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1 tj-i^inokriflino* ring Juni 1, 1977 ce R. M. Campau T, J, Foley J, C . Gagliardi D. F. Hagen H, J.' Strovea F. A. Voraldl M. H. Whitney i t / ... I Subject: Asbestos Usage Reference: Fey Issue Report dated April, 1977 from Vehicle Materials Engineering - Susie Subject flackrrrnnd: _ A significant number of asbestos containing components ore purchased from outsida suppliers. Many suppliers aro becoming incrc-s.sir.fly alarced at the chanping Q3HA regulations 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 1973, Suppliers who can comply predict severe prcciec: with cr.y further restrictions. Ducusoicr.s are currently going or ir *sri,,gten to further rsstrlet the limit to the lowest mnasurable level-eutimitcu timing ]c/77, 1900. The drivii g force for theso ptojectcd 0SiJA stem." fr;m vonau0 studies which indicate teat there la no "safe" level of exposure. If them further restrictions are enacted Into law a serious supply problem will occur at Ford. Anti am A comprehonsive company worSc plan with timing has beon dovtlopcd by Staff organizations to assess current asbestos usage and te riutemno the abilities of the suppliers to comply with the proposed 0.5 fiber/cc CShA regulation. In order for Engine Engineering to comply with the above company plan, the following Information must be supplied to G. A. Schley, Engine Design and Materials Engineering Department, by Juob 15, 1977. - A complete part number listing including suppliers or all 177B role tied, new, proposed, and futura model year advanced components containing tsbectjs fibers ia their make-up. . Tour ontiastad Liming required to develop, test, and release substitute materials for all asbestos applications. C Attachment JASjbbw F 003132 105508 PRODUCED BY FORD * ^Product Engineering OHico Engine Division 0.11 ...April y? icm Is. Mr. P. A. Martel iflfrt, ec P. A. Vsrnldi M. H, Whitney '" "' ' ' J, D. Kalmbach___________ iuOCt Anbestos Usage ' PicnHiW fiMCfiPinwi "' '' 111 Tha latest communication Cram. Vehicle Materials Engineering assigns three areas of responsibility to Engine Engineering with completion dates of 5-15-77, 5-50-77, and 7-15-77 respectively. We do not know who in Engine Engineering committed to these dates and if anyone is answering the latest document or establishing Project Ordors. Complete DVS testing requirements will prohibit the impleraentation oT any short-lead subct.tuticns and thereby negating the 5-15 and 5-30 due dates; however, the approval of development programs for long-lead substitution (with csrline introduction targeted) due 7-15-77 still needs area of responsibility direction. Action Plan: In order to accomplish this objective direction should be given to Materials Engineering and overy Product Engineer (including advanced concepts) to review tha requirements of each application and recommend a substitution plan with testing requirements. Tha Project Engineers would then have to write Project Orders to implement this program. Effect!venoms: Wo do not believe that Engine is in a position to accept this task without revising the projected dates. Modal lenr 1930 would be the earliest date for at least partial model substitution. It should also be noted that the list of components using asbestos fibers submitted by ua to the Vehicle Materials Engineering Office is not necessarily complete. JASibbv V. < ,/* tv , J. D. Kalmbach I 003133 n#UJACt Uiiortmii^i ^ ______ 2, 3. 4. Asbestos linage -1 Vehicle Materials Lnginooring April, 19/7 Asbestos Usage Enpino Materials bigi hearing March 15, ViU Anbastos Usago Vehicle Material r bnfimiariiic PuLmi a , Farts CantaininE Asboatea Enrinc Material n HnHTu.*mWi, ' I r '/ PRODUCED BY FORD K&SZl-SlTZS iJLB tiTOi 3 UfJ 1.1..Z It POSIT! Q_S 5 CatftTMCt TO SlJUmmfS te-aie Paha Linings 4 frimw */ a/ a/ EES m EE .Beading inataad of riTetiag .Elixinsts Grtadiag-Holded tpr-naeh being nild,n .Industrial Hffiiwi heaoures .Ho imediata place far automation .*300,000 to eatflf pij tUj,tW0 aanmilT THICKCL Front Died feds Hear Dies Pads OS HO ns .Process change froo esapraseiois to lajesticr naldiBg-J! .2 eilllon loreetaeat-wouis mqjira req'viiIT lection .Non-sabecvsa substitute presently amiable-one year lead tiu for wehi.le testing required UISES7QS Clutch facisgs IS ID HO .Industrial Hygiene Beaaures to nyproecb 1 flher/c. iltaroatlTa How Materials being eanaidered- glass. mineral snot, combination of fiber .jLil SkO focused on oon-^abestoe products ilHX 1 Clutch dioe aaa'y friction faeingi IES HJ 7SS III personnel wearing head hood filters 1003 of tba tin* CE.'EUL nmtsTRas Sahara HO HO NO ..1. cease operations If forced to asenpt staidur Dicma ewf] HJSCH H K. PffiTHi TdEBHOlD 017 fUac*,or Clutch Dice Shoe Lining ias'y-frant nod Hair US HO HQ as HD iss 3EHEH Shoo * Liaise US HO US .Will etoo ismufanturo of asbestos products if forced to accept standard Pall 74 presentation oa onn-eabestaa elpteh faelflf to Pord-hegatiwe response-cost equiTalaat Xhllltj w coat facings to reduce ftber/ee iawel at io extra eoat Juodard of .1 will prohibit astestoa usage Brake substitute inereaae weight and cnot-one four load tine 1 r el ilioa to mat 1 Fiben/ce lixit ,;.5 aiiiioJi and I-' yra to Boat , 5 fiber licit .Impassible to Beet .1 lewel .Bern-metallic disc brakes asbestos-free bee id nr to be completed by fall east Locreoent 1.2-1.e z weight Increment 1.3 I .fiberglass linings oh drun-good is let, not so good os road .Critical isaue-na product for drum !rakes-19A3-3l snail year projection .Wet sanding 4 grinding could be instituted imi Huffier Wap US HO IBS CatalyUo CoBrirter Seal JOfflS-tUHVILIJE Haw Material lobes*.as fiber 10 JO 30 .Compliance to .$ flber/ec level thru aliaination of asbestos in the muffler wrap assembly .fa.Planned ctinge to fiberglass by 1979 prasent alternate far COBwarter Seal .In almost all aperations 5 flber/cc .Be January 1979 2 7iber/ce in all hit 30 stations .Guiaeilnes Lu effaet la Quebec not as aerere as 0. .Startles indicate Z flber/cc to be a safe leral a/ eoepUaoee to prelent ? flber/cc etd. present ooepllenne to propaeed ,5 flber/cc etd. j/ ability to met ,J flber/cc lewel 003134 --------- ----------------, JUHEt 1777 PRODUCED BY FORD ASSESSffiJT {continued) The foregoing can be coppered with the different results npected If the standard la abruptly aet at .5 fiber/cc by January 1, 1979. Ihia is Judged unlikely. . Coart challenges delay implementatian for at laut a year. ? . Investments in new or old mines curtailed, but supply not lHadlataly affected, a Trices rise on related components--scoe parts suppliers Inform nrto laiuatry of impending curtailment of production. - a Costly crash programs an substitutes initiated in auto industry, target Job 1, OSflO. Even less likely is a standard of .1 fiber/ce because it is 'very near he^VgwwnA level. IMPACT ON FORD -A study of the engineering uaes of asbestos has shown that Ford la directly concerned only with the friction naterlsls segment of the asbestos industry (an outlined in Attachment 33* Ford purchases transmission bands, brake and clutch friction materials that contain asbestos, and thus would be affected by tha impacts of regulatory action. These impacts are of two types: internal, and in the supply chain. Ford h*q n0 internal compliance problems because purchased parts contain only bound asbestos fibers that da not contaminate the environment.* Supply chain compliance problems were recently investigated by HAAO Purchasing (Materials Planning Department). This study assumed an orderly tightening of the standard concluded that: ' , -Major parts and materials suppliers are just now reaching compliance with the 2 fiber/cc standard and have plans or active programs to meet the proposed standard. 1 The severity of the problems depends on the standard. , Nearly all suppliers wish to continue to supply Ford with asbestos-containing products. Our assessment of the supply situation is that asbestos products will continue to be available for the next several years, but that costs will rise as suppliers install control equipment. Ford should continue to rely on suppliers to solve their compliance problems and supply parts to Ford. HECCMMENPATTOHS The above assessments predict an orderly tightening of the asbestos standards and a resulting cost increase in asbestos--containing parts. It is concluded that the Company must respond to this situation with programs in the following areas to ensure that it remains cost competitive. Wear debris from brake and clutch friction pads are nonfibrous and therefore ncncarcinogenic. Sons monitoring of brake and clutch repair areas for loose asbestos fibers may be nacessaiy., ,i:.\ 003135 1MJSU JfH >J! ^ ji. - PRODUCED BY FORD htmflflUDillOMii (coatiaa*4) o 1. Continue to aonltor mppllar eenplihoee programs tad remits. RaspanaifalUtr; WD4P and KJjLO Psrchasing. Continue to aanitor easts of asbestos-containing components cad tempers these Jdth those far alternate Materials. Responsibility: fiUO Purchasing end 7ME*?, . J -ruPtfP* -k luM Initiate idruaced fiifiJieeriafi projects for in Chassis and 1 jjtr Xrunniseion and Ixle Engineering Offices to assess the caste and probleas ^ associated tflth alternate materials for dutch and brake linings and transaiaalna / . bends. &eoe projects would rely os significant supplier input coordinated f through dueller Besearch, {the suppliers are interested.) They heed not be <H"S targeted for specific model yeers but nay be seen as Insurance projects to protect against costly crash progress later. They hnn1H include studies cu er^//, friction materials compatible vlth aluminum dims, discs and clutch plates. Responsibility: PEO's {id-runcad, Engineering). Support the engineering effort vlth perallel projects within the alreadyelating friction materials study group within Research Staff. Responsibility: Engineering and Research Staff. 5. Renew supplier asbestos compliance and angineering programs, cos comparisons, and Ford programs prior to the 1979 advanced budget allocations to determine course of action for 1S79. Haa-pacalbility*- TOD&F. o I . I I -J Vehicle Materials Development & Planning August 26, 1977 ` * 1" 003136 PRODUCED BY FORD