Document O31ZaXZJBod0eqVGQyEMx7xgK
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Key Issue Report
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Subject: Asbestos Usage -1*
1 Background
Ford is essentially out of the asbestos product manufacturing business. A significant
number of key components containing asbestos are however purchased from outside sup
pliers. Many suppliers are becoming increasingly alarmed at the changing OSHA regu-
lations and have already expressed an inability to meet the proposed OSHA limit of
0-5 fibers/cc `which is expected to pass by late 1977 or 78* The situation could
develop into a serious supply problem for Ford.
|Key Factors
o Tighter OSHA restrictions on airborne asbestos levels in production environments expected in late 1977 r 1978* Will directly affect Ford suppliers.
o Compliance with this new limit - impossible for some suppliers. Suppliers who can comply predict severe problems with any further restrictions.
o Discussions going on in Washington to further restrict limit to the lowest measurable level - estimated timing 1979> 19^0.
o Driving force for these projected OSHA changes stems from various studies which indicate that there is no "safe" level of exposure.
| Actions"!
A comprehensive company work plan has been developed (attachment l) to assess current asbestos usage and determine the abilities of the suppliers to comply with the proposed 0.5 fiber/cc OSHA regulation. The plan includes the establishment of material con tingency actions for short-lead items and cooperative development programs for longleac substitutions.
|Status-Work Plan Items}
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o Compile comprehensive asbestos components list - complete except - (attachment 2) Heavy Truck
o Conduct a supplier OSHA compliance ability survey
- in progress
- (attachment 3)
o List the cooperative develop programs . required for the long lead substitution
, - preliminary list - (attachment 4) ' completed
o First supplier meeting scheduled with Raybestos to discuss relative positions
- scheduled for May 11, 1977
P.OCd
Note: For additional background see the Chronology (attachment 5)
HFM -003319
Vehicle Materials Engineering n April, 1977
SCF-FORD-1404
HFM - 003320
| attac
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Connanv Asbestos Work Plan
Resnonslbllitv
Scheduled Coppletion
Currer.. ,, Stlt'-r
o Monitor the Federal Register and other indicators for legislative direction.
Supply Strategy/ Industrial Hygiene
o Monitor rav material availablllty/cost implications
.
Supply Strategy/ NAAO Purchasing
o Initial assessment of company asbestos usage
. VMD&P
o Compilation of comprehensive asbestos components list
VMD&P
o Survey of suppliers of all above asbestos components with respeot to the proposed OSHA specifications
a. component status
b. material status
c. raw material status
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o Establish contingent materials and mech^iisms for short lead (12 months) substitutions
- NAAO Purchasing/ VMD&P
PCPE/BEPS
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NAAO Purchasing
o Initiate short-load substitutions in which there are no major design or cost issues. Put remaining short-lead substitutions (those with design or cost Issues) on hold.
pcpe/bepe
~6~ "Meet with major suppliers of the long lead substitution components who predict sh OSHA compliance problem and developi a. Projected supply implications with respect to their components, materials and raw materials. b. Projected cost/investment implications of asbestos substitution vs continued production of current products uifter increased controls.
c. Cooperative development programs with timing required to accomplish a substitution (status shown as Attachmenth)
NAAO Purchasing/ Supply Strategy/ VMD&P
NAAO Purchasing
PCPE/BEPE/VMEScP
o. Meet with major raw materials suppliers. Develop cost and availibility projections.
Supply Strategy/ NAAO Purchasing/
VMD&P
o Approval of required development programs for long-lead substitution, (with carline introduction targeted)
a. Presentation to KAAO Management and/or Advanced Review Committee to provide
* * funding to begin the approved programs
T.
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PCPE/BS*E VMD&P
On-going On-going
2-10-77 2-25-77 4-15-77
5-15-77 5-30-77 6-30-77
6-30-77
7-15-77 7-30-77
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5
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Cr.--oing
On-going Complete Complete In-progress
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t? 0 0 ci 4,61* r
Vahiola Materials Engineering April, 1977
Company Asbestos Components (for Supplier Survey)
ATTACHMENT 2 Page 1 of 2
PEO_______________ _______________ Part Name|
Chassis
Hydraulic Brake Booster Assembly (LTE)
Front Disc Erake Outer Shoe & Lining
" Front Disc Brake Inner Shoe & Lining
Rear Drum Erake Lining (LTE)
Rear Drum Erake Lining (LTE)
Rear Disc Brake Outer Shoe & Lining
Rear Dice Erake Inner Shoe & Lining
Rear Drum Erake Primary Lining
Rear Drum Brake Secondary Lining
- Insul - Parking Brake Control, Heat
Gasket Assembly-Rson Inlet Pipe
Gasket As?embly-Rson Inlet Pipe
Insul - Frt. Wheel Brk
Insul - F:t. Wheel Brk - Inner
Insul - RR Wheel Brk - Outer
Insul - RR Wheel Brk - Inner
Gasket - Frt. Susp. Lower Ann Ball Joint -
Gasket - Front Susp. Lower Arm Ball Joint
Gasket - Front Susp. Upper Arm Ball Joint
Muffler Wrap Inside Muffler Assembly
Part Number a/
Basic 2005 2018
2019 2209 ' 2210 . 2218 2219
2284 2285 D52A-2B608-AA D5AA-5B266-AA D50A-5B266-AA D20A-2B321-BA D20A-2B525-BA D5MA-2B586-AA D5MA-2B587-AA D12A-3A472-AA C20A-3A472-C D00A-3A273-A Numerous Basic Nos. b/
Transmission & Axle
% '
,
Engine
/
Converter Reactors (Phenolic) Thrust Washers (Phenolic) Clutch Plates (Forward & Reverse) Clutch Plates (Forward & Reverse) Clutch Plates (Forward & Reverse) Transmission Bands Transmission Bands Transmission'Bands Transmission Bands Gasket - Servo Cover Gasket - Servo Cover Gasket - P.T.0. (LTE) Gasket - Front Pump . Clutch Driven Members (LTE) Gasket - Housing to Carrier Gasket - Housing to Carrier Gasket - Housing to Differential Carrier Gasket - JRousing to Differential Carrier Gasket - Housing to Differential Carrier Gasket - Housing to Differential Carrier Limited Slip Differential Disc Limited Slip Differential Disc
Seal - Catalytic Converter End Gasket - Front Cover, Timing Chain Gasket - Cylinder Head Seal - Crankshaft Rear Oil Gasket - Oil Level Indicator Boss Gasket - Crankcase Oil Cooler
Basic 7934
7937 7B164
7E311 7E312 7D034
7D095 7A612 7A176 C7AP- 7D026-A C3AP- 7D026-AA Basic 7086 C6AP-7A136-B Basic 7550 C20W-4035-A C6AW-4035-A D0AW-4036-B \ . DUW-4036-B D12W-4036-C D12W-4036-F C90W-4797-B C90W-4A325-B
Basic 5E245 6020
- 6051 6701
6753 ---$839
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HFM - 003321
ATTACHMENT 2 Page- 2 of 2
PEO Engine (cont)
EED
BEPE ' Heavy Truck
CCD
Part Name
Gasket - Water Outlet Connection Gasket Gasket - Vater Pump Gasket - Water Pump Cover Casket - Fuel Pump Mounting Gasket - Int. Man -- Cylinder Head Gasket - Carb. Intake Manifold Gasket - Exhaust Manifold ' Gasket - Carb. Thr^tle Body Gasket - Exhaust Air Supply Tube Assembly Gasket - Exhaust Air Supply Tube Assembly Gasket - Carb. Intake Manifold Spacer Gasket - Intake Manifold Opening Cover Gasket - Intake Manifold Opening Cover Gasket - EGR Valve Gasket - EGR Cooler Outlet Tube Gasket - Intake Manifold Cover Gasket - EGR Valve Adapter Gasket - Exhaust Control Valve
Gasket - Carb. Kt Shield Spacer Gasket - EGR Cooler Tube Outlet Gasket - EGR Cooler Tube Outlet
* Part Humber a/
' 8255
8607 8513 9417 9^39 9447 . 9448 .
9516
9<*35 9C436
9C477 9C484 9D440
9D476 9D478 9E436 9E464 9E486
.
9E795 9F470 9F478
Gasket - Water Temp. Switch Commutator - Starter Gasket - Horn Motor - Seat Motor - Power Window Motor & Tube Assembly-Antenna Gasket - Window Regulator Motor
Motor - Sun Roof Gasket - W/Wpr Gear Cover Commutator - W/S Washer Motor Gasket - W/Wpr Motor Seal Commutator - Heater, A/C, W/S Motor & Tube Assy - Antenna (1977) Motor & Tube Assy - Antenna (1978) Locks, Power Door
10914 11015 13817 14547 14553 18850 14A427
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15B689 17A529 17B616 17C430 18B374 18B800 i8b8oi 218A42
3: 0-
Mastic Sound Deadener-Spray on Mastic Sound Beadener-Shefet
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TBD
ESB-M5G25-A Numerous Part Nos.
None
zj When basic part number only is given, usage is across all carlines with the possible exception of some Engine parts.
b/ All cars have the asbestos wrap but part numbers are not given be .. cause of the large number.
HFM - 003322
Vehicle Materials Engineering April, 1977
HFM - 003323
Asbestos Supplier Survey (Component. Material. Rav Material^ a/
CoTCorent Part Humber
Comoonent Hairs
D52A-7550-AA
2018/9
4 2218/9 JE245
5230
D^Ca-61037-AA D52A-2B608-U D5AA-5B266-AA D50A-5B266-AA a:ffTESB-X5S25-A
.
ESB-M4G141-A
ESB-M^GtO-A ES3-M4G32-A
D7E3-6260122-AA
B7D3-6660122-A
(Numerous Part Numbers)
Clutch Disc
Shoe & Lining-Front
Shoe & Lining-Rear
Seal-Catalytic Converter
Muffler Assombly
Heat Shield Assembly
Gasket
Gasket Casket
Sound Deadener Sound Deadener
Sound Deadener
Sound Deadener
Insulator, Seat Belt
Insulator, Seat Belt
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Sound Deadener - Heat Bondable
End Item ,
i/ 2/
yes TBD yes no yes no yes yes yes yes yea yes yes no yes no yea no yes yes yes yes yes yes yea yes -
fabricator
y s7
yes yes yes yea yes yes yes yes yes
TBD no no yes yes yes no no no
Rav Material
y s/
yea yes yes yes yea yes yeSc yes yes yes
yes yes yes no no no ? ? ? 7
yes yes
yes yes
Comments '
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n/ results to date; 71 ltesis to be completed
b/ meats current OSHA specifications
c/ can ,ceet proposed OSHA specification
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ATTACKMEKT 3
Supplii ?oliov-t Yea ti
X
X .X
X X
X X X X
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X X X !
X
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h002 >'='
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Vehlole Materials Engineering April, 1977
HFM - 003324
ATTACHMENT J
Components Requiring Development Programs for Substitution
Component
Transmission Gaskets Axle and Drlvesh&ft Gaskets P.uiiler trap
Transmission Converter Thrust VasheA
Alternate
Nitrile Cellulose Nitrile Cellulose Glass-Paper
Glass & Clay/Phenolio
Projected Timing (months) (Start to Produotion
6-9 - 6-9
8 (on-going) a/
8
. Transmission Converter Reactor (Re-Engineer)
Aluminum
12
Catalytic Converter Seal
Possible use of Grafoll
12
Engine Gaskets (high temperature)
Possible use of Grafoll
12-36
Transmission Band Linings Limited Slip Differential Discs
Possible use of Impregnated * Papers
Materlala similar to brakes
12-36 12-36
Brake Linings
Semi-Metallio; Glass/Resin Organlo/Resln
36
Transmission Clutch Plate Faeings
TBD
12-36
a/ On-qolrg development -Expeoted tp be ready for incorporation by 10/77
b/j ,/ilJsUy truck - TBD
*
`_ Variable Coat Effect
TBD TBD Expected Cost Wash
TED
Cost'Inorease
TBD
TBD
TBD
TBD
Expeoted 50? material coat Increase
TBD
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8902 l-feSl ii
Vehiole Materials Engineering . April, 1977
Asbestos Usace
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Chronology of Events in Strategy Development
attack;kit 5 _
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1/77-3/77
2/2/77
VMDScP investigation of company PEO's, Materials Groups, Industrial Hygene, Purchasing and Supply Strategy experiences with the total asbestos situation.
ESBS Materials letter requesting a company position on asbestos usage; letter also states that several suppliers can meet the proposed .5 fibers/cc limit.
2/10/77
VMD&P assessment of current company asbestos situation. Request for PEO input to company asbestos plan.
2/23/77
Chassis response sited increasing government regulation on asbestos limitsj stated that significant action is necessary todevelop
asbestos-free friction materiasl for brake and clutch components; recommended that required development programs be funded.
3/23/77
Transmission and Axle response requested a Corporate position including a contingency plan for substitutes be established. Provided substitutional development timing for major items. Recommended evaluation of each component on an individual basis.
2/25/77
VMDSiP letter to NAAO Purchasing presented initial comprehensive asbestos component listing to be used for buyer/supplier survey by component. Letter also requested corrections by all company material activities.
3/9/77 3/24/77 .
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NAAO Purchasing letter requesting all affected buyers to survey asbestos component sources on three levels: end item; material fabricator and raw material supply; component list and work ' sheets were supplied.
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Body and Assembly Purchasing initial survey respoqpe.
4/6/77
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VMDScP Key Issue Report: Asbestos Usage
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4/11/77 '
Supply Strategy scheduled meeting with Raybestos - a major asbestos supplier.
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' Vehicle Material*- Engineering Aprils 1977
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HFM - 003325