1. HGears-Project Kick-off Meeting
KIM Dong-Hwan

2. Introduction 1. Project Team Organization 2. Main program information
3. Product Pictures & BOM
2. Main program information
4. Design Overview
5. Process Overview
6. Customer Planning / Timing
7. Planning(S&S INC)
1. Project Team Organization
8. Open Issue Review

3. 1. Project Team Organization
PSW > > 2. Process Flow Chart > > 3. Process FMEA short result > > 4. Process Control Plan > > 5. Ballooned drawing > > 6. Inspection report > > 7. Process Capability of the critical dimensions > > 8. MDS report
회의 참석자
Project Leader
차성수 상무
Project Manager
김동환 차장
1. Sun Gear Part
: 이상민 과장
2. Gear Shaft Part
: 안민규 사원
해외 영업팀
이승호 과장
품질확보팀
임지민 대리
SQE
구동근 과장
생산 1,2 ,3팀
정인선 부장
김선도 차장
정성균 차장
관리팀
김진태 차장
기술연구소
이의철 부장
생산관리팀
박민수 과장

4. 2. Main program information
Industrial Key data
Major Project Information
Customer: hGears Italy
Description: Sun Gear 4 ea
Sun Gear Shaft 1 ea
Project: Audi E-Tron Project
Key dates
SOP date: Mar (1분기)
PPAP: Sep. 2017
VFA Pilot (700 pcs): Jun. 2017
0-Series (500 pcs) : Sep. 2017
Volume
Customer Volume - Total: 260,000 sets, Average/yr: 70,000 sets
Plant information
Customer plant: Padova, Italy
S&S INC plant: Boryeong
Key figures
Product life time: 7 yr
Forecast of Sales(Max): 17억

5. 3. Product Pictures & BOM Picture No Part No Part Name Material Remark
Qt’y
Material
Remark 1
EDP F
SUN GEAR SHAFT
16MnCr5(DIN EN 10084)
FRT Axle 2 F
SUN GEAR 3 F 4 F
RR Axle 5 F

6. 1. Sun Gear Shaft (EDP-F-621734-01-2091)
4. Design Overview
1. Sun Gear Shaft (EDP-F )
■ 현 도면 사양
■ 검토 및 변경 요청 사항
1. 원 소재 재질 변경 요청 제안
: 16MnCr5(DIN EN 10084) → 17CrMnNiMo
(대체 재질 사용 가능 확인 - 세아)
=>사유 : 원 소재 수급 곤란.
대체 재질 사용 가능 확인 완료
: 해외 영업팀

7. 1. Sun Gear Shaft (EDP-F-621734-01-2091)
4. Design Overview
1. Sun Gear Shaft (EDP-F )
■ 현 도면 사양
■ 검토 및 변경 요청 사항
1. SPEC 변경 요청 제안 : Run out 0.02 → Run out 0.04
=>사유 : 도면 사양 만족 어려움
Run out 0.02
가공 업체 도면 이슈 사항(M-TECH)
: INC 해당 無

8. 4. Design Overview 2. Sun Gear (621734-02-1041 & 621735-02-1041)
PROPOSE 1 2
1. After broaching, these dimensions are no use
1. Need a new drawing with turning and broaching
New drawing for broaching without turning dim.
will be issued.
가공 업체 도면 이슈 사항(M-TECH)
: INC 해당 無
1. Too tight tolerance of Run out 0.03
Need to loosen Run out Spec
Run out > 0.05
=>To improve productivity
Can decide after CRP program (6 months later)

9. 2. Sun Gear (EDP-F-621734-02-1041 & EDP-F-621735-02-1041)
4. Design Overview
2. Sun Gear (EDP-F & EDP-F )
NO.
DESIGN
PROPOSE 3 4
1. Roughness requirement too tight
1. Request to loosen Roughness regulation
Ra 1.6 -> Ra 3.2
=> Too tight for turning process to meet Ra 1.6.
It should bring an additional process to meet
Ra > Low productivity
가공 업체 도면 이슈 사항(M-TECH)
: INC 해당 無
1. Too tight tolerance of Roundness & Cylindricity
1. Need to loosen Roundness & Cylindricity regulation
1) Roundness > 0.05
2) Cylindricity > 0.05
=> To improve productivity
=> Will be decided after 6 mon (same with No.2)

10. 2. Sun Gear (EDP-F-621734-02-1041 & EDP-F-621735-02-1041)
4. Design Overview
2. Sun Gear (EDP-F & EDP-F )
NO.
DESIGN
PROPOSE 5 6
1. Too tight tolerance of Out Dia.
1. To loose the tolerance of Out Dia.
Φ /  Φ51.75±0.04 (revised)
=> This is machining area by mnGears after heat treatment, request to loosen that turning tolerance in order for productivity
=> Grinding may be not stable ,need to consider later.
가공 업체 도면 이슈 사항(M-TECH)
: INC 해당 無
1.Too tight tolerance at Nose R
1. Request to loose the tolerance at Nose R
R0.6 ±0.1 -> R0.6 Max
=> To improve productivity
=> Wating for Schaeffler (±0.2)

11. 2. Sun Gear (EDP-F-621734-02-1041 & EDP-F-621735-02-1041)
4. Design Overview
2. Sun Gear (EDP-F & EDP-F )
NO.
DESIGN
PROPOSE 7 8
1. No chamfer at Broach area
1. Need a chamfer at Broach area
No Chamfer in red -> Proposal Chamfer C1
To be updated (mnGears)
=> Create chamfer when turning in order to prevent
from bur pushed back by Broaching
=> Need to answer from Schaeffler
가공 업체 도면 이슈 사항(M-TECH)
: INC 해당 無
1. Missing Spline data on hGears drawing
1. Need an additional
Spline Spec
as Luk’s drawing
2. Broaching data
will be given
by mnGears.

12. 2. Sun Gear (EDP-F-621734-02-1041 & EDP-F-621735-02-1041)
4. Design Overview
2. Sun Gear (EDP-F & EDP-F )
▶Drawing
Open issue Point
EDP F
EDP F 1 2 3 4 5 6 7 8
가공 업체 도면 이슈 사항(M-TECH)
: INC 해당 無

13. Missing some necessary specifications
4. Design Overview
2. Sun Gear (EDP-F & EDP-F )
▶▶Drawing Issue List
NO.
Issues Point
Spec
Propose
Remark F F
Description 1
Pre broach hole
Φ /0
Need update
New dimension needed 2
Run out
0.03 A ↑
0.05 A 3
Roughness
Ra 1.6
Ra 3.2 4
Roundness
0.02
0.05
Cylindricity
0.03
0.07 5
Out Dia.
Φ51.7 0/-0.046
Φ51.75 ±0.05 6
Nose R
R0.6 ±0.1 -
R0.6 Max 7
BROACH Chamfer 없음
Need Chamfer C1 8
Spline SPEC.
Missing some necessary specifications
Additional Spec
가공 업체 도면 이슈 사항(M-TECH)
: INC 해당 無

14. 3. Sun Gear (EDP-F-621734-02-1081 & EDP-F-621735-02-1081)
4. Design Overview
3. Sun Gear (EDP-F & EDP-F )
NO.
DESIGN
PROPOSE 1 2
1. After broaching, these dimensions are no use
1. Need a new drawing after turning and broaching
가공 업체 도면 이슈 사항(M-TECH)
: INC 해당 無
1. Too tight Run out 0.03
1. Request to loose Run out Spec
Run out > 0.05
=> For productivity

15. 3. Sun Gear (EDP-F-621734-02-1081 & EDP-F-621735-02-1081)
4. Design Overview
3. Sun Gear (EDP-F & EDP-F )
NO.
DESIGN
PROPOSE 3 4
1. Too tight Roughness regulation
1. Request to loosen Roughness regulation
Ra 1.6 -> Ra 3.2
=> Too tight for turning process to meet Ra 1.6.
it should bring an additional process to meet
Ra > Low productivity
가공 업체 도면 이슈 사항(M-TECH)
: INC 해당 無
1. Too tight Roundness, Cylindricity Tight
2. Φ /-0.04 too Tight
Need to loosen Roundness & Cylindricity regulation
1) Roundness > 0.05
2) Cylindricity > 0.05
=> To improve productivity
2. Φ /-0.04 & Roundness 0.02
No machining on this area 
Need to be modified after some production trial.
1) Φ / > Φ32.3±0.03 (revised)
2) Roundness > 0.05

16. 3. Sun Gear (EDP-F-621734-02-1081 & EDP-F-621735-02-1081)
4. Design Overview
3. Sun Gear (EDP-F & EDP-F )
NO.
DESIGN
PROPOSE 5 6
1. Too tight Out Dia.
1. Request to loosen Out Dia. tolerance
1) Φ / > Φ51.75±0.05
2) Φ / > Φ38.15±0.05
=> This area is a machining area by mnGears after heat treatment : To improve productivity
=> After test, mnGears can decide the final tolerance
=> Datum C for OD should be added (taper arbor)
Datum C modification accepted
가공 업체 도면 이슈 사항(M-TECH)
: INC 해당 無
1. Too tight tolerance at Nose R
1. Request to loosen Nose R tolerance
R0.6 ±0.2 -> R0.6 Max
=> To improve productivity

17. 3. Sun Gear (EDP-F-621734-02-1081 & EDP-F-621735-02-1081)
4. Design Overview
3. Sun Gear (EDP-F & EDP-F )
NO.
DESIGN
PROPOSE 7 8
1. Too tight at Angle tolerance
1. Request to loosen Angle tolerance
1) 33˚±1˚ -> 33˚±3˚
Too tight tolerance
=> Wating for Schaeffler’s opinion
가공 업체 도면 이슈 사항(M-TECH)
: INC 해당 無
1. No chamfer at Broach area
1. Need a chamfer at Broach area
No chamfer in red -> Proposal with Champer C1
=> Create chamfer when turning in order to prevent from burr pushed back after broaching
=> Wating for answer from Schaeffler

18. 3. Sun Gear (EDP-F-621734-02-1081 & EDP-F-621735-02-1081)
4. Design Overview
3. Sun Gear (EDP-F & EDP-F )
▶Drawing
Open issue Point
EDP F
EDP F 1 2 3 4 5 6 7 8
가공 업체 도면 이슈 사항(M-TECH)
: INC 해당 無

19. 3. Sun Gear (EDP-F-621734-02-1081 & EDP-F-621735-02-1081)
4. Design Overview
3. Sun Gear (EDP-F & EDP-F )
▶Drawing Issue List
NO.
Issues Point
Spec
Propose
Remark F
1081 F
Description 1
Pre broach hole
Φ /0
Need update
New dimension needed 2
Run out
0.03 A ↑
0.05 A 3
Roughness
Ra 1.6
Ra 3.2 4
Roundness
0.02
0.05
Cylindercity
0.03
0.07
Roundness & Out Dia
0.03 & Φ /-0.04 -
0.05 & Φ32.3±0.1 5
Out Dia.
Φ /-0.046
Φ51.75 ±0.05
Φ38.1 0/-0.039
Φ38.15 ±0.05 6
Nose R
R0.6±0.2
R0.6 Max 7
Angle
33˚±1˚
33˚±3˚
가공 업체 도면 이슈 사항(M-TECH)
: INC 해당 無

20. 5. Process Overview Process Flow
▶ Sun Gear Shaft(EDP-F )

21. 5. Process Overview Process Flow
▶ Sun Gear(EDP F & EDP F )
Cutting
Up-setting
Blocker
Finisher
Piercing
Operation
(OP#10)
Incoming Inspection
for Materials
(OP#20)
Materials Heating
(OP#30)
Hot-Forging
(OP#40)
Heat Treatment
Equipment Name
Spectrometer
Induction Heater
Sakamura HF
Quenching Tempering
Process
Q’ty of Equip. 1
Location
In-house
Out-Source

22. 5. Process Overview Process Flow ▶ Sun Gear(EDP F-621734.02-1081)
Cutting
Up-setting
Blocker
Finisher
Piercing
Operation
(OP#10)
Incoming Inspection
for Materials
(OP#20)
Materials Heating
(OP#30)
Hot-Forging
(OP#40)
Heat Treatment
Equipment Name
Spectrometer
Induction Heater
Sakamura HF
Quenching Tempering
Process
Q’ty of Equip. 1
Location
In-house
Out-Source

23. 5. Process Overview Process Flow ■ Sun Gear(EDP F-621735.02-1081)
Cutting
Up-setting
Blocker
Finisher
Piercing
Operation
(OP#10)
Incoming Inspection
for Materials
(OP#20)
Materials Heating
(OP#30)
Hot-Forging
(OP#40)
Heat Treatment
Equipment Name
Spectrometer
Induction Heater
Sakamura HF
Quenching Tempering
Process
Q’ty of Equip. 1
Location
In-house
Out-Source

24. 6. Customer Planning / Timing
Development Plan

25. 7. Planning(S&S INC)

26. 7. Planning(S&S INC)

27. 8. Open Issue Review
Open Issue List