SGM618發(fā)動(dòng)機(jī)無(wú)法停止或延遲停止的經(jīng)驗(yàn)教訓(xùn)

LessonsLearnedLessonslearned

for

SGM618EnginecannotstoporstopdelaySGMSQE/PATAC2008.6.28LessonsLearnedforXXX發(fā)動(dòng)機(jī)延時(shí)熄火或無(wú)法熄火。EnginestopdelayorcannotstopafterIGNoff.案例描述

IssueDescription:LessonsLearnedfor

XXX為解決發(fā)動(dòng)機(jī)熄火瞬間儀表指示燈暗亮問(wèn)題，線束在S3階段增加二極管，此舉加劇了發(fā)電機(jī)對(duì)ECM的干擾。Toresolveclusterindicatorsflashproblem,weaddonediodeonwiringharness,thisactionresultedinGeneratoreffectingECMmoreseriously.發(fā)動(dòng)機(jī)熄火瞬間，單功能調(diào)節(jié)器在F端繼續(xù)輸出電流，電流沿著黃色路徑流經(jīng)儀表，導(dǎo)致其閃亮．為解決閃亮問(wèn)題，線束在圖示紅色位置增加二極管，電流沿著藍(lán)色路徑流動(dòng)，不會(huì)影響儀表但加劇了對(duì)ECM的影響．導(dǎo)致ECMC3端口電壓升高，ECM誤判斷鑰匙仍在點(diǎn)火位置．AfterIGNoff,therestillcurrentoutputfromFterminalofgeneratorwithmono-functionregulator.Thecurrentflowalongyellowpathshowninrightpicture.Thisresultsinindicatorsflash.Toresolveaboveproblem,weaddonediodeinwiringharness.thediodestopcurrentflowintoclusterbutcauseallcurrentflowintoECM,sothevoltageofECMC3terminalbecomeshigherthanbefore,ECMstill“think”ignitionkeystillat“IGNon”stage.此處電壓高于6.3伏，ECM認(rèn)為鑰匙處在點(diǎn)火狀態(tài),根本原因分析RootCauseAnalysis：LessonsLearnedforXXX對(duì)應(yīng)措施和驗(yàn)證Action&Validation：1，短期措施：

Short-termsolution:

申請(qǐng)PAA，將熄火瞬間產(chǎn)生電流的發(fā)電機(jī)更換為多功能調(diào)節(jié)器發(fā)電機(jī)（多功能調(diào)節(jié)器的發(fā)電機(jī)熄火后不會(huì)產(chǎn)生電流），這樣儀表燈閃亮的問(wèn)題也可以解決。

ApplyPAAtoreworkproblemvehiclesandapplytousegeneratorwithmulti-functionregulator(Newgeneratorwon’toutputcurrentafterkeyoff).

申請(qǐng)PAA將增加的二極管刪除

ApplyPAAtodeletethediodeonwiringharnessPAA:196622，長(zhǎng)期措施：

Long-termsolution:

申請(qǐng)EWO將熄火瞬間產(chǎn)生電流的發(fā)電機(jī)更換為多功能調(diào)節(jié)器的發(fā)電機(jī)（多功能調(diào)節(jié)器的發(fā)電機(jī)熄火后不會(huì)產(chǎn)生電流），這樣儀表燈閃亮的問(wèn)題也可以解決。

ApplyEWOtoreworkproblemvehiclesandapplytousegeneratorwithmulti-functionregulator(Newgeneratorwon’toutputcurrentafterkeyoff).將增加的二極管刪除

Deleteredundantdiode.EWO:19520措施斷點(diǎn)：2008-4-21BP:2008-4-21LessonsLearnedforXXX經(jīng)驗(yàn)教訓(xùn)/舉一反三措施LessonslearnedandActionsPlan：有流程，沒(méi)有嚴(yán)格執(zhí)行。Thereisprocedure,butdidn’tcarryoutstrictly.沒(méi)有流程，或流程不明確。Noprocedure,ornotveryclearlystipulated.其它Other說(shuō)明：

1,如果有流程，但沒(méi)有嚴(yán)格執(zhí)行，要從加強(qiáng)執(zhí)行力方面汲取該經(jīng)驗(yàn)教訓(xùn)，制定具體措施，確保流程能?chē)?yán)格執(zhí)行。要有負(fù)責(zé)部門(mén)/人員和完成日期。

2,如果沒(méi)有流程，或流程不明確，要制定新的流程或修改流程，要有負(fù)責(zé)部門(mén)/人員和完成日期。

3,流程包括，但不僅限于TIR,EWO,ETR,DFMEA,工程認(rèn)可流程,SOR,

PPAP,PQRR,PDI,PFMEA,雨淋試驗(yàn)流程,CVIS,PTR,SOS,JIS,等。Note:1,Ifthereisaprocedure,butnotstrictlyimplemented,weneedtogetlessonslearnedfromhowtoenhancetheimplementation,andhaveactionplan,toensuretheprocedurecanbestrictlycarriedout.TheremustbetheOwner/personandcompletedate.2,Ifthereisnoprocedure,ortheprocedureisnotveryclearlystipulated,thenwemustdeveloporupdatetheprocedure,withOwner/personandcompletedate.3,Theproceduresincludes,butnotonly:TIR,EWO,ETR,DFMEA,EngineeringApprovalProcedure,SOR,

PPAP,PQRR,PDI,PFMEA,WaterTestProcedure,CVIS,PTR,SOS,JIS,etc.LessonsLearnedforXXX有流程，沒(méi)有嚴(yán)格執(zhí)行。Thereisprocedure,butdidn’tcarryoutstrictly.沒(méi)有流程，或流程不明確。Noprocedure,ornotveryclearlystipulated.1，設(shè)計(jì)經(jīng)驗(yàn)不足：改型過(guò)程中忽視了單功能調(diào)節(jié)器發(fā)電機(jī)F端的電器性能以及其對(duì)整車(chē)的影響．導(dǎo)致儀表燈閃亮問(wèn)題．

Designexperiencelack:Duringengineeringchange,weignoredthecharacteristicofgeneratorwithmono-functionregulator.措施:

將此lessonslearned轉(zhuǎn)化為Bestpractice,

作為項(xiàng)目開(kāi)發(fā)工程設(shè)計(jì)的輸入。在新項(xiàng)目及年度改型中整車(chē)構(gòu)架工程師會(huì)將發(fā)電機(jī)對(duì)整車(chē)電器影響作為工程檢查的一部分。

負(fù)責(zé)部門(mén):

Elec./杜祖楠；完成日期:6/25Action：

ConvertthislessonslearnedtoaBestpractice,

thisBPwillactasanengineeringdesignguidelineforfutureprogram.Weaddthislessonslearnedtoengineeringchecklist,sothatarchitectureengineerwillcheckgeneratoreffectduringengineerchange.

Owner:

Elec.Mr.DuZunan;

CompleteDate:

6/25其它OtherX經(jīng)驗(yàn)教訓(xùn)/舉一反三措施LessonslearnedandActionsPlan：LessonsLearnedforXXX有流程，沒(méi)有嚴(yán)格執(zhí)行。Thereisprocedure,butdidn’tcarryoutstrictly.X沒(méi)有流程，或流程不明確。Noprocedure,ornotveryclearlystipulated.其它Other

2，工程驗(yàn)證必須完全符合設(shè)計(jì)要求：工程ETR時(shí)，為線束更改方便，二極管安裝位置與實(shí)際更改的位置不同。這掩蓋了發(fā)動(dòng)機(jī)無(wú)法熄火的問(wèn)題．(見(jiàn)下頁(yè)圖片)Validationmustmeettherequirementofdesign:ForETR,weaddedthediodeatadifferentpositionwhichisdifferentfromproduction,That’sthereasonwhywehaven’tfoundthisproblemduringETR.（seenextpagepicture）措施:強(qiáng)調(diào)ETR的準(zhǔn)確性，必須嚴(yán)格按照更改的實(shí)際狀態(tài)進(jìn)行試驗(yàn)，增加經(jīng)理檢查制度。負(fù)責(zé)部門(mén):

Elec./XXX；完成日期:6/25Action：ETRshouldbedoneexactlyaccordingtoproductionstatus,

addingmanagercheckprocess.

Owner:

Elec.Mr.XXX;

CompleteDate:

6/25經(jīng)驗(yàn)教訓(xùn)/舉一反三措施LessonslearnedandActionsPlan：LessonsLearnedforXXX有流程，沒(méi)有嚴(yán)格執(zhí)行。Thereisprocedure,butdidn’tcarryoutstrictly.X沒(méi)有流程，或流程不明確。Noprocedure,ornotveryclearlystipulated.

3,SDM開(kāi)發(fā)周期縮短ShortenSDMcalibrationduration:

由于開(kāi)發(fā)周期縮短，需要更新開(kāi)發(fā)計(jì)劃，在此過(guò)程中沒(méi)有充分考慮SDM標(biāo)定失敗的可能性，在更新的開(kāi)發(fā)計(jì)劃中縮短了標(biāo)定周期，沒(méi)有預(yù)留出由于標(biāo)定失敗造成重新標(biāo)定的時(shí)間。Formeetingcompressedvehicledevelopmentduration,

weshortentheSDMcalibrationtimingnotincludetheSDMre-calibrationbasedonourwrongevaluationabouttheSDMcalibrationfailpossibility.措施:

嚴(yán)格按照GVDP的開(kāi)發(fā)過(guò)程，制定并執(zhí)行標(biāo)定計(jì)劃。修訂MastTiming審批流程，凡要壓縮計(jì)劃的，要報(bào)EQMC批準(zhǔn)。

負(fù)責(zé)部門(mén):

EQD/張振宇；完成日期:6/25Action：

AccordingtotherelatedrequirementinGVDP,defineandImplementSDMcalibrationplanstrictly.

UpdateMastTimingapprovalprocedure,ifthetimingissqueezed,needtogetapprovalfromEQMC.

Owner:

EQD/Mr.ZhangZhenyu;

CompleteDate:

6/25其它Other經(jīng)驗(yàn)教訓(xùn)/舉一反三措施LessonslearnedandActionsPlan：LessonsLearnedforXXX有流程，沒(méi)有嚴(yán)格執(zhí)行。Thereisprocedure,butdidn’tcarryoutstrictly.沒(méi)有流程，或流程不明確。Noprocedure,ornotveryclearlystipulated.4,沒(méi)有足夠的知識(shí)和經(jīng)驗(yàn)Withoutenoughknowledgeandexperience:

對(duì)SDM標(biāo)定的技術(shù)細(xì)節(jié)(這些技術(shù)細(xì)節(jié)是SDM供應(yīng)商的技術(shù)核心)缺乏了解。LackingexperienceandknowledgeforSDMcalibrationtechnicalissues(thesearesupplier’sknowhow).措施Action:

開(kāi)展與SDM供應(yīng)商間的技術(shù)交流。(目前已經(jīng)和博世,德?tīng)柛?大陸進(jìn)行了一輪技術(shù)交流)。

OrganizetheworkshopwithSDMsupplierforstudyingtheissueincalibrationprocess.(finishedworkshopswithBOSCH,Delphi,Continental)

負(fù)責(zé)部門(mén)Owner:

Elec/沈海東Mr.ShenHaidong；完成日期CompleteDate:6/25措施Action：

與GMNA/GME聯(lián)系，進(jìn)行有關(guān)SDM標(biāo)定計(jì)算機(jī)輔助分析的培訓(xùn)。在項(xiàng)目的早期對(duì)SDM標(biāo)定的風(fēng)險(xiǎn)進(jìn)行評(píng)估。

RunningSDMcalibrationCAEtraininginGMNA/GME,doriskevaluationASAP.負(fù)負(fù)責(zé)部門(mén)Owner:

Elec/沈海東Mr.ZhangZhenyu；完成日期CompleteDate:

6/25其它OtherX經(jīng)驗(yàn)教訓(xùn)/舉一反三措施Le