Document 3e1GjQeJ4Y0XEyDNDp08kmQmJ

1 _ VQU (1 POTENTIAL OSSA BEGGLAIXON CHANGES - ASBESTOS SHAKE LDTEM (, v - c This papar reviews current end projected future a511 asbestos requirementa relative to dlao and drum brake linings, including the potential affects os capital invoatmant and pioce east. Alternate supplier tin-lug nutoriel pro gram status is also reviewed. , Background ` His current CSKA lav aliovs two flbora/cc air sampled over an eieht-hour period with, no single reading to exceed ton fibera/cc air. Moat affected lining suppliers have indicated that they expact OSHA to lower the permissible fiber count ftom 1.0 to 1.Q sometime In 1970,with further re ductions possibly down to 0*5 or lovor lchgar tarn. Bendlx expsebs tfc9 new law will ba 0.5 not 1.0 fibor/cc. These changes may have a significant inpact ea the ability of the lining material suppliers and the suppliers involved in shoe and .lining assembly (Bsndix Hydraulics Division, Borsdix Brake and Steering Division, and Kalooy Says a) to continue to provide asbestos based linings on a cost effective basis if at all. HAAQ Purchasing, Material flashing ccsduoted a series of Hustings with all affected suppliers to identify current fiber counts, notions to asst the proposed new standard, and costa far moating new Standards including capital expenditures and alternate materials and processes. Supplier Resconcea Supplier information provided at the NAAO Purchasing meetings and followup discussions sines are summarised as follows. . Generally the suppliers indicated that based on past experience with OSHA, whatever new lower fiber limit la adopted they could continue production as long ao a plan and timetable to achieve the new limit van established end they could continue to demonstrate progress relative to the plan time table. Sovoral suppliers indicated, for example, that tbsy continued pro ducing linings out of compliance to the IB fiber/ce limit for two years . after it was made law. 5 .. 'i . AT t suppliers ere currently complying with the 2 fiber/sc lav. - i fiber ec Unit - Vfith the exception of thiokol, major capital expenditures and lead times are expected: Bendix: $1 .JM, 1 year, Hiermoid: $0.5^, 6 months, Kaybostosi $13H, 3 years, Uiioknl: conforms. Piece cost increase - Thlokol, none, Thermald, 1 to $%, *t,l other suppliers 'substantial" but undefined. - 0-5 fiber/eo limit - Thiakol is installing new preform equipment with ufaiob they expect to meet 0-5 limit. If not, a new tumbler and voah aystom will be required; $1.1M, 9-12 months, Thermoid: same expenditures as quoted above for 1 fiber/ce limit. Bondloc: $5*5M, timing undetermined, may be impossible, Rayboatos: axpenditurea undefined, may be impoeeibla. Piece coot Increase - undefined* . SuppLior aea-ubestoc lining progran statue ie as fellows: , ` - Baadlmt Devalnpmant of non-astasias lining materials is in progroas for disc end drum beaks applications. Test ports should be available to Ford , with supporting test data by early 1970* Semi-nistallio dine pods with asbootoe in the booking layer only are a-imilable now and in use for heavy duty PqIAqo cor applications* This lining, however, compared to the current ' released asbootaa lining is noisier, has 30$ to 40$ less lining life, sad le a $1.20/vohieLa cost penalty. . - ------- unuM .a'' ' 'P-.w* _.. ,, 003124 PRODUCED BY FORD 105510 I :frippller Ms*ting Results (continued) ; '\Jr ' j? - Dilokolj A non-aabeBtoa organia lining is being developed* Supplier eon dunted teats on initial phase ports vers aocoptablfl for lining noise and war. Ford conducted FMVSS 10J-75 taot3( hovever, indicated that the oaterial is too brivtla j the lining fractured due to the extrema temperatures during this test* The lining compound is being revised) timing has not been estab lished for revised parts and supporting test data. - lharaoid! A non-asbestos Hn<ng is being developed on a second priority basis* Parts and supporting test data could be provided to Ford within six months if the program is accelerated. -- Roybestoei Programs have been Initiated to develop non-asbestos drum . disc brake materials, both semi-metallic and non-mstaUlc. Timing for teat part availability to Ford with supporting test date is not established. Competitive-Position . In 1^77 CK used send-metallic linings with an asbestos backing on the Tega, Monas, Comoro, Nova and Chevells station wagon in sdditlon to Police appli cations.. In 1978 semi-metallic usage la extended to include all "A" shell care -(Oldsaohilo Cutlass, Pontiac LeMans, Bulck Regel and Chavelle Malibu Classic)* Dolco presented Ford test data shoving that their nev semi-metallic lining having no asbestos backing released for 1978 on soma of the "A" shell ears is much improved for noise end cold vaar over existing seal-metallic linings. A letter was sent to Delco bbraine requesting that they initiate tasting of their proposed nev material on a Ford vehicle to selected Ford test procedures and to provide estimated piece costs for various assumed volumes- Delco Moraine is expected to respond shortly. However, Ford evaluation of this Delco Moraine seal-metallic lining on an OldamohUe vas Unacceptable (rated 5) for noise- la 1977 Chrysler, like Ford, used 3ami-metallic linings only for heavy duty Police applications. The 1978 semi-metallic usage is extended to include the new "1TM car (similar to W Rabbit). Conclusions and Recommendations . based on past experience with OSHA, if the QSHA requirement is changed, as expected, sufficient time vill be given to make an orderly transition to either an aabostos lining complying vith the nev requirement if determined feasible, or an alternate non-asbestos lining. Funding to support 8 man years labor and $1*5M material and test should be provided to develop a non-asbestos lining for release by 19SO on selected car lines to gain- production experience sad on all car lines by 1901 if determined advantageous or required. The work plan to acociqiliah this Is u foliovs; Item Review eupplier preliminary test data Jbnitor additional Ford requested supplier teats Review supplier teat data, select best proposals for Estimated TSmSnv 3^75 6-1-78 7-1-78 Ford testing Conduct Ford brake tests including Floet Evaluations, 6-1-79 FM/33 105-75, Durability, City Traffic, Hountain. Rateat now submissions if required 2-1-80 Release on selected car lines to gain production experience Job ^, 1980 '( Relsaeo all oar lines if advantageous or required Job #1, 1981 003125 "vumsks; e J Brake envelopment June 29, 1977 PRODUCED BY FORD PRODUCED BY FORD 1778 LINING USA CHARI V Car Line Front Lining Number Supplier Rear Lining Number Supplier Pinto/Bobcat/)tistang FMT7157A Bendix yainDont/2aPtl7r Sedas S/W and Police IP-1353 IP-1353 Ibiakol Thiokol Qranada/hbaar cl Rear Drum Rear Disc FMJ7157A Bendix FMJ7157A Bendix T*21rd/SR7' TF1353 LID n/Cougor/Ford/ lfercury except HD Police thiokol T-TD Il/Cougar/Ford/ Marcury HD Police FMD7131N/0 Bendix Ford/Marcury Rear Disc TP1353 except Hi-Ferf Police Tblakol Ford/Marcury Rear Disc FMD7131N/0 Bendix Hl-Peri Police Lincoln Rear Drum Rear Disc FHD7157A Bendix FMD7157A Bendix Hark T Rear Disc FND7157A Bendix 4641A/E3133 Bendix H-4797-5/ R-4924-1 4641A/H3133 Raybe etc s Bendix 464WH3133 FMD7157A 4641VE3133 Bendix Bendix Bendix 4641VE3133 Bendix IP1353 Ulokol FM7713IN/0 Bendix 4641a/H3133 FMD7157A FMC7157A Bendix Bendix Bendix 1 , /" * ............................................. ...... Brake Development June 2S, 1977 003127 PRODUCED BY FORD