Engineering 470 Final Design Project
Ball Loader
Objective
The scope of the project is to design a multi-operational
machine that will decrease assembly time and reduce the set-up time of
the assembly line. Guidelines for production was acquired by Industrial
Engineering and Manufacturing Engineering Management. Data for criteria
was gathered by engineering from the plant foremen, machine operators and
assembly line set-up personnel.
Design Approach
The design approach that was used to create design ideas
was the "Cross-Functional Team Method". The team consisted of both design
& manufacturing engineering personnel, tool builder, set-up personnel,
and machine operator. The goals of the team was to discuss and satisfy
the following areas:
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Design Feasibility
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Assembly Line lay-out
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Existing Problems
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Problem Solutions
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Critical Design Criteria
Use of the cross-functional team will allow the design to
be as complete as possible. In addition, by incorporating plant floor employees
gives the opurtunity for the employees to acquire a better understanding
of the machine's operation and instill "pride-in-work".
Design Procedure
The process of creating the design began by using the
original design as a model for modification. The various alternatives for
the design that was considered was :
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New Design - Outsource entire project - Costly & Timely
(Not Feasible)
-
Modify - Re-do machine - Down Time & Old Concept (Cost
More than New Design)
-
Re-Design - Old COncept with New Design - Desired Design
(Criteria, Resources In-House i.e. Consulting, testing)
Production Output
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Projected (Conservative)
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New Machine - Increase production by 7% (new product)
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Machine Speed - 22ppm
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Efficiency - increase by 25%
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Actual
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New Machine - Increase of 5.8% (over first 6 months)
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Machine Speed - 29ppm
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Efficiency - Increase of 18%
Cost
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Material
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Steel
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Pneumatics
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Electrical (including PLC)
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Conveyors
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Labor
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Machine Build
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PLC Programming
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Electrical Cabinet Wiring
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Machine Assembly
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Miscellaneous
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Administrative
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Over Time
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Down Time
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Testing Material
-
Total
Photographs
