Assembled Product Design Score Card Assembly Name: Turbocharger Parts DPU 0.007541
Top-Level Product Sigma -> Assembly Part Number TS-99 Process DPU 0.032438 Performance DPU 0.101156 Predicted Field DPU 0.005829
3.290
Assembly Turbocharger
Total DPU 0.147
Total DPU Opportunities Top-level ST Sigma
0.007541 1 3.93
0.032438 1 3.35
0.101156 1 2.77
0.005829 1 4.02
0.146964 4 3.28982394
0.120000
0.100000 0.080000 0.060000 0.040000
Total DPU
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DESIGNSCORE-EN-XLS
http://templatestaff.com
2 LT Defect Proces Rate or Process Step Step Sigma ST Machining Turbines 1 3.8 Machining Compressors 2 4.5 Bearing Install to shaft 3 0.001 Assemble to Shaft 4 3.6 Balance Shaft Assy. 5 0.001 Final Assembly 6 0.0005 Totals: 6
P/N: Next Assy: 1
3 # of Applic. 10 20 2 3 2 5
4
5
Short Term Sigma: Expected long term Yield DPMO 6 7
3.90 99.189% 8145 8
Process Product Opport. Oppor. 1 10 1 20 1 2 1 3 1 2 2 10 47
dpmo 1072 67 500 5955 500 50 8145
Prod/Proc Yield DPU 99.8928% 0.0107241 99.9933% 0.0013499 99.9500% 0.001 99.4045% 0.0178644 99.9500% 0.001 99.9950% 0.0005 99.189% 0.0324384 Z-score 1.8533243
1- Generate flow chart of manufacturing processes & list in order of major process steps 2- List performance of each process step in either a defect rate (<1) or a sigma (>1, as applicable). 3- Enter number of times process is applied to make one unit 4- Retrieve the number of process opportunities from process map or Process Engineer. 5- Product Opportunities through process (5) = (3) x (4) 6- Defects per Million Opportunities 7-Expected long term yield 8- Calculated DPU for total number of applications of each process
7000 6000 5000 4000 3000 2000
Machining Turbines
As
Bearing Install
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DESIGNSCORE-EN-XLS
Avg. Part Sigma IS THIS DATA LONG TERM? yes Program: Aftermarket Auto Turbo Charger Assembly/Sub-Assembly P/N#: Supplier Part No. Description Qty. PPM Total DPU Supplier A B322 Assembly bolts 12 3 0.000036 Supplier A ASQJ562 Center Housing 1 3 0.000003 Supplier A CGS24 Cold Gas seal 1 50 0.00005 Supplier A Sl293 Compression Seal 2 500 0.001 Supplier B ASQJ563 Compressor Housing 1 45 0.000045 Supplier F WHL22 Compressor Wheel 1 0 0 Supplier B CS2 Hot Gas Carbon seal 1 2000 0.002 Supplier E CONN31 Oil Feed Inlet Connector 1 1 0.000001 Supplier E CONN32 Oil Outfeed Connector 1 1 0.000001 Supplier E OR198 O-Ring 4 0 0 Supplier E WSR11 Shaft lock washer 2 0 0 Supplier E NUT76 Shaft locking nut 2 75 0.00015 Supplier C SL282 Shaft Seal 1 10 0.00001 Supplier B SRA1 Snap Rings - A 2 0 0 Supplier C SRB1 Snap Rings - B 2 0 0 Supplier B THRB44 Thrust Bearing 1 45 0.000045 Supplier B TBR9 Thrust Bearing Retainer 2 1500 0.003 Supplier B ASQJ564 Turbine Housing 1 500 0.0005 Supplier D SHFT3 Turbine Shaft Rough 1 700 0.0007 Supplier F WHL24 Turbine Wheel Blank 1 0 0 Total Part Opportunities 40 TDU 0.007541 Note: In-house items get defects counted in process sheet Zscore 2.43 enter yes or no
5.06
LT Yield 99.249% TDU 0.00754
Total DP
4.E-03
3.E-03
3.E-03
CS2
2.E-03
2.E-03
Sl293
1.E-03
5.E-04
B322 CGS24 WHL22 CONN32 ASQJ562 ASQJ563 CONN31
0.E+00
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DESIGNSCORE-EN-XLS
Short Term Sigma: IS THIS DATA LONG TERM? yes enter yes or no Expected long term Yield DPMO
3.78 98.882% 11239.6 DPU Submitted 0.013645 0.001868 0.000088 0.001351 0.000000 0.084204 0.000000 0.000000 0.000000 0.101156 90.379% 1.30
Specified Performance Parameter Start Torque in-oz Compression Ratio NA Inlet Pressure differential PSI Max Airflow lbs/min Max Pressure PSI Temp Rise Deg.C Noise Amplitude, Max. dB
Target
Units
0.003 3.2 0 30 35 0 0
0.5 2
25 10
Z, Z, MSA ยต, mean std.dev. USL LSL Results 0.058 0.2 2.21 3 3.29 0.1 2.9 0.5 0.4 3.75 28 31 1 3 30 34 0.67 5.97 18 5 1.4 8 0.33 6.06
USL
LSL
0.090000 0.080000 0.070000 0.060000 0.050000 0.040000 0.030000 0.020000 0.010000 0.000000
Temp Rise
Yield, RTY 98.645% 99.813% 99.991% 99.865% 100.000% 91.924% 100.000% 100.000% 100.000% TDU yield Z-score
Start Torque Compression Ratio Max Inlet Pressure differential Airflow Max Pressure
Compressi on Ratio Max Pressure Max Airflow Temp Rise
Inlet Pressure differential
Noise Amplitude, Max.
Noise Amplitude, Max.
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Start Torque
DESIGNSCORE-EN-XLS
ITEM No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
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Enter lifetime 4.67E+07 cycles units of lifetime MCBF 7.98E+09 cycles Reliability at 46666666.6666667 0.994171438 additional calculations Probability of failure % 0.58% 50000 Rev/min Failing PPM (DPMO) 5829 1% duty cycle Expected Units Shipped 250000 70000 lifetime miles Expected field failures 1457 93333.3 minutes Estimated Field Sigma 4.022 933.3 minutes "on" Is this Long Term MCBF Data? yes 46666667 revolutions ENTER Item Name MCBF Failure rate Turbine Wheel 1.00E+11 1.000E-11 1.200E-10 Compression Wheel 1.00E+11 1.000E-11 Center Bearing 9.50E+09 1.053E-10
1.000E-10
Center Bearing
8.000E-11
6.000E-11 4.000E-11 2.000E-11 Turbine Wheel Compression Wheel
0.000E+00
Turbine Wheel Compression Wheel Center Bearing
DESIGNSCORE-EN-XLS
Reference Data Opportunities: TDU 0.0000034 0.00003179 0.000232 0.0003 0.0004 0.0005 0.0006 0.0007 0.0008 0.0009 0.00135 0.002 0.003 0.004 0.005 0.00621 0.007 0.008 0.009 0.01 0.023 0.03 0.04 0.05 0.069 0.07 0.08 0.09 0.1725 0.2 0.3 0.369 0.5 0.6 0.7 0.8 0.9 DPMO 3.4 31.79 232 300 400 500 600 700 800 900 1350 2000 3000 4000 5000 6210 7000 8000 9000 10000 23000 30000 40000 50000 69000 70000 80000 90000 172500 200000 300000 369000 500000 600000 700000 800000 900000 1 Yield Z-score ST Sigma 0.999997 4.500 6.000 0.999968 3.999 5.499 0.999768 3.501 5.001 0.9997 3.432 4.932 0.9996 3.353 4.853 0.9995 3.291 4.791 0.9994 3.239 4.739 0.9993 3.195 4.695 0.9992 3.156 4.656 0.9991 3.122 4.622 0.998651 3.000 4.500 0.998002 2.878 4.378 0.997004 2.748 4.248 0.996008 2.653 4.153 0.995012 2.577 4.077 0.993809 2.501 4.001 0.993024 2.459 3.959 0.992032 2.410 3.910 0.99104 2.367 3.867 0.99005 2.328 3.828 0.977262 2.000 3.500 0.970446 1.887 3.387 0.960789 1.760 3.260 0.951229 1.657 3.157 0.933327 1.501 3.001 0.932394 1.494 2.994 0.923116 1.426 2.926 0.913931 1.365 2.865 0.841558 1.001 2.501 0.818731 0.911 2.411 0.740818 0.646 2.146 0.691425 0.500 2.000 0.606531 0.270 1.770 0.548812 0.123 1.623 0.496585 -0.009 1.491 0.449329 -0.127 1.373 0.40657 -0.236 1.264
6.000
Z-score
ST Sigma
5.000
4.000
3.000
2.000
1.000
0.000
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4
TDU
Page 6