation Driver controls and information Fuel mode, fuel amount, manual and automatic switching
Test and validation documentation EPA 75 testing routine for MPG and emissions
Society of Manufacturing Engineers (SME)
Comply with product engineering specifications
Globally accepted documentation ISO TS 16949
ISO TS 16949
Industry Standards
Legal vehicle compliance
Legal vehicle compliance
Comply with mandated safety standards
Globally accepted engineering specs
Comply with mandated MPG and emissions standards
Globally accepted engineering specs
Technical documentation package
Program management system
Safety inspection and certification
Comply with FMVSS mandates
Test and validation documentation
Comply with manufacturing specifications
Globally accepted documentation
Dynamic drive testing
Maintain Gross Vehicle Weight class Minimal weight added
Maintain current vehicle performance
Maintain current vehicle performance Dyno testing for horsepower, torque and power curve
Drive evaluation testing
Less than 12 month ROI
Reduction of total fuel costs
Maintain towing capacity
Customer Expectation
Seamless change does not effect drivability
Automatic change between all fuel modes
Reduction in emissions
Seamless change does not effect drivability
Maintain chassis, suspension, structure, acceleration, braking
413 pounds of torque in all fuel modesNo loss of torque
Maintain ambient temp, altitude, cooling and exhaust ranges
Return on Investment (ROI) customer acceptance
No loss in functionality
No loss in drivability
Use vehicle in normal conditions
Stay in EPA current class
Safe vehicle operation Inspection protocols
Use vehicle in normal conditions
Category Customer Need
Reasonable timeframe of return
Maintain current vehicle performance
Return on Investment (ROI)
Safe vehicle operation
Maintain torque
Mechanical change between all fuel modes
Safe vehicle operation Safe use of CNG use and storage Type 3 CNG tanks, venting, PRV, auto shut off, plumb @ 3600 PSI
FMVSS and CARB
Society of Engineers (SAE)
Total vehicle safety Comply with FMVSS mandates for vehicle class
FMVSS
Test and validation documentation
Test and validation documentation
No loss in horsepower and torque 515 HP and 269 pounds of torque
Maintain vehicle overall dimensions No change in vehicle dimensions Maintain length, width, height, wheelbase, ground clearance
Sufficient cargo space Loss of trunk space Loss of 10.9 cu ft in trunk
Key Product Characteristics
Increase mileage range Less fuel fill stops Maintain gasoline fuel tank and add 7.8 DGE of CNG fuel
Performance
3, 6 and 12 month inspection protocols and certification
Safety
Bi-Fuel mode will not change MPGMaintain current miles per gallon
Maintain horsepower
Comply with FMVSS mandates Test and validation documentation
Maximum of 100 pounds added for CNG components
Physical test on fuel storage and delivery to engine
Reduction in maintenance Lower maintenance costs 20% reduction in maintenance costs
Comply with FMVSS mandates
CNG is lower cost than Premium Gasoline Premium Gasoline $2.82 per gallon, CNG $2.00 GGE
Formal Test Procedures
Reasonable ROI on conversion project Test and validation documentation Acceptable ROI for specific vehicle usage
Dimensions
Cost Savings
Test and validation documentation Design reviews and CAE simulation analysis on crash
Reduction of total fuel costs Reasonable Return on Investment (ROI)
2003 Ford Mustang GT Program Bill of Materials (BOM) page 1 of 2
Quantity Quantity Measure
Make or Purchase
Tooling Cost
Fabricate Labor Cost
Material Cost
Piece Cost
1 Item Purchase 1,100$ 2 Item CNG United1 Item CNG United1 Item CNG United1 Item CNG United1 Item CNG United2 Item CNG United2 Item CNG United2 Item CNG United8 Item CNG United1 Item CNG United1 Item CNG United1 Item CNG United1 Item CNG United1 Item CNG United
50 Item Purchase 5.00$ 1 Item 215.00$ 1 Item1 Item1 Item1 Item
1 Item Make 3,000$ 25.00$ 10.00$ 12.00$ 1 Item Make 1,000$ 25.00$ 10.00$ 6.00$ 2 Item Make 2,000$ 25.00$ 10.00$ 3.00$ 6 Item Purchase 2.00$
2 Item Make 3,000$ 25.00$ 20.00$ 20.00$ 6 Item Make 1,000$ 25.00$ 20.00$ 24.00$ 6 Item Make 500$ 5.00$ 5.00$ 6.00$ 6 Item Purchase 5.00$ 2 Item Purchase 8.00$
-$ -$
-$ -$
6.00$
-$
-$
-$
36.00$ Performance Alt Fuels
-$
Deluxe Gas Gauge EK-110
Energy Kinetics Kit
-$
Catalog-$
Pressure Sensor MAP (Manifold Absolute Pressure)CNG Port Injector Rail Assembly -$
1,100.00$
215.00$ 250.00$
-$ -$
-$
Low Pressure Fuel Filter
-$
CNG United
Wiring Harness - OEM ECM to CNG ECUWiring Harness - CNG ECU to Injector Rail
-$
-$
Sequential Port Injection 8 Cylinder Auto Gaz Kit
-$
Energy Kinetics KitEnergy Kinetics Kit
12.00$ Rear Compartment Venting
CNG Tank Mounting Assembly
30.00$
144.00$
12.00$
40.00$ C Channel Longitudinal RailCNG Fuel Tank Strap
16.00$
CNG Pressure Regulator AssemblyCNG Electronic Control Unit (ECU) Assembly
SupplierTotal Piece CostPart Name
6.00$ Performance Alt Fuels
Energy Kinetics KitEnergy Kinetics Kit
Performance Alt FuelsPerformance Alt Fuels
Catalog
Performance Alt FuelsPerformance Alt Fuels
Catalog
Catalog
Hose ProtectorVacuum Hose
Ram Air Intake LH/RHRam Air Tubing LH/RHRam Air BezelScrews - Ram Air Bezel
CNG Manometer (read CNG fuel amount)Blue High Performance CNG InjectorsHigh Pressure Fuel LineLow Pressure Fuel LineCoolant Hose
Hardware (hoses, brackets, screws, T's and clamps)
GaugePressure SensorElectronic Control BoardWiring Harness
CNG Fuel Tank IsolatorBolt, Nut, Washers - CNG Fuel TankCNG Fuel Tank Jack Screw Assembly
2003 Ford Mustang GT Program Bill of Materials (BOM) page 2 of 2
Quantity Quantity Measure
Make or Purchase
Tooling Cost
Fabricate Labor Cost
Material Cost
Piece Cost
1 Item Purchase 5.00$ 1 Item Purchase 8.00$
10 Feet Purchase 25.00$ 8 Item Purchase 0.25$ 8 Item Purchase 0.10$ 2 Item Purchase 3,000$ 25.00$ 20.00$ 5.00$ 1 Item Purchase 3,000$ 25.00$ 20.00$ 5.00$ 1 Item Purchase 1,000$ 25.00$ 20.00$ 8.00$ 1 Item Purchase 1,000$ 25.00$ 20.00$ 8.00$ 1 Item Purchase 5,000$ 25.00$ 20.00$ 12.00$
40 Item Purchase 5.00$ 10 Item Purchase 25.00$ 5 Item Purchase 5.00$ 5 Item Purchase 5.00$ 5 Item Purchase 5.00$
50 Item Purchase 20.00$ 3 Item Purchase 1,000$ 3 Item Purchase 45.00$ 2 Item Purchase 75.00$ 1 Item Purchase 135.00$ 1 Item Purchase 66.00$
1/4 Turn Shut Off Valve 1 Item Purchase 120.00$ 1 Item Purchase 40.00$ 1 Item Purchase 10.00$ 1 Item Purchase 55.00$ 3 Item Purchase 3.00$ 1 Item Purchase 2.00$
50 Item Purchase 5.00$ 10 Feet Purchase 1.00$ 40 Item Purchase 5.00$
Total 23,500$ Total Piece Price20 Vehicles 1,175$ Assembly Labor Cost Rate Hours40 Vehicles 587.50$ Total Cost 65.00$ 2060 Vehicles 391.67$ Total Price Profit 35%
1,300.00$ 9,182.80$
12,396.78$
250.00$ Catalog25.00$ Catalog
250.00$ 2.00$
200.00$
5.00$
8.00$
Injector Adaptors
Pressure Regulator - Mounting Bracket
High Pressure Fuel Line
12.00$
0.80$ 10.00$
Compression Ferule Fittings
Fuel Filler Nozzle
2.6 GGE CNG Fuel Tank Assembly Type 3 (American CNG)
Hardware (hoses, brackets, screws, T's and clamps
High Pressure Fuel Filter
MAP Sensor - Mounting BracketPressure Regulator - Coolant Adapter Pipe
SupplierTotal Piece CostPart Name
10.00$
2.00$
55.00$
5.00$
200.00$
40.00$
135.00$ 150.00$ 135.00$
7,882.80$
66.00$ 120.00$
250.00$ 10.00$
8.00$
3,000.00$
8.00$
Catalog
CatalogCatalogCatalog
Catalog
Performance Alt Fuels
Catalog
CatalogCatalogCatalog
Performance Alt FuelsPerformance Alt FuelsPerformance Alt Fuels
Catalog
Vacuum HoseHardware (hoses, brackets, screws, T's and clamps)
Catalog
CatalogCatalogCatalog
Catalog
Catalog
Catalog
Catalog
Catalog
Catalog
9.00$ CatalogPressure Relief Valve - Hose
High Pressure Fuel LineLow Pressure Fuel LineCoolant Hose
Pressure Relief Valve
Fuel Filler Check Valve
Pressure Regulator - Coolant Adapter Engine Block
Pressure Relief Valve - Bezel
Injector Rail - Mounting Bracket
Fuel Fill Pocket Housing
Hardware (elbows, T's and clamps)High Pressure Fuel LineHardware (hoses, brackets, screws, T's and clamps
Shut Off Valves
Gas Gauge - Pressure SensorGas Gauge - Wiring Harness
Rear Compartment High Pressure Fuel Filter Mounting Bracket
25.00$ Catalog25.00$ Catalog
1,000.00$ Catalog
2003 Ford Mustang GT Program Design FMEA (11) pages
Controls Prevention
Occu
rrenc
e
Criti
calit
y
Controls Detection Protocol De
tect
ion
Recommended Action
Name Date Actions Taken
Seve
rity
Occu
rrenc
e
Dete
ctio
n
RPN
8Pow er supply cannot take on added demands
Pow er supply specif ication
3 B 1, 2, 3 5 120
Correlate the application
analysis, concept & f inal design to the
vehicle build
Daryl Patrishkoff 11-Jul-13All review s
conducted and approved
8 3 2 48
8 Wiring shorting outWiring specif ication
and protection 3 B 1, 2, 3 5 120
Correlate the application
analysis, concept & f inal design to the
vehicle build
Daryl Patrishkoff 11-Jul-13All review s
conducted and approved
8 3 2 48
8Connectors not
conducting electricity
Connector specif ication 3 B 1, 2, 3 5 120
Correlate the application
analysis, concept & f inal design to the
vehicle build
Daryl Patrishkoff 11-Jul-13All review s
conducted and approved
8 3 2 48
10Fuel Line not
containing CNGFuel line
specif ication 3 B 1, 2, 3 5 150
Correlate the application
analysis, concept & f inal design to the
vehicle build
Todd Connolly 11-Jul-13All review s
conducted and approved
10 3 2 60
10Connectors not containing CNG
Connector specif ication 3 B 1, 2, 3 5 150
Correlate the application
analysis, concept & f inal design to the
vehicle build
Todd Connolly 11-Jul-13All review s
conducted and approved
10 3 2 60
Softw are FailureShut dow n of
vehicle 8Softw are code not
applicable to the application
Application Analysis 3 B 1, 2, 3 5 120
Correlate the application
analysis, concept & f inal design to the
vehicle build
Daryl Patrishkoff 11-Jul-13All review s
conducted and approved
8 3 2 48
Components BreakShut dow n of CNG
fuel system 6
Component mounting scheme not structurally
suff icient
Design review for structural and
vibration forces3 B 1, 2, 3 5 90
Correlate the application
analysis, concept & f inal design to the
vehicle build
Todd Connolly 11-Jul-13All review s
conducted and approved
6 3 2 36
6High Pressure input
ineffective for application
Pressure Regulator specif ication 3 B 1, 2, 3 5 90
Correlate the application
analysis, concept & f inal design to the
vehicle build
Todd Connolly 11-Jul-13All review s
conducted and approved
6 3 2 36
6Low Pressure
output ineffective for application
Pressure Regulator specif ication 3 B 1, 2, 3 5 90
Correlate the application
analysis, concept & f inal design to the
vehicle build
Todd Connolly 11-Jul-13All review s
conducted and approved
6 3 2 36
6Coolant input and output ineffective
for application
Pressure Regulator specif ication 3 B 1, 2, 3 5 90
Correlate the application
analysis, concept & f inal design to the
vehicle build
Todd Connolly 11-Jul-13All review s
conducted and approved
6 3 2 36
6Vacuum output ineffective for
application
Pressure Regulator specif ication 3 B 1, 2, 3 5 90
Correlate the application
analysis, concept & f inal design to the
vehicle build
Todd Connolly 11-Jul-13All review s
conducted and approved
6 3 2 36
Key components needed to convert the vehicle to run
on CNG
1.0 CNG Conversion Kit
Seve
rity
RPN
Action ResultsAssignments
Item / Function Requirement Potential Failure Mode
Potential Effect(s) of Failure
Electrical FailureShut dow n of
vehicle
Potential Cause(s)of Failure
Current Design
Safe
ty R
elate
d
CNG Leak Fire in the vehicle
Pressure RegulatorShut dow n of CNG
fuel system
2003 Ford Mustang GT Program Design Controls
1 2 3 4 5 6 7 8Detection Number Test Description
ElementsControls Detection Name Frequency Key Product Characteristics
1 Application Analysis Review and Approval
Once, at the end of Application Analysis
Vehicle PerformanceDaryl, Todd review the application sheet and comment on the various
challenges to the project. Propose any required changes and get 100% consensus of the group. Approve the application sheet.
Vehicle DimensionsFormal Test ProceduresIndustry Standards
2 Concept Design Review and Approval
Once, at the end of Concept Design
Vehicle PerformanceDaryl, Todd review the concept design and comment on the various challenges to the project. Propose any required changes and get 100% consensus of the
group. Approve the concept design.
Vehicle DimensionsFormal Test ProceduresIndustry Standards
3 Final Design Review and Approval
Once, at the end of Final Design
Vehicle PerformanceDaryl, Todd review the final design and comment on the various challenges to the project. Propose any required changes and get 100% consensus of the
group. Approve the final design.
Vehicle DimensionsFormal Test ProceduresIndustry Standards
4 Build Review and Approval
Once, at the end of Vehicle Build
Vehicle PerformanceDaryl, Todd review the vehicle build and comment on the various challenges to the project. Propose any required changes and get 100% consensus of the
group. Approve the vehicle build.
Vehicle DimensionsFormal Test ProceduresIndustry StandardsVehicle Performance
Daryl, Todd review the final vehicle review and comment on the various challenges to the project. Propose any required changes and get 100%
consensus of the group. Approve the final vehicle review.
Vehicle Dimensions5 Final Vehicle Review
and Approval
Once, at the end of Vehicle Test and
Validation Formal Test ProceduresIndustry Standards
2003 Ford Mustang GT Program Test and Validation Plan
1 T3 Dyno Specs
2 T2 Measure Specs
3 T7 Review Accepted
4 T4 Dyno Specs
5 T4 Dyno Specs
6 T3 Dyno Specs
7 T5 Road Specs
8 T6 Road Evaluation
9 T1 Review Specs
10 T1 Review Specs
11 T6 Road Evaluation
12 T2 Measure Specs
13 T3 Dyno Specs
14 T5 Road Specs
15 T2 Measure Specs
16 T4 Dyno Specs
17 T1 Review Specs
18 T1 Review Specs
19 T7 Review Accepted
20 T7 Review Accepted
21 T7 Review Accepted
T1 Review Specs
T2 Measure Specs
T3 Dyno Specs
T4 Dyno Specs
T5 Road Specs
T6 Road Evaluation
T7 Review Accepted
A T3 Dyno Specs
B T3 Dyno Specs
C T1 Review Specs
D T1 Review Specs
E T1 Review Specs
F T1 Review Specs
G T1 Review Specs
H T1 Review Specs
Drive evaluation testing
Formal Test Procedures
Safety
Test Method
Primary Fuel
KPC Number
Displaced Percent
Validation Protocol
Alternative Fuel
25% reduction in dual fuel modes
CNG
413 pounds of torque in all fuel modes
515 HP and 269 pounds of torque
Maintain length, w idth, height, w heelbase, ground clearance
Test NumberMeasurable Customer Expectation
12 Miles Per Gallon in all fuel modes
Maintain gasoline fuel tank and add 7.8 DGE of CNG fuel
Return on Investment (ROI) customer acceptance
515 HP in all fuel modes
Adjust investments to meet criteria
Premium Gasoline
CNG Bi-Fuel 100%
Design review s and CAE simulation analysis on crash
Physical test on fuel storage and delivery to engine
EPA 75 testing routine for MPG and emissions
Dyno testing for horsepow er, torque and pow er curve
Dynamic drive testing
CNG fuel tank and plumbing regulations
Program management system
Premium Gasoline CNG Bi-Fuel 50%
ISO TS 16949
ISO TS 16949
Project Management Institute (PMI)
Technical documentation package
Bi-Fuel 100%
Premium Gasoline
CNG Bi-Fuel 100%
Cost Savings
Maximum of 100 pounds added for CNG components
Comply w ith FMVSS mandates for vehicle class
Engine Calibration Model characteristics
Engine Calibration Model characteristics
Performance
Type 3 CNG tanks, venting, PRV, auto shut off, plumb @ 3600 PSI
CNG Bi-FuelPremium Gasoline
Adjust investments to meet criteria
Develop engine calibration model
Fuel mode, fuel amount, manual and automatic sw itching
3, 6 and 12 month inspection protocols and certif ication
Maintain ambient temp, altitude, cooling and exhaust ranges
Maintain chassis, suspension, structure, acceleration, braking
Loss of 10.9 cu ft in trunk
Less than 12 month ROI
Dimensions
Premium Gasoline CNG
Premium Gasoline
Premium Gasoline $2.82 per gallon, CNG $2.00 GGE
FMVSS and CARB
Society of Engineers (SAE)
Society of Manufacturing Engineers (SME)
Acceptable ROI for specif ic vehicle usage
Industry StandardsFMVSS
20% reduction in maintenance costs
Adjust investments to meet criteria
Technical documentation package
Develop engine calibration model
Develop engine calibration model
Design and build changes
Design and build changes
Develop engine calibration model
Design and build changes
Design and build changes
Comments
Develop engine calibration model
Design and build changes
Design and build changes
Fuel Configure
Develop engine calibration model
Develop engine calibration model
100%
Bi-Fuel 100%
Quality documentation package
Technical documentation package
Quality documentation package
Compliance to FMVSS standards
Design and build changes
Design and build changes
EPA 75 testing protocol
EPA 75 testing protocol
Road testing and data gathering
Technical documentation package
Road testing and evaluation
Design and build changes
Develop engine calibration model
Design and build changes
Adjust investments to meet criteria
Develop engine calibration model
Adjust investments to meet criteria
2003 Ford Mustang GT Program Design Validation Plan and Report (DVP&R)
Start Complete Quantity LevelT1 Program P Manager Feasibility Production Weekly Program 19-Aug-14 Pass
T2 Prototype Engineer Prototype Prototype 6 Prototype 19-Aug-14 Pass
T3 Prototype Engineer Prototype Prototype 1 Prototype 19-Aug-14 Pass
T4 Prototype Engineer Prototype Prototype 1 Prototype 19-Aug-14 Pass
T5 Prototype Engineer Prototype Prototype 1 Prototype 19-Aug-14 Pass
T6 Prototype Engineer Prototype Prototype 6 Prototype 19-Aug-14 Pass
T7 Program P Manager Feasibility Production Phase Program 19-Aug-14 Pass
DynoHP, Torque, Pow er Curve Specif ication Compliance
Road CourseDynamic Drive Specif ication Compliance
Road CourseEvaluation Drive Specif ication Compliance
Financial Return MapReturn on Investment (ROI) Customer Acceptance
Responsible Timing Sample Date CompletedTest ID
Design Stage
Specif ication Compliance
Specif ication ComplianceEPA 75 Protocol
Open Issues Log
Fuel Storage and Delivery
MPG and Emissions
Physical Measurements
Test Report
Acceptance Criteria
Specif ication Compliance
Test Plan
ResultsTest MethodTest DescriptionPass Fail
Weekly Design Review s
2003 Ford Mustang GT Program Process Failure Modes Fishbone Analysis
Break Press Machine
System Failures
Design For Manufacture
Manufacture Parts CNG Fuel Tank Box Assembly
Engine Modifications
Tooling
System Failures
Potential Process Failure Modes
Exterior Body Modifications
Interior Body Modifications
Body Wiring Modifications
Machining Tools
System Failures
Purchasing
Quality Assurance
Quality Control
Methodologies
Design For Assembly
Plumbing
Isolation
Sealing
Fasteners
Brackets
Connectors
Components
Process Failures
Torque
Assembly Tools
Purchasing
Quality Assurance
Quality Control
Methodologies
Design For Assembly
Plumbing
Isolation
Sealing
Fasteners
Brackets
Connectors
Components
Process Failures
Torque
Purchasing
Quality Assurance
Quality Control
Methodologies
Isolation
Sealing
Fasteners
Brackets
Connectors
Components
Process Failures
Torque
Machining Tools
System Failures
Purchasing
Quality Assurance
Quality Control
Methodologies
Design For Assembly
Plumbing
Isolation
Sealing
Fasteners
Brackets
Connectors
Components
Process Failures
Torque
Assembly ToolsMachining Tools
System Failures
Purchasing
Quality Assurance
Quality Control
Methodologies
Design For Assembly
Plumbing
Isolation
Sealing
Fasteners
Brackets
Connectors
Components
Process Failures
Torque
Assembly Tools
Machining ToolsAssembly Tools
Machining Tools
System Failures
Purchasing
Quality Assurance
Quality Control
Methodologies
Design For Assembly
Wiring
Isolation
Sealing
Fasteners
Brackets
Connectors
Components
Process Failures
Torque
Assembly Tools
2003 Ford Mustang GT Program Manufacturing Process FMEA (2) pages
X System POTENTIALSubsystem FAILURE MODE AND EFFECTS ANALYSISComponents (Process FMEA) PFMEA Number 1
Description Mounting Brackets Prepared By PatrishkoffModel Year(s) 2003 Process Responsibility Performance Alt Fuels PFMEA Date (Orig.) 9/27/2012
Vehicle Ford Mustang GT Key Date A.S.A.P. Revision Date Core Team M. CHESTER(MFG ENG), D. OWENS(ASM ENG), S. BELLOLI(QLTY ENG), J. PRICE(TIER SUPPLIER INTERG), A.PRATT(PROD DES ENG)
Action Results
Line
No.
Item / Function Potential Failure Mode
Potential Effect(s) of Failure
SEV
Potential Cause(s)
/ Mechanism(s) of Failure
OCC
Current Design Controls
DET
RPN
Recommended Action (s)
Responsibility & Target Completion
DateActions Taken
New
SEV
New
OCC
New
DET
New
RPN
SHRINK RATE EXCESS SHRINKAGE
7 INCORRECT TEMPERATURE
6 CHECKING FICTURES
1 42 ADD TEMPERATURE GAGES
0
VOLUME THIN WALLS 7 INSUFFICIENT MATERIAL
5 CHECKING FICTURES
1 35 CORRECT GATE PRESSURE
0
CYCLE TIME BAD CLASS A SURFACE
4 MACHINE CLEAN OUT
3 MAINTENANCE SCHEDULE
5 60 NONE 0
DEFECTS PITTING 4 DIRTY MOLDS 6 VISUAL CHECK EACH HOUR
5 120 INSTANT SPRAY CLEANER
0
PLASTIC INCORRECT MATERIAL
8 ERROR IN MATERIAL ORDER
2 VERIFY ORDERS 5 80 NONE 0
COLOR INCORRECT SHADE
1 POOR APPEARANCE
5 COLOR MATCH 6 30 NONE 0
CHEMISTRY ROUGH 2 MATERIAL NOT TO SPEC
2 CHECK MATERIAL DATA SHEET
5 20 DOUBLE CHECK MATERIAL DATA SHEET
0
TEMPERATURE SCRAP 8 MACHINE SET UP 4 PERIODIC CHECK OF TEMPERATURE BEFORE SET UP
1 32 CHECK TEMPERATURE BEFFORE EACH CYCLE
0
INJECTION MOLD CLOGGING SPRAY HEADS
4 DIRT OR EXCESS FLASH
8 VISUAL CHECK EACH HOUR
4 128 CLEAN AND SPRAY HEADS
0
PRESS INOPERATIVE 8 INADEQUATE VENTING
4 CLEAN BETWEEN EACH RECYCLE
3 96 PREVENTATIVE MAINTENANCE
0
VACUUM MALFUNCTION
INTERMITTENT OPERATION
3 INSUFFICIENT MATERIAL
4 VISUAL INSPECTION
5 60 INSTALL FLOW SENSER
0
CHECKING FIXTURE DEFORMED
PART DOES NOT FIT
8 WORN LOCATER 3 FINAL ASSEMBLY
3 72 TEST FIXTURES PERIODICALLY
0
ERGONOMICS OPERATOR MISHANDLES PART
7 DEFECTIVE PARTS
5 POSTED OPERATOR INSTRUCTION
3 105 ADDITIONAL TRAINING
0
LACK OF TEAM WORK
ENDANGERS OPERATOR
1 INJURED EMPLOYEE
2 POSTED OPERATOR INSTRUCTION
2 4 ADDITIONAL TRAINING
0
INSUFFICIENT TRAINING
ENDANGERS OPERATOR
1 INJURED EMPLOYEE
2 POSTED OPERTOR INSTRUCTION
1 2 EMERGENCY SHUT OFF SENSOR
0
MISCOMMUNICATON DAMAGES EQUIPMENT
8 INCOMPLETE PART EJECTION
3 POSTED OPERATOR INSTRUCTION
2 48 AUTOMATED PART TRANSFER
0
EQUIPMENT3
PEOPLE4
MEASUREMENT1
2 MATERIAL
2003 Ford Mustang GT Program Manufacturing Process Quality Control Plan
CONTROL PLANControl Plan Number Key Contact/Phone [email protected] Date (Orig.) Date (Rev.)07075-00ASSY Jim Bowdler 734-261-6700 5/2/2007 5/2/2007Part Number/Latest Change Level Core Team (734) 261-6700 Customer Engineering Approval/Date (If Req'd.)
C. Murawski, K. Lerg, J. Bowdler, S. Bain, C. Pensom, M. Anderson,R.Waggoner N/APart Name/Description Supplier/Plant Approval/Date Customer Quality Approval/Date (If Req'd.)Panel Hood Assembly N/ASupplier/Plant Supplier Code Other Approval/Date (If Req'd.) Other Approval/Date (If Req'd.)Quality Metalcraft Inc. 32223 N/A N/A
MACHINE,PART/ PROCESS NAME/ DEVICE, SPECIAL
PROCESS OPERATION JIG,TOOLS, CHAR. PRODUCT/PROCESS ERROR EVALUATION/ SAMPLE CORRECTIVE REACTIONNUMBER DESCRIPTION FOR MFG. NO. PRODUCT PROCESS CLASS SPECIFICATION/ PROOFING MEASUREMENT SIZE FREQ. CONTROL ACTION PLAN
TOLERANCE TECHNIQUE METHODSP1501-00FP-03
Receiving inspection None 1 Corrosion Inhibitor
Receiving Inspection
SP1501-00FP-03Corrosion InhibitorChemical 707
None Visual Examination of
the Part/Supplier PPAP/
Per Sampling
Plan
Per Run Receiving inspection form-QC041
N/A Per WI 8.2.4 Inprocess Product Monitoring
SP1501-00FP-05
Move to Next Operation Hi-lo 2 SP1501-00FP-03
Move Move through Plant without damaging Material
None Visual examination of
parts throughout move
As required As required
Per WI 7.5.5.1A Storage and Preservation of Product
N/A Per WI 7.5.5.1A Storage and Preservation of Product
CSP2179-00FP-03
Receiving inspection None 3 Reinf. Assy Hood Inner Panel
Receiving Inspection
CSP2179-00FP-03Reinf. Assy Hood Inner Panel Hinge
None Visual Examination of
the Part/Supplier PPAP/
Per Sampling
Plan
Per Run Receiving inspection form-QC041
N/A Per WI 8.2.4 Inprocess Product Monitoring
CSP2179-00FP-05
Move to Next Operation Hi-lo 4 CSP2179-00FP-03
Move Move through Plant without damaging Material
None Visual examination of
parts throughout move
As required As required
Per WI 7.5.5.1A Storage and Preservation of Product
N/A Per WI 7.5.5.1A Storage and Preservation of Product
SP1499 FP-03
Receiving inspection None 5 Hem Adhesive
Receiving Inspection
Hem AdhesiveVesri LOK 262/254
None Visual Examination of
the Part/Supplier PPAP/Check the date
on the Vesri LOK
Per Sampling
Plan
Per Run Receiving inspection form-QC041
N/A Per WI 8.2.4 Inprocess Product Monitoring
SP1499 FP-05
Move to Next Operation Hi-lo 6 SP1499 FP-03
Move Move through Plant without damaging Material
None Visual examination of
parts throughout move
As required As required
Per WI 7.5.5.1A Storage and Preservation of Product
N/A Per WI 7.5.5.1A Storage and Preservation of Product
CHARACTERISTICS METHODS
AA82211065
Prototype Pre-Launch Production
2003 Ford Mustang GT Program Assembly Process FMEA (8) pages
System POTENTIALSubsystem FAILURE MODE AND EFFECTS ANALYSIS
X Components (Assembly Process FMEA) PFMEA NumberPower Steering Reservoir Bottle & Wiring Harness Page
Model Year(s) Process Responsibility Prepared ByVehicle Key Date PFMEA Date (Orig.)
Core Team
Action Results
Controls Prevention
Occu
rrenc
e
Controls Detection
Dete
ctio
n
RPN
Actions Taken
Seve
rity
Occu
rrenc
e
Dete
ctio
n
RPN
Place material in the wrong storage area
Correct material will not be available
2 Operator store material in the wrong location
Labels above storage area 5 Bin labels 7 70 0
Damage to material Part shortage or defective part
7 Operator damaged part Parts in bins, operators trained in moving parts
3 Visual 9 189 0
Mix material with other material
Part shortage or defective part
7 Operator store material in the wrong location
Training 5 Visual 8 280 0
Record material wrong as incoming
Part shortage or defective part
7 Input wrong into system Training 2 3 point system check, visual
6 84 0
Insure area is clear of all non SVT parts
Non SVT parts are left in the area
Incorrect build 6 Operator did not follow process
Training 6 Fixture check 1 36 0
Batch build 100 Hood Latch Asm once per week
Not enough material to make batch build
Not making production volumes
6 Not enough material Incoming material check 3 Daily releases, inventory management
4 72 0
Batch volume does not meet the volume need for the SVT production run
Not making production volumes
6 Not enough material Planning volumes 2 Daily releases, inventory management
4 48 0
Did not build the entire 100 batch build
Not making production volumes
6 Operator stopped short Cycle count 2 Production plan 8 96 0
Move SVT Hood Latch to work cell
Move wroing material Incorrect build 6 Operator did not follow process
Training 6 Fixture check 1 36 0
Mix material with other material
Not making production volumes
6 Not enough material Incoming material check 3 Fixture check 1 18 0
Put material in the wrong location
Not making production volumes
6 Operator did not follow process
Training 5 Visual 8 240 0
Damage to material Not making production volumes
6 Operator damaged part Parts in bins, operators trained in moving parts
3 Visual 8 144 0
Reconfigure fixture to the SVT build location
Fixture is not reconfigured correctly
Incorrect build 6 Operator did not follow process
Supervisor check 3 Fixture check 1 18 0
Fixture is damaged Incorrect build 6 Preventitive maintanance Training 5 Visual 8 240 0
Pick SVT Hood Latch Picked the wrong Hood Latch
Not making production volumes
6 Operator did not follow process
Training 5 Fixture check 1 30 0
Place SVT Hood Latch to fixture
Hood Latch is placed in the wrong position on the fixture
Incorrect build 6 Operator did not follow process
Training 5 Fixture check 1 30 0
Place in SVT Hood Latch Asm bin
Hood Latch Asm is placed in the wrong bin
Incorrect build 6 Operator did not follow process
Training 5 Fixture check 1 30 0
Damage to material Part shortage or defective part
7 Operator damaged part Training 3 Visual 8 168 0
Move SVT Hood Latch Asm bins to storage area
SVT bins not stored in the correct location
Incorrect build 6 Operator did not follow process
Training 6 Visual 8 288 0
Clear all SVT material from fixture, table, line and area
SVT parts are left in the area
Incorrect build 6 Operator did not follow process
Training 6 Visual 8 288 0
Reconfigure fixture to non SVT location
Fixture not configured correctly
Incorrect build 6 Operator did not follow process
Supervisor check 3 Fixture check 1 18 0
Bob Holloway, Kinda Bargy, Terrell Gibbs, Ahmed Hassen, Ahmed Elraee, Karl Szulczewsik
Karl SzulczewskiBob Holloway15 June preproduction build
Hood Latch, Bolster Asm, Hood Bumper LH/RH,
2010Ford F-150 Pick Up Truck SVT specific build requierments 5/4/2009
Responsibility & Target Completion
DateSeve
rity
Clas
sific
atio
n
Potential Cause(s)of FailurePotential Failure Mode Potential Effect(s)
of Failure
Current Design
Recommended ActionProcess Step / Function Requirement
Hood Latch Assembly (Station 80) batch
volume of 100 assemblies for the SVT specific requirements
Incoming Material Material comes into the plant: to PPAP quality standards, with correct labels and in the correct bins
2003 Ford Mustang GT Program Assembly Process Quality Control Plan
Control Plan Number Key Contact/Phone Date (Orig.) Date (Rev.)
Less Finish Part # Core Team Customer Engineering Approval/Date (If Req'd.)
Part Name/Description Customer Quality Approval/Date (If Req'd.)
Supplier/Plant Supplier Code Other Approval/Date (If Req'd.) Other Approval/Date (If Req'd.)
MACHINE,PART/ PROCESS NAME/ DEVICE, SPECIAL
PROCESS OPERATION JIG,TOOLS, CHAR. PRODUCT/PROCESS EVALUATION/ SAMPLE REACTIONNUMBER DESCRIPTION FOR MFG. NO. PRODUCT PROCESS CLASS SPECIFICATION/ MEASUREMENT CONTROL PLAN
TOLERANCE TECHNIQUE METHOD
1Move SVT Bolster Asm racks to work cell
Forklift Product integrity Handling procedure PCOP-07 Set up As required XXX sign over
storage areaPiston Procedure
QCOP-10
2Move SVT Grille Bumper LH & RH to work cell
Forklift Product integrity Handling procedure PCOP-07 Set up As required XXX sign over
storage areaPiston Procedure
QCOP-10
3 Read pick light on what to build Pick light Product integrity Operator visually
reads light SVT build Issues found at work cell All All Visual Follow work
instructions
4Pick correct SVT Bolster Asm Product integrity
Operator selects correct bolster
off rackSVT Bolster Asm Issues found at
work cell All All Visual Follow work instructions
5 Install Bolster Asm
6Pick and install Secondary Hood Latch Cable
7 Pick and install (4) Push Nuts
8Pick and install correct SVT Grille Bumper RH
Product integrityOperator selects
correct Grille Bumper
SVT Grille Bumper Issues found at work cell All All Light curtain in
binFollow work instructions
9Pick and install correct SVT Grille Bumper LH
Product integrityOperator selects
correct Grille Bumper
SVT Grille Bumper Issues found at work cell All All Light curtain in
binFollow work instructions
10 Pick (4) Grille Bumper Screws
11 Drive Screws with torque gun
12 Push release from cell button
Bolster Assembly to Assembly Line - Station 115
CHARACTERISTICS METHODS
SIZE FREQ.
Latest Chg LevelHolloway, Bargy, Gibbs, Hassen, Elraee, Szulczewski
CONTROL PLAN
Bob Holloway 6-May-09
Hood Latch, Bolster, Hood Bumper LH/RH, PS Reservoir Bottle &
Piston Automotive Group LLC DSBOB
Supplier/Plant Approval/Date
Prototype Pre-Launch ProductionPrototype Pre-Launch ProductionPrototype Pre-Launch Production
www.performaltfuels.com www.cpspoly.com www.dptechservices.com
Daryl Patrishkoff, PMP
Owner and Chief Engineer 248-505-7426 [email protected]