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?