BRIGGS & STRATTONAuburn University Design ProjectCorporation 2 & Corporation 3V-Twin Sump Sub-Assembly Production Line ImprovementsCorporation 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 WalkerExisting 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 sealThe Production ProblemThe current assembly of the sump does not meet future production rate requirements.§ Current Assembly Line Time StudyCurrent Assembly Line Time Study # Element Description Time #1 Time #2 Time #3 Time #4 Time #5 Time #6 Time #7 Time #8 Average Station 1 24.8 1/10 Arrange sumps/insert oil tube 71.65 83.28 93.28 8.273667 Retrieve sump 2.46 2.56 2.78 2.782.59 2.78 5.15 3.53 3.07875 Ball, spring, plug installed, oil tube align 7.37 5.43 7.46 9.005.03 4.93 11.53 6.31 7.1325 Cycle Machine 4.03 3.50 3.21 3.403.65 3.40 3.31 3.34 3.48 Remove sump & set aside 3.12 3.09 2.71 2.563.02 2.46 2.87 3.18 2.87625 Station 2 25.4 Retrieve part, place in fixture 2.53 2.12 3.71 1.594.90 2.21 3.43 2.87 2.92 Put screen in press 1.84 1.81 5.84 2.655.21 2.25 3.28 2.81 3.21125 Screw in oil nipple 3.50 4.59 3.81 2.344.06 2.46 4.56 8.59 4.23875 Cycle machine 10.12 10.93 10.28 13.43 10.46 14.46 16.00 16.00 12.71 Remove and set aside 2.34 2.43 2.06 2.092.18 2.35 2.40 2.87 2.34 Station 3 33.5 Retrieve and place in fixture 5.40 4.09 4.96 2.502.96 4.71 5.00 4.53 4.26875 Assemble plug & bushing to press 6.00 5.50 6.00 5.217.96 7.53 12.78 22.68 9.2075 Cycle machine 2.96 3.59 2.37 3.563.62 5.90 6.75 2.84 3.94875 Remove oil filter from carton, dip install 9.96 12.37 11.93 9.2811.75 24.34 17.81 17.12 14.32 Remove sump & set aside 1.00 1.50 2.84 1.761.75 1.84 1.63 2.00 1.79 Station 4 41.5 Retrieve sump & torque oil press C.V. 8.21 13.75 7.53 4.817.06 6.84 6.34 7.12 7.7075 Position governor & install E-clips 15.96 14.93 20.81 14.03 22.06 15.34 13.21 22.93 17.40875 Assemble governor seal to sump 10.28 6.21 6.46 8.626.03 6.87 9.40 7.75 7.7025 1/3 Assemble washer and bushings 22.78 27.28 21.28 32.78 24.87 30.71 24.65 24.84 8.71625Current Assembly Line Time Study24.825.433.541.5051015202530354045Time (sec)1 2 3 4Station NumberThe Production ProblemThe current assembly of the sump does not meet future production rate requirements.§ Current Assembly Line Time Study§ Current Assembly Line Production CapabilityØ 650 sumps per each 7 ½ hour shiftDesign GoalOur goal is to increase the efficiency of the assembly line in order to produce 1000 sumps per shift.V-Twin Sump Assembly Design ProposalNew Assembly Line LayoutStation 1 - LayoutStation 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 asideStation 1 - Table DesignStation 1 - Table DesignStation 1 - Bill of MaterialsQuantity Description SourceManufacturer Part NumberPriceSpacers and BracketsSouthern Tool & Steel $3001 Bushing Ram Parker 06.00KC2AU14A14A4.00 $916.201 Oil Tube StakeColumbia Marking Tools Inc.751-OC-2.5 $8441 Cap Press Parker 06.00KC2AU14A14A6.500 $963.602 Clamps Bannel Clamp H 30 200045 $2252 Light Curtains Banner Light $291.071 Pallet Southern Tool & Steel $100Miscellaneous Expenses$500$4,655.94TOTALStation 2 - LayoutStation 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 asideStation 2 - Table DesignStation 2 - Oil Nipple DesignThe 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 Materials1 Pneumatic Cylinder Motion IndustriesBimba -TA-MS1D-6X5-HLC2-KK2$570 2 Linear Thrusters Motion Industries ¾ Bore $190 2Pneumatic Cylinder (for securing sump)Motion Industries Bimba $50 1Fixtured Cleomatic NutrunnerCooper Tools 88MA5-R5-3/8 $2,022 1Fixtured Cleomatic NutrunnerCooper Tools 45MA2-R8-3/8 $1,297 1 Light Curtain Banner Light $291.07Sheet Metal for BracketsSouthern Tool & Steel $100 1 Pallet Southern Tool & Steel $200 Miscellaneous Expenses$500 $5,460.07 PriceTOTALQuantity Description SourceManufacturer Part NumberStation 3 - LayoutStation 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 asideStation 3 - E-clip PressStation 3 - E-clip Press HeadStation 3 - Press StandStation 3 - Table DesignStation 3 - Bill of MaterialsE-Clip Press Stand MaterialsSouthern Tool & Steel A-6036 sheet $200 2ClampsBannel ClampH 30 200045$225 1 Pneumatic Press Motion IndustriesBimba TA-MX2-1 ½ x121" Rod 3/4 - 16 Rod Thread$213.29 1PalletSouthern Tool & Steel$100 Bolts$75 E-Clip Head MaterialsSouthern Tool & Steel $150 Miscellaneous Expenses$350 $1,538.29 PriceQuantity Description SourceManufacturer Part NumberTOTALIntermediate TablesIntermediate Table DesignTable Foot DesignThe main station tables will be bolted to the floor. The intermediate tables will be free standing.PneumaticsPneumaticsControls§ Brief control explanation for each station§ Sample Control Sequence§ Bill of Materials for ControlsStation 1 - ControlsStation 2 - ControlsStation 3 - ControlsSample Control Sequence - Station 31. Operator presses the opti-touch push buttons. PB 31 (INPUT)2. Sump clamped into pallet. FWD SOL (OUTPUT)3. Is E-clip press fully retracted? PROX 31 (INPUT)4. E-clips in press? PROX 32 (INPUT)IF 1-4, THEN 5-6 (5-6 start simultaneously)5. E-clips pressed into sump. FWD SOL (OUTPUT)6. Is E-clip press fully extended? PROX 33 (INPUT)IF 5-6, THEN 7-8 (7-8 start simultaneously)7. E-clip press is retracted. REV SOL (OUTPUT)8. Sump is unclamped from pallet. REV SOL (OUTPUT)Note: After 1. if the light curtain in front of the station