1 Clutch Selection for American Marine Z-Drive Product ETM 5121 Project Proposal Phillip Magee Feb 16, 2004

2 Introduction Proposal Individual effort Introduce self selected project to American Marine Management and MSETM Faculty Unclassified Company names, product names, and data are sanitized to protect trade secrets and proprietary information

3 Opportunity Statement American Marine designs and manufactures z-drive marine power systems Z-drive product description Transmit power from an automotive style engine to a propeller Steer, trim, and trailer the gearcase and propeller Provide for shifting power (Forward – Neutral – Reverse)

4 Opportunity Statement American Marine currently produces the following z-drive products to serve the recreational and light commercial marine market Charlie drive Basic design – 300 HP Single propeller only Several gear ratios Delta Drive Basic design – 575 HP Single sport, low speed, and dual propeller Several gear ratios Standard, Diesel, Performance, and Racing versions

5 Opportunity Statement Charlie and Delta drives are similar simple and robust 2002 and 2003 J.D. Power surveys ranked them below their only major competitor (Volvo) in shift characteristics Small incremental improvements have been made to the clutch and drivetrain components for over 40 years The current shift mechanism designs are nearing the end of their life span and are difficult to improve A new z-drive program has been approved and opportunities to improve the shift characteristics (Noise, Vibration, Harshness) are available

6 Measures Timeliness Projected schedule vs. actual schedule Professionalism Clear and concise documentation Team Member Buy-In How many other decisions uses these processes in 2004 and 2005? Ability to select clutch and obtain approval Is the outcome of the effort successful?

7 Project Objectives Provide useful and relevant information to American Marine Mgmt. regarding clutch selection for future z- drive products Information on available clutch types Information on clutch safety Information on clutch performance attributes and cost Suggestion for future clutch type

8 Specific Deliverables Benchmark study Internal, competitive, functional Energy trace and barriers diagram (ETBD) Preliminary hazard list Preliminary hazard analysis Failure modes and effects analysis process Decision analysis

9 Alternatives to be Considered Clutches currently used in the marine, automotive, or off- highway vehicles will be considered Dog Clutch Charlie drive, all outboard engines Cone Clutch Delta drive, all Volvo drives Wet Disk Clutch Inboard marine transmissions, automatic automotive and off- highway transmissions Dry Disk Clutch Manual or automated manual automotive and off-highway transmissions

10 Project Approach & Criteria for Evaluating Alternatives Proposal Completion Individual effort Benchmarking Research and Documentation Individual effort with support of internal experts ETBD Individual effort that diagrams energy flow and barriers to better understand the clutch’s role in safe operation Preliminary Hazard List Team brainstorming effort, Benchmarking and ETBD will be presented to team

11 Project Approach & Criteria for Evaluating Alternatives Preliminary Hazard Analysis Team FMEA Decision Analysis Team effort, criteria for evaluating clutch alternatives will be generated and weighted Project Documentation and Final Report Individual effort, combines the data from all of the processes and contains suggestion for clutch selection

12 Project Plan

13 Project Plan

14 Project Plan

15 Planned Use of ETM Materials Benchmarking The benchmarking portion of this report will use the concepts learned for process benchmarking in a light product benchmarking exercise. System Safety The PHL and PHA processes learned in the system safety class will be utilized in order to help direct a design choice in early design stages. Failure Modes and Effects Analysis FMEA processes presented in the FMEA course will be used to complete the PHA Problem Solving and Decision Making The Kempner Tregoe decision analysis process presented in the problem solving and decision analysis course will be utilized to evaluate the clutch alternatives

16 References Kotler, Phillip. Marketing Management. Upper Saddle River, NJ: Prentice Hall, 2001 Camp, Robert. Business Process Benchmarking. Milwaukee, WI: ASQ Quality Press, 1995 Stephenson, Joe. System Safety New York, NY: John Wiley & Sons, Inc., 1991