FORD W-CMS-2014 CONTROL OF CASTING MANUFACTURING PROCESSES (3rd Edition).pdf

1、FORD MANUFACTURING STANDARDCONTROL OF CASTING MANUFACTURING PROCESSESW-CMS3rd EditionStanda r d : W - C MS I ssue D at e: 14 - J uly - 08 G loba l M a nuf a ct uring S tandards R ev i si on D at e 14 - D ec - 11 W-CMS 3rd EditionGIS1 Item Number: N/AGIS2 Classification: ProprietaryPage 1 of 10Ford M

2、otor Company Date Issued: 14-Jul-2008 Date Revised: 14-Dec-2011W-CMS DEVELOPMENT TEAM:Executive Sponsor:Terry AldeaAuthor:Tim CovertChris GambinoJames LoefflerGlobal Contributors:Glenn Austin Chris MoranoPaul Ballas Venkat NaraDennis Barbier Ed OswaldDr Alexandre Barros Dr Ozgur OzdemirDr Julian Bas

3、sett Brian NellenbachJoe Caruso Eben PrabhuAlan Cooke Patrick PryceDavid Croom Ratan RayRodrigo Cunha Tom RecchiaBill Curtiss Tom ScislowiczRoger Davis Vijay ShendeJoe Filipovich Randall ThomasBrad Guthrie Frank TibaudoPaul Harrison Reiner TillenburgRon Hasenbusch Uemit UrsavasStefan Heinz Zhi Jian

4、(Eddie) Wang Martin Jones Mike WarrenMike Judd Glen WeberJani KalidindiStanda r d : W - C MS I ssue D at e: 14 - J uly - 08 G loba l M a nuf a ct uring S tandards R ev i si on D at e 14 - D ec - 11 W-CMS 3rd EditionGIS1 Item Number: N/AGIS2 Classification: ProprietaryPage 2 of 10Ford Motor Company D

5、ate Issued: 14-Jul-2008 Date Revised: 14-Dec-2011ITEM SUBJECT PAGE1. DESCRIPTION AND REQUIREMENTS 41.1 SCOPE 41.2 SPECIFICATION OF REQUIREMENTS 51.3 PROCESS SPECIFICATION 51.4 PROCESS AND QUALITY CONTROLS 51.5 CONTROL PLAN 51.6 STATISTICAL METHODS AND PRE_CONTROL CHARTING 62. COMPUTER AIDED ENGINEER

6、ING GUIDELINE 7CASTING SIMULATION MODELING GUIDELINE2.1 FLUID FILL variation is in the measuring system). In some cases the process variable naturally demonstrates a small variation between samples or drift, as long as it doesnt go too close to the pre-established control limit. Some examples of key

7、 process input variables where pre-controls work well: Time dependant process factors (i.e. Mg fade in ductile iron) naturally drift, which is acceptable if controlled to a safe margin within the process limits. Alloy chemistry demands allow nominal offset biased targeting from the specification mid

8、 point. Pre-control provides key metal casting processes with pre-established control limits, process specification limits and reaction points to assure process control for those process characteristics indentified as HICs in W-CMS. The application of Pre-control charting is broken down into the fol

9、lowing 2 steps: A. Collection of Data. The process characteristic being monitored shall have its data displayed in a defined frequency, time-dependent plot. By charting the process data, trends are displayed for the attending operator and site management to quickly assess the variable being monitore

10、d. Utilized for those process-specific HICs. Charting system must provide trending assessment. B. Control of Process. Establishing pre-set or fixed control limits that are safely within the process or specification limits, the process shall be controlled against shifting or drifting outside of the p

11、rocess limits. Using the universal Green-Yellow-Red traffic light color codes, the attending operator and site managers shall implement reaction steps, contain suspect product, and prevent casting parts with a process factor out of specification. In-station warning or indicator methods should be in

12、place to trigger a reaction from the operator Instructions must indicate reaction points and plans: *Yellow = Adjust Process at Pre-set or Fixed Control Limits *Red = Stop Process, Contain Aluminium HPDC: o X-Ray Acceptance Criteria ASTM E-505 Level X maximum for all types or Porosity specified to l

13、evel X or better Ductile Iron castings: o X-Ray Acceptance Criteria ASTM E-446 Level X maximum for all types *(Where X is defined in the ASTM standards as a number in the range 1 to 4) The scope of the X-ray Quality Operating System Guideline is primarily for the non-destructive testing and inspecti

14、on of metal cast components from supplier production operations of ferrous and non-ferrous materials. It is applicable to all X-ray inspection systems including 100% production inspection, production sample audit and diagnostic inspection type systems. Non-destructive testing using x-ray inspection

15、applies as a detection method for casting failure modes such as: shrinkage porosity, sponge porosity, gas porosity, inclusions (foreign material of dissimilar metal density differences), cold shot (cold flow) - porosity trails, and large voids/large cracks. Capability of detection for x-ray systems

16、may be limited by the geometry/size of the defect and may therefore be inadequate for detecting: cracks (tightly closed), inter-metallic inclusions (oxides, sulphides, etc), cold shuts, non-knits, folds, or core contamination. The purpose is to provide a guideline for safe operation of x-ray inspect

17、ion in accordance with applicable regulations and to communicate the x-ray inspection quality operating system expectations for global standardization by promoting best practices. An x-ray checklist (see X-ray Checklist Tab) is available for x-ray system evaluations to these expectations. The checkl

18、ist covers the key aspects of x-ray inspection systems including: Safety (including linkage to local regulations) Manipulation (Part and/or X-ray Equipment) X-ray Source Image Quality Operating Systems Preventative Maintenance This guideline does not specify the type of x-ray system or image quality

19、 to detect a given casting anomaly. The guideline is intended to be a tool to enhance operation of x-ray inspection systems but does not make any guarantees of the x-ray inspection process because quality assurance is the responsibility of the supplier according to the processes defined in the contr

20、ol plan The x-ray specific standardization team included: Glenn Austin, Tim Covert, Bill Curtiss, Roger Davis, Brad Guthrie, Ron Hasenbusch, Martin Jones, Mike Judd, Jim Loeffler, and Glen Weber. Standa r d : W - C MS I ssue D at e: 14 - J uly - 08 G loba l M a nuf a ct uring S tandards R ev i si on

21、 D at e 1 4 - D ec - 11 W-CMS 3rd EditionGIS1 Item Number: N/AGIS2 Classification: ProprietaryPage 9 of 10Ford Motor Company Date Issued: 14-Jul-2008 Date Revised: 14-Dec-2011Standa r d : W - C MS I ssue D at e: 14 - J uly - 08 G loba l M a nuf a ct uring S tandards R ev i si on D at e 1 4 - D ec -

22、11 5. SAFE LAUNCH GUIDELINES A safe launch workplan is an important tool in verifying and validating casting quality and conformance to requirements during the product development or change management process. The objective of the safe launch workplan is to demonstrate stability and control of a cas

23、ting process through key product inspection, material testing and Non-Destructive Testing (NDT) results. A safe launch workplan is applicable for new casting production processes, a change in the casting manufacturing location or changes within the process or product including any tooling changes th

24、at affect the Production Part Approval Process status. This Safe Launch Guideline provides an outline of the key characteristics, sample sizes for both inverted delta components and all other components from the production events of Part Production Approval Process (PPAP) run-at-rate to production r

25、uns 1 5 (unless otherwise agreed upon). The Safe Launch Guideline tables are available for the most common casting processes: Ductile Iron, Gray Iron, and Aluminum Casting. Principles of the Safe Launch Plan Guidelines: All customer specifications or requirements or control plan agreements take prec

26、edent over the Safe Launch Guidelines when more stringent. The customer defined sample size shall become the specified sample size if it is greater than specified within the guideline table. All samples shall be randomly taken over the entire production lot from beginning, middle & end of the produc

27、tion run preferred including specific cavity sampling. A nonconformance found at any stage requires the sampling process to restart after containment and corrective actions are implemented for the specific item until the agreed upon consecutive production lots have met expectations A casting safe la

28、unch plan is not expected for the following requirements: Supplier Request for Engineering Approval (SREA) or PPAP for changes not related to the casting process Subcontractor process change unless the subcontractor is a casting supplier Product modified by an engineering change in which the part nu

29、mber and/or revision level changes on the tooling, but does not change the basic tooling (i.e., branding part number change) For questions, contact the Ford Motor Company Supplier Technical Assistance Engineer At the conclusion of each production event the individual characteristic should be rated t

30、o the standard G-Y-R ratings based on evidence provided to the following criteria and submit to customer: (G) - Green: Meets deliverable requirements with supporting quality of event evidence (Y) - Yellow: Does not meet deliverable requirements, containment is in place protecting Ford from receiving

31、 non-conforming material and there is an agreed upon corrective plan (R) - Red: Does not meet deliverable requirements, supplier is at risk of shipping non-conforming material and no corrective action in place. (N/A) - the item is not applicable for the specific manufacturing process A nonconformanc

32、e found at any stage requires the sampling process restart after containment and corrective actions are implemented for the specific item until the agreed upon consecutive production lots have met expectations. Once successfully completed the production control plan sample size and frequencies are to be followed. W-CMS 3rd EditionGIS1 Item Number: N/AGIS2 Classification: ProprietaryPage 10 of 10Ford Motor Company Date Issued: 14-Jul-2008 Date Revised: 14-Dec-2011