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Senior Design II Project Presentation P10008 ArcWorks Cap Tube Assembly. Team Members:Faculty Guides: Adam JanickiMatthew Marshall Andrew Lawlor Chris Somers John Zeffer. Project Description Customer Needs Improved Process Original Testing Method Test Fixture Issues. Agenda. - PowerPoint PPT Presentation
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Senior Design II Project Senior Design II Project PresentationPresentation
P10008 ArcWorks Cap Tube AssemblyP10008 ArcWorks Cap Tube Assembly
Team Members: Faculty Guides:Adam Janicki Matthew MarshallAndrew LawlorChris SomersJohn Zeffer
AgendaAgendaProject DescriptionCustomer NeedsImproved ProcessOriginal Testing MethodTest FixtureIssues
Project DescriptionProject Description
Design and implement an improved testing method
Improve assembly line process
Customer NeedsCustomer NeedsCustomer
Need #Importance Description Comments/Status
Safety
CN1 1 The device must not create ergonomic or safety hazards. Functionality
CN2 1 The test fixture must be reliable Minimum 8 hour consistent use
CN3 1 Must consistently and accurately determine part pass or failure
CN4 1 Intuitive test result indication CN5 1 Shorten test time for the testing station CN6 2 Productivity of the line must increase 10% Production increaseCN7 2 Fixture must function without regular maintenance
CN8 3 Eliminate the need for water to be involved in the testing process
CN9 2 Fixture can be used reguardless of operator ability Compatibility
CN10 1 Test fixture must be able to fit in current station limits
CN11 2 The device must be adaptable to test multiple part sizes 3 combinations of part sizesCN12 2 Must use plant's current resources
Cost
CN13 2 Needs to be affordableComponents of system have to be
inexpensive
Bill of MaterialsBill of MaterialsDescription Vendor CostHold Down Clamp McMastar Carr 19.56Brass Fittings McMastar Carr 2.66Toggle Switch McMastar Carr 5.3Brass Tube Fitting (4) McMastar Carr 32.2Push To connect Fittings (4) McMastar Carr 9.24Brass Push to connect fitting McMastar Carr 4.62Wye 1/4" Tube fitting McMastar Carr 4.91Ridged White Tubing McMastar Carr 9.75Aluminum Block McMastar Carr 17.86Aluminum Block McMastar Carr 113.48Socket Cap Screws McMastar Carr 10.32Push to Connect Adapter McMastar Carr 18.12Vacuum McMastar Carr 236.03Neoprene Rubber McMastar Carr 14.93Aluminum Angle McMastar Carr 49.66Pressure Sensor Omega 509Pressure Sensor Omega 509Power Supply Automation Direct 76.75Isolated Relay Output Automation Direct 44Micro Anlg PLC Automation Direct 1292-way Valve Clippard Minimatic 45.8Neoprene Rubber McMastar Carr 20.88Toggle Clamp McMastar Carr 19.56Micro 24V PLC Automation Direct 69Programmable Cable Automation Direct 1418" Wire leads Roessel 47.51/4" Tubing Roessel 60Assorted LEDs Radio Shack 2.99LED Holders Radio Shack 4.47Push Button Radio Shack 5.38
Total 2105.97
• Budget is approximately $2500• Total Cost to date is $2105.97
Process ImprovementsProcess Improvements• 5S•Time studies to indicate bottle neck station•Water test is the bottle neck station•After implementation of new test fixture output of line should increase•New layout proposed but never implemented
Original Testing MethodOriginal Testing MethodIssues with the Water Test• Messy• Slow• Difficult to determine the outcome
ProgrammingProgramming Ladder Logic
◦ How it works◦ Difficulties
faced◦ Parameters
set
ResultsResultsWater Test 1st
Part Combo
Water VacuumNumber of Parts Failed by Water but passed by VacuumGood Bad Good Bad
Little-Little 91 9 80 20 0
Big-Little 62 0 58 17 0
Big-Big 94 0 89 15 0
Vacuum Test 1st
Part Combo
Water VacuumNumber of Parts Failed by Water but passed by VacuumGood Bad Good Bad
Little-Little 197 12 183 36 1
Big-Little 62 0 60 4 0
Big-Big 90 5 73 22 1
• Water tested parts for 30 seconds could see air bead on some parts •Vacuum fails more parts than water test• Two cases of vacuum test passing parts that the water test failed
Vacuum Test FixtureVacuum Test FixtureLEDs
Rubber base for seal
Push Button startVacuum
PLC
Pressure Sensor Valve
Power Supply
Issues With DesignIssues With Design Rubber base has different threshold dependent on wear of
rubber Complicated programming difficult for ArcWorks to change 2 parts were passed with vacuum test and failed by the
water test No long term testing has been completed Unknown if critical points are valid Part is still suctioned on to rubber after test is complete
Suggestions for future workSuggestions for future workTest Fixture
◦Development of new sealing mechanism◦Further testing to develop more clear
thresholds ◦Increase speed of test
Process◦More 5S activities◦Change Layout
Difficulties FacedDifficulties FacedOrdering of partsDetermining Final DesignProgramming
◦LanguageScheduling
◦Fell behindCommunicationCompletion of tasks
?
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