Maria Krutikova

2013 vs 2014 Jigging Specifications for Comparison

The goal for the 2014 jigging was to reduce jig manufacturing time and make jig assembly as efficient as possible. This was done in several ways:

Reduce the number of tapped holes. Reduction of additional manufacturing processes reduces time.

Reduce the number of “vertical holes”. Due to limitations of our manufacturing equipment, drilling holes vertically into tall pieces of steel requires a complicated set up, which increases manufacturing time.

While the amount of jigs increased slightly, the complexity of jigs decreased, therefore decreasing manufacturing time.

For ease of assembly, jigs were designed symmetrically. Left side jigs can be interchanged with Right side jigs due to their symmetry. This decreases the need for reassembly.

2013 vs 2014 Jigging Comparison via CAD

2013 Jig Design

Specification 2013 2014Number of Chassis Jigs 53 54Number of Suspension Jigs 52 59Number of Jigs with Vertical Holes 14 6

2014 Jig Design

Maria Krutikova

Complexity of Jigging Assembly Simplified for 2014

Note the suspension jig structures shown in green in both models. The 2013 design contains jig assemblies of up to 7 jigs. Almost all suspension jig assemblies in the 2014 model consist of 2 jigs.

2013 Jig Design2014 Jig Design

Maria Krutikova

Reduction of Vertical Holes

Due to limitations of the mills in our machine shop, drilling vertical holes takes more set up and therefore more time. Rather than drilling holes vertically into tall jigs as seen in the 2013 design, the same structure can be achieved with holes being drilled into the short part of the jig rather than the tall part.

Optimize Jig Location for Welding Ease

2014 Jig Design2013 Jig Design

2013 Jig Design

2014 Jig Design

The purpose of jigging the chassis is to provide accurate tube placement for welding. The 2014 Jig Design allows for unobstructed access to joints, allowing a welding torch to pass through with ease. The 2013 Jig Design has jigs placed near joints, so jigs have to be taken off in order to access the joint for welding. This defeats the purpose of jigging since the chassis is no longer securely fixtured. The 2014 design allows for ergonomic welding and more precise tube placement. No jigs need to be removed for welding and then replaced, which saves chassis assembly time.