A presentation encouraging automotive teams to stop, collaborate and listen early in the design process in order to ensure success, presented during the SAE 2014 Brake Colloquium & Exhibition 32nd Annual Panel Discussion.

1. STOP, COLLABORATE, & LISTEN
Ryan French, Trelleborg Sealing Solutions
2014.10.05
Encouraging Early Design Collaboration To Ensure Success

2. SAE INTERNATIONAL 2
STOP…

3. SAE INTERNATIONAL 3
collaboration
/kə labə rāSHən/ˌ ˈ
noun
the action of working with someone to produce or create
something

4. SAE INTERNATIONAL
Historical Workstream
4

5. SAE INTERNATIONAL
Conventional Problem Solving
5
Snowball effect…

6. SAE INTERNATIONAL
We need to ask ourselves…
6
1. Is this the most effective way to problem solve?
2. How can we better utilize our resources and expertise to
provide the best possible solutions?
3. Can we make data-driven decisions early on that will
prevent risk and potential issues?

7. SAE INTERNATIONAL 7
Collaborate…

8. SAE INTERNATIONAL
Recommended Workstream
8

9. SAE INTERNATIONAL 9
Main System Interfaces – Noise Resolution

10. SAE INTERNATIONAL
Think Outside the Box
10
Solution
data
data
data

11. SAE INTERNATIONAL
Example (Think Outside the Box)
11
Problem: Increase MPG on Ford F-150
Inside The Box: Weight and/or Drag Reduction
Outside the Box: Build an Aluminum F150
-700 lbs

12. SAE INTERNATIONAL 12
Listen…

13. SAE INTERNATIONAL
Focused Collaboration
13
1. Design For Manufacturing (DFM)
• Prior to initial drawing release
• Full supply base input provided (Tier 1, Friction, Insulator)
• Initial prototype options evaluated early on
2. Establish Bond Process “Best Practice”
• Each application/system has guidelines established
• Full supply base input provided (Tier 1, Friction, Insulator)
• Initial bond study (including T-pull, adhesive coverage) carried
out with prototypes from DFM review, allowing established
guidelines and subsequent data to pre-certify materials
3. Establish Noise Resolution Process
• With input from DFM & bonding “Best Practice”, conduct a full
system review --> understand sensitivities early on!
• Full team including OEM, Tier 1, Friction, Insulator Suppliers
• Allow the data to drive additional decisions, changes, next steps

14. SAE INTERNATIONAL
Temperature Effects on PSA’s
14
Adhesive Temperature
Adhesive
FlowCarbonization
(no recovery)
+-
Optimal NVH

15. SAE INTERNATIONAL
Process Matters
15
Bonding Issues Fixed
With Process Change =

16. SAE INTERNATIONAL
NVH + Shim Durability
16
0% noise result mDVP&R for Pre-Release of
Insulator (project specific)
+

17. SAE INTERNATIONAL

18. SAE INTERNATIONAL
Success Story
18
Chrysler KL Rear (Jeep Cherokee)
 0% noise solution (dyno &
vehicle sign-off)
 Insulator pre-release
mDVP&R
 OE/Tier1/Friction/Insulator Bond
Process Sign-off (multi locations)
 No post-launch NVH/bond
concerns (12 months in service)

19. SAE INTERNATIONAL 19
"If everyone is moving forward together,
then success takes care of itself."
Henry Ford

20. SAE INTERNATIONAL
Thank you!
20