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Product Engineering, Component Supply and Vehicle Assembly are the main forces that transform ideas, customer research and technical information into products. Quality professionals, and others, have advanced many concept models about improved Product and Process Development based upon the application of new tools and systems to Engineering, Procurement/ Supply and Manufacturing/Assembly relationships. Regardless of the concept model, the problem of effecting operating change in U.S. automotive business practices has both behavioral and technical implications. While many studies have emphasized the application of quality tools and systems as a means to improve Product/Process development, they often overlook the cultural change that is necessary to transition from a 75-year history of strong vertical organizations to the “Networking” implicit with new concept models. The availability of improved tools and systems alone will not insure behavioral change.

THIS STUDY WAS DEVELOPED in response to a component fatigue strength test which determined that if the current #3 engine bearing cap were used in the 2.5L Turbo application, it would be over stressed. Proposed solutions for solving this problem included: a redesigned grey iron cap with additional material in the highly stressed areas, or a cap made from either nodular iron or a free machining steel using current specifications. One of the manufacturing concerns about switching materials is the perceived difference in the machinability of nodular iron and steel. A single point turning evaluation was carried out by Chrysler Motors' Machinability Development Laboratory to compare the machinability of various materials proposed for use in engine bearing caps. Materials tested included: SAE G2500 grey cast iron, the current production material; SAE D45-12 nodular cast iron; and SAE steel grades 1117, 1137, 1215, 12L14, 1215, and 1215 modified (Incut 200).

The manufacturing analysis of molded plastic parts is described in detail. A PC based program is presented to analyze the material and capital cost. The program listing is included.

The increased use of a wide variety of recently developed engineered materials and associated processes, for producing vehicular components, has posed a significant challenge to those charged with the responsibility of knowing, developing and/or applying inspection and testing technology to support the quality assurance of these materials, processes and resulting products. This challenge can be more easily and effectively met, within the constraints of time, expertise and other available resources, if computerized knowledge-based systems are employed to enhance the identification, acquisition and application of advanced inspection technology. This paper provides an overview of developments underway to implement this approach in an automotive environment.