Mustang Rear Stabilizer Bar Bushing Squawk

6-PANEL6-PANEL

6 Panel Team Leader Corporate 6-PANEL Template version 3.3.ppt

Originated: March 12, 2002 Updated: April 29, 2009

STANDARD REPORTING METHODSTANDARD REPORTING METHOD FOR PROBLEM SOLVING FOR PROBLEM SOLVING

© 2002-2005, Ford Motor Company Page 1 of 19

Mustang Rear Stabilizer Bar Bushing Squawk

Project Leader: Rod Watts

Project Champion: Jeff Check

Commodity Manager: Brent White

Process Owner: Mike Wroblewski

Organization: Chassis / Vehicle Engineering

Project Location: Flat Rock Assembly Plant

Project Completion Date: Feb 28th, 2013

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Originated: March 12, 2002, Updated: April 29, 2009Corporate 6-PANEL Template version 3.3.ppt

© 2002-2005, Ford Motor Company

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PROJECT

CLASSIFICATION:

Quality Issue

Rear Stabilizer Bar Bushing Squawk

2013 MY

Max of R1000 = 0.56

DEFINE VOICE OF THE CUSTOMERDEFINE VOICE OF THE CUSTOMER

DDDD MMMM AAAA IIII CCCC RRRR

VOICE OF THE CUSTOMER: From initial concern notice verbatim “CUSTOMER STATES SQUEAKING NOISE REAR OF CAR OVER BIG BUMPS”CTQ STATEMENT (Customer Requirement): No audible bushing noises for life of the stabilizer bar assembly.

DEFECT DEFINITION for Y (Objective Metric): Audible squawk inside of vehicle from rear stabar bushings.

COST OF POOR QUALITY: Cost TBD, collected from containment, replacement, disposition, repair.Average cost to date $106 per repair.PROBLEM STATEMENT, SCOPE, AND GOAL Squawk noise in vehicle from rear stabilizer bar link bushing. Issue effecting all parts built since May 2013 change. Goal is to reduce stabar bushing noise in vehicle to zero.

Flat Rock Assembly PlantFlat Rock Assembly PlantSuspensionSuspensionChassisChassis

2013 S197 Mustang Rear Stabilizer Bar Assembly2013 S197 Mustang Rear Stabilizer Bar Assembly CR33-5A771-A BAR ASY RR STABCR33-5A771-A BAR ASY RR STAB

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MEASURE CTQ (y) CAPABILITYMEASURE CTQ (y) CAPABILITY


Process ElementsElement OK AInvestigating BElement Not Capable CElement Removed D

Cause & Effect Diagram w/ Ranking:

CONTAINMENT (state reasoning if not required): Process Owner Date Before Data After Data

Each rubber batch is audited for squawk noise on bench 14F Grant Massey 10/1/2013 All Zero

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MEASURE CTQ (y) CAPABILITYMEASURE CTQ (y) CAPABILITY


Noise and Force Measurement of BOB and WOW:

CONTAINMENT (state reasoning if not required): Testing shows noise present at low temperature for all bushings. Above data is for bushings using normal soapy water installation at MSSC.

High Force Bushing(WOW) Temperature

-20 deg F-20 deg F -10 deg F 0 deg F 10 deg F 20 deg F 30 deg F 40 deg F 50 deg F

Noise Noise Noise Noise No Noise No Noise No Noise No Noise

-10 deg F-10 deg F 0 deg F 10 deg F 20 deg F 30 deg F 40 deg F 50 deg F

Noise Noise Noise Noise No Noise No Noise No Noise

0 deg F0 deg F 10 deg F 20 deg F 30 deg F 40 deg F 50 deg F Noise Noise Noise No Noise No Noise No Noise

High force bushings are from material lot 8/22/12 01235157. Average rotational force on 6 parts was 20.60 lbf.

Low Force Bushing (BOB) Temperature

-20 deg F-20 deg F -10 deg F 0 deg F 10 deg F 20 deg F 30 deg F 40 deg F 50 deg F

Noise Noise No Noise No Noise No Noise No Noise No Noise No Noise

-10 deg F-10 deg F 0 deg F 10 deg F 20 deg F 30 deg F 40 deg F 50 deg F

Noise Noise No Noise No Noise No Noise No Noise No Noise

0 deg F0 deg F 10 deg F 20 deg F 30 deg F 40 deg F 50 deg F No Noise No Noise No Noise No Noise No Noise No Noise

Low force bushings are from material lot 12/12/12 01347031. Average rotational force on 6 parts was 7.27 lbf.

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ANALYZE y=f(x)ANALYZE y=f(x)


Vehicle warranty returns showed evidence of reversion and high friction on noisy bar surface under the link

Testing showed that moving the noisy link / bushing to the opposite side resulted in the noise moving along with it.

Warranty return vehicle parts along with normal non noisy parts were sent to Akron Rubber Development Labs for complete analysis of the following:

1.Pyro-GC/MS

2.Polymer ID by FTIR

3.Thermogravimetric Analysis for composition comparison

4.Crosslink Density – state of cure

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9/18/12 - Noisy10/2/12 - good Quiet

10/16/12 - best Quiet

As received links assembled in can (convex) (concave) (convex) (concave) (convex)

(concave)

1seal bead ID 15.9 15.6 15.81 15.61 16.02 15.732seal bead ID 16.05 15.5 15.81 15.68 16.08 15.7

1A dimension ID 19.15 18.3 18.95 18.6 19 18.652A dimension ID 19.31 18.17 19 18.65 19.1 18.54

Link bushings removed - rest 24hrs.

9/18/12 - bad Noisy 10/2/12 - Quiet 10/16/12 - Quiet

(convex) (concave) (convex) (concave) (convex)(concave)

1seal bead ID 16.82 16.79 16.6 16.52 16.9 16.622seal bead ID 16.76 16.5 16.74 16.6 16.68 16.72

1A dimension ID 20.03 19.83 19.8 19.56 19.96 19.652A dimension ID 20.05 19.62 19.95 19.63 19.86 19.78

1OD 42.6 42.62 42.3 42.33 42.5 42.42OD 42.31 42.54 42.52 42.33 42.3 42.5

Dimensional Comparison: Dimensional studies revealed no difference between bushings that made noise in a cold test vs.

bushings that did not. The only noticeable item was slightly more distortion present in the as received parts from Zhongding.

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ARDL Analysis of BOB and WOW: BOB = No noise found, part pulled from OK buildWOW = Noisy bushings from high rotational force build

No differences found – the slight difference evident in crosslink density was within typical rubber tolerances

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ARDL Analysis of Warranty Returns vs. Quiet Parts: Part 1,3 were quiet with no noise. Parts 2,4,5 are noisy warranty

return parts.

No unusual differences found in these compounds

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Force Measurements 22mm Brown

Assembled 12/19/12 shift 3 Measured

1/24/2013 rack was outside for 5 hours

cold weather

24mm Blue Assembled 1/24/13 shift

3 Measured 1/24/2013 rack was outside for 5 hours

cold weather

movement with hand

squeak test

movement with hand

squeak test

11.40 Yes = noise 24.40 Yes

10.90 No 24.10 Yes

13.00 No 20.70 Yes

12.00 No 26.20 Yes

13.70 Yes 21.85 Yes

12.30 No 22.40 No

Link Rotational Force vs. Bushing Squawk: Typical production variation in bushing forces shown below did not directly correlate with audible bushing

noise in MSSC cold testing of full bar assemblies.

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Theoretical Bushing Rotational Forces and Friction Simulation: Link bushings were sent to Axel Products in Ann Arbor, MI for rubber property analyses. This friction and hyperelastic

data was utilized in Ansys as a basis for simulating the expected link rotational forces.

24mm LinkForce (N)

Trial1 24.252 21.93 23.554 24.555 24.66 19.67 22.28 22.559 20.810 25.05

22mm LinkForce (N)

Trial1 13.052 15.253 11.94 14.055 12.556 13.157 14.358 13.59 10.9510 11.85

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Theoretical Bushing Rotational Forces and Friction Simulation: The theoretical force values of 10.1 lbs (45.0N) for 22mm and 11.3lbs (50.66N) for 24mm were lower than what was

measured at MSSC and FRAP. The difference shows us that there is another factor causing of higher efforts apart from simple geometry and the material variation.

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IMPROVE y=f(x)IMPROVE y=f(x)


DOE Screening Study – Installation Lubricants: Initial testing at Zhongding showed the change from soap installation lubricant to NYE Gel recommended

by Keith Aubuchon [email protected] was successful in eliminating the squawk noise in a lab test!

2/4/2013

ROTATIONAL / NOISE TESTING

Note: Gage not required. Part is pulled by hand.

Procedure: Apply Fluorocarbon Gel 880 NYE Lubricant to one 24mm link. Gel is applied to bushing ID with a brush.

Apply soap solution (4oz soap to 3L water) to one 22mm link. Soap is applied by dipping the bushing end of the link into the solution.

Install 24mm bars into the bushings and let parts sit a minimum of 24 hours prior to testing.

Assemble link with bushing/ bar into test fixture.

Place fixture into chamber. Soak in chamber with liquid nitrogen at correct temperature for 10 minutes.

Remove after soak and place fixture into vise.

Immediately rotate and evaluate for noise. Rotation is to be one back and forth movement of 30o each direction.

Repeat rotation every 10oF and evaluate for noise.

Record results.

Temperature Noise

-40 deg F Low Squeak.



-10 deg F None

0 deg F None

Temperature Noise

-40 deg F None

-30 deg F None

-20 deg F None

-10 deg F None

0 deg F None

Link is rotating around the bar.







Specify whether link or can is rotating around the bar.

NYE Gel

Specify whether link or can is rotating around the bar.



Soap

Can is rotating around the bar.

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DOE Screening Study – Installation Lubricants: MSSC testing of full assemblies built using the NYE 880 lubricant also had no noise, and installation

efforts with significantly improved.

Note: temperature around -4C feels like -13C when measured did not hear a squeak.

Left (Tape) Right Left (Tape) Right1 8.60 7.65 1 11.30 8.002 7.95 7.65 2 10.05 7.753 7.65 9.10 3 7.70 6.504 9.10 8.40 4 8.45 8.355 10.45 9.60 5 9.70 7.406 9.35 9.70 6 8.70 8.30

Forces 22mm Brown Assembled 1/30/2013 Measured 1/31/2013

Forces 24mm Blue Assembled 1/30/2013 Measured 1/31/2013

NYE 880 Silicone + PTFE NYE 880 Silicone applied to insideof link bushing using an applicator.

24mm NYE 880 Silicone acted similar to rose waterwhen the link bushing was pushed

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Bushing Noise DOE – Three high importance factors from cause and effect diagram:

1. Time of wax addition 1st pass or 3rd pass2. State of cure – high or low3. Install lubricant – soapy water or alternative.

std. order run order center point blocks Wax Install Lubricant State of cure7 1 1 1 1st pass add NYE 880 lube high8 2 1 1 3rd pass add NYE 880 lube high6 3 1 1 3rd pass add soapy water high5 4 1 1 1st pass add soapy water high2 5 1 1 3rd pass add soapy water low4 6 1 1 3rd pass add NYE 880 lube low1 7 1 1 1st pass add soapy water low3 8 1 1 1st pass add NYE 880 lube low

Assumptionstesting done at -40F at Zhongding Parts must sit for 24hrs after soap or oil install before test

std. order run order center point blocks Wax Install Lubricant State of cure7 1 1 1 1st pass add Naphthenic oil high8 2 1 1 3rd pass add Naphthenic oil high6 3 1 1 3rd pass add soapy water high5 4 1 1 1st pass add soapy water high2 5 1 1 3rd pass add soapy water low4 6 1 1 3rd pass add Naphthenic oil low1 7 1 1 1st pass add soapy water low3 8 1 1 1st pass add Naphthenic oil low

Assumptionstesting done at -40F at Zhongding Parts must sit for 24hrs after soap or oil install before test

DOE #1 – Soapy water vs. NYE 880

DOE #2 – Soapy water vs. Naphthenic Oil

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DOE – Results: Raw data recorded at Zhongding

2/13-15/2013

ROTATIONAL / NOISE TESTING D.O.E. TRIALS

Purpose: Requested by Ford & MSSC.

Bushings: 0488BBar: 22mm

Images below show rotational force testing. Noise testing is performed the same but part is pulled by hand rather than by the force

instrument.Wax State of Cure1st Pass = Wax in MB (Current ZD022S Material) High = 360 Seconds3rd Pass = Wax in Final (Trial EX2332 Material) Low = 270 Seconds

LubricantsSoapy Water - (4oz soap - 3L water) Applied by dipping the bushing end of the link into the lubricant.

NYE 880 Gel - (straight) Applied to bushing ID with a brush.Napthetic Oil - (straight) Applied to bushing ID by finger.

PreparationApply lubricant to bushing ID. Install bar into bushing ID. Let parts sit 24 hours prior to testing.

Testing (after 24hr rest)

*Rotate parts 30o and record force using handheld force instrument.

Assemble link with bushing/ bar into test fixture.Place fixture into chamber. Soak in chamber with liquid nitrogen at correct temperature for 10 minutes.Remove after soak and place fixture into vise.

Immediately rotate and evaluate for noise. Rotation is to be one back and forth movement of 30o each direction. Specify whether the link or can is rotating around the bar.

Repeat rotation every 10oF as part warms, evaluate for noise and specify whether the link or the can is rotating around the bar. Record results.

Install Lubricant: Soapy Water Temperature / Noise Test Results Specify whether link or can is rotating around the bar. Also specify at what temperature.Wax State of Cure Rotational Force (lbf.) -40 F -30 F -20 F -10 F 0 F

1st Pass Add Low 5.80 Squeak Squeak None None None Link rotating around bar. (All temperatures)1st Pass Add High 6.20 Squeak Squeak Squeak None None Link rotating around bar. (All temperatures)3rd Pass Add Low 4.60 Squeak None None None None Link rotating around bar. (All temperatures)3rd Pass Add High 4.40 None None None None None Link rotating around bar. (All temperatures)

Install Lubricant: NYE 880 Gel Temperature / Noise Test Results Specify whether link or can is rotating around the bar. Also specify at what temperature.Wax State of Cure Rotational Force (lbf.) -40 F -30 F -20 F -10 F 0 F

1st Pass Add Low 2.00 None None None None None Link rotating around bar. (All temperatures)1st Pass Add High 1.80 None None None None None Link rotating around bar. (All temperatures)3rd Pass Add Low 1.80 None None None None None Link rotating around bar. (All temperatures)3rd Pass Add High 2.00 None None None None None Link rotating around bar. (All temperatures)

Install Lubricant: Napthetic Oil Temperature / Noise Test Results Specify whether link or can is rotating around the bar. Also specify at what temperature.Wax State of Cure Rotational Force (lbf.) -40 F -30 F -20 F -10 F 0 F

1st Pass Add Low 7.20 None None None None None Link rotating around bar. (All temperatures)1st Pass Add High 6.80 None None None None None Link rotating around bar. (All temperatures)3rd Pass Add Low 5.60 None None None None None Link rotating around bar. (All temperatures)3rd Pass Add High 5.80 None None None None None Link rotating around bar. (All temperatures)

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DOE – Results: Assembly lubricant is main factor affecting noise. Both NYE 880 and Naphthenic oil eliminate bushing squawk noise in this experiment.

DOE #1 – Naphthenic Oil vs. Soapy Water

DOE #2 – NYE 880 vs. Soapy Water

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CONTROL X’sCONTROL X’s


LONG TERM PERMANENT CORRECTIVE ACTIONLONG TERM PERMANENT CORRECTIVE ACTION

Item Control Date Responsible

Apply NYE 880Install machine required with controlled metering of NYE 880 2/22/13 Ken Kanthook, Rich Bhode

At Tier 2 Zhongding Location

Implement error proofing for no lube or insufficient lube 2/22/13 Ken Kanthook, Rich Bhode

Remove large clumps of NYE 880 from production assemblies 2/18/13 Brad Crawford

Control PlanUpdate control plans at Zhongding and MSSC 2/22/13 Brad Crawford, Mackenzie Allen

FMEAUpdate FMEA with current failure mode and outcomes 2/22/13 Jeff Check, Brad Crawford

ADDITIONAL INTERIM ACTIONSADDITIONAL INTERIM ACTIONS

Item Control Date Champion

MSSC Audit for Noise and efforts

Sample 6 stabars from each bin for install efforts and noise 2/14/13 Brad Crawford

Verify interim NYE 880 application has error proofing in place for no lube or insufficient lube 2/18/13 Brad Crawford

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REPLICATEREPLICATE


PROJECT END – PROOF OF SUSTAINMENT:

REPLICATION (who else across Ford Motor Company could benefit?): Key Actions Is this Replicable? If Yes, Where? Responsibility

Note: Recommend initiating Global Corporate Learning E Tracker and complete Prevent Action Health Chart to assure replication AND corporate memory is

updated and critical x’s are replicated in current and future models. http://www.etracker.ford.com/apps/AddIssues/AddIssue.asp?ProjectID=GCORPLRN

UPDATES TO CORPORATE KNOWLEDGE BASE (what core documents or processes require update?): Core Book Change Made Owner Agree? Document/ E Tracker # Completed

Requirements (SDS/VDS: Trustmark, GAP, Spec.) Foundation FMEAs CETP GPDS MDS LQOS Warranty Savings Checklist Other (Specify):List available at web link: http://www.quality.ford.com/warranty/html/gcl_pr.htm

Replicate: Who else at Ford can benefit from the project findings?

What has been done to update the corporate knowledge?

(Six months later…) Is the improvement sustained?

Corrective and Preventive ActionsCorrective and Preventive Actions

By signing this document, I agree that the project has been completed and that the design requirements / process standards have been implemented as declared above.

Project Leader Name……………………………..Signed…..……….…..…..Date…………

Project Leader & Commodity / Process Owner (LL5) Sign-off:

Commodity Manager (LL5)………………………Signed…………..……..…Date….……..

Process Owner (LL5)………………..……………Signed…………..……..…Date….……..

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Checklist for Warranty Savings Opportunities: YESYES

YEYESS

NNOO

1. Are warranty costs associated with the issue? If no, do not continue w/checklist

2. Has causal part driving the issue been identified? If no, return to checklist when causal part identified3. Does the QB/Function responsible for the part have the causal part on their top spend list and/or IFR list? (For contacts, see Quarterback Functional Matrix link on 6-Panel website)

If causal part not on QB’s lists, do not continue w/checklist Name of Quality QB rep contacted: 4. Has the QB/Function reviewed the warranty spend reduction tools for additional warranty reduction opportunities?5. Has the QB/Function identified potential warranty reduction opportunities through the warranty spend reduction tools?6. Has the QB/Function engaged FCSD to support delivery of the identified warranty reduction opportunities?7. Has the QB/Function identified savings and developed action plans for implementation of the opportunities?8. Have the opportunities been implemented and can warranty spend savings be booked in project’s 6-panel?9. If the causal part is supplied by outside resource, has the QB/Function engaged the supplier in the spike recovery process?

YESYES

6-panelUnXchecklistv2.ppt02/27/2009

NOTE: When causal part is determined to be on QB top spend pareto, problem solver is required to ensure follow up with QB/Function for closure on the identified warranty savings opportunities.

REPLICATEREPLICATE


REPLICATEREPLICATEUPDATE

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Mustang Rear Stabilizer Bar Bushing Squawk

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