Engineering Specification
ESFU5A-8079-AA
PART NAME: PART NUMBER:
N/A (Seamless Coolant Hose Port) ESFU5A-8079-AA
LET
FR
LET
FR
DATE LET SECT REVISION DR CK PREPARED BY:
Nader Noureddine
04-17-2015 N/A N/A Initial Release- Notice # AC00-E-12322631-088 N/A N/A CHECKED BY:
N/A
DETAILED BY:
N/A
REFERENCE:
N/A
APPROVAL
Coolant Hose TS:
Jeff Luther
STANDARD NOTES:
FOR CURRENT RELEASE STATUS, SEE WERS ENGINEERING NOTICE.
CONTROL ITEM –IDENTIFIES CRITICAL CHARACTERISTICS DESIGNATED BY THE CROSS FUNCTIONAL
TEAMS DEVELOPING THE PRODUCT. THESE, AND ADDITIONAL CRITICAL CHARACTERISTICS IDENTIFIED
BY PROCESS REVIEWS, MUST APPEAR ON THE CONTROL PLANS ACCORDING TO ISO/TS 16949. THESE
CONTROL PLANS REQUIRE PRODUCT ENGINEERING APPROVAL.
GIS1 Item Number: 27.60
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Engineering Specification
ESFU5A-8079-AA
1. GENERAL
The purpose of this specification is to define the measurement engineering requirements of a seamless coolant
port. This specification is a supplement to the released drawing, and all requirements must be met. Exceptions to
this specification are not permitted.
SAFETY NOTE: The test procedures in this specification are specifically designed to evaluate part performance
and durability failure mechanisms. Temperature and pressure extremes, mechanical loading, and chemical
exposure are all used to create simulated part failures. The testing facility is responsible to ensure all required
laboratory safety precautions are followed.
2. SUMMARY OF DESIGN VERIFICATION, PRODUCTION VALIDATION, AND IN-PROCESS TESTING
Design Verification (DV) tests verify the part design meets functional engineering requirements. DV testing
completion, and Ford Product Development Engineering approval of Design Verification Plan and Report (DVPR),
is required prior to any design being approved for production tooling.
Production Validation (PV) tests validate the production manufacturing process produces parts as designed. PV
testing completion, and Ford Product Development Engineering approval of Production Validation Plan and Report
(PVPR), is required prior to any manufacturing process being approved for production.
In-Process (IP) tests ensure the production manufacturing process remains capable and stable. Ford Product
Development Engineering approval of manufacturing process control plan, and associated In-Process Testing
Plan, is required prior to any manufacturing process being approved for production. IP testing is also commonly
known as Continuing Conformance (CC) testing.
All sample sizes defined in this specification are minimum required per part number. Ford may require increased
PV quantity, and / or increased IP quantity, and / or increased IP frequency after manufacturing process and
control plan review. Any test plan, including use of surrogate data or additional test quantities to ensure statistical
conformance, must be approved by Ford Product Development Engineering. Any sample size identified as
"Testing not required", only implies conformance testing demonstration is not required. "Testing not required"
does not permit acceptance criteria nonconformance. Ford reserves the right to require acceptance criteria
conformance demonstration testing at any time.
DV, PV, and IP sample size and acceptance criteria are summarized in Table 1.
Table 1. Test summary provided as reference only. See specific test for complete details and requirements.
DV PV IP
Test Name Sample Sample Sample Acceptance Criteria
Size Size Size
- LSL < Land Measured Points < USL
Seamless Coolant Port 3-Plane 30 parts / - Land Diameter Capability ≥ 1.67
3.1 - -
Measurement tool cavity - LSL < Bead Measured Points < USL
- Bead Diameter Capability ≥ 1.67
3. TEST PROCEDURES AND ACCEPTANCE CRITERIA
3.1. 3 Plane Measurement
3.1.1.Instrumentation
Coordinate Measuring Machine – CMM
3.1.2. Ambient conditions.
Temperature: 20+/-10 C
Absolute Pressure: 101.3+/-20 kPa
Relative Humidity: 50+/-40%
GIS1 Item Number: 27.60
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Engineering Specification
ESFU5A-8079-AA
3.1.3.Procedure
Test must be performed on all Seamless Coolant Ports.
All samples must have same orientation through the measurement process.
Locate the nominal axis line for the port with respect to the datum referenced on the part drawing.
Measure the outer land radius of the port at 3 land planes (1, 2, and 3) for 360 degrees, every 12
degrees (30 points per plane). See Figure 1.
- Land plane 1 must be 5mm from hose stop.
- Land plane 3 must be 5mm from back of the bead.
- Land plane 2 must be the middle plane between land plane 1 and land plane 3.
Similarly, measure the outer bead radius of the bead at 30 points with the same angularity.
Enter the land radius measurements in an Excel spreadsheet and calculate the average land radius
for all the samples in each land plane. See Figure 2
Similarly, enter the bead radius measurements in a separate Excel spreadsheet and calculate the
average bead radius for all the samples.
Using a Spider Plot/Graph, plot the average of the land radius value for all samples taken at the same
angular point. See Figure 3
Similarly, plot the average of the bead radius value for all samples taken at the same angular point.
Generate and complete the "spider plots" to provide a graphical view of the port concentricity at each
Land plane. See Figure 3
Similarly, generate and complete the "spider plots" to provide a graphical view of the port concentricity
at the bead plane.
Compare the spider plots with the Upper Spec Limit (USL) and Lower Spec limit (LSL). See Figure 3
Calculate the diameter values for each plane (0-180, 12-192, 24-204…etc.). See Figure 4
USL x
Calculate the capability for each calculated diameters; Capability= Min
3S
; x 3SLSL ). See
Figure 4
Test report must include all records, calculations, and data files.
3.1.4.Sample Size
Note: this test takes place at tool validation
DV: Testing not required
PV: 30 parts / tool cavity
IP: Testing not required
3.1.5.Acceptance Criteria
All measured land radii must be between LSL and USL
All calculated land diameter capability must be ≥ 1.67.
All measured Bead radii must be between LSL and USL
All calculated land diameter capability must be ≥ 1.67.
GIS1 Item Number: 27.60
GIS2 Classification: Confidential FRAME 3 OF 5
Engineering Specification
ESFU5A-8079-AA
Fig 1
Fig 2
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Engineering Specification
ESFU5A-8079-AA
Fig 3
Fig 4
GIS1 Item Number: 27.60
GIS2 Classification: Confidential FRAME 5 OF 5
