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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