the beginning of the us automotive industry -...

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

https://www.youtube.com/watch?v=3Bvuwu_xDlo

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 Phase 1 – Design Feasibility

2003 Ford Mustang GT Program Phase 2 – Prototype Design

2003 Ford Mustang GT Program Phase 3 – Test and Validation

2003 Ford Mustang GT Program Phase 4 – Production Launch

2003 Ford Mustang GT Program Phase 5 – Continuous Improvement

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



Yes

Retail 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


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






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


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


Stored in truck box

FMVSS 304

FMVSS 304



-20° F to 160° F

Sea Level to 10,000 feet

193°F to 205°F


Trunk Maximum ChangedMaintain Current

Maximum Changed

Approach Angle Maintain Current Maximum Changed



CNG tanks in trunk


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


Torque Bi-Fuel Drive Evaluation Dyno Tested

Drive Evaluation

Torque Dual Fuel


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


12 Miles per Gallon

470 Horsepower at rear wheels

470 Horsepower at rear wheels



Expect 25% to 35% reduction in dual fuel mode


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



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


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



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


Performance Alt FuelsPerformance Alt FuelsPerformance Alt Fuels

Catalog

Vacuum HoseHardware (hoses, brackets, screws, T's and clamps)

Catalog


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 CNG Dual Bi-Fuel Plumbing Block Diagram

2003 Ford Mustang GT Program Dual Bi-Fuel Wiring Block Diagram

2003 Ford Mustang GT Program Design Failure Modes Fishbone Analysis

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



vehicle build



8 3 2 48

8Connectors not

conducting electricity

Connector specif ication 3 B 1, 2, 3 5 120



vehicle build



8 3 2 48

10Fuel Line not

containing CNGFuel line

specif ication 3 B 1, 2, 3 5 150



vehicle build

Todd Connolly 11-Jul-13All review s


10 3 2 60

10Connectors not containing CNG

Connector specif ication 3 B 1, 2, 3 5 150



vehicle build



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



vehicle build



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



vehicle build



6 3 2 36

6High Pressure input

ineffective for application

Pressure Regulator specif ication 3 B 1, 2, 3 5 90



vehicle build



6 3 2 36

6Low Pressure

output ineffective for application




vehicle build



6 3 2 36

6Coolant input and output ineffective

for application




vehicle build



6 3 2 36

6Vacuum output ineffective for

application




vehicle build



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.


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.


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




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)


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



Performance

Type 3 CNG tanks, venting, PRV, auto shut off, plumb @ 3600 PSI

CNG Bi-FuelPremium Gasoline


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





Design and build changes





Comments




Fuel Configure



100%

Bi-Fuel 100%




Compliance to FMVSS standards



EPA 75 testing protocol

EPA 75 testing protocol

Road testing and data gathering


Road testing and evaluation







2003 Ford Mustang GT Program Dyno Testing Wiring Block Diagram

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





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 Assembly Process Work Instructions

2003 Ford Mustang GT Program Conversion Plant

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 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


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


CSP2179-00FP-03Reinf. Assy Hood Inner Panel Hinge


the Part/Supplier PPAP/

Per Sampling

Plan



CSP2179-00FP-05

Move to Next Operation Hi-lo 4 CSP2179-00FP-03







SP1499 FP-03

Receiving inspection None 5 Hem Adhesive


Hem AdhesiveVesri LOK 262/254


the Part/Supplier PPAP/Check the date

on the Vesri LOK

Per Sampling

Plan



SP1499 FP-05

Move to Next Operation Hi-lo 6 SP1499 FP-03







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


6 Not enough material Planning volumes 2 Daily releases, inventory management

4 48 0

Did not build the entire 100 batch build


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


Mix material with other material


6 Not enough material Incoming material check 3 Fixture check 1 18 0

Put material in the wrong location


6 Operator did not follow process


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


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


6 Operator did not follow process


Place SVT Hood Latch to fixture

Hood Latch is placed in the wrong position on the fixture



Place in SVT Hood Latch Asm bin

Hood Latch Asm is placed in the wrong bin



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



Clear all SVT material from fixture, table, line and area

SVT parts are left in the area



Reconfigure fixture to non SVT location

Fixture not configured correctly


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]

http://www.performaltfuels.com/

http://www.cpspoly.com/

http://www.dptechservices.com/

the beginning of the us automotive industry -...

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