BRIGGS STRATTON Auburn University Design Project Corporation 2 Corporation 3 V Twin Sump Sub Assembly Production Line Improvements Corporation Members Bradley Cordell Marie Craig Ben Daniel Marcus Drain Brad Fickett Adam Frey Scott Frishman Ben Garner Jason Garrette Paul Geldmeier Chris Gregson Jon Hammett Spencer Harris Chris Walker Existing Assembly Process Station 1 Ball Spring and Cap Oil Tube Station 2 Screen Oil Nipple Station 3 Bushing Drain Plug Station 4 Check Valve Governor and E clips Governor seal The Production Problem The current assembly of the sump does not meet future production rate requirements Current Assembly Line Time Study Current Assembly Line Time Study Element Description Station 1 1 10 Arrange sumps insert oil tube Retrieve sump Ball spring plug installed oil tube align Cycle Machine Remove sump set aside Station 2 Retrieve part place in fixture Put screen in press Screw in oil nipple Cycle machine Remove and set aside Station 3 Retrieve and place in fixture Assemble plug bushing to press Cycle machine Remove oil filter from carton dip install Remove sump set aside Station 4 Retrieve sump torque oil press C V Position governor install E clips Assemble governor seal to sump 1 3 Assemble washer and bushings Time 1 Time 2 Time 3 Time 4 Time 5 Time 6 Time 7 Time 8 71 65 2 46 7 37 4 03 3 12 83 28 2 56 5 43 3 50 3 09 93 28 2 78 7 46 3 21 2 71 2 78 9 00 3 40 2 56 2 59 5 03 3 65 3 02 2 78 4 93 3 40 2 46 5 15 11 53 3 31 2 87 3 53 6 31 3 34 3 18 2 53 1 84 3 50 10 12 2 34 2 12 1 81 4 59 10 93 2 43 3 71 5 84 3 81 10 28 2 06 1 59 2 65 2 34 13 43 2 09 4 90 5 21 4 06 10 46 2 18 2 21 2 25 2 46 14 46 2 35 3 43 3 28 4 56 16 00 2 40 2 87 2 81 8 59 16 00 2 87 5 40 6 00 2 96 9 96 1 00 4 09 5 50 3 59 12 37 1 50 4 96 6 00 2 37 11 93 2 84 2 50 5 21 3 56 9 28 1 76 2 96 7 96 3 62 11 75 1 75 4 71 7 53 5 90 24 34 1 84 5 00 12 78 6 75 17 81 1 63 4 53 22 68 2 84 17 12 2 00 8 21 15 96 10 28 22 78 13 75 14 93 6 21 27 28 7 53 20 81 6 46 21 28 4 81 14 03 8 62 32 78 7 06 22 06 6 03 24 87 6 84 15 34 6 87 30 71 6 34 13 21 9 40 24 65 7 12 22 93 7 75 24 84 Average 24 8 8 273667 3 07875 7 1325 3 48 2 87625 25 4 2 92 3 21125 4 23875 12 71 2 34 33 5 4 26875 9 2075 3 94875 14 32 1 79 41 5 7 7075 17 40875 7 7025 8 71625 Current Assembly Line Time Study 41 5 45 40 33 5 Time sec 35 30 24 8 25 4 25 20 15 10 5 0 1 2 3 Station Number 4 The Production Problem The current assembly of the sump does not meet future production rate requirements Current Assembly Line Time Study Current Assembly Line Production Capability 650 sumps per each 7 hour shift Design Goal Our goal is to increase the efficiency of the assembly line in order to produce 1000 sumps per shift V Twin Sump Assembly Design Proposal New Assembly Line Layout Station 1 Layout Station 1 Operations Arrange sumps in bin as needed Insert oil tubes into sumps as needed Retrieve sump and place in fixture Insert ball and spring into sump Place bushing and cap into presses Align oil tube Cycle machine using opti touch buttons Remove sump and set aside Station 1 Table Design Station 1 Table Design Station 1 Bill of Materials Quantity Description 1 Spacers and Brackets Bushing Ram 1 Oil Tube Stake 1 2 2 1 Cap Press Clamps Light Curtains Pallet Miscellaneous Expenses TOTAL Source Manufacturer Part Number Southern Tool Steel Parker Columbia Marking Tools Inc Parker Bannel Clamp Banner Light Southern Tool Steel Price 300 06 00KC2AU14A14A4 00 916 20 751 OC 2 5 844 06 00KC2AU14A14A6 500 H 30 200045 963 60 225 291 07 100 500 4 655 94 Station 2 Layout Station 2 Operations Retrieve sump and place in fixture Insert drain plug into gun socket Insert oil nipple into gun socket Place screen in press Cycle machines using opti touch buttons Remove sump from fixture Install check valve with hand gun Set sump aside Station 2 Table Design Station 2 Oil Nipple Design The oil nipple will be redesigned with a hexagon interior This will allow for faster loading times and the use of a non reversing gun This design change will add 0 16 to the total cost of each sump Station 2 Bill of Materials Manufacturer Part Number Quantity Description Source 1 Pneumatic Cylinder Motion Industries 2 Linear Thrusters Pneumatic Cylinder for securing sump Fixtured Cleomatic Nutrunner Fixtured Cleomatic Nutrunner Light Curtain Sheet Metal for Brackets Pallet Miscellaneous Expenses Motion Industries Bimba TA MS1D 6X5HLC2 KK2 Bore Motion Industries Bimba 50 Cooper Tools 88MA5 R5 3 8 2 022 Cooper Tools 45MA2 R8 3 8 1 297 2 1 1 1 1 TOTAL Price 570 190 Banner Light 291 07 Southern Tool Steel 100 Southern Tool Steel 200 500 5 460 07 Station 3 Layout Station 3 Operations Retrieve sump and place in fixture Position governor in sump Spread bushings on governor shaft Cycle e clip press using opti touch buttons Remove sump from fixture Assemble oil seal to governor Set sump aside Station 3 E clip Press Station 3 E clip Press Head Station 3 Press Stand Station 3 Table Design Station 3 Bill of Materials Source Manufacturer Part Number Price Southern Tool Steel A 6036 sheet 200 Bannel Clamp H 30 200045 225 Pneumatic Press Motion Industries Bimba TA MX2 1 x12 1 Rod 3 4 16 Rod Thread 213 29 Pallet Bolts E Clip Head Materials Miscellaneous Expenses Southern Tool Steel 100 75 Southern Tool Steel 150 Quantity Description 2 E Clip Press Stand Materials Clamps 1 1 TOTAL 350 1 538 29 Intermediate Tables Intermediate Table Design Table Foot Design The main station tables will be bolted to the floor The intermediate tables will be free standing Pneumatics Pneumatics Controls Brief control explanation for each station Sample Control Sequence Bill of Materials for Controls Station 1 Controls Station 2 Controls Station 3 Controls Sample Control Sequence Station 3 1 Operator presses the opti touch push buttons 2 Sump clamped into pallet 3 Is E clip press fully retracted 4 E clips in press PB 31 FWD SOL PROX 31 PROX …