My presentation for a Lean Program Engineering Class in which we reduced the cost and weight of individual parts of a vehicle using lean product development techniques
- 1. 04/16/2012AUTO 512LEAN PROGRAM ENGINEERING MILESTONE 2
Instrument Panel Reinforcement AssemblyREINF ASY I_PNL 5R33 6304304
A PIA2 ANIRUDDHA MYSORE SRINATH
2. The Boundary Diagram- Understanding the Part Part Set: REINF
ASY I_PNL 5R33 6304304 A PIA2 Engineer: Aniruddha Mysore Srinath
Part Set: Part Set:Part Set: Part Set:Part Set: Electronic CD
Passenger airbag Driver or passengerInstr Cluster AssyDriver or
passenger Radio MP-6R33-012003-G3collides with airbag 7R3V-10849-B
operates inst. Cluster7RCT-18C815-S Part Set: 4R3X-6304545-A_PIA
141 Beam Cross Car DS Driver or passenger 4R3X-6304545-A_PIA 140
Beam Cross Car PSoperates radio/CD 4R3X-6304545-A_PIA 153 Airbag
support bkt Part Set: 4R3X-6304545-A_PIA 136 Ctr Beam Supt bkt
4R3X-6304545-A_PIA 125 Glove box upper railWater from
4R3X-6304545-A_PIA 109 PS lower railsplashing 4R3X-6304545-A_PIA
108 DS lower rail4R3X-6304545-A_PIA 107 DS knee
bolster4R3X-6304545-A_PIA 105 Glove box bolster 4R3X-6304545-A_PIA
102 Lh Cowl side bkt Part Set:Part Set:Part Set:Part Set:Part Set:
Part Set:Body dash & cowl Driver operates Steering ColumnMost
Brake Pedal -DS- I/P wiring 7R33- MP-7R33-110400- Driver applies
brakeS197-060602- MP-6R33-010102-B1 steering wheel important
180102-D1C1 00004interaction External Interfaces External
Interfaces Type ImpactType Impact (1)= Negative Influence (1)=
Negative Influence 1 = Positive Influence 1 = Positive
InfluenceGeometryGeometryMaterialMaterialEnergyEnergyDataData#
Interfaces Vehicle Attribute#InterfacesVehicle Attributee1Glove box
l1 Reinforcement & support e8Driver/passenger inst. Clusterl 1
NVHe2Instrument clusterl1 Reinforcement & support
e9Driver/passenger w radio/CD plyrl 1 NVHe3Electronic CD radio l1
Reinforcement & support e10 Driver applying brake l 1 NVHe4Trim
cowl l l(1) NVH (vibration) e11 Driver operating steering wheel l 1
Crash Impacte5Front door assembly l l(1) NVH (vibration)
e12e6Steering column l1 Reinforcement & support
e13e7Driver/passenger with aribag l 1 Crash Impacte14 3.
FMEA-Design 4. FMEA-Manufacturing 5. FMEA-Assembly 6. Project
Status at M1 stageMilestone 1Confidence M1 Countermeasure
Assessment Green = Confidence > 85% Yellow = Between Red &
Red = Confidence 90% Yellow = Between Red & Red = Confidence
41.42)DS LOWER RAILM06 WELD HEX FLG 08PIN LOCATOR 8X4 WELD 1 8 2
4R3X-6304545-A_PIA108 (RH)
W520720-S4R3X-6304545-A_PIA1541.521.421.37 Project Target:- Reduce
mass by 15 %, (10.06->8.55) G_BOX UPPER RAIL AIRBAG SUPT LH
BKT4R3X-6304545-A_PIA1254R3X-6304545-A_PIA153 (LH)0.380.34 Subtotal
$3,000$21,000$21,000$21,000 EA PASS RH BKT 4R3X-6304545-A_PIA132
0.32 Probable methods:- G_BOX UPPER RAIL AIRBAG SUPT LH BKT 1
24R3X-6304545-A_PIA125 4R3X-6304545-A_PIA153 (LH)1.361.19 Probable
methods:- 4R3X-6304545-A_PIA143 G_BOX BOLSTER BEAM TO CTR SUPT
BRKT4R3X-6304545-A_PIA105 (RH)0.280.27 EA PASS RH
BKT24R3X-6304545-A_PIA132 1.13 1. Reduce cost of individual
components G_BOX BOLSTER 2 4R3X-6304545-A_PIA105 (RH) 1.00 1.
Reduce mass of individual components RH COWL SIDE BKT COWL TOP ATT
BRKT 4R3X-6304545-A_PIA103 4R3X-6304545-A_PIA1440.240.08 BEAM TO
CTR SUPT BRKT 14R3X-6304545-A_PIA143 0.95 2. Reduce the quantity of
individual components BOLT WELD M8-1.25X40 RH COWL SIDE BKT 4
14R3X-6304545-A_PIA1474R3X-6304545-A_PIA1030.910.85 2. Reduce the
quantity4R3X-6304545-A_PIA147 BOLT WELD M8-1.25X40 PS REINF STRAP
of individual components 4R3X-6304545-A_PIA1510.080.07PS REINF OTR
STRAP 4R3X-6304545-A_PIA1560.06 3. Eliminate the
componentsM5X0.8X30 WELD PILOT BOLT COWL TOP ATT BRKT 3
1BOLT-N0808475-M54R3X-6304545-A_PIA1440.360.29 3. Eliminate the
components RADIO SNUBBER BKT 4R3X-6304545-A_PIA1160.05 PS REINF
STRAP14R3X-6304545-A_PIA151 0.24M5X0.8X30 WELD PILOT
BOLTBOLT-N0808475-M5 0.05PS REINF OTR STRAP 14R3X-6304545-A_PIA156
0.22PLMN ATT INNER RH BKT 4R3X-6304545-A_PIA145 0.05 RADIO SNUBBER
BKT 14R3X-6304545-A_PIA116 0.19 PLMN ATT OUTER BRKT
4R3X-6304545-A_PIA148(LH)0.04PLMN ATT INNER RH
BKT24R3X-6304545-A_PIA145 0.17M06 WELD HEX FLG 08W520720-S0.03PLMN
ATT OUTER BRKT24R3X-6304545-A_PIA148(LH) 0.14 PIN LOCATOR 8X4 WELD
4R3X-6304545-A_PIA154 0.03 MO6*12_MO6*13.8 EXT LOB PIL08
1W702909-STU 0.03 MO6*12_MO6*13.8 EXT LOB PIL08
W702909-STU0.01TOTAL 67 48.54 TOTAL 10.09 4. Crash Impact- modal
frequency (Hz)- lesser is better 5. Observed NVH 6 Impact of human
(displacement of knee during crash) FEA test forVarious modal
frequencies for different materials NetFEA test for modal frequency
at various
interactionsdisplacementhttp://papers.sae.org/982412/Dinesh
Seksaria
http://www.sciencedirect.com/science/article/pii/S0263823103000508ww.nhtsa.gov/cars/rules/regreb/evaluate/807203.htmlw
9. M2 Assumptions Sheet- Design ComparisonProposed Design Proposed
Design- M22. Integrated beams-No center support bracket 1.
Magnesium beamsWeightCost Present ProposedPresent Proposed 1.
magnesium beam1.35 0.95 14.24 11.39 2. Using locknut 1.61 1.06 5.68
2.84 3. No beam to ctr supt bkt 0.27 0.00 0.95 0.003.23 2.01 20.87
14.23 1.236.64 New Part 8.8641.99NO DESIGN CHANGES-Eliminate nuts
which were usedSingle Jackto join PS & DS beamSingle Jack Screw
Nut3. Nylock nuts-21 nos Screw NutIdea 1:- Use Magnesium beam
instead of aluminumReason for using:- Magnesium is 33% less denser,
costs 50% less to make (though the raw material cost ofboth are
almost the same ) & has better strength characteristicsImpact
on target:- +ve - 1- Cost, 2-weight, 4- Crash impact, 5- Observed
NVH, 6- impact on human; -ve - NoneIdea 2:-Integrate the driver
side and passenger side cross car beamReason for using:-Can
eliminate the part holding the two beams, some fastenersTorsional
strength of the material is also improvesImpact on target:- +ve -
1- Cost, 2-weight, 4- Crash impact, 5- Observed NVH; -ve - NoneIdea
3:- Use nylock nuts instead of the U-net (21 nos in the
assembly)Reason for using:- Reduce cost and weight (nylock nuts are
lighter & cheaper), reduce vibrationin the system as fastening
is betterImpact on target:- +ve - 1- Cost, 2-weight, 4- Crash
impact, 5- Observed NVH, 6- impact on human; -ve - None 10. M2
Assumptions Sheet- Change in Part B/ (W) Change/Part# of UnitsNew
Part Projection B/ (W) Change/Part# of Units New Part
ProjectionChange from BaselineMass (kg) Cost ($) Per VehicleMass
(kg)Cost ($)Change from M1 Mass (kg) Cost ($) Per VehicleMass (kg)
Cost ($) Use nylock nuts 0.530$2.8421 1.076$2.84Use nylock nuts-
Eliminate nuts 0.230 $0.8118
0.846$2.03Carryover0.000$0.0021.045$3.69Carryover 0.000
$0.0021.045$3.69Carryover0.000$0.0020.940$3.32Carryover 0.000
$0.0020.940$3.32Carryover0.000$0.0010.882$3.12Carryover 0.000
$0.0010.882$3.12Use Magnesium & integrate with PS (0.082)
($2.19) 10.950 $11.39Carryover0.000 $0.00
10.950$11.39beamCarryover0.000$0.0020.824$2.91Carryover 0.000
$0.0020.824$2.91Carryover0.000$0.0010.626$2.21Carryover 0.000
$0.0010.626$2.21Eliminate by integrating with the DS 0.476$5.040
(0.000) $0.00Carryover 0.000 $0.000 (0.000)
$0.00beanCarryover0.000$0.0010.430$1.52Carryover 0.000
$0.0010.430$1.52Carryover0.000$0.0010.384$1.36Carryover 0.000
$0.0010.384$1.36Carryover0.000$0.0020.338$1.19Carryover 0.000
$0.0020.338$1.19Carryover0.000$0.0020.321$1.13Carryover 0.000
$0.0020.321$1.13Carryover0.000$0.0020.283$1.00Carryover 0.000
$0.0020.283$1.00Eliminate0.269$0.9500.000$0.00Carryover 0.000
$0.0000.000$0.00Carryover0.000$0.0010.242$0.85Carryover 0.000
$0.0010.242$0.85Carryover0.000$0.0010.081$0.29Carryover 0.000
$0.0010.081$0.29Carryover0.000$0.0040.080$0.91Carryover 0.000
$0.0040.080$0.91Carryover0.000$0.0010.068$0.24Carryover 0.000
$0.0010.068$0.24Carryover0.000$0.0010.061$0.22Carryover 0.000
$0.0010.061$0.22Carryover0.000 $0.00 10.055$0.19Carryover0.000
$0.00 10.055$0.19Carryover0.000$0.0030.050$0.36Carryover 0.000
$0.0030.050$0.36Carryover0.000$0.0020.048$0.17Carryover 0.000
$0.0020.048$0.17Carryover0.000$0.0020.040$0.14Carryover 0.000
$0.0020.040$0.14Carryover0.000$0.0080.030$1.42Carryover 0.000
$0.0080.030$1.42Carryover0.000$0.0020.030$1.37Carryover 0.000
$0.0020.030$1.37Carryover0.000 $0.00 10.010$0.03Carryover0.000
$0.00 10.010$0.03 8.9 $41.98.7 $41.1 11. M2 Assumptions Sheet-
Change in InvestmentTooling$ Tooling$Machining for new lock nut
$3,000Machining for new lock nut $3,000Machining for two fasteners
which interact with the cross car beam (refer to tooling
worksheet)$6,000Machining for two fasteners which interact with the
cross car beam (refer to tooling worksheet)$6,000Molding of cross
car beam $22,000Molding of cross car beam + machining finishing
using 3 axis set up+safety precautions$35,000Stamping of LH beam
center support bracket$21,000Stamping of LH beam center support
bracket$21,000Stamping of LH & RH cowl side bracket
$42,000Stamping of LH & RH cowl side bracket $42,000$94,000.0
$107,000.0Test Plan RemarksM1 Risk Assessment Test Plan Remarks M1
Risk AssessmentCost calculated through reverse engineering for M1,
obtain cost estimate for M2 & detailed cost for M3 from
supplier Y Cost calculated through reverse engineering for M1,
obtain cost estimate for M2 & detailed cost for M3 from
supplier GMass calculated through reverse engineering for M1,
obtain BOM for M2 & weigh prototype for M3 Y Mass calculated
through reverse engineering for M1, obtain BOM for M2 & weigh
prototype for M3 GInvestment estimated throughout the project, will
meet target requirements but will be monitored at each milestone G
Investment estimated throughout the project, will meet target
requirements but will be monitored at each milestone GDesk study
for M1, CAE analysis for M2 & prototype testing including
fatigue testing for M3Y Desk study for M1, CAE analysis for M2
& prototype testing including fatigue testing for M3YDesk study
for M1, CAE analysis for M2 & prototype testing including
fatigue testing for M3Y Desk study for M1, CAE analysis for M2
& prototype testing including fatigue testing for M3GDesk study
for M1, CAE analysis for M2 & prototype testing for M3; fatigue
testing is not required G Desk study for M1, CAE analysis for M2
& prototype testing for M3; fatigue testing is not required
G$52,720.0$52,720.0Investment Status:$146,720.0 G Investment
Status: $159,720.0GPayback (years) 0.126G Payback (years) 0.137G
12. M2 Assumptions Sheet- SummaryMajor Issues: DescriptionNeed to
count weight save at $4/kg to achieve M1 targets for part cost2
unit cost New material (magnesium) being used, performance not
established3New fasteners used, assembly process sequence needs to
bestandardizedImplications at M1 stage1 If we use this, will
achieve a variable cost of $37 which will vastly improve my project
performance (target is $41.25 )We need to conduct more tests to
gain confidence, investment is not an issue but would like to
frontload testing in order to2 run more testsCan build only the
part assembly and check for any problems in fastening, again
require frontloading in order to understand3 any problem in process
w.r.t workability, sequence and qualityStatus/Implications at M2
stage1 Have met weight and cost requirements of project, this
assumption is no longer requiredTesting is done and we are
confident of part performance. We have also introduced precautions
in case of fire while machining magnesium2Process training is going
on as part of production preparation. Process can be done as per
requirements.3 13. Any Questions [email protected]
