Cummins PPAP Deviation Form – Scania D7 “Keb” Engine
Part Number / 5398220Noun Name / Flywheel
Revision Level / 00
Release Phase Code / P
PPAP Status on PPAP engine / Reworked PPAP part
Date for PPAP parts at Cummins / Week 23 2017
Date for planned full PPAP / Week 23 2017
Tool Status / Production
Supplier Status / Production
Part Image:
Description of the Deviation:
The 5398220 was released to production status in September 2016 following completion of engineering activities. Since this date two CRB’s have been requested:
-CRB#114 to increase the PCD of the balance holes, to increase the clutch mounting hole thread depth and to add a chamfer to lead the clutch into position on assembly.
-CRB#122 to correct the “TDC UP” Timing mark
The PPAP batch received at Cummins incorporated neither of these changes, CRB#114 was agreed to be a SOCOP introduction and CRB#122 was not raised when the PPAP batch was received. However CRB#122 is an important feature for service and it was agreed that this should be addressed for the PPAP engines. The flywheels on the PPAP engines will have a reworked “TDC UP” timing mark. The proposal shown below to add a wider mark has been agreed between Cummins and Scania.
Deviation Closure Plan
The first part of the closure plan will submit a Cummins Engineering Release to address the machining changes to the TDC UP mark, the balance holes and the clutch mounting hole thread depth. The new P/N will be 5447893.
The requirement for a chamfer is still under review at Scania as this would require a modification to the tool, should this go ahead, 5447893 would be superseded by another new part number.
The machining changes incorporated on 5447893 would be introduced for SOCOP.
Part Number / 5396554Noun Name / TUBE,OIL GAUGE
Revision Level / 00
Release Phase Code / P
PPAP Status on PPAP engine / PPAP’d 5396554 will be used
Date for PPAP parts at Cummins / Week 26 2017 for new part
Date for planned full PPAP / Week 26 2017
Tool Status / Production
Supplier Status / Production
Part Image:
Description of the Deviation:
Issues have been detected with both the Cummins and Scania diptube/dipstick assembly which affects the oil level calibration in the oil sump. The Cummins diptube has a steel adapter at the base of the tube which is inserted into the cylinder block. The current adapter design can vary in how far it inserts into the block. A revised adapter is being introduced to rectify the issue.
Deviation Closure Plan
To support PPAP builds, Scania will be manually adjusting and calibrating the dipstick assembly. Cummins will release the new diptube 5448042 to minimise the tolerance stack-up caused by the diptube in the overall assembly.
Part Number / 5349695; 5368879; 5400537Noun Name / TUBE,AIR
Revision Level / 01
Release Phase Code / L
PPAP Status on PPAP engine / PPAP approved
Date for PPAP new parts at Cummins / Week 5 2017
Date for planned full PPAP / Week 14 2017
Tool Status / Production
Supplier Status / Production
Part Image:
Description of the Deviation:
Air tubes 5349695 (1 – NEW: 5442543) and 5368879 (2 – NEW: 5442544) will be modified to change the tube end form and mounting nut to suit the male unions supplied with the Scania Air Control Valve (Scania p/n 2021085). Existing parts have been designed to suit Cummins supplied unions. The tube routing remains unchanged.
Air Tube 5400537 (3 – NEW: 5444542) will be modified to prevent the turbo wastegate hose from kinking (FIRG 54547). The revised design is shown in the image above.
Deviation Closure Plan
ER 160047-143 will structure the revised parts into the option for SOCOP.
Noun Name / COMPRESSOR,AIR
Revision Level / 02
Release Phase Code / L
PPAP Status on PPAP engine / Source Release
Date for PPAP parts at Cummins / March-May 2017
Date for planned full PPAP
Tool Status / Production
Supplier Status / Production
Part Image:
Description of the Deviation:
No external design changes anticipated. This form is for information purposes:
During the PPAP build, the supplier detected some air leak issues from the air manifold which forms part of the cylinder head assembly. These issues have been traced to an issue with the plugs which insert into the manifold. The leaks are being captured as part of the supplier internal quality check process, so no defective parts are entering service. Resolution of this issue may drive some internal machining changes to the plug ports.
Deviation Closure Plan
The supplier is still working to resolve the issue, the exact resolution is still being defined but is likely to require some process and machining changes to the plug ports. The PPAP date is currently uncertain due to the full resolution still being in process. PPAP could be between 2-5 months dependent on the level of change.
Part Number / 5341208Noun Name / SEAL,O RING
Revision Level / 02
Release Phase Code / P
PPAP Status on PPAP engine / Source Release
Date for PPAP parts at Cummins / Week 23 2017
Date for planned full PPAP
Tool Status / Production
Supplier Status / Production
Part Image:
Old: New:
Description of the Deviation:
The 5341208 is a former direct to buy part used to seal the intake connection to the air control valve. In July 2016, Scania advised of a design change to their part to incorporate some pips to the inner diameter to aid assembly (Scania p/n 2342794 will replace 2073511). Cummins missed this change request and the parts stocked therefore do not incorporate these additional pips. The seal Cummins will build on the PPAP engine was supplied to Cummins from Scania and is from the production source.
Deviation Closure Plan
Cummins will release the new seal with the additional pips for SOCOP.
Part Number / 5361286Noun Name / UNION,MALE
Revision Level / 01
Release Phase Code / P
PPAP Status on PPAP engine / Scania sourced
Date for PPAP parts at Cummins / Week 6 2017
Date for planned full PPAP
Tool Status / Production
Supplier Status / Production
Part Image:
Description of the Deviation:
The 5361286 was a former assigned part that Cummins has re-sourced as the Scania supplier was unwilling to supply to Cummins. The parts used on the PPAP engine were supplied to Cummins by Scania and are from the Scania source.
Deviation Closure Plan
The Cummins source will supply PPAP parts to close this deviation.
Part Number / 5442375Noun Name / SHIELD,HEAT
Revision Level / 01
Release Phase Code / L
PPAP Status on PPAP engine / Source Release
Date for PPAP parts at Cummins / Week 9 2017
Date for planned full PPAP
Tool Status / Prototype
Supplier Status / Prototype
Part Image:
Description of the Deviation:
The heat shield was re-designed to accommodate changes to the Scania Air Control Valve. Issues with finding a production supplier delayed the implementation of this part and Cummins will therefore only have prototypes available for the PPAP build. The prototypes will be source released. The heat shield is a small layered pressed metal component, use of a prototype presents a low technical risk.
Deviation Closure Plan
Introduction of PPAP parts from production tooling will close this deviation.
Part Number / 5396557Noun Name / BRACKET,AIR TUBE
Revision Level / 00
Release Phase Code / P
PPAP Status on PPAP engine / PPAP’d
Date for PPAP parts at Cummins / Dependent on change
Date for planned full PPAP
Tool Status / Production
Supplier Status / Production
Part Image:
Description of the Deviation:
The air tube bracket has suffered three test cell failures on Beta engines. Investigations into the failures are still in progress but it appears to be a fatigue related crack across the bracket. The air tube is removed from the bracket in the test cells and this may be a contributing factor. The bracket passed all strain and vibration work during validation so the issue is unexpected. Although the failure is limited to the test cell, modifications may be made to improve the resilience of the parts to unexpected operation.
Deviation Closure Plan
To be confirmed following FIRG investigation.