Product development project

Student: Cillian O Sullivan

Number: 0661716

Course Title: Product Design and Technology

Module: PT4427 (Design for Manufacture)

Lecturer: Dr. Con Sheahan

Cillian O Sullivan 0661716 Product Design & Technology

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Contents

Product Development Project ................................................................................................... 4

Abstract .................................................................................................................................. 4

Introduction ........................................................................................................................... 4

Background ............................................................................................................................ 5

Current Approach .................................................................................................................. 6

Objective (Key Concepts) ....................................................................................................... 7

Business Opportunity ............................................................................................................. 7

Survey of existing solutions ................................................................................................... 8

Project Justification .............................................................................................................. 13

Project Plan .......................................................................................................................... 13

Design Approach ...................................................................................................................... 14

Literature Review ................................................................................................................. 14

QFD....................................................................................................................................... 15

Voice of the Customer ......................................................................................................... 16

Evaluation Criteria................................................................................................................ 17

Evaluation of existing solutions ........................................................................................... 19

Final Customer Requirement ............................................................................................... 21

Conceptual Model ................................................................................................................ 21

Use Description .................................................................................................................... 22

Product Development Specification .................................................................................... 23

Detailed Requirement Analysis ............................................................................................ 31

Design Requirements ........................................................................................................... 31

Manufacturing Requirements .............................................................................................. 32

Manufacturing Process Map ................................................................................................ 32

Final System Specification & Test Plans ............................................................................... 33

Prototype Manufacture ........................................................................................................... 34

Prototype Design ................................................................................................................. 34

Prototype Build .................................................................................................................... 36

Prototype Proof of Concept ................................................................................................. 39

Evaluation of Design ................................................................................................................ 40


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DFA Analysis ......................................................................................................................... 40

DFM Analysis ........................................................................................................................ 41

DFE Analysis ......................................................................................................................... 41

Discussion and Conclusions ..................................................................................................... 42

Proof of Concept as compared to Specification .................................................................. 42

Superiority over current system .......................................................................................... 42

Cost Benefit Analysis of this Approach ................................................................................ 42

Learning outcomes............................................................................................................... 42

Discussion............................................................................................................................. 43

Conclusions .......................................................................................................................... 43

References ........................................................................................................................... 45

Appendices ........................................................................................................................... 46


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Product Development Project

Abstract

This report deals with the problems facing a mechanic (automotive technician) while

working underneath and design and manufacture of a product that aid them while there.

The customer requirements are detailed and matched with design and manufacturing

requirements. The design and build of a concept model are included along with proof that

the concept carries out the tasks required of it.

Introduction

Automotive technicians have a very labour intensive job as jobs tend to go. The physical toll

taken on one’s body can lead to one being unable to work through one’s prime. The goal of

this project is to alleviate part of the physical toll by means of designing a device to aid

mechanics while they work on the underneath of a car. It can be taken for granted that

working underneath a car is an unpleasant experience. Modern techniques for working

underneath the car involve the vehicle be lifted, by means of a mechanical lift, above the

head of the mechanic.


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Background

Illness and injuries among mechanics are very common for example,

• Asbestosis

• Skin cancer

• Strains (muscles and joints)

• Trapped limbs

• Cuts

• Head injuries

• Burns

• Heart Attacks (over exertion)

There is a wealth of products already on the market that provide mechanics with solutions

to most of these problems. Rubber gloves to protect from skin cancer and dust masks to

prevent asbestosis. There are engine cranes and jacks to aid with lifting and to prevent

falling objects. However gaps are still present where a mechanics health and safety is at risk.

For example when removing a gearbox from a car both to replace the clutch or the gearbox


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itself the market only provides jacks that take the weight of a

gearbox(between 20 and 60kgs) none provide a means of aiding

the mechanic in pulling the gearbox (red) away from the engine

block (blue). This is a key cause of over exertion due to the weight

of the box and the use of one’s hands over heart level doing a strenuous exercise.

The convenience factor is another issue dealt with by mechanics. Having ones tools to hand

is important. Trying to reduce the need to pick tools of the ground or having to run over and

back to a work bench isn’t an appealing option for mechanics.

Current Approach

At the moment there are solutions on the market for both issues raised above, gearbox

jacks and tool trays.

To remove a gearbox the mechanic must first load a tool tray with all the appropriate tools

needed to separate the gearbox from the engine. This tray is then wheeled into position

under the car. At gearbox jack is the wheeled into position under the gearbox and lifted up

under the box to take the weight. The gearbox is then unbolted form the engine block and

the mechanic physically pulls the box out from the block. The gearbox is then dropped down

and the mechanic proceeds with the task at hand.


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Objective (Key Concepts)

To create a jack that eliminates the need to carry both a tool tray and a gearbox jack

under the car

To create a jack the eliminates the need for the mechanic to physically pull out the

gearbox by hand

Make a more secure jack plate to ensure the gearbox does not fall during the task

Make the product as user friendly and adjustable as possible

Account for varying sizes of gearbox

Business Opportunity

There are many mechanics in operation in the working world. Clutches and gearboxes have

to be replaced all the time and for this to be done jacks and tool trays are needed. All

products have a lift span so when a mechanic needs to invest in a new tray or jack why

wouldn’t they invest in a product that offers more than the traditional one.


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Survey of existing solutions

Car lift that allows the mechanic

access to the underneath side of the

car.

Trolley Jack allows restricted access to the

underside of a car and can also be used to

support a gear box as car be seen bellow.


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A gearbox removed from car at ground level with a

trolley jack.

Gearbox jack for when the car is close to the

ground.

Similar jack to the previous but with added support

to prevent gearbox from falling.


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A gearbox jack for working at height.

Similar jack with chains to restrain the gearbox


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Simple tool tray for moving tools to the work

area


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Tool tray with added light on castor wheels


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Project Justification

The need exists for a product on the market for mechanics that provides adequate

adjustability to grip a gearbox while a mechanical system eliminates the need for the

mechanic to physically exert oneself while removing a gearbox. This product also needs to

have sufficient tool storage to abolish the need for a mechanic to use a separate tool tray.

Project Plan

Test existing products

Talk to the user

Research and solve mechanical problems

Explore various ideas to improve convenience

Acquire gearbox for testing

Test prototypes for functionality

Attain relevant feedback from the user


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Design Approach

Literature Review

US Patent 5139233

Abstract

A lift jack adaptor for cradling a heavy irregularly shaped object such as an automotive

transmission includes a rigid base for mounting to a lift jack and pairs of laterally spaced

arms extending up from the base, the upper ends of those arms being terminated by flanges

for engaging the underside of the object cradled in the adaptor. These flanges are fastened

to the object and positively connect the object to the adaptor so that one can raise and

lower the object using the jack and repair the object in relative safety.


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QFD

A system for translation customer requirements into design and manufacturing

requirements. It reduces the number of design changes thus saving time.


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Voice of the Customer

Ways chosen to research the customer and get their opinion.

Online forums

Driver.ie

Car Mechanics Discussion Forum

Interviews

Observation

The online forums provided a lot of solid information that was really helpful in directing the

project. After asking mechanics online questions like

Could you describe your job in three words?

Have you ever been injured on the job?

Do you suffer from any long term injury or illness that you attribute to your job?

Does anything bother you about your line of work? E.g. fear, anger, annoyance.

With the answers acquired online it was time to visit the user in person and ask them some

questions for example.

Why do mechanic sometimes describe their jobs as being dangerous?

Why do back and neck injuries seem to be the most prominent injuries?

What annoys you about working underneath a car?

What dangers are underneath the car?


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From taking to various mechanics they all have the general consensus that working with

gearboxes at the height in question is dangerous and the effort needed to remove the box is

greater that it needs to be. Convenience is also an important factor for mechanics. A

product that solves more than one problem is a worthwhile investment.

Evaluation Criteria

Weight of a gearbox(20-60kgs)

Variations of gearboxes ( Rear wheel drive, front wheel drive, four wheel drive)

Jobs done on gearbox (clutch , replacing box itself)

4WD Gearbox

heaviest box at around 60kgs

Larger size due to more gearing


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RWD Gearbox

Middle weight at around 40kgs

Longer than the other boxes due to it being positioned along the length of the car

FWD Gearbox

Lightest at around 20-30kgs

Shortest and thinnest due to it position beside the engine block.

Replacing clutch

Multitude of tools needed

Large ammount of bolts to be removed

Many parts of a clutch( clutch plate, friction plate etc)


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Evaluation of existing solutions

Gearbox (transmission) jacks come in a wide variety of shapes and size but generally they all

perform the basic requirements needed.

Taking the weight of the gearbox

Providing basic stability for the gearbox

Simple jack with a supporting plate

No tool tray

No pulling movement

Slight adjustability

Simple jack with a supporting plate

No tool tray

No pulling movement

No adjustability


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large and bulky

Risk of losing nuts and bolts

Not very manoeuvrable

Separate item to jack

large and bulky

Not very manoeuvrable

Separate item to jack


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Final Customer Requirement

A safe and secure way to remove the gearbox

A place to lay or store tools when they are not being used

Easily accessible tools

A secure place to store nuts and bolt to prevent them from falling on the floor and

being lost

A jack that is easily cleaned and stored

Portable

Convenience

Conceptual Model

Top plate of the jack modelled in card board to help in working out sizes. Because it was

modelled around a standard size gearbox and the fact that it’s adjustable means that it can

support a range of different sized gearboxes


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The sliding mechanism was deveolped to be as simple as possible. It also features a standard

fitting so that a mechanic car use a simple ratchet or impact wrench to manoeuver the

gearbox.

Use Description

The jack positioned under the gearbox and rose into place. The side supports are slid into

place to prevent the gearbox from rocking and a strap is added to secure the gearbox to the

jack. The gearbox can then be pulled out mechanically using an impact wrench or a socket

wrench. All tools used can be placed on a tool tray attached to the jack.


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Product Development Specification

Performance

The jack should be able to take a considerable amount of weight above and beyond the

weight of a gearbox.

Shock loading should also be a factor if the gearbox or ever the engine block should fall on

the product.

The hydraulic ram should rise and fall under weight at a constant speed. It should not drop

quickly with a large weight on top.

Environment

The product should be able to withstand dust and dirt of all types. Being in a mechanics

garage the jack should perform in a dirty environment.

It should be able to withstand being covered in oil and grease (prolong the product by

preventing rust)

The castor wheels should be able to run over rough and cracked concrete floors without the

risk of it toppling over.

Service Life

The jack should have a long service life. The longer the service life is the better the

reputation for the product.

A jack that is robust and that lasts a long time is likely to create a good market for itself by

both reputation and word of mouth.


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Maintenance

The maintenance of the product should be kept to a minimum. The mechanics job is to

maintain cars so the less maintenance that needs to be done the better.

The storage and supporting plate should be virtually maintenance free expect for a clean

ever so often.

The hydraulic ram, for safely reason, should be checked for jack creep (slow descent under

pressure) often and repaired when necessary.

Target Costs

Retail costs for transmission jacks range from between 150 to 350 Euros. With the added

features for that jack being designed the retail price would be on the top end on the price

scale if not more. This is acceptable because of the extra features including the tool tray

itself.

The cost of manufacture can be kept low by buying in standard parts like the ram and castor

wheels. The use or standard nuts and bolt will also keep the cost down. Machining being

kept to a minimum will also allow for a long manufacturing cost.

Target cost too make would be 200 euro depending on the quality of materials and

machining.


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Competition

Competition exists on the market when one looks at existing gearbox jacks but the safety

and convenience of the sliding jack come tool tray hasn’t yet been seen and fills a hole in

the market at a price not far from an inferior product.

Shipping

The product will be bought by internet tool suppliers in the form of a flat pack kit. These

suppliers buy in bulk if they see a market for the product you are supplying.

The customer will then search for the product online or from a catalogue and place the

order. The company will then send the order flat packed though a courier service ready for

the customer to do the final assembly.

Product Volume

As the product has a long life span it would not have the product volume of a consumable.

However there is a very large market for the jack due to the nature of the product

(mechanics are worldwide).

One would be looking at a long term market gradually phasing out the existing products on

the market with a superior one as they have to be replaced.


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Packing

Plastic packing around all part to prevent water damage during transportation.

Parts separated by packing foam to stop denting or paint chipping.

Cardboard box to make shipping easier

The parts in the box should be orientated in such a way as to reduce packaging

Manufacturing Facility

The product could be manufactured in and existing plant. The only exception is that the

amount of parts increases and the assembly line lengthens.

Size

The jack should be big enough to hold the weight of a gearbox safely and prevent buckling

on the jack when being moved under weight. The jack should be the same size as a regular

jack so a mechanic can store it in the same place as the original jack.

Weight

The weight of the jack should be kept to a minimum without impeding the strength of the

jack as it will have to be moved around by hand with and without a gearbox on it.


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Aesthetics and Finish

Aesthetically the jack has to long robust to give the mechanic a sense of reliability at a first

glance. The main features of the jack must be noticeable at a distance and there function

must be recognised at a glance.

A bright colour should be used so that the jack can be seen at a distance and can be found

quickly in a garage environment.

The finish on the jack must be strong and well able to withstand scratching and chipping. It

must also be able to withstand oil soaking and discolouration.

Materials

Recycled steel

Bought in parts

Product Life Span

The product life span is hard to say as cars are changing all the time and with diminishing oil

resources who can say that a whole new generation or car won’t come into use.

Ergonomics

The handles and trays have to be at comfortable height to reduce stain of being over and

risk of the jack being pulled over. The working height has to be at stomach height.


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Customer

The customer expects

Reliability

Cheep cost

Safety

Convenience

Speed

Low maintenance

Quality and Reliability

The product has to be that of high quality as it will be expected to have a long life being put

under pressure.

Failure on the job would be unacceptable as a fail could result in serious injury to the user.

Shelf Life

Due to the robust nature of the product a long shelf life is possible as there are no

perishable parts.

Manufacturing processes

Milling

Drilling

Tapping

Spraying(painting)


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Timescales

This product was brought to the proof of concept stage in twelve weeks. Testing should take

place for a period of time. Tool manufacture is irrelevant because no specialist tools are

needed to manufacture. With a working solid works model the product could go to primary

manufacture for testing.

Testing

Each jack will have to be individually tested under weight to ensure that it meets safety

standards.

Safety

Safety is a big issue with this product. It has to be manufactured and assembled to a high

quality to ensure the safety of the user. The user is working with heavy object so the jack

has to guarantee no to bend, buckle or give under pressure.

Company Constraints

The product will be manufactured by a company that currently manufactures similar

automotive product therefore the only company constraint is that it is manufactured to a

similar standard as the existing products.


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Market Constraints

As cars are the same the world over there are few if no market constraints. High quality

tools are generally known and used worldwide.

Patents, Literature and Product Data

US Patent 5139233 - Transmission jack adaptor

US Patent 3735958 – Transmission Jack

Political and Social Implications

The product in question prevents possible injuries to mechanics thus impacting on a social

level.

Disposal

Due to the product being manufactured almost entirely out of steel and the fact that it is

easily disassembled because of the use of standard bolts and screws it is easily recycled.


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Detailed Requirement Analysis

The product must be

Safe

Reliable

Cheep( comparing existing products)

Cleaning and maintenance

Easy to clean

Resist scratching or any aesthetic damage

Easy to maintain and repair

The product must carry out the tasks the customer expects it to

Allow the gearbox to be removed with minimal effort

Allow for quick task completion

Have a designated area for tools

Design Requirements

The jack must be designed in such a way that it carries out the tasks expected by the

customer.

All parts should be mirrored to make the manufacturing process easier.

It must be designed so that a standard hydraulic jack can be used in the assembly process to

reduce the overall manufacturing cost.

Allowances should be made for easy repair and maintenance. The design can also account

for the disposal at the end of its like. If design properly and if the right materials are used

the jack should be easy to recycle.


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Manufacturing Requirements

The jack has to be manufactured to a high standard to ensure that it is a safe product and

doesn’t fail during operation. A fail could result in serious injury to the user.

The manufacturing costs have to be kept to a minimum so that the customer gets a good

price and the manufacturer makes a profit. A competitive market price is also important.

Manufacturing Process Map


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Final System Specification & Test Plans

A jack that is fully adjustable and portable. It should aid the mechanic in pulling out the

gearbox from the engine block.

Adequate tray area for tools and nuts and bolts should be incorporated.

The jack will have to be tested in a real life situation. Tool tray will need to be used to show

the convenience aspect. The pulling mechanism will have to be shown in detail working.


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Prototype Manufacture

Prototype Design

The prototype design varies a good deal from the final design. The prototype is used to

prove a concept so changes to materials and looks can be made while keeping the

functionality of the product.

Sketching and sketch models were an important commodity in coming up with the overall

final design.

In the original design to allow the gear box to be moved away from the engine a hydraulic

jack seemed to be the way to go. However this idea merely inspired a simpler system


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whereby a mechanic would be able to use tools already in use when removing the gear box,

such as an impact wrench or ratchet.

The system work similar to a bench vice whereby a treaded bar when turned would slide a

plate backwards or forwards depending on the rotation of the bar. As seen below.

The top plate consisted of an adjustable platform with an accompanying strap to secure the

gearbox when in motion


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Castor wheels and storage were next on the agenda in the design. Castor wheel were a

simple and necessary addition to give the jack mobility around the garage area. The storage

on the other hand was a simple addition but it gives this jack a lot more than just being a

jack. Aside from the fact that it allows one to carry all that is needed for a job in one system

(tools, jack, power, etc) it also gives the jack a lot of stability and structural strength.

Prototype Build

The materials and processes in the prototype build were kept basic. This allowed for a cheap

build as well as a quick built. Also almost all machining and casting processes were avoided.

The model is simply buts using wood, MDF, treaded bar, nuts, bolts, cardboard and some

salvaged scrap items to mimic movements and parts needed to prove the concept works.


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Top plate attached to sliding mechanism

Strap for holding gearbox in place

Adjustable top plate for different size gear boxes

Finished sliding mechanism


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Height adjustment and clip to mimic the hydrolic jack up and down movement.

Tool storage unit built in prototype out of cardboard allow quick access to tools while

providing overall strength to the product.


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Prototype Proof of Concept

Table top with lips on the edges to allows for quick retrival of tools while working and the

prevention of tools and accessories falling on the floor.

Tool and part storage.

The jack takes the strain of the gearbox even after being built from low fidelity materials.


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Evaluation of Design

DFA Analysis

Design for a minimum number of parts. Keeping parts to a minimum aids in the assembly as

the assembly line will be shorter and the assembly will be easier. Ready assembled parts

such as the hydraulic jack and castor wheel will also reduce assembly time and cost.

Standard bolts throughout will reduce confusion and speed up the assembly process.

Tapped holes eliminate the need for bolts and washers thus reducing the number of overall

parts. Mirrored holes and centred parts allow for quick and easy assembly as well as the

option for automated assembly.

The jack is designed in such a way that once the castor section is assembled the hydraulic

ram and storage unit can be lowered and fastened from the top down. The top section for

supporting, restraining and moving the gearbox can then be lowered and secured from the

top also. Having all the individual sections ready assembled manually,

Storage unit

Castor wheels

Hydraulic Jack

Top supporting unit.

The entire piece can then be assembled top down along the vertical axis.

Standard size parts such as bolts and screws situated in easily accessible places not only

provide easy assembly but they also provide easy disassembly for maintenance, service,

repair or recycling of the jack.


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DFM Analysis

Reducing the number of processes used to manufacture the product greatly reduces the

time the product spends in production thus increasing the overall yield. Also reduced is the

total cost of manufacture.

While some of the components for the jack can be part cast and part

machined, if these part were designed symmetrical just the

machining process would be needed. This would be a more suited

process as it provides greater accuracy and a good surface finish.

The accuracy provided by machining would ensure less wear and a

longer lift for the jack. The good surface finish would allow the parts to be painted without

the need to be worked on further.

DFE Analysis

The jack in question will be manufactured from steel for the most part, which can be bought

in as a recycled product thus reducing this products impact on the environment and on the

worlds steel resources.

Having steel as the dominant material and the easy disassembly of the product

also allows the jack to be easily recycled come the end of its life span.


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Discussion and Conclusions

Proof of Concept as compared to Specification

The jack preformed well for the proof of concept. It was safe (gearbox was secure). It was

convenient (allowed for easy access to tools)

It was impossible to prove the maintenance issues as the model was only built from low

fidelity materials.

Superiority over current system

The new system provides more adjustability to the user when taking into account the

varying size of gearboxes. It also allows the user to remove a gearbox with considerably less

effort that the jacks that are currently on the market.

The convenience of this system is something that hasn’t been seen before. It ensures that

the user can have everything needed to do a job at hand rather than having to walk over

and back across a workshop getting tools or tool trays.

Cost Benefit Analysis of this Approach

The product designed allows the user to purchase one product rather that purchasing two

separate products. This also saves the user money on shipping costs

Learning outcomes

Learned how much work has to go into bringing an idea from design through to

manufacture.

Learned how to do a Product Specification report.

Learned how building a conceptual model benefits proving one concept


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Discussion

As a whole mechanics face a lot of dangers in a working day. Many can be avoided with the

right use of equipment and exercising caution however there are still areas where there are

still problems with equipment being inferior to what a mechanic needs.

This report dealt with the task of removing a gearbox from a car either to replace the

gearbox or to replace a clutch. To do this the weight of the gearbox needs to be supported

while the mechanic unbolts it and pulls it out by hand. This task puts huge strain on

mechanic due to the weight of the gearbox. This coupled with inconvenience of dealing with

tools either on a separate tool tray or on the floor makes for a very undesirable job.

The report also deals with the design and manufacture of a new jack that deals with the

problems outlined above. Customer requirements are outlined along with design and

manufacturing requirements in detail. The prototype design and build is outlined and

tested.

Prototyping allowed for a proof of concept to be achieved and problem in the design to be

worked out.

Conclusions

Problems were identified with and existing gearbox jack

Only took the weight of a gearbox

Didn’t provide tool storage

Mechanic had to physically move the gearbox

Chance of the gearbox slipping of the jack

These problems were then evaluated and solutions found.

The jack designed takes both the weight of the gearbox and supports it from falling. The

gearbox can then be moved mechanically so the mechanic doesn’t have to use physical


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effort. Tool storage is accounted for as a large work area is provided. The need for a

separate tool tray is eliminated.


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References

Health and Safety at Work etc Act 1974

Vehicle workshop health & safety policy manual

Goss, A. (1992). Transmission jack adaptor, Google Patents.

Hollingsworth, E. (1973). HIGH RISE TRANSMISSION JACK, Google Patents.

Keyserling, W., T. Armstrong, et al. (1991). "Ergonomic job analysis: A structured approach

for identifying risk factors associated with overexertion injuries and disorders." Applied

Occupational & Environmental Hygiene 6(5): 353-363.

Munck-Ulfsfält, U., A. Falck, et al. (2003). "Corporate ergonomics programme at Volvo Car

Corporation." Applied Ergonomics 34(1): 17-22.

Pheasant, S. and C. Haslegrave (2006). Bodyspace: anthropometry, ergonomics, and the

design of work, CRC Press.

Sauter, S., L. Schleifer, et al. (1991). "Work posture, workstation design, and musculoskeletal

discomfort in a VDT data entry task." Human Factors: The Journal of the Human Factors and

Ergonomics Society 33(2): 151-167.


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Appendices

Health and Safety

Good health and safety practice is an essential part of realising the

Ambulance Trust’s mission values in respect to care.

It is also a factor which directly impacts upon business performance through

its effect upon staff morale, employee relations, absenteeism, productivity,

accident costs and damages, legal enforcement measures and public

image. Good health and safety practice must therefore be an integral part


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of good business management to which everyone in the workplace can

effectively contribute.

There are increasing legal obligations affecting employers in the field of

health, safety and welfare at work is beyond doubt. The health and safety

at work act 1974 has been the most significant piece of legislation which, as

an ‘enabling’ Act, has empowered the Secretary of State for Employment to

subsequently introduce regulations and code of practice on a range of

health and safety matters. More recently, the European Council has

focused appreciable attention on health and safety with the result that

additional regulations introduced in 1993 will inevitably increase demands

upon management, and generally raise the profile of health and safety on

the business agenda.

The Trust’s policy and Code of Practice ensure compliance with legal

obligations. They also recognise the business advantages of applying best

practice in the management of health and safety, against which the Trust

will be judged by the Health and Safety Executive inspectors. The Codes of

Practice form extensions of the Trust’s policy statement, and provide

frameworks upon which the section management can build its own specific

structures, policies, practices and standards.

Applying these Codes of Practice is not just about complying with the law, it

is about establishing and fostering a safety culture that enables everyone to

help make the business better.


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Faulty equipment

Tools and equipment need regular inspection, checking and cleaning with

any defects being recorded. Under no circumstances should you continue

to use equipment such as a defective jack and especially where safety is

involved, you must notify your supervisor who will arrange repairs or

replacement.

Trolley jacks

Staff should monitor the condition of the jack. During every day use,

checks for leaks, general condition and the jack descending (creep), should

be monitored. It is the responsibility of staff to carry out these checks until

such time as the defect can be reported to the supervisor who then

assumes responsibility for removing the jack from service. At least annually

the jack should be tested by placing under a suitable vehicle which should

be lifted until a “test piece” such as a block of wood can be placed under

the wheel with an additional clearance of approximately 2cm. If after 30

minutes the jack has descended, so that the wood cannot be removed, the

jack should be withdrawn from service.

Safety Equipment

The following safety equipment is supplied free of charge and must be

worn/used at all times when applicable:-

• Overalls

• Safety Shoes

• Reflective Jacket

• Protective Gloves

• Safety Goggles


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• Barrier Cream

• Face Masks (Disposable)

• Plastic Suit for steam cleaning

• Hard hats

Jack and Axle Stands

Jack vehicles only on a level undamaged floor with a trolley jack rated to lift

the weight safely. The correct jacking points must be used and handbrake

and/or chocks must be used.

The jack must be used for lifting the vehicle only, then axle stands must be

properly positioned in order to support the vehicle weight. Ensure that the

correct support pins in good condition are used for the extendable columns

of the axle stands.

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