S&R Best Practice Test Track:
Generic Layout – Surface Details
Mark Shkoukani
VO -FAE
Squeak & Rattle
8/26/2003
1
1
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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2
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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3
Best Practice S&R Test Track Layout
Cobblestone
Washboard
Vienna Block
Rope
Raised
Vienna Block
Angle Iron
DPG RB / EB
Body Twist
Straight
Body Twist
on Turn
Speed
Transition
400’
See following slide for details.
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4
Best Practice S&R Test Track Layout
Section
Concerns Identifiable
Driver Actions
Distance
(ft)
Speed
(mph)
Time
(sec)
Signs
1. Cobble Stone
Chassis clunk and pop, loose
stock
Maintain steady 5 mph
30
5
4.1
COBBLE STONE
Suspension, Frame, Mounts
2. Vienna Block
Interior trim S&R
Accelerate smoothly to 15 mph
100
5 -> 15
6.3
VIENNA BLOCK
Interior (e.g. door panel)
3. Raised Vienna
Block
Interior trim S&R
Maintain steady 15 mph
100
15
4.5
RAISED VIENNA
Interior
4.Rough Brick/
European Brick
Chassis clunk and pop
Maintain steady 15 mph
100
15
4.5
ROUGH BRICK/ EUROPEAN BRICK
Underbody, Chassis, Frame, Mounts
5. Transition
Not applicable
Decelerate to 2.5 mph
30
15 ->5
6. Body Twist on Turn
Body creak, chassis clunk and
pop
Maintain steady 2.5 mph
70
5
9.5
7. Transition
Not applicable
straighten vehicle out
20
5
2.7
8. Washboard
Specific interior trim S&R
frequencies
Accelerate smoothly to 15 mph
100
5 ->15
6.3
WASHBOARD
Interior (e.g. IP)
9. Ropes
Interior trim S&R noticeable with
lighter impact force inputs
Maintain steady 15 mph
100
15
4.5
ROPES
Interior
10. Angle Iron
Chassis S&R requiring greater
impact force inputs
Maintain steady 15 mph
100
15
4.5
ANGLE IRON
Underbody, Frame, Suspension, Mounts
11. Transition
Not applicable
Decelerate to 2.5 mph
30
15 ->2.5
12. Body Twist
Straight
Body creak, chassis clunk and
pop, loose stock
Maintain steady 2.5 mph
40
2.5
1.7 DECELERATE
TURN & TWIST
Body, Frame, Suspension, Mounts
2 DECELERATE
10
13. Exist
BODY TWIST
Body, Frame, Suspension, Mounts
Exit
5
Total:
820 ft
60.6 sec
5
5
7/1/2001
0
8/7/2001
0
6/30/2001
1
8/6/2001
7
6/29/2001
0
8/5/2001
Test Track Total Concerns After Shutdow n
Im proved Test Track
6/28/2001
2
8/4/2001
6/27/2001
2
8/3/2001
3
6/26/2001
3
8/2/2001
7
6/25/2001
0
8/1/2001
6/24/2001
2
7/31/2001
2
6/23/2001
1
7/30/2001
0
6/22/2001
2
7/29/2001
6/21/2001
6/20/2001
3
7/28/2001
4
6/19/2001
2
7/27/2001
2
6/18/2001
1
7/26/2001
2
6/17/2001
0
7/25/2001
1
6/16/2001
2
7/24/2001
2
6/15/2001
3
7/23/2001
6/14/2001
1
7/22/2001
6/13/2001
2
7/21/2001
6/12/2001
0
7/20/2001
1
6/11/2001
2
7/19/2001
6/10/2001
4
7/18/2001
10
9
8
7
6
5
4
3
2
1
0
6/9/2001
6/8/2001
1
7/17/2001
7/16/2001
Internal S&R Data - KTP
Te s t Track Total Conce rns Be fore Shutdow n
Old Te s t Track
10
1.28 C/1000
9
8
7
6
5
4
3
2
1
0
0
3.67 C/1000
9
8
7
6
4
5
5
2
3
1
0
6
182% Increase in Internal Concern findings
6
Internal S&R Data - OAP
S&R - Oakville Assembly
Concerns Before/After Best Practice Test Track Installation
63
70
80% Increase
60
50
C/1000
35
40
30
20
10
0
June 25
Before BP Test Track
July 23
After BP Test Track
Week
7
7
External Data - KTP
Squeak & Rattle Frt & RR UnderBody - KT P
R/1000 (N50 & N51)
16
Test Track Modifications
14
3.5% Improvement
10
8
3MIS
6
4
2
1
Ju
n01
Ju
l-0
1
A
ug
-0
1
S
ep
-0
1
O
ct
-0
1
N
ov
-0
1
D
ec
-0
1
ay
-0
M
A
pr
-
01
01
ar
M
Ja
n01
Fe
b01
ec
-
00
00
D
ov
N
O
ct
-0
0
00
ep
-
S
ug
-
00
0
A
R/1000
12
Month of Production
Total S&R Data - KTP
247
20% Improvement
6% Improvement
198
250
185
200
TGW
150
100
50
0
2001
2002
2003 YTD
Model Year
Best Practice Test Track contribution : ~ 1R/1000, and 7 to 10 TGW based on KTP.
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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 Estimates
Plant
Plant Contact
FAE Cost Estimate
Shkoukani, Mark
Test-Track
Cost $000
Enclosure
Cost $000
Re-arrange.
Cost $000
$400.000
$350.000
$377.199
$973.770
$1,236.084
Total Cost
$000
$750.000
Comments
This cost does not include any re-arrangement
cost
AAI
Watson, Paul (P.)
Atlanta
Kromer, Mark (M.)
Chicago
Gupta, Ajay (A.)
$700.00
$500.00
$1,140.00
Cuautitlan
Barba, Jose (J.I.)
$210.00
$350.00
$1,180.00
Dearborn Car
Klebe, Daniel (D.F.)
$600.00
$500.00
$150.00
Dearborn Truck
Thien, Do
$406.10
$500.00
$0.00
$906.10
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
$0.00
$727.53
Edison
Kentucky Truck
Rearrangement cost includes Services/Safety,
and engineering work
This cost is to implement the track outside. It will
$2,340.000
cost 3.26M if inside.
$2,587.053
$1,740.00
Rearrangement cost includes Services/Safety,
and equip. for data collection
$1,250.00 Need cost breakdown
Total test track cost is $613K. P221 Redbook
will cover $207.9K
$0.00
Gharib, Mohammed
$727.53
Lorain
$0.00
Louisville
Massengill, David
Michigan Truck
Lucas, James (J.O.)
$429.00
$450.00
$669.00
Norfolk
Dick Kraft
$500.00
$700.00
$2,900.00
Oakville
Moss, Gay (G.)
$0.00
$865.00
$0.00
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
$1,075.00
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
Total
Leppi, Christophe
$440.00
$810.00
$1,001.00
$2,251.00
$8,375.33
$13,741.80
$9,153.41
$32,387.54
$500.00 In Door Track
$1,548.00
Need to acquire property, and many other misc.
$4,100.00 items
$865.00
Need cost breakdown. Rearrangement includes 2
bay w/repair hoist, and clear vision runway
* Cost variation exist since the cost/analysis was provided by the individual plants and since rearrangement 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
Length:
30 ft
Width:
10 ftand Operator Training
Test Track Layout
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12
Surface 2 & 3: Vienna Block
Length:
100 ft Uniform Vienna Block, 100 ft Stepped Vienna Block
Width:
104”
Uniform Vienna Block
Stepped Vienna Block
40”
24”
40”
40”
24”
40”
TBD
100’
Track Width ~ 66”
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13
Surface 2 & 3: Vienna Block
Uniform Vienna Block
Stepped Vienna Block
(~1” Step in Height)
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14
Surface 2 & 3: Vienna Block Specification
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15
Surface 4: Rough Brick / European Brick
Length:
100 ft Rough Brick / European Brick side-by-side
Width:
10 ft
Currently no spec available on brick or layout
Rough Brick
Rough Brick
European Brick
European Brick
30”
30”
30”
30”
100’
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Track Width ~ 66”
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Surface 5: Transition
Length:
Width:
30 ft
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:
Width:
20 ft
10 ft
Brushed concrete section used to straighten the vehicle out from the turn.
20
20
Surface 8: Washboard
Length:
Width:
100 ft
10 ft
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Surface 9: Ropes
Length:
Width:
Spacing:
100 ft
10 ft
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 surface
Length:
100 ft
Width:
10 ft
Assume ave. spacing: ~ 5ft
Pieces required:
~ 20
23
23
Surface 11: Transition
Length:
Width:
30 ft
10 ft
Brushed concrete surface used to brake from 15 mph to 2.5 mph.
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24
Surface 12: Body Twist - Straight
Length:
40’
Width:
10 ft
Wavelength: 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:
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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
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