Integrated Quality Assurance in Engine Assembly

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1 Integrated Quality Assurance in Engine Assembly ThyssenKrupp System Engineering

2 ThyssenKrupp System Engineering Division Testing Solutions ThyssenKrupp System Engineering - internationally operating group company of ThyssenKrupp Industrial Solutions AG system partner of the automobile industry for all major process chain components of car body and powertrain. The new business fields include automation solutions for alternative accumulator and drive systems, solutions for innovative lightweight construction concepts as well as assembly and test systems for the aircraft industry. ThyssenKrupp System Engineering Division Testing Solutions - Core business as a developer, designer, manufacturer and supplier of turn-key testing facilities in associated aggregate assembly processes for powertrain for the automotive and automotive supply industries. Professional testing solutions for engines, transmissions and axles guarantee quality and improve productivity. As a turnkey supplier we work with our customers to develop strategies and solutions for highly complex product and assembly requirements. We are securing our technological edge with newer and newer developments. By doing so, we benefit from our comprehensive, internally bundled expertise in the fields of service, test and assembly. Decades of experience in measurement and instrumentation technology, the successful development of customized test benches as well as entire test areas and highly qualified, service-oriented employees are an essential benefit for our customers. We determine the optimal parameters for product testing in our own development centers. As part of our simultaneous engineering services, we support our customers in developing their very specific quality strategy for assembly. The diversity of our ability ranges from integrated tests, leakage tests, function tests as well as customized measurement technology and even includes engineering services of the purest kind.

3 What is meant by Integrated Quality Assurance (IQA)? For tomorrows markets high quality and low costs are essential factors of success. IQA is defined as the integration of systematic testing into the assembly process in order to achieve total customer satisfaction by improved quality and reduced costs. IQA stands for the systematic development and integration of a quality assurance process into the manufacturing process of a product. The IQA development process takes all input parameters and boundary conditions into account and weights them according to the customer requirements, for example: engine defect possibilities engine design assembly process assembly concept qualification of operators available area budgets / costs This method reproducibly assures the most cost effective solution for the desired quality level of a product.

4 Quality Improvement and Cost Reduction Detect faults before the customer does! The IQA strategy provides improved quality due to tailor-made test pro-cesses with enhanced defect detec-tion allowing a systematic improve-ment of the assembly process. Several in-line tests improve testing accuracy and allow to determine defects causes. Detect faults before they get expensive! Lower repair costs because of shorter defect running times and continuous improvements Lower warranty costs by higher quality and the ability for specific call backs Lower invest costs compared to traditional hot testing due to less stations and less space requirement Lower operating costs by automation and less environ mental risks

5 IQA-Example Valve leak test Valve collet check Crankshaft with piston turnover Piston ring detection Correct position of emblem on cover? Valve clearance correct? Valve keys present? Is timing correctly adjusted? Make sure, that the ignition is working! Make sure, that the injection system works! Are all sensors correctly wired? Detect faults before the customer does. Recognise leaking valves before the engine is completely assembled! Does the oil pump provide sufficient oil pressure? Leak not to be detected by oil drops only, but before oil is filled! Is the oil circuit faulty? Detect faulty installed piston rings before the engine has ignited for the first time! Is the axial clearance correct? Detect excessive bearing friction on crankshaft installation ENGINE OK! IQA is a flexible concept. The illustrated assembly line with realised IQA strategy is an example to show the No Fault Forward principle. No Fault Forward means minimization of: defect running times non value-adding operations repair expenditures. Leak test complete engine Engine function test as cold test AUDIT hot test End of line test Unload engine Load block Crankshaft turnover

6 Test Technology Engineering For the systematic development of a quality assurance concept considering all product and assembly requirements we are supporting our customers within engineering projects. The integration of all involved departments both in your and in our company ensures the development of an optimal test concept. The extent of the SE project depends on the planning level of your project and your special requirements. The possible range of approaches reaches from Workshops for individual test station concepts to long-term Simultaneous Engineerings for complete IQA concepts. The following topics could be addressed within of an Engineering engine design to test assembly process FMEA test + repair philosophy system layout floor space budget costs planning inquiry/specification In over 45 accomplished Engineering projects we successfully developed various Test Concepts together with our customers.

7 Test Technology Development As the complexity of engine technology is increasing rapidly and each engine can surprise by unexpected characteristics or requirements the development of test methods is essential. Our test technology laboratory team consists of 5 dedicated experts: engineers in mechanical/ electrical engineering physicist master craftsman Another 6 electrical engineers are developing test specific hard- and software solutions for the electric and electronic engine systems. Possessing 3 development test stands we are able to offer the full range of cranked mappings from heavy duty diesel engines to passenger car engines to single components. We have the strong believe that innovation can only be successful in the long run, when its quality has been proven. Therefore also our ideas will be tested on the same benches your products are examined on. Through own Development Projects our people create solutions for your products of tomorrow already today. The tasks of our development team consist of: preliminary investigations to check cold test ability of engines project specific developments R/D projects with customers for new test methods own R/D projects

8 Leak Testing Leakages belong to the most often assembly and component failures. In order to avoid that the customer finds out about those failures first, we supply the solution for your specific test application. Choosing the optimum test method requires competence and experience. Working together with all major leak test device suppliers in the world, our experts can help you from the start, to find suitable measuring technologies. Our long lasting experience guarantees a successfull integration into production, independently if it is a simple air leak test, a test with a robotled sniffling sensor or a hydrogen based test method. The following applications show examples of leak test systems: component leak test (e.g.cylinder heads) engine system leak test (e.g. fuel/injection systems) complex system leak test (e.g.short/long block leak test)

9 Engine Function Test (EFT) Worldwide, leading car and truck manufacturers assure their engine quality with our Engine Function Tests (EFT) without having started them once. The EFT checks the mechanical integrity the electrical integrity and the functionality of engine systems. By testing the interaction of all engine components assembly faults or component defects can be detected accurately and reliably. Station concepts may range from manual laboratory beds for your own development to semi-automatic and automatic production test benches. Concepts are depending on your requirements like test content, available cycle time and available qualified operation staff. Depending on your engine design the following - partly patented - tests could be part of an engine function test: mechanical integrity test of crank and valve drive function test of sensors and actuators function test of ignition system verification of noise and vibration behavior (NVH) functionality test of turbo or supercharger functionality test of injection system (gasoline and diesel common rail) Specific tests for special compo-nents or systems are developed together with our customers beside the above mentioned general test methods.

10 Integrated Tests at IQA Component Checks help avoiding missing or wrongly assembled parts by presence or geometry checks using various test methods like: laser air pressure picture processing system Where tolerances have to be checked Dimensional Checks are used to measure length or distance: bearing diameters bump height squish height valve crearance The assembly quality and component behavior of moving engine parts can be checked by integrated Torque to Turn Measurements during single assembly steps: crankshaft assembly piston assembly camshaft assembly

11 Quality Data Analysis and Management Fotocase.de ThyssenKrupp System Engineering offers software tools for all tasks of the quality control in the assembly process from the data acquisition through the evaluation to the data management. ups64, the tool for measurement and evaluation QDM, the software for analysis and data management The permant enhancement of the universal test software ups64 during the last 15 years and the experience from more then 230 applications is the base for the The quality data management tool QDM combines all data of the production process. These are data from test stations data from assembly machines data of components To optimize the test and production processes the available statistical analysis can be used to correlate the different data. Additional a part tracking system for components and sub-assemblies is integrated in the software. extensive state of the art methods for measuring and evaluation easy to handle wizards for the parameterization and the test procedure management

12 Worldwide References 320 Cold Test Stands sold to 59 Customers in 25 Countries 53 Simultaneous Engineering Projects sold to 25 Customers in 11 Countries

13 ThyssenKrupp System Engineering GmbH Richard-Taylor-Str. 89 D Bremen Phone Fax /2011

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