Document Qk94Zodo9nabxNEY3NovzZ3vk
FILE NAME: Ford (FD)
DATE: 1977 April
DOC#: FD072
DOCUMENT DESCRIPTION: Internal Report - Asbestos Usage with Company Asbestos Work Plan & List of Company Asbestos Components
Ford is essentially out of the asbestos product manufacturing business. A significant
wnwihoy of key components containing asbestos are however purchased from outside sup pliers. Many suppliers are becoming increasingly alarmed at the changing 0S11A regu lations and have already expressed an inability to meet the proposed OSHA limit of
0.5 fibera/cc which is expected to pass by late 1977 or 78. The situation could
develop into a serious supply problem for Ford.
jK ey Factors|
o Tighter CSHA restrictions on airborne asbestos levels in production environments expected in late 1977 or 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 1980.
' 0 Driving force for these projected OSHA changes stems from various studies
which indicate that there is no "safe" level of exposure.
( ..tions I
A comprehensive company work plan has been developed (attachment 1) 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 abort--lead items and cooperative development programs for long-
lead substitutions.
'
Status-VIork Plan items!
o Compile comprehensive asbestos components list - complete except Heavy Truck
- (attachment 2)
0 Conduct a supplier OSHA compliance ability
survey
0 List the cooperative develop programs __
required for the long lesd substitution
- in progress
- (attachmejt 3)
- preliminary list
completed
"
- (attachment h)
o First supplier meeting scheduled with Raybestos to discuss relative positions
- scheduled for M ay 11 1977
( ___
\
I Mote: For additional background see the Chronology (attachment 5)
8 0 G 1 Ib53
Vehicle Materials Engineering April, 1977
ppnrvr rrun p v p o p h
O -rsnr Arv*stos V.':rk Plan
K.-r.ltor the Federal Register and other Indicators for legislative direction.
\
1'
o Initial assessment or corpany eabestoe usiga
o Cuopliatlcr. of compre :ier.sUe ssbiatos component* lis t
1
o Surrey of .jp p l l . r . c i . : i e to T .> .b *.to a componente Uh respect to the proposed OSHA specification.
a. component statua r
b. t a r l a i status i
,
a . raw material statua
>
a Establish contingent t a r l a la aid mechanisms for short lead (15 months) aubatltutlona
6 'p ittata short-lead substitution! In vhloh thara ara no major design or coat lssu si. Put romalnlnc sh.-rt-leed substitutions (those with design or cost Issues) on ho.d.
o y*,t with major suppliers of the long laad substitution eomoonents vho predict an OSHA compliance problem " ^ ` " ^ i t e d a.jpply i p licatio n s with respsct to their components, materials and raw
b. projected"cost/inrlstr.ent implications of asbestos substitution ts eonUnued produotlon
* of current product ur.dsr Increased controls.
......
e. Cooperativa dsvsletasr.t programs with tlairg required to accomplish a autstltutlon
(status shown at Attachment * )
o Heel with major raw materials a u L lie re . Develop coat and a v alllb llltjr projaetlona.
I
o Aprroval of required development! programs for long-lead aubstltutlon. (with carlina Introduction targeted)
a. Presentation to NJJfc> Management and/or Advanced Review Committee to provide funding to begin the approved programs
AHA^ir
. U
R`5?.2PP(UI;j :
Schedule*
'! Cttff}
. k ra lttlc n Iv-
! >!,
Supply Strategy/ IiriuetrlalRjrglene 1 Supply Strategy/ NAA3 Purchasing
VKt&P
On-tnt t / ` \
On-golng t-'I * .'/it
S-10-77 ;
: Mr' -4 .
?r
. J.l Oomj
V! '.Li?
i-55-77-
C-iv
NAA3 Purehaalng/ W OkP PCPE/MPS NAAQ Purehmstrg
^ >*5-77 'A.
.
'U
' V:: ''. V W
5-15*77 ; `
PCPE/BEPS
. * 5-30-77 . r
I1AA0 Purchasing/ Supply Strategy/ VMDVP
NAA3 Purchasing
PCPE/BEPF/.7C4P
1 ,
'
1
1e''i*',
6-30-77 r> ; *
r 't
I
0f' ,
' *r> , ' I1
` . *f f
Supply Strategy/ RAAO Purchasing/ VKIBtP
6-30-77 ;
PCFE/BKPE VK.TSP
7-15-77 ' ` 7-33-77
ROOi 1654
P" O
Vehlola M ateriale Engineering
A pril, 1977
{ ijffSi
J*-.'r 1
\ ,
.{ Chassis .'*A v/ ."
Hydraulic Brake Booster Assembly (LTE)
Trout Disc Broke Outer Shoe & Lining
I^ont Disc Brake Inner Shoe & Lining
Rear Drum Brake Lininc (LTE) .
Rear Drum Brake Lining (LTE) ' .
Rear Rise Brake Outer. Shoe & Lining
Rear Disc Broke Inner Shoe & Lining
Rear Brum Brake Primary Lining
Rear Drum Brake Secondary Lining
Insul - Parking Brake Control, Heat
- Gasket Assembly-Rson Inlet Pipe . ,
.
Casket Assembly-Rson Inlet Pipe- '
Insul - Frt. Wheel Brk
.
.
Insul - FTt. Wheel Brk - Inner '
Insul - RR Wheel Brk - Outer
Insul - HR Wheel Brk - Inner
Gasket - Frt. Susp. Lower Arm Ball Joint
Gasket - Front Susp. Lower Arm Ball Joint
Gasket - Front Susp. Upper Arm Ball Joint
Muffler Wrap Inside Muffler Assembly
Transmission &
rip
C
.
`
"-- ' ^
. Converter Reactors (Phenolic)
Thrust Washers (Phenolic) Clutch Plates (Forward & Reverse) Clutch Plates (Forward & Reverse) Clutch Plates (Forward & Reverse) Transmission Bands Transmission Bands Transmission Bards Transmission'Bards 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 - Housing to Differential Carrier Gasket - Housing to Differential Carrier Gasket - Housing to Differential Carrier
Slip Differential D i s c _ _ ___
" limited Slip'Differential"'Disc `
Enpine
,
(
Seal - Catalytic Converter End Gasket - Front Cover, Timing Chain GaBket - Cylinder Head Seal - Crankshaft Rear Oil Gasket - Oil Level Indicator Boss Gasket - Crankcase Oil Cooler
*'r **
a.1..` :ii '
*
* -
? -
" y*rt Humber-
Basic 2005
22001169`<
2209 2210 - v 2218
' 2219
:225i
2285 " . B52A-2B606-AA -.V'.l.li'.ik.rTO'l.
D5AA-5B266-AA.il t & & b
D50A-5B266- A *
D20A-2B521-BA -
;.Va
B2DA-2E525-M D5KA-2r536-AA
' -vi'
D5MA-2B?37-AA
B12A-3A472-AA
C20A-3A1J72-C
D00A-3A273-A
Numerous Basic Nos. Hfz
***"*?--
Baeio 793^
'i**'--*- tf\i~
7937
.
7B164 .t,
7E311 .. . 7E312 7D03^ ' *3 *
7D095 7A612
7A176 C7AP- 7D026-A .
C3AP- 7DC2-AA
Basic 7086
C6AP-7A136-B
Basic 7550 C20W-A035-A
C6AW-U035-A
DOAW-L036-B
M-,-
DIAW-h036-3 \
D12W-V036-C
D12W-J+03&-F
C90W-797-B
`^'C90W=h'A325~B^:
Basic
5E2^5
6020
6051
6701
6753
6839
; w.
B00 1655
DDnnTTrrn d v conn
peo
E tirine (coni)
EP
BEFE Heavy Truck CCD
Part Wane
Gasket - Water Outlet Connection Cask;! Gasket - Water Pump Casket - Water Pump Cover Gasket - Fuel Pump Mounting Gasket - Int. M a n - Cylinder Head Gasket - Curb. Intake Manifold Gasket - Exhaust Manifold Gasket - Carb. Throttle Body Gasket - Exhaust Air Supply Tube Assembly Gasket - Exhaust Air Supply Tube Asse-biy Gasket - Carb. Intake Manifold Spacer Gasket - Intake Manifold Opening Cover Gasket - Intake Manifold Opening Cove" Gasket - EGR Valve Gasket - EGR Cooler Outlet Tube Gasket - In Lake Manifold Cover Gasket - EGR Valve Adapter Gasket - Exhaust Control Valve Gasket. - Carb. lit Shield Spacer Gasket - EGR Cooler Tube Outlet Gasket - EGR Cooler Tube Outlet
Gasket - Viater Temp. Switch Commutator - Starter Gasket - Horn Kotor - Seat Motor - Power Window
Motor L Tub:; Assembly-Antenna
Gasket - Window Regulator Motor
Part Rur.hr-r bL
88G25057
8513 9*17 9*3? 9**7 9**8 9516
99C0**3365
9C*77
9C*8*
9D**0 9D*76 9D*78 9E*36 9E*6* 91*66
9E795 9F*70 9F*73
1091* 11015 13817 1*5*7 1*553 18350 1*A*27
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 St Tube Assy - Antenna (1978)
Locks, Power Door
Mastic Sound Deadener-Spray on Mastic Sound Deadener-Sheet
I5B089
17A529
17E616
17C*30
'
18B37*
18P800
I8E8OI
218a*2
ESB-E5G25- Numerous Part Nos.
TBD
None
a/ When basic part number only is given, usage is across all carlines with the possible exception of scro Engine parts.
b/ All cars have the asbestos wrap but part numbers are not given be
cause of the large number.
8C01 i656
Vehicle Materials Engineering
April, I977
pp nrvr irpn d v c o d
-5 D O r > T Tr~'T7T'i D V T T ^ > r> T ^
l ' -V ;
.
\\ -,'V * e>-^
1
inicfficn
-
0
Cor.ooner.ts Reculrirn Develoisent Programs ic r Substitution
Cccnoner.t
Transmission Gaskets Axle and Drlveshaft Caskets Muffler Wrap
.
Alternate
N itriie Cellulose M irile Cellulosa Glass-Paper
Tranamleolon Converter Thrust Washer
Glass k Clay/Phenollc
Transnleglon Converter Reactor (Re-Engineer)
Al insinuo
Catalytic Converter Seel
Possible use of Grafoll
Entire Gaekets (high temperature)
Possible use of Crafoll
Transmission Band Linings Limited Slip Differential Discs
Possible use of Iapregnated Papers
Materials similar to brakes
Brake Linings
Seoi-Metallic) Glass/Resln
Organlc/Sesln
Transmission Clutch Plate Facings
TBD
%! O.i-goirg development - Expected to be ready for Incorporation by 10/77 5/ heavy truck - TED
Projected Tilting (month*) (Start to Production
6-9 6-9 8 (on-going) /
8
12 12
12-36
12-36 12-36 36
12-36
. . !
. -- VtrUhlfl Cnt fftmet
TBD
TBD
Cipected Cost Veab
.
!
TBD
T
Cost Inertooo
TBD
.
TBD
TBD
TBD
Expsctsd 50Jt xatsrlal oost 1 aerea
ISO
PpnnTTr'Prt n v c n c n
01 If'ba P Q
Vehicle Materiale Engineering April, 1977
I
Chronology of Brents In Strategy Development
V 77-3/77
VMEKcP investigation of company FEO's, Materials Groups, Industrial Hygeno, Purchasing and Supply Strategy experiences with the total asbestos situation.
2/2/77
2/10/77
E&RS Materials letter requesting a company position on asbestos usage; letter also states that several suppliers cun meet the
proposed .5 fibers/cc limit.
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 limits; stated that significant action is necessary to d evelop asbestos-free friction materiasl for brake and clutch components; recommended that required development programs be funded.
2/23/77
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 baais.
2/25/77
VMD&P letter to NAAO Purchasing presented initial comprehensive asbestos component listing to be used for biyer/supplicr survey by component. Letter also requested corrections by all company material activities.
3/9/77
NAAO Purchasing letter requesting all affeetpd buyers to Burvey asbestos component sources on three levels: end item; material fabricator and raw material supply; component list and work sheets were supplied.
3/2V77
k/6/71
Vll/77
Body and Assembly Purchasing initial survey responce.
VMD&P Key Issue Report: Asbestos Usage
Supply Strategy scheduled meeting with Raybestos - a major asbestos supplier.
Vehicle Materials Engineering
'
April, 1977
8001 i659PQ
PP O T V Trpn T> \r T:r\T> r>