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P15665 GLEASON GEAR JAW METRICS
PROBLEM DEFINITION REVIEW9/11/14
KATIE BALDWIN
JOSH SMITH
DOUG PERRY
EVAN MOLONY
AGENDA
➢Team Info
➢Stakeholders
➢Project Background and Problem
Statement
➢Customer and Engineering Requirements
➢Benchmarking
➢Risk Analysis
➢Project Plan
THE TEAM
MEMBER ROLE
Katie Baldwin IE/Team Leader
Josh Smith ME/Budget & Supplies
Doug Perry ME
Evan MolonyME/Documentation
Tracking
STAKEHOLDERS
➢Gleason
❖ Gleason Operators
❖ Gleason Customers
➢MSD Group
➢Gerald Garavuso
PROJECT BACKGROUNDA gear loader jaw assembly is responsible for holding a gear blank while being transferred in and out of the work chamber of the Gleason machine. This is typically part of an automation option for high production use at companies like Ford and GM. Currently Gleason inspects individual components of the gear jaws but doesn't inspect the final assemblies. This has led to machining errors at the customer level due to tolerance stacks and other factors.
PROJECT BACKGROUND
PROBLEM STATEMENTDetail Components of gear positioning assemblies are not adequately inspected or toleranced allowing out-of-spec assemblies to produce non-conforming gears
ASSUMPTIONS & UNKNOWNS
➢We only need to measure surfaces which
contact the working part
➢We have not been provided with a list of
jaws yet
➢Drawings will be provided before the device
is tested
➢Images, models, or drawings of each
component will be provided
CUSTOMER REQUIREMENTSCustomer Rqmt. #
Importance Description Comments/Status Why is This a Requirement?
1 1Take accurate measurements of all surfaces
which contact gear or arborTop Priority
This is the only way to ensure the gear jaws are within the expected tolerances relative to oneanother.
2 1 Secure positioning of the assembly Ensures assembly does not shift during measurement.
3 1 Conform to predefined budget The customer cannot exceed their spending limit without approval from
an executive.
4 1 Pro-E files of all components The customer has specifically requested these for documentation and
device replication purposes.
5 2 Safe to use The device can not be detrimental to operator health.
6 3 Portability The device will need to be transported between RIT and the facility and
may need to be moved on the shop floor. The device should be movable by fewer than four people.
7 2 Easy to use Ease of use for the inspection operator will reduce necessary training and increase inspection efficiency thereby increasing customer profits
and satisfaction.
8 3 Rapid positioning of the assembly Reduced inspection time increases profitability for the customer.
9 2 Digitally record measurements The customer needs a way to store and record the measurements
10 1 Output corrective actions to spreadsheet If parts do not conform, the customer needs to know how to fix them.
11 1Accommodate three specific machines (GP400,
GP300, 130/210)
This was specifically requested and the device will not meet customer requirements without this functionality. The customer would also like
additional space to accommodate future machines.
12 3 Rapid measurement Reduced inspection time increases profitability for the customer.
13 1 Device measures critical surfaces All arbor contact surface profile and position are critical to design intent.
Based on customer feedback.
14 2 Device fits in available shop space The device will not meet Gleason's needs if it does not fit in their shop.
TOP PRIORITIES
Customer Rqmt. #
Importance Description Comments/Status Why is This a Requirement?
1 1 Take accurate measurements Top PriorityThis is the only way to ensure the gear jaws are within the expected tolerances relative to oneanother.
2 1 Secure positioning of the assembly Ensures assembly does not shift during measurement.
3 1 Conform to predefined budget The customer cannot exceed their spending limit without approval from an executive.
10 1 Output corrective actions to spreadsheet If parts do not conform, the customer needs to know how to fix them.
11 1Accommodate three specific machines (GP400, GP300, 130/210)
This was specifically requested and the device will not meet customer requirements without this functionality. The customer would also like additional space to accommodate future machines.
13 1 Device measures critical surfaces
All arbor contact surface profiles and position are critical to design intent. Based on customer feedback.
ENGINEERING REQUIREMENTS
rqmt. # Importance Source Function Engr. Requirement (metric)Unit of
MeasureMarginal
ValueIdeal Value
Test (how are you going to verify satisfaction)
1 1 CR 1 AccuracyGage Error From Ideal Over Full Measurement Envelope
inches ± 0.0002* 0 Gage Calibration
2 1 CR 1 Accuracy Rail Hole Position Tolerance inches ± 0.0002* 0 Rig Calibration (CMM)
3 3 CR 12 Efficiency Process Time minutes <20* <5 Stopwatch
4 2 CR 6, 14 Size Device Footprint sq ft <16 <9 Tape Measure
5 1 CR 3 Cost Prototype Cost $ <7000 <4000 Bill of Materials
6 2 CR 5, 6 Ergonomics Table Height ft ± 0.050 3* Tape Measure
7 2 CR 6 Ergonomics Device Weight Lbs <200* <120 Scale
8 3 CR 7 EfficiencyAverage Training Time Required by 90% of People Over the Age of 18
minutes <20* <10 Stopwatch
9 3 CR 1 AccuracyNumber of Components in Measurement System (Excluding Gages and Fasteners)
units <10* <5 Bill of Materials
10 1 CR 2 Accuracy Bolt Torque (Clamping Force) In-Lbs (Lbs) ±10 400* Torque Wrench
11 2 CR 11, 12 Efficiency Number of Operators Able to Work Simultaneously units 2 3 Count
12 1 CR 12 Versatility Specified Machines Accommodated binary Yes Yes Binary
13 1 CR 1 Accuracy Measurement System & Output Error ** inches ± 0.001 0 Rig Calibration (CMM)
14 1 CR 4 Docmentation Designs Delivered in Pro-E Format binary Yes Yes Binary
15 1 CR 1 Precision Measurement Results Repeatable inches ± 0.001 0 Rig Calibration (CMM)
16 2 CR 13 AccuracyAbility to Measure All Gear Contacting Surfaces on Existing Jaws
binary Yes Yes Binary
INITIAL SPEC
Need Priority Gag
e E
rror
Fro
m I
deal
Ove
r F
ull
Mea
sure
men
t E
nvel
ope
Rai
l Hol
e P
ositi
on T
oler
ance
Pro
cess
Tim
e
Dev
ice
Foo
tpri
nt
Pro
toty
pe C
ost
Tab
le H
eigh
t
Dev
ice
Wei
ght
Ave
rage
Tra
inin
g T
ime
Req
uire
d by
90%
of
Peo
ple
Ove
r th
e A
ge o
f 18
Num
ber
of C
ompo
nent
s in
Mea
sure
men
t S
yste
m (
Exc
ludi
ng G
ages
and
Fas
tene
rs)
Bol
t T
orqu
e (C
lam
ping
For
ce)
Num
ber
of O
pera
tors
Abl
e to
Wor
k S
imul
tane
ousl
y
Spe
cifie
d M
achi
nes
Acc
omm
odat
ed
Mea
sure
men
t S
yste
m &
Out
put
Err
or
Des
igns
Del
iver
ed in
Pro
-E F
orm
at
Mea
sure
men
t R
esul
ts R
epea
tabl
e
Abi
lity
to M
easu
re A
ll G
ear
Con
tact
ing
Sur
face
s on
Exi
stin
g Ja
ws
Take accurate measurements 1 x x x x xSecure positioning of the assembly 1 x xConform to predefined budget 1 xPro-E files of all components 2 xSafe to use 1 x xPortability 2 x xEasy to use 1 x xRapid positioning of the assembly 1 xDigitally record measurements 1 xOutput corrective actions to spreadsheet 2 xAccommodate three specific machines (GP400, GP300, 130/210)
3 x x
Rapid measurement 2 xDevice measures critical surfaces 3 xDevice fits in available shop space 1 x
Un
it o
f M
easu
rem
ent
Inch
es
Inch
es
Hou
rs
Fee
t
$
Fee
t
Pou
nds
Hou
rs
Uni
t
Lb-i
n (L
bs)
Uni
t
Bin
ary
Inch
es
Bin
ary
Inch
es
Bin
ary
INITIAL SPEC
Need Priority Gag
e E
rror
Fro
m I
deal
Ove
r F
ull
Mea
sure
men
t E
nvel
ope
Rai
l Hol
e P
ositi
on T
oler
ance
Pro
cess
Tim
e
Dev
ice
Foo
tpri
nt
Pro
toty
pe C
ost
Tab
le H
eigh
t
Dev
ice
Wei
ght
Ave
rage
Tra
inin
g T
ime
Req
uire
d by
90%
of
Peo
ple
Ove
r th
e A
ge o
f 18
Num
ber
of C
ompo
nent
s in
Mea
sure
men
t S
yste
m (
Exc
ludi
ng G
ages
and
Fas
tene
rs)
Bol
t T
orqu
e (C
lam
ping
For
ce)
Num
ber
of O
pera
tors
Abl
e to
Wor
k S
imul
tane
ousl
y
Spe
cifie
d M
achi
nes
Acc
omm
odat
ed
Mea
sure
men
t S
yste
m &
Out
put
Err
or
Des
igns
Del
iver
ed in
Pro
-E F
orm
at
Mea
sure
men
t R
esul
ts R
epea
tabl
e
Abi
lity
to M
easu
re A
ll G
ear
Con
tact
ing
Sur
face
s on
Exi
stin
g Ja
ws
Take accurate measurements 1 x x x x xSecure positioning of the assembly 1 x xConform to predefined budget 1 xPro-E files of all components 2 xSafe to use 1 x xPortability 2 x xEasy to use 2 x xRapid positioning of the assembly 2 xDigitally record measurements 2 xOutput corrective actions to spreadsheet 2 xAccommodate three specific machines (GP400, GP300, 130/210)
1 x x
Rapid measurement 2 xDevice measures critical surfaces 1 xDevice fits in available shop space 1 x
Un
it o
f M
easu
rem
ent
Inch
es
Inch
es
Hou
rs
Fee
t
$
Fee
t
Pou
nds
Hou
rs
Uni
t
Lb-i
n (L
bs)
Uni
t
Bin
ary
Inch
es
Bin
ary
Inch
es
Bin
ary
BENCHMARKING➢Coordinate-Measuring
Machine (CMM)
❖Automated or Manual
❖Five degrees of
freedom
❖Can be very accurate
❖Large measurement
envelope
BENCHMARKING CONT’D
➢ Mitutoyo Crysta-Apex EX 544TCMM Benchmark
Property Crysta-Apex EX 544T
Type Bridge
Range - mm (in)X-axis 500 (19.68)Y-axis 400 (15.74)Z-axis 400 (15.74)
Resolution - mm (in) 1x10-4 (4x10-6)Guide Method Air bearing
Degrees of Freedom 5Cost $$$
Total Mass - kg (lbs) 536 (1181)
BENCHMARKING CONT’D
➢ Crysta-Apex Cons
❖ Expensive
❖ Heavy
❖ “overkill” for this application
➢Don’t need automation
➢Don’t need controller
➢0.1 µm resolution not necessary
BENCHMARKING CONT’D
➢ Indicator
Indicator
Model
Property LH-600E/EG QM-Height Series 518-221
Crysta-Plus M443/574/710
6 Series 196
Resolution .000001 m .00005 m .000019 m
Accuracy (1.1+0.6L/600)μm
(.00011+.0002L/40)in
(3.0+4.0L/1000)μm
Envelope .972m .715m .4x.4x.3 m
Battery Life 5 hours/charge 260 hours / ∞ N/A
Degrees of Freedom 1 1 5
Cost $7,630 $2,701 ?
Mass 24 kg 22 kg 360 kg
RISK ANALYSISID Risk Item Effect Cause Likelihood Severity Importance Action to Minimize Risk Owner
1
Inaccurate gauges
The inspection measurements will not be accurate enough
Failure to benchmark and research indicators that will work best for the application
1 9 9
We will prevent and reduce this risk by putting in the time to properly benchmark and research measurement instrumentation
Katie, Evan, Josh, Doug
2
Station fails to support all machine models
Customer will not be able to inspect all machine models
Failure to receive drawings and prints of all models and jaws.
1 9 9
We will reduce the risk by communicating to the customer project developments and needs
Katie, Evan, Josh, Doug
3
Unable to accurately secure Jaws
The inspection measurements will not be consistent enough
Failure to secure rails onto inspection station. (regular assembly method will be employed for assembling jaws)
3 9 27
This risk can only be reduced by locating the mounting rails as accurately as possible.
Katie, Evan, Josh, Doug
4
Running out of time
The customer will not receive a finished working part.
Poor planning and execution of project aspects and deliverables
1 9 9
This risk will be prevented by the group following a strict schedule for project deliverables
Katie, Evan, Josh, Doug
PROJECT PLANMicrosoft Project Schedule:
PROJECT PLAN
Next Steps:
➢ Continue to update/meet with Richard
➢ Begin concept development
➢ Work on HOQ, making sure to adjust to any
customer or engineering requirement
changes
➢ Further explore benchmarking ideas
➢ Visit a nearby metrology lab