TECH Project Design and Manufacturing Control Process for Formula SAE Analyze Phase Date: 11/19/2014 Team members: Chris Lawrence

Brief Review of Project Charter Purpose of project is to create and implement a process that students must follow in order to produce defect free parts for the vehicle. Desired result is significant reduction in combined design and build time, while improving overall vehicle design and build quality. – Uniform quality standards – Reduced packaging issues: identification of problems before assembly – Only good parts are manufactured (in theory) – More time spent in design (CAD) and less time in build

CTQ Tree(s) Part fits/functions in theory (CAD) Approved Design Approved Drawing Part is made to Drawing Design & Mfg Completed to Schedule Critical to Quality Part fits/functions in real life Part has design consistent with car concept KPOV Parts are done on time Approved Concept KPIV Brainstorm process Conceptual Design process Engineering calcs verified CAD Fitment verified GD&T verified Engineering drawing verified Quality control verifies dims Schedule and deadlines VOC/SWOT Summary “Good” Design No Bad Parts Car is done on Time

Data is being collected using the process observation worksheet, checksheet, and a weekly progress tracker. All data collected on a weekly basis at minimum Notes on these sheets are very important due to the small quantity of quantitative data Data Collection

Graphs

Comparison of 2013 vs 2014 System implemented in Fall 2014, comparison of effectiveness of new system Design Cycle StartEndNo. Days 20135/15/20124/26/ /6/201411/19/ Manufacturing Cycle StartEndNo. Days 20137/10/20126/2/ (planned)12/1/20143/1/ Milestones in Schedule : First Drive 2. Competition Brainstorm 2: Conceptual Design 3. Detailed Design 4. Drawings 5 Manufacture of all Parts 6. First Drive 7. First Test (with aerodynamics) 8. Competition

Cause and Effect Matrix Inputs are KPIV variables, outputs are KPOV variables Cause and Effect Matrix Formula SAE 0 = no correlation, 1 = low correlation, 4 = moderate correlation, 9 = high correlation Input Approved Concept Approved Design Approved Drawing Passes QA Kept on Schedule Score Notes Days Spent Brainstorm Days Spent Conceptual Design Days Spent Detailed Design Detailed Design is Critial to Process Days Spent Engineering Drawings # of Rejections # of Ignored "Design Tollgates" # of Missed Meetings # of Missed Weekly Progress Consistent Weekly Progrees is Critical

Analysis Phase Conclusions Of the KPOV’s, the most important to this project is TIME (Design and Mfg. on Schedule). It affects all of the other KPOV’s. Any KPIV that can adequately track the likelihood of completing the project on time, and/or track the effort being displayed by each system/team member is critical. The most important KPIV variables are – Deadline Pass/Fail and #of days past due – Pass/Fail of progress each week by each system – Detailed Design phase time length, quality (subjective) – Number of milestones: more milestones means earlier detection of problems