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

2. 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

3. 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

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

5. 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

6. 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

7. 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 = $
# Assy. Lines
Hourly Throughput
Shifts required to meet demand
Labor Cost
Cost per part (labor only) 1
720
397
$142,920 $ 2
1440
199
$143,280 $ 3
2160
133
$143,640 $
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

8. 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

9. Most Viable Candidates
Modified Work Bench
SCARA Robotic Arm
Anna

10. 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

11. Flowchart for Work Bench
Anna

12. 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.

13. 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

14. 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 = $
# of automated lines
Hourly Throughput
Shifts required to meet demand
Labor Cost
Cost per part (labor only) 1
1200
239
$86040 $ 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

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

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

17. 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

18. Feasibility Summary
Scoring Legend:
Carlton

19. Bill of Materials
Carlton

20. Risk Assessment
Carlton

21. 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

22. Questions/Feedback