Preliminary Detailed Design Review Hilltop Business Services at the Arc of Livingston-Wyoming Window Latch Assembly Automation

Agenda Goal of Phase/Process Map Feasibility Summary Preliminary Ideas (from Phase II) Vibratory Bowl Feeder Rotary Index Table Assembly Line Rotating Fixture Most Viable Options Modified Work Bench SCARA Robotic Arm Feasibility Summary Bill of Materials Risk Assessment Plans for Next Phase Questions/Feedback Maura

Preliminary Detailed Design Goal The goal of this phase was to model the design for the high risk areas of the system, meet with subject matter experts to assess the design ideas, and make test plans for these designs. Problem Definition Systems Design Preliminary Detailed Design Detailed Design Build and Test Prep Subsystem Build and Test Integrated System Build and Test Customer Handoff Maura

Preliminary Ideas (Phase II) Vibratory Bowl Feeder Rotary Index Table Assembly Line Rotating fixture Maura

Vibratory Bowl Feeder Cost criteria Feeder Prices $28,800 - carrier Output rate Table/base plate. Hoppers Controls Track Length Cost criteria Size of the part Bowl finish Purge Gate Linings Complexity of the part Feeder Prices $28,800 - carrier $18,800 - cam Chioma

Rotary Index Table Automated process for each step Carrier Subassembly Rotary Index table allows for multiple assemblies to take place simultaneously Total cost of all components more expensive than we expected Rails and fixture still viable designs Carrier Subassembly Carrier, Top View Finished Product Bin Fixture Cam Subassembly Rotary Index Table Cam, Top View Maura Finished Product, Top View Lock, Top View Lock Subassembly

Assembly Line Labor Cost Assumptions: 2M parts per year 7 hours productive time per 8 hour shift Assembly wage = 15$/hr 1 Assembly line = 3 employees 1 Assembly line throughput rate = 1 part / 5 sec (12 parts / min, 720 parts / hr) Current material handler can be leverage and their wage is included in overhead cost Current state fully burdened cost per part = $0.04686 # Assy. Lines Hourly Throughput Shifts required to meet demand Labor Cost Cost per part (labor only) 1 720 397 $142,920 $0.07146 2 1440 199 $143,280 $0.07164 3 2160 133 $143,640 $0.07182 Concerns: is material handler included in their overhead. Do they include the person material handleing currently as overhead? (I assume so) Provided results for two material handler options: new material handler added to payroll, or leverage existing material handler. Cost increase – Not feasible

Rotating Fixture Utilizing the fixture design that already exists Idea consists of adding a servo or stepper motor Only to increase speed and accuracy Anna

Most Viable Candidates Modified Work Bench SCARA Robotic Arm Anna

Modified Work Bench Individually load 5 parts Have parts in easily accessible places near bench Cuts the longest process time to ⅕, since it’s done in one step Can be manual or automated Anna

Flowchart for Work Bench Anna

High precision & Repeatability SCARA Robots High precision & Repeatability Functionality Fast cycle times User Interface Low price point High value / low cost relative to comparable automation Automates all 3 assy. operations Adjustable to meet changes in staffing and demand “Set – and – forget” compatible & easily adapted to more automation SCARA Robots – Type of robot with a jointed two-ink arm which is fixed in the Z-axis but free in the XY axes. Ideal for assembly operations.

SCARA Robots Manufacturers Starting at ~$7,500 + FANUC Epson Omron Toshiba Mitsubishi Electric Staubli Starting at ~$7,500 + Key differences in repeatability, speed, work envelope & programing interface Determine the least expensive model that best suits process requirements

SCARA Robot Labor Cost Pick & place robot with manual feeds: Assumptions: 2M parts per year 7 hours productive time per 8 hour shift Assembly wage = 15$/hr 3 employees feeding parts System throughput rate = 1 part / 3 sec (20 parts / min, 1200 parts / hr) Current material handler can be leverage and their wage is included in overhead cost Current state fully burdened cost per part = $0.04686 # of automated lines Hourly Throughput Shifts required to meet demand Labor Cost Cost per part (labor only) 1 1200 239 $86040 $0.04302 2 2400 120 $86400 $0.0432 261 Working days in a year. 2 robot system meets demands in half a year if continuous. 3 robot system cost = $.0432 (same as 2 robot system). Difference between our labor cost and hilltops fully burdened cost is an annual $7680. if annual overhead applied to our labor cost is > 8040, then our system is the same cost point as hilltop, but reduced required workforce to only 3 + MH. 70% workforce redeployed while throughput maintained

Sorting and Feeding Replaces Vibratory Bowl feeder Operator sort and feed carriers, cams, and locks in correct orientation. Gravity fed Create surplus Chioma

Flowchart for Robotic Assembly can replace the manual feeding with vbf later in the future Chioma

SCARA Robot system meets level 2 or 3 How much Automation? 1. Machine Cycle 2. Unload Machine 3. Load Machine 4. Transfer part Order to Automate: Ryan SCARA Robot system meets level 2 or 3 Ideal future state (level 4 or 5) achievable through addition of automated feeding

Feasibility Summary Scoring Legend: Carlton

Bill of Materials Carlton

Risk Assessment Carlton

Plans for Next Phase Detailed Design - Phase IV: Final drawings of design Final Bill of Material Final test plan Continued prototyping and analysis Continued risk assessment Run simulation of final design Talk to machine shop about design ideas Maura

Questions/Feedback