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S&R Best Practice Test Track:Generic Layout – Surface Details
Mark Shkoukani
VO -FAE
Squeak & Rattle
8/26/2003
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Background
The test track is designed to provide the desired input energy (frequency range and amplitude) to excite specific squeak & rattle concerns (based on benchmarking Volvo, NA Plants, and DPG) . Interior squeaks & rattles Body Creaks Chassis Clunk / pop / other noise Loose stock
The surface lengths are optimized to allow sufficient time for the track to excite concerns and for the driver to recognize and locate the source.
The S&R test track should be covered to eliminate effect of snow, rain, ice (provides a consistent environment)
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Current Status
The Best Practice S&R test track has been installed at the following plants (enclosure is not included) OAP in July, 2001 (funded by facility/new launch f KTP in July, 2001/May, 2002 (funded by PVT / 2002 FAE Quality
Budget) DTP in June, 2003 (funded by facility/new launch)
Requested funding to implement the Best Practices S&R test track for the following plants (request was rejected): LVL & KCAP-SUV (2002 & 2003 Quality Budget) LVL (U251 program) Strategy to implement 2 plants per year (5 year migration plan)
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Best Practice S&R Test Track Layout
Vienna Block
Cobblestone
RaisedVienna Block
Rope
Angle Iron
Washboard
Body Twist Straight
DPG RB / EB
Body Twist on Turn
SpeedTransition
400’
See following slide for details.
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Best Practice S&R Test Track Layout
Section Concerns Identifiable Driver ActionsDistance
(ft)Speed (mph)
Time (sec)
Signs
1. Cobble StoneChassis clunk and pop, loose stock
Maintain steady 5 mph 30 5 4.1COBBLE STONESuspension, Frame, Mounts
2. Vienna Block Interior trim S&R Accelerate smoothly to 15 mph 100 5 -> 15 6.3VIENNA BLOCKInterior (e.g. door panel)
3. Raised Vienna Block
Interior trim S&R Maintain steady 15 mph 100 15 4.5RAISED VIENNAInterior
4.Rough Brick/ European Brick
Chassis clunk and pop Maintain steady 15 mph 100 15 4.5ROUGH BRICK/ EUROPEAN BRICKUnderbody, Chassis, Frame, Mounts
5. Transition Not applicable Decelerate to 2.5 mph 30 15 ->5 1.7 DECELERATE
6. Body Twist on TurnBody creak, chassis clunk and pop
Maintain steady 2.5 mph 70 5 9.5TURN & TWISTBody, Frame, Suspension, Mounts
7. Transition Not applicable straighten vehicle out 20 5 2.7
8. WashboardSpecific interior trim S&R frequencies
Accelerate smoothly to 15 mph 100 5 ->15 6.3WASHBOARDInterior (e.g. IP)
9. RopesInterior trim S&R noticeable with lighter impact force inputs
Maintain steady 15 mph 100 15 4.5ROPESInterior
10. Angle IronChassis S&R requiring greater impact force inputs
Maintain steady 15 mph 100 15 4.5ANGLE IRONUnderbody, Frame, Suspension, Mounts
11. Transition Not applicable Decelerate to 2.5 mph 30 15 ->2.5 2 DECELERATE
12. Body Twist Straight
Body creak, chassis clunk and pop, loose stock
Maintain steady 2.5 mph 40 2.5 10BODY TWISTBody, Frame, Suspension, Mounts
13. Exist Exit
Total: 820 ft 60.6 sec
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Internal S&R Data - KTPTest Track Total Concerns Before Shutdown
Old Test Track
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2
0
2
1
2
3
2
0
1
2
3
2
1
2
0
3
2 2
0
1
0 00
1
2
3
4
5
6
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10
6/8
/2001
6/9
/2001
6/1
0/2
001
6/1
1/2
001
6/1
2/2
001
6/1
3/2
001
6/1
4/2
001
6/1
5/2
001
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6/2
001
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0/2
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7/1
/2001
Test Track Total Concerns After ShutdownImproved Test Track
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54
21
2 2
4
9
3
0
2
7 7
3
87
6
0
5 5
0123456789
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7/1
6/2
001
7/1
7/2
001
7/1
8/2
001
7/1
9/2
001
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0/2
001
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1/2
001
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001
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3/2
001
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0/2
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8/1
/2001
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/2001
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/2001
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/2001
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1.28 C/1000
3.67 C/1000
182% Increase in Internal Concern findings
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Internal S&R Data - OAP
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63
0
10
20
30
40
50
60
70
C/1000
June 25 Before BP Test Track
July 23 After BP Test Track
Week
S&R - Oakville Assembly Concerns Before/After Best Practice Test Track Installation
80% Increase
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External Data - KTP
247198
185
0
50
100
150
200
250
TGW
2001 2002 2003 YTD
Model Year
Total S&R Data - KTP
Squeak & Rattle Frt & RR UnderBody - KTPR/1000 (N50 & N51)
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2
4
6
8
10
12
14
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Month of Production
R/10
00
3MIS
Test Track Modifications 3.5% Improvement
20% Improvement 6% Improvement
Best Practice Test Track contribution : ~ 1R/1000, and 7 to 10 TGW based on KTP.
improvements will vary based on the vehicle line and existing S&R test track layout.
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Best Practice S&R Test Track Cost EstimatesPlant Plant Contact
Test-Track Cost $000
Enclosure Cost $000
Re-arrange. Cost $000
Total Cost $000
Comments
FAE Cost Estimate Shkoukani, Mark $400.000 $350.000 $750.000This cost does not include any re-arrangement cost
AAI Watson, Paul (P.)
Atlanta Kromer, Mark (M.) $377.199 $973.770 $1,236.084 $2,587.053Rearrangement cost includes Services/Safety, and engineering work
Chicago Gupta, Ajay (A.) $700.00 $500.00 $1,140.00$2,340.000
This cost is to implement the track outside. It will cost 3.26M if inside.
Cuautitlan Barba, Jose (J.I.) $210.00 $350.00 $1,180.00 $1,740.00Rearrangement cost includes Services/Safety, and equip. for data collection
Dearborn Car Klebe, Daniel (D.F.) $600.00 $500.00 $150.00 $1,250.00 Need cost breakdown
Dearborn Truck Thien, Do $406.10 $500.00 $0.00 $906.10Total test track cost is $613K. P221 Redbook will cover $207.9K
Edison $0.00
Hermosillo Torres, Susana $109.00 $0.00 $0.00 $109.00 Enclosure may not be required
Kansas City-Car Shibley, William $453.00 $1,127.950 $0.00 $1,580.95
Kansas City-Com.Shibley, William $453.00 $1,127.950 $0.00 $1,580.95
Kentucky Truck Gharib, Mohammed $0.00 $727.53 $727.53
Lorain $0.00
Louisville Massengill, David $500.00 In Door Track
Michigan Truck Lucas, James (J.O.) $429.00 $450.00 $669.00 $1,548.00
Norfolk Dick Kraft $500.00 $700.00 $2,900.00 $4,100.00Need to acquire property, and many other misc. items
Oakville Moss, Gay (G.) $0.00 $865.00 $0.00 $865.00
Ohio Assy Spencer, Michael $453.00 $1,127.950 $0.00 $1,580.95 Estimated based on the U204 track cost
Ontario Truck D'Souza, Orpheus $450.00 $1,150.00 $0.00 $2,217.00
St. Louis Novotny, Brett (B.H.) $250.00 $1,300.00 $200.00 $1,750.00
St. Thomas Coveny, Jim (J.J.) $462.00 $225.00 $388.00 $1,075.00Need cost breakdown. Rearrangement includes 2 bay w/repair hoist, and clear vision runway
Twin Cities Joyce, James (J.E.) $1,312.35 $706.65 $160.00 $2,179.00
Wayne Myers, Steven (S.E.) $770.678 $600.00 $129.322 $1,500.00
Wixom Leppi, Christophe $440.00 $810.00 $1,001.00 $2,251.00
Total $8,375.33 $13,741.80 $9,153.41 $32,387.54
* Cost variation exist since the cost/analysis was provided by the individual plants and since re-arrangement requirement varies between them.
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Other steps to Improve S&R Process
• S&R QOS• NOMAD (S&R objective measurement to validate
product/process changes)• Formal training (includes a training video tape) • Provide a reflective sound walls• S&R test track minor Modifications and continuous
coaching as required.• Speed signs / Visual Aids as required.
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Appendix
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Surface 1: Cobblestone
Test Track Layout and Operator Training
Length: 30 ftWidth: 10 ft
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Surface 2 & 3: Vienna Block
Length: 100 ft Uniform Vienna Block, 100 ft Stepped Vienna BlockWidth: 104”
40” 40”24”
Track Width ~ 66”
40” 40”24”
100’
TBD
Uniform Vienna Block Stepped Vienna Block
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Surface 2 & 3: Vienna Block
Uniform Vienna Block
Stepped Vienna Block(~1” Step in Height)
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Surface 2 & 3: Vienna Block Specification
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Surface 4: Rough Brick / European Brick
Length: 100 ft Rough Brick / European Brick side-by-sideWidth: 10 ftCurrently no spec available on brick or layout
30” 30”
Track Width ~ 66”
100’
Rough Brick
30” 30”
Rough BrickEuropean Brick European Brick
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Surface 5: Transition
Length: 30 ftWidth: 10 ft
Brushed concrete surface used to brake from 15 mph to 5 mph.
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Surface 6: Body Twist-on-Turn – “In-Line”
If Twist-on-Turn is in a straight line between the preceding and following sections, the KTP style surface can be used.
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Surface 6: Body Twist-on-Turn – 180º
If Twist-on-Turn consists of a 180º turn, the following surface is used.
Radii will vary based on vehicle turn radius.
Ramp height = 18”
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Surface 7: Transition
Length: 20 ftWidth: 10 ft
Brushed concrete section used to straighten the vehicle out from the turn.
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Surface 8: Washboard
Length: 100 ftWidth: 10 ft
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Surface 9: Ropes
Length: 100 ftWidth: 10 ftSpacing: 1 ft
• Steel strip with welded eyelets OR• Eyelets embedded directly in cement• Polypropylene ¾” diameter rope held with cable clamp or U-bolt
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Surface 10: Angle Iron
Similar to existing MTP surfaceLength: 100 ftWidth: 10 ftAssume ave. spacing: ~ 5ftPieces required: ~ 20
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Surface 11: Transition
Length: 30 ftWidth: 10 ft
Brushed concrete surface used to brake from 15 mph to 2.5 mph.
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Surface 12: Body Twist - Straight
Length: 40’Width: 10 ftWavelength: Varies depending on vehicle
Example (MTP):
Wavelength = 2*x =WB / 1.5
For Expedition, WB = 119” Wavelength ~ 80” x ~ 40”
For 5 waves, L = 5*80” = 33’ 4”
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S&R Test Track Enclosure - Example
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S&R Test Track Enclosure Requirement
Initial Requirements are:• Test Track and Enclosure location to allow to future enclosure repair including foundation rework• Provide relocatable test track enclosure similar to suppliers Clamshell, Rubb and Sprung• Foundation system per enclosure suppliers specifications• Enclosure width to allow two lanes - test track lane and service lane for safety & access to stalled vehicle• Enclosure width 20' minimum plus adequate site distances around turns• Enclosure length as required to meet Test Track specifications• Enclosure height 10' clear at edge of lanes• Two lane wide 20' long Entrance and Exist vestibules (Entrance/Exit open, no vehicles doors)• Pedestrian doors with exterior hoods at 200' spacing including egress signage• One 10' x 10' rolling service door (location TBD), provided by enclosure supplier• Exterior lighting at pedestrian doors and both vestibules• Automatic & manually controlled interior lighting at site parking/road lighting level • Automatic & manually controlled ventilation, grade mounted (1.5 cfm per s.f. of enclosure including
vestibules)• Three plant telephones inside the enclosure (location TBD)• No Enclosure fire protection unless required by local building codes• No Energy Management System required