Design for Manufacturing project applied to an Automatic Transmission Oil Pump System

1. Stanford
University
ME217 Design for Final Presentation - ME217B
Manufacturability
Improved Oil Pump System for
the 4L60-E Transmission
GM of Mexico The Pumpkins
Ramos Arizpe Complex
June 2000 Paulino Rivera Carlos B. Ramirez Fernando J.
Valdes
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2. Stanford Project Advertisement
University
ME217 Design for
Manufacturability
Introduction
Background
Product Definition
Concept Development
Design Recommendation
Competitive Analysis
GM of Mexico
Ramos Arizpe Complex
June 2000
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3. Stanford Market & Competition
University
ME217 Design for • GM’s transmissions have a rich tradition of
Manufacturability
excellence
• GM Powertrain dominates the
Introduction
Background Automatic Transmisison
Product Definition business, with 43% share,
Concept Development
Ford 29%, DC 28%
Design Recommendation
Competitive Analysis
• 4L60-E Automatic Transmission Produced
in Ramos Arizpe since 1999
• Applications: Suburban, Tahoe, Yukon,
GM of Mexico
Ramos Arizpe Complex
C/K (domestic and export)
June 2000
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4. Stanford Problem Statement
University
ME217 Design for • The oil pump system is critical for the
Manufacturability
performance of the transmission
• A large number of transmission failures
Introduction
Background
are associated with the oil pump
Product Definition
Concept Development
Design Recommendation
Competitive Analysis
• Goal of this project:
Improve the Reliability of the 4L60-E Oil Pump
GM of Mexico System, while reducing its cost
Ramos Arizpe Complex
June 2000
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5. Stanford Product Definition - ME217A
University
ME217 Design for • Edith Wilson’s Checklist Improved
Manufacturability • 4L60-E Pump Benchmarked vs. Ford and
DaimlerChrysler Transmissions
• CVCA showed multiple customers
Introduction
Background
Product Definition
Concept Development
Design Recommendation
Competitive Analysis
54
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GM of Mexico
Ramos Arizpe Complex
June 2000
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6. Stanford Key Relationships
University
ME217 Design for
• Value Graph: showed importance of two
Manufacturability key internal components: Rotor and Slide
• QFD Phase I: showed DPTV’s and End
Introduction Clearance as highest relative E.M.’s
Background
Product Definition • QFD Phase II: Rotor, Pump Body & Slide
Concept Development most important
Design Recommendation
Competitive Analysis • Cost-Worth identified candidates for:
• Cost Reduction: Cover & Shaft, Pump
Body
• Enhancement: Rotor, Slide, Slide
GM of Mexico
Springs
Ramos Arizpe Complex
June 2000
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7. Stanford Function-Structure Tree
University
ME217 Design for
• Revealed Product Complexity: functions
Manufacturability not related to the Pump Oil main function
1. Displace fluid
Introduction 2. Regulate fluid
Background 3. Provide structure
Product Definition
• Seal
Concept Development
Design Recommendation • Support
Competitive Analysis
• Most Important
Discovery in
GM of Mexico ME217A
Ramos Arizpe Complex
June 2000
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8. Stanford Pareto was right...
University
ME217 Design for • Fishbone Diagram and DFA showed
Manufacturability
redundancy in Rotor/Slide selection
process
Introduction
Background • FMEA revealed Rotor/Slide Stucked as
Product Definition
main cause of oil
Concept Development
Design Recommendation
pump failure 500 1.000
Competitive Analysis
• SMA: easier to replace 375 0.750
entire oil pump than to 250 0.500
125 0.250
service 0 0
Rotor/Slide Stucked
Defective Parts
Pump Body Distortion
No Accesibility
External Leaks
Missing Parts
Improper Assembly
Pump Cover Convex
High Temperature
Engine Input Speed High
GM of Mexico
Ramos Arizpe Complex 70%
June 2000 CAUSE
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9. Stanford Concept Development
University
ME217 Design for • Design Criteria expanded from QFD:
Manufacturability
Introduction
Background
Product Definition
Concept Development
Design Recommendation
Competitive Analysis
• Morphological Analysis generated 3
concepts: Single Slide/Rotor, Pump-in-a
Box and Three-in-One Pump
GM of Mexico
Ramos Arizpe Complex
June 2000
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10. Stanford Three-In-One Pump
University
ME217 Design for
• Pugh Analysis revealed as better concept
Manufacturability
COVER SUPPORT
COMPONENTS
& SHAFT
Introduction
Background
PUMP
Product Definition PUMP OIL
SUPPORT
Concept Development
Design Recommendation
Competitive Analysis CASE SEAL
COVER TRANSMISSION
• Improved: Reliability, FTY, DPTV, Robust
GM of Mexico
Design, Performance
Ramos Arizpe Complex • Use of a Single Slide/Rotor (5 to 1)
June 2000
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11. Stanford Current vs Proposed
University
ME217 Design for
Manufacturability
COVER & SHAFT COVER & SHAFT CASE COVER
Introduction
Background
Product Definition
Concept Development
Design Recommendation
Competitive Analysis PUMP BODY PUMP
SUPPORT
CURRENT 3 in 1 Concept
GM of Mexico
Ramos Arizpe Complex
June 2000
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12. Stanford Design Recommendation
University
ME217 Design for
Manufacturability Product Specification
• Same size than current oil pump
• Weight assumed unchanged
Introduction • Case Cover error proofed for alignment
Background
• Case Cover made of Aluminum SAE 390
Product Definition
Concept Development
Process Specification
Design Recommendation
• Sub-Assembly: one machine less (Rotor/Slide),
Competitive Analysis
one worker reduced, fixtures error proofed
• Machining: Pump Support line from existing
PumpBody cell, addition of Case Cover cell, lean
manufacturing, error proofing devices, no impact
GM of Mexico in labor
Ramos Arizpe Complex
June 2000
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13. Stanford Competitive Analysis
University
ME217 Design for • Business Case
Manufacturability
• Payback: 1 Year
• ROI: 94.6%
Introduction • Investment: $ 2.12 MUSD
Background • NPV: $ 2.22 MUDS
Product Definition
Concept Development • Development Time
Design Recommendation • 18 months from project approval
Competitive Analysis
• Risks
• Envisioning: limited product life
• Design: packaging within envelope, same weight
• Execution: material cost increase, validation fails
GM of Mexico
Ramos Arizpe Complex
June 2000
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14. Stanford Quality Scorecarding
University
ME217 Design for • Project Objective (Biggest Y)
Manufacturability Improve the Net Present Value (NPV)
• Objective Measures (Y)
Introduction
Improve the Reliability measured in Defects per
Background Thousand Vehicles (DPTV’s) and First Time Yield
Product Definition (FTY) in the assembly line.
Concept Development • Control Factors (vital X’s)
Design Recommendation End clearance between the Rotor/Slide and Pump
Competitive Analysis Support face, Pump Main Line Pressure.
• Noise Factors (V’s)
Oil Pump Support distortion, manufacturing variation of
Slide/Rotor/Pump Face.
GM of Mexico • Transfer Function
Ramos Arizpe Complex Cashflow Analysis Spreadsheet
June 2000
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15. Stanford Conclusions and
University
Recommendations
ME217 Design for
Manufacturability
Conclusions
• Robust Product Definition
Introduction
• Strong Business Case
Background
Product Definition • Higher Risk: limited product life
Concept Development • Still profitable! (trucks)
Design Recommendation Recommendations
Competitive Analysis • Obtain management commitment
• Form project team
• Enhance communication
• Keep focus on customer
GM of Mexico • Revisit dfM tools to measure results
Ramos Arizpe Complex
June 2000
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16. Stanford
University
ME217 Design for
Manufacturability
QUESTIONS
&
ANSWERS
The Pumpkins
GM of Mexico
Ramos Arizpe Complex Paulino Rivera Carlos B. Ramirez Fernando J.
June 2000 Valdes
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Tuesday, March 13, 2012