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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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Test Track Total Concerns After ShutdownImproved Test Track

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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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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

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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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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