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Technical Paper

Experimental Learning: Hands on Experiments for Six Sigma Green and Black Belt Training, Part I – Manufacturing Environments

Six Sigma methodologies in combination with Lean thinking have made considerable inroads as continuous improvement tools initially in manufacturing and more recently for service and transactional processes. There is considerable interest globally in training professionals on the use and application of these tools appropriate to either operational or transactional areas. It has long been realized that adult learning is at its best when participants are involved in relevant “hands-on” experiments. Six Sigma training has seen the use of class room demonstrations ranging from the use of playing cards, simulations and to the use of sophisticated experiments to illustrate concepts of factorial designs. This paper will focus on a series of simple but modular experiments that were developed over the past two years illustrating the application of all the Statistical tools that are taught as a part of Six Sigma Green and Black Belt body of knowledge.
Technical Paper

Flexible Fuel and manufacturing dispersion

Back to the non Flex Fuel vehicles, the knock control system was designed and calibrated to absorb differences between engines (mainly compression ratio) and to protect the engine against knock damage (a correction up to 4 degrees BTDC was usually enough). But now, two new variables get in the scene: Flexible Fuel strategy, working from E22 to E100 (all blends in between) and small displacement (1.0 liter) high compression ratio engines. In this new scenario the system must be capable of correcting all spark advance differences, once knock control system acts as a safety feature, protecting the engine even if the fuel learning shows some deviation. In addition to that, we have the compression ratio variation between minimum and maximum limits. Since the engine is small (as well its combustion chamber), each tenth of a millimeter difference during manufacturing process, results in an important final compression ratio variation.
Technical Paper

Reduction of Instrument Panel Manufacturing Cost by Using Design Optimization

This paper highlights the application of design optimization in reducing product manufacturing cost without compromising product performance. By using a topology optimization method, the manufacturing cost of a clam shell has been reduced by approximately one-third, while maintaining the NVH performance of the steering column that is connected to the instrument panel (IP) through the clam shell. Two different optimization approaches and two different topological weld deployments are investigated. It is found that a fully-deployed seam weld approach with automatic optimization provides the best design results.
Technical Paper

Correlation of Thermal Cycle Tests to Field Usage Profiles for Solder Joints in Automotive Electronics

This paper reviews the physics-of-failure model for accelerated thermal cycle tests of solder joints associated with various electronics components, summarizes the parameters of the automotive environment, and discusses the methods for developing thermal cycle tests for reliability validation for automotive electronics. The paper proposes an approach to develop the requirements for validation tests based on the customer usage profiles and the desired product life goal. This requirement determines the nominal testing duration based on the equivalent damage generated from the worst-case field applications.
Technical Paper

Throttle Position Sensor Components Assembly Integrated into the Throttle Body Manufacturing Process

In the engine management systems field, there is lack of sensors locally built and available for sale in Brazil. Therefore, many auto parts companies have to import them affecting directly the final products costs (technology know-how/development costs, import taxes and other material handling/custom related costs). This paper was motivated to study an alternative for a simple, cheaper and locally made throttle position sensor. The choose of this part was because the fact that it is one of the most expensive in the throttle body bill of. For developing this new alternative, it was used a tool called value analysis and value engineering. The outcome of this study was a throttle position sensor function integrated to the throttle body manufacturing line with the advantages that 100% components can be locally purchased, improved robustness against humidity and component quantity reduction by 40%. Therefore achieving more value added.
Technical Paper

Application of a Lean Cellular Design Decomposition to Automotive Component Manufacturing System Design

A design framework based on the principles of lean manufacturing and axiomatic design was used as a guideline for designing an automotive component manufacturing system. A brief overview of this design decomposition is given to review its structure and usefulness. Examples are examined to demonstrate how this design framework was applied to the design of a gear manufacturing system. These examples demonstrate the impact that low-level design decisions can have on high-level system objectives and the need for a systems-thinking approach in manufacturing system design. Results are presented to show the estimated performance improvements resulting from the new system design.
Technical Paper

A Journey Towards Technical Competency in Plastics Process Simulation

Plastics manufacturing technology is rapidly changing. The use of process simulation to increase competitiveness has proliferated. Visteon Automotive Systems is committed to developing competent workforce and niche capabilities in plastics processing simulation. In this paper the current capabilities and future development plan for plastic process simulation are discussed. An integrated concurrent engineering process has been developed and implemented to deliver high quality robust plastics automotive products and systems. This paper highlights the technological advancements achieved by Visteon in the field of analytical simulation of common manufacturing processes. In addition, future development initiatives towards the technical competency in plastics manufacturing simulation are discussed throughout the manuscript.
Technical Paper

Seat System Key Life Test

An accelerated seat durability test was developed to identify potential problems in areas with traditionally high warranty cost and customer dissatisfaction: squeak & rattle and mechanism looseness & efforts. The test inputs include temperature, humidity, road vibration, occupant movements, and mechanism cycling. These inputs were combined into a single 14-day test profile that simulates 10 years and 250,000 km. (approximately 150,000 miles) of 95th percentile customer usage. Various components of the seat assembly are tested together as a system. The test was performed on two current production programs. The test produced issues similar to those found in warranty repair data and evaluations of used seats from high-mileage customer-owned vehicles.
Technical Paper

Lightweight Thermoplastic Composite Throttle Bodies for Car and Truck Applications

The drive to reduce weight, simplify assembly, and cut total system cost in today's vehicles is relentless. Replacing metal systems with thermoplastics has been of considerable interest in the engineering community. The current generations of engineering thermoplastic resins are enabling the use of plastic systems in demanding underhood applications. Technical data and discussion regarding the materials, design, molding, and assembly of lightweight composite throttle bodies will be presented in this paper. Comparisons with machined aluminum throttle housings are drawn to establish a baseline with the throttle body housing component that is most common in production today. Design flexibility and process simplification are some of the approaches highlighted. Much of the technical information provided in the paper applies to both cable driven mechanical throttle bodies as well as electronic throttle bodies under development.
Technical Paper

Part I: Development of an Automotive DVD (Digital Versatile Disc) System

This paper provides a technical overview of the components contained in an automotive DVD system. Discussions are limited to present in-vehicle applications of DVD-Video, DVD-ROM and DVD-Audio. Future papers will present the environmental operating requirements.
Technical Paper

Engineering the 1999 Mercury Cougar Hybrid Instrument Panel

In a joint effort between Ford Motor Company, Visteon Automotive Systems, Textron Automotive Company, and Dow Automotive the 1999 Mercury Cougar instrument panel (IP) was designed and engineered to reduce the weight and overall cost of the IP system. The original IP architecture changed from a traditional design that relied heavily upon the steel structure to absorb and dissipate unbelted occupant energy during frontal collisions to a hybrid design that utilizes both plastic and steel to manage energy. This design approach further reduced IP system weight by 1.88 Kg and yielded significant system cost savings. The hybrid instrument panel architecture in the Cougar utilizes a steel cross car beam coupled to steel energy absorbing brackets and a ductile thermoplastic substrate. The glove box assembly and the driver knee bolster are double shell injection molded structures that incorporate molded-in ribs for added stiffness.
Technical Paper

Scratch Resistance of Automotive Plastic Coatings

The scratch resistance of automotive plastic coatings has been studied extensively over the past few years. Most testing methodology to correlate damage of the coating to field conditions has been in the form of small particulate wearing, e.g., alumina oxide abrasive, or indentation resistance of the coating to an external probe, e.g., a nanoindentation device. The subsequent damage imparted to the coating has generally been analyzed by the amount of coating mass lost in the wear event or through a ratio of optical reflectance of the damaged area to the undamaged surface. In this paper, we attempt to delineate surface damage resistance of several automotive clearcoats through an optical interferometry methodology developed to measure volume and depth of damage incurred with small particle alumina oxide erodents in a simulated wear environment.