Download - Presentation of Phase 3 Monday 12/11/2006 Nick DePompeo, Brian Hufe, Mike Sacra, Ben Stuchlik
Presentation of Phase 3
Monday 12/11/2006Nick DePompeo, Brian Hufe, Mike Sacra, Ben Stuchlik
Southco Over the past 60 years, Southco has grown
through innovation, strategic acquisitions and overseas investments into a global leader in Engineered Access Hardware.
DZUS quarter-turn fasteners provide quick, effortless access/fastening for military and aerospace applications.
Project Scope Definition
To accurately design and manufacture an interface between an MTS machine and required fasteners to produce an efficient and safe testing process for all required tests.
Current Process
Utilizes 3 machines Utilizes compressed air
Requires skilled, trained operator Tensile, shear and torsional tests are performed
Tensile/ShearFastener Testing
Tensile/ShearReceptacle Testing
TorqueFastener Testing
Why Change? Three required machines to run tests Extensive Testing time Repetitive Testing Process Testing process may be inaccurate Southco has an MTS machine available
Customer Wants
Decrease skill requirement of testing procedure
Decrease testing time Maintain testing safety standards Develop an interface with available
MTS Machine Increase repeatability and accuracy
Metrics
Number of machines Testing time Accuracy Repeatability Durability
Benchmark-Target Value Comparison
1) 3 Machines 1) 1 Machine (MTS Machine)
2) Approximately 8-9 hours 2) Less than 4 hours per lot
3) Unknown 3) 10% more accurate than what is being tested
4) Unknown 4) 10% more repeatable than current process
5) N/A 5) Operational for a minimum of 10 years
Benchmark Values Target Values
Selected Concept: Single
interface for all tests
Reduced setup time between tests
Easily allows for “nesting” feature
Key Pieces1) Top U Piece2) Bottom U Piece3) Nesting4) Rotator Pieces
3
1
4
2
Assembly Model
Nesting
Nesting allows for adaptation. New fasteners may be tested through the use of new nesting pieces.
Locking/Unlocking Fastener
Shear to Tensile Test Re-Positioning
Design Schematic
Testing Procedure
1) Attach interface to MTS machine2) Load TestWorks and initialize test3) Calibrate machine4) Performed 3 trials of testing for 3-
fastener lots using required testing order
5) Record data and analyze results
Testing Results
Interface works as intended. Testing time reduced to target value.
Test Validation- Ease of Use
Current System:Requires three Machines
New System:Requires 1 Machine
Test Validation- Testing Time
Testing Time has been reduced by approximately 4 hours
Current testing time take approximately 8 hours per lot
Test Validation- Accuracy Load Cell is much
more accurate than the current compressed air system which can have leaks.
The new system is calibrated every time a new testing shift begins.
Test Validation- Repeatability
Testing showed a high degree of repeatability. Testing time had a
low std. deviation
Value to Southco
Decreased testing time More lots can be tested in a given time.
Set testing procedure Detailed step-by-step procedure
Minimizes operator skill requirements Takes up less space
Project Costs
Implementation Plan
Southco will be provided with the interface and necessary hardware/software.
Southco will be provided with a detailed operations manual, including engineering drawings.
Southco will be provided with a first-hand training session for operators.
Financial Payback
Skilled operator salary: $30/hrCurrent Test Time: 8.5 hrTests per day: 1 test
= $255.00 per test
Skilled operator salary: $30/hrNew Test Time: 4.5 hrTests per day: 1 test
= $135.00 per test
Estimated Savings = $120.00 per test
At a total cost of $2410.85, it would takeSouthco approximately 20 days of testing tocompletely pay off the new testing system.
Questions?