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Correlation Analysis of EOL Test Stand Results for Re-evaluated Modules - July 2004

On July 26, 2004, ten modules returned to Metaldyne underwent subjective evaluation by HMC. Results indicated varying acceptance statuses: 6 modules (IAL, KTR, KUG, KVP, KYN, KXJ) were OK, while 4 (KUI, KTY, JZC, FKP) showed issues. These modules were tested on a new production end-of-line test stand to verify performance correlation. Key parameters included an RPM sweep from 0-1000 and acceleration summation of the 75-78.5th orders. The new test method correlates well with prior evaluations, and further sampling is planned for better assessment and acceptance criteria.

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Correlation Analysis of EOL Test Stand Results for Re-evaluated Modules - July 2004

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  1. New Production EOLTest Stand CorrelationData 26 July 2004

  2. Background • 10 modules were returned to Metaldyne that had been subjectively evaluated and ranked by HMC. • IAL OK • JZC NG • KTR OK • KTY NG • KUG OK • KUI NG • KXJ OK • KYN OK • KVP OK • FKP “marginally acceptable”

  3. Background • The 10 modules were then tested on the new production end of line test stand to verify correlation. • The best correlation results were achieved with the following test parameters. • RPM sweep from 0 – 1000 • Acceleration summation of 75 – 78.5th orders for entire sweep. • Please see next slide for correlation and levels. • Module FKP tested at 106.7g level so that this should be recognized as a preliminary acceptance criteria until more modules can be tested to better understand the output.

  4. Transfer Gear EOL Data

  5. Conclusion • The new test stand and test sequence correlates well with the modules that have been tested at HMC. • Metaldyne will run more samples the week of 26 July to confirm new fallout at various acceptance criteria • Metaldyne will propose new criteria to HMC by 28 July for production.

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