PowerPoint Presentation by 5mn92N

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									             2.875
    Mechanical Assembly
and Its Role in Product Design




    Pencil Sharpener Presentation#1
          November 14, 2001
             Hernan Joglar
             John Sharkey             1
                      Presentation Contents
•   Product Description
•   Company Background
•   CAD Exploded view
•   Parts and Material List
•   Photo of Product Disassembly
•   Product Structural Decomposition
•   Major Sub-Assemblies
•   Critical Mates and Clearances
•   Gearbox Key Characteristics and Datum Flow Chain
•   Assembly liaison diagram
•   Assembly Time Analysis
•   Example Assembly Process
•   Fixtures and Special Tooling
•   Potential Problems and Risks
•   Suggested Assembly Improvements
•   Backups
     – DFA Gross Motions                     - Product Structural Decomposition
     – DFA Fine Motions                      - Part Liaisons and Mates
     – Related Product Line
                                                                                  2
             Boston Stapler Product Description
• Battery Operated Pencil Sharpener: Model #16750 (black)
   –   Referred to as a “razor spiral cutter” model
   –   Operation activated by axial force of pencil insertion
   –   Safety lockout feature prevents operation without receptacle
   –   Features 1 year warranty
        • No replaceable parts, Hunt simply replaces defective units
• Product Assembly Specifications:
   – 29 identified parts, comprising 7 sub-assemblies
   – 35 assembly features and liaisons
   – Physical dimensions: 4.75” x 3.00” x 2.25” at 6.1 ounce weight
• Popular with graphic artists and designers
   – provides clean, sharp pencil points for a wide range of pencil types,
     including composite pencils
• Approximately 250,000 units sold last year
   – Distributed through all major office supply retail stores
        • Staples, Office Depot, Wal-Mart, Target, etc
   – Typically sells for around $5.00                                        3
                  Hunt Manufacturing Corporation
• Founded in 1899 by George Bartol
• Went public in 1982 after a series of expansions and acquisitions.
• Corporate headquarters in Statesville, NC
     • Donald L. Thompson became president and CEO in 1996
     • Product design center located in Statesville, NC
     • Outsources most manufacturing within the United States
     • Boston Series of pencil sharpeners manufactured in China
     • 1300 employees nationwide
     • Sales revenue of $286M in 2000, 1.6% increase over 1999
• Main product lines is graphics equipment and office supplies
     • A global leader in the pencil-sharpener market
     • Boston family of pencil sharpeners and
       staplers accounts for 40% of company sales
     • Other significant products lines include:
           • Exacto razor blades
           • Conte crayons and pastels
           • Bienfang paper, painter markers,
            foam boards and laminates
           • Seal imaging equipment                                    4
     CAD Exploded View




                                                          5
[ Model developed using Autodesk Inventer Version 3.0 ]
                            Parts and Material List
P/N                     Part Name                       Qty                  Material Description
 1    Base Screws                                        2    Self-threading steel screw
 2    Pencil guide                                       1    Injection molded plastic
 3    Battery compartment screw                          1    Self-threading steel screw
 4    Shavings receptacle                                1    Injection molded plastic
 5    Sharpener base                                     1    Injection molded plastic
 6    Rubber foot (Underneath of base)                   1    black rubber
 7    Sharpener case                                     1    Injection molded plastic
 8    Contacts on battery compartment cover              2    stainless steel contacts with plastic rivets
 9    Battery compartment cover                          1    Injection molded plastic
10    Rubber foot (Underneath of battery comp. cover)    1    black rubber
11    Battery Compartment housing                        1    Injection molded plastic
12    Contacts and rivets on battery compartment         3    stainless steel contacts and brass rivets
13    Battery installation paper guide                   1    white paper with black graphic print
14    Blue wire                                          1    22 gage aluminum braid wire
15    Gearbox housing                                    1    Injection molded plastic
16    Output Gear                                        1    Injection molded plastic
17    Intermediate Gear                                  1    Injection molded plastic
18    Driven Gear                                        1    Injection molded plastic
19    Gearbox cover screw                                1    Self-threading steel screw
20    Electric motor                                     1    Brush commutated DC permament magnet motor
21    Safety lever                                       1    Injection molded plastic
22    Lubrication                                        1    red petroleum jelly on gears and motor
23    Contacts and rivets on gear housing cover          3    stainless steel contacts and brass rivets
24    Red wire                                           1    22 gage aluminum braid wire
25    Black wire                                         1    22 gage aluminum braid wire
26    Gearbox cover                                      1    Injection molded plastic
27    Blade screw and nut                                1    Machine screw and hex nut
28    Blade                                              1    Stainless steel razor blade
29    Blade holder                                       1    Injection molded plastic                       6
          Photo of Product Disassembly
                14                    9
                     24     15   25       5           8        4



 12

11




                                                                    23



                                                                         2
7




     21                                                        11
                                                                    20



                     17   18 19 1     3 26    27 28       29
           16



                                                                             7
                    Product Structural Decomposition
                                                            Complete Assembly




Pencil guide   Base screws                           Bat. Comp.       Shavings       Battery          Sharpener   Base
                                  Motor Gearbox
                                                       screws         receptacle   Compartment           case


                                                                                                                   Sharpener
                                                                                      Bat. Comp.
                                             Gearbox                                                                 base
                         Black wire                                                    housing
                                            cover screw
                         Gearbox             Electric                                                               Rubber
                                                                                      Bat. Comp.
                         housing              motor                                                                  foot
                                                                                       contacts

                        Output gear         Safety lever                                                             Battery
                                                                                      Bat. install.                Comp. cover
                        Intermediate                                                    guide
                                            Lubrication
                            gear
                                                                                                                         Contacts battery
                        Driven gear                                                                                       Comp. cover
                                            Gearbox cover
                                                                                                                            Battery
                         Cutter                                                                                           Comp. cover
                          Unit                    Gearbox cover
                                                    contacts                                                               Rubber
                                                                                                                            foot
                     Blade nut                     Red wire
                     and bolt
                                                   Blue wire                                   General Assembly
                       Blade

                                                  Gearbox cover                                Sub- Assembly
                    Blade holder

                                                                                               Part

                                                                                                                                            8
                                           Major Sub-Assemblies
                                                                                         Safety lever pin
   Motor rim                    Gearbox Cover                                Input contact
                                                                                                      Edge
                  Output gear
                                        Driven
                                        gear




                                                                                                  Intermediate
Motor                                                                                             contact

                                                                     Output contact
                                      Intermediate gear
        Gearbox housing

        Motor Gearbox Sub-Assembly                        Gearbox cover Sub-Assembly

                                                                              Mating
                      Blade              Blade holder                         features


           Bolt




                                                                           Electric in-out
                                Nut                                        contacts        Electric contact
                                                          Red and black
                                                          electric wires                   rivets
          Cutter Unit Sub-Assembly                        Battery Compartment Sub-Assembly                       9
                Critical Mate and Clearance Ratio #1
                                        Slots




Shaver Receptacle to Shaver Case

clower 
           1.990  2.019  0.014
              2.019
cupper 
         1.713  1.792  0.044
             1.792




                                      Rims




                                                       10
                      Critical Mate and Clearance Ratio #2
                           Base to Sharpener Case Edge Interface

   crim slot 
                   2.114  2.097  0.007
                                                                           Holes
                        2.097




c peghole #1 
                   0233  0.200  0.142
                                                                          Slot along
                        0.233                                             edge



                                                                   Slot


c peghole # 2 
                   0229  0.200  0.127   Rim along
                                            edge
                       0.229                                                 Rim

                                                                                Pegs



        Note: Clearance ratio requires                                       Sliding
                                                                             surfaces
        Gearbox and battery compartment
        sub-assemblies to be inserted.
                                                                                        11
                   Critical Mate and Clearance Ratio #3

                                           Rim and
                                           snap fit




crim slot 
               1.567  1.692  0.0798
                   1.597


                                                             Slots

                                                      Rims




                                                              Slot




                                                                     12
             Gearbox DFC and Key Characteristics
                                          3                      5    6
                      2                            4                                     1Gear housing cover
1
                                                                                         2Driven gear block
                                                                                         3Intermediate gear block
                                                                                         4Output gear block
                                                                                         5Top lateral stopping peg
                                                                                         6Top central stopping peg
                                                                                         7Motor Location pegs
                                                                                         8Gear housing
                                                                                         9Motor gear
                                                                                         1Driven gear input pinion
             Z        13
                                                                                         1Driven gear output pinion
                                      17
                                                                                         1Driven gear stand
                 10                                    18
                                              14
         9



     8



                                11
                            X                                              1 Driven gear pin
                                                                           1 Intermediate gear input pinion
                                                                           1Intermediate gear output pinion
                            12       15       16                           1Intermediate gear stand and hole
                                                            19        21
7                                                                20        1Intermediate gear pin
                           22
                                                                           1Output gear
    24                     23                                              1Output gear stand
                                                                           2Bottom lateral stopping peg
                                                                           2Bottom central stopping peg
                                                                           2Top part of motor compartment in gear housing
                                                                           2Hole in gear housing for motor location
                                                                           2Motor




                                                                                                                            13
                                             z axis pre-load                                              Output Gear
                                                                        Output Shaft
    Motor                                                                                                 Upper Surface
    Gearbox                  Flex                                           Center
                                                                                                          Output Gear
    Base
                    Bored
                            Contact      Bored
                                       Stanchion
                                                                            Hole
                                                                                                                                      Integrated
                  Stanchion
                                                Bored
                                                                                                   Outer Pitch Circle
                                                                                                                                  Datum Flow Chain
                Squared
                                              Stanchion                          KC #3
                 Step                                                                                Inner Pitch Circle           for Motor/Gearbox
                 Outside
                Perimeter
                                               Bored
                                             Stanchion
                                                                            Center
                                                                            Hole                          Intermediate Gear
                                                                                                                                    Sub-Assembly
                                   Thin
                                Stanchion
                                                                                                     Outer Pitch Circle
                                                                  5 dof
                                                                                 KC #2
                                                                                                     Inner Pitch Circle

                                z , x , y                                   Center
                                                                             Hole                          Driven Gear
                                      Inside    Hole &
                                      Perimeter Low                 5 dof
                                                Stand                                                        KC #1
          x , y , z       Squared           Axle &                              Outer Pitch Circle
                              Notch           Med Stand                  5 dof
                                                                                                               Pinion
                                                           Axle &                                              & Rotor 5 dof
                          Threaded                         Tall Stand                                     Top
                          Stanchion                                                                       Centering           Base
                                                          Centering
                                                          Hole                                x,y             Boss            Centering   Motor Case & Rotor
                               Peg on                                                                                                     w/pinion gear
    Thru Hole                                                                                                                 Boss
                            Stanchion          Cylindrical Base
                  5 dof                        With                                    x , y , z , z           Top
                                                                                                                  Surface
                                               Dimples                                                            W/Holes
                                 Edge
                                 Guides
Safety Lever
                     Motor/Gearbox Housing
                                                                                                               6 dof
                                                                                  Box            Base
                                                                                 Guides         Center
  Note: 5 dof = { X , Y , Z, X , Y }                                                           Hole
                                                                                                             Assembly Fixture                                  14
Simplified Gearbox DFC: Driven to Intermediate Gear
                                                        Co-planarity KC                                      Top surface
                   Bottom surface                                                                            driven gear
                   input pinion                                                                              input pinion
     Intermediate                                                                      Pitch circle                            Driven gear
     gear                                                                              driven gear
                           Pitch circle input pinion                                   output pinion
                                                                                                       Top surface
                                                                Tangency KC                                                    Gear hole
                                     Gear hole                                                            Bottom
     Top surface                                                                                          surface
                         Bottom
                         surface

                                                               X ,Y                                    Z , y , x    X ,Y
                                                                                                                            Driven gear
                                                               Z , y , x                 Intermediate Driven gear         pin
                                                                                           gear pin     stand


                      Driven                                                    Intermediate
                      gear                                                      gear stand                             Gear
                      block    Top Stopping pegs
                                                               Z , y , x                                             Housing
    Intermediate               and contact end                                 Bottom stopping pegs
    gear block                                                                 and contact surface          Rim
                                              Edges               X , Y , z
                                                                                                                  Pitch circle of            Bottom Stopping
                                                                                                                  driven gear                pegs
                         Gear Housing cover


            Gear pins
                                                                                                                                                          Rim




                                                       Gear stands
                                                                                               Pitch circle of
                                                                                                                                    Gears top surfaces         15
                                                                                               intermediate gear
               Pencil Sharpener Liaison Diagram and Fasteners Classification

p14     c26         p12                   c24
                                                          p11              c6
                    p13                   c25

      c38                                                                                                                          p6                              C37
                                    c15                                                                               c22

                                                           p4         c1        p7         c3            p5                                     c23          p10
              p20
                                               c5
                                                                                                                      c2           p9
                                                                      c18                  c13                                                  c31           p8
                               c4
                                                                                p2
                                                                                                                             c20            p27
                                                                      c17                        c14          p29
                                                                                                                                                      c21
                                                                                                                             c12            p28
        c10               c7                                          p21

                                                                                     c16                                                                           p24
                                                                                                                                          c34
                                                                      c19
                                                                                                 p26          c32           p23

                                                                                     c8                                                   c35               p25
                                                                      p15
                                                                                                   c11
              p18                         c9
                                                                                                                c33

                                                    c29                                                                                               Liaisons Using
              c27                                                                                                       Permanent Liaisons            Threaded Features
                                p17                             c30
                                                                                                                            Rivets                         Screws

                                                                                                                             Adhesive                       Nut & Bolt
                                    c28                   p16


                    C36                                                                                                       Soldering                     Other mates



                                                                                                                                                                          16
                      Assembly Time Analysis
• Throughput requirement based on production volume
   – 250,000 units/year @ 250 workdays/year = 1000 units/day
   – 1000 units/day @ 8 hours/day = 125 units/hour = 2.08 mins/unit
• Assembly time per Boothroyd Handling and Insertion Times
   –   Handling Time per unit                          =           106.98 (sec/unit)
                                                                                       207.18
   –   Location Time per unit                          =            47.50 (sec/unit)
                                                                                        (sec)
   –   Reversible Fastening Time per unit              =            54.20 (sec/unit)
   –   Irreversible Fastening Time per unit            =           121.00 (sec/unit)
   –   Total predicted assembly time                   =           329.68 (sec/unit)
                            Note: does not include inspection and test time

• Measured Handling, Location and Reversible Fastening Times
   – Test#1       309 sec                              - Test#4      169 sec
   – Test#2       222 sec                              - Test#5      153 sec
   – Test#3       198 sec
• Assembly Efficiency
   – Three “un-necessary parts: Sharpener case, paper guide, and pencil guide
   – Assembly efficiency 
                              19 parts * 3 sec/ part       57 sec
                                                                         17 .3%
                              (total assembly time )        329 .68 sec                         17
                     Example Assembly Process

   SA 7            SA 7
 Cutter Unit     Cutter Unit
   Assy           Inspect
   18.25 sec        5 sec
                                                    SA5
    SA6             SA 6               SA5a         SA5a           SA5a
Gearbox Cover   Gearbox Cover         Gearbox      Gearbox        Gearbox
    Assy           Inspect             Assy         Solder          Test
   48.06 sec                                Motor/Gearbox Assy
                    5 sec

                                                 87.30 + 30 sec
     SA5             SA 5
Battery Comp.   Battery Comp.                                                    SA1        SA1
     Assy          Inspect                                                       Final      Final
                                                                                 Assy      Inspect
  19.62 sec        5 sec
                                                                              101.83 sec       20 sec
     SA3            SA 3                            SA2
Battery Cover   Battery Cover                       Base                                   Package
    Assy           Inspect                          Assy                                   & Ship
  19.62 sec         5 sec                         33.5 sec                                     30 sec


                       Note: Test, inspection and packaging times are SWAGS                          18
                   Fixtures and Special Tooling
Fixtures
•   Riveting fixture. or special tooling, for battery compartment
•   Riveting fixture, or special tooling, for gearbox cover
•   Bending fixture for gearbox cover electrical contacts
•   Bending fixture for battery cover electrical contacts
•   Bending fixture for battery compartment electrical contacts (nice to have)
•   Soldering station and fixture for electric motor (black and blue leads)
•   Soldering station and fixture for battery compartment (black and red leads)

Standard Tools and Special Tooling
•   Heat stake tooling for battery compartment electrical contacts
•   Magnetic Phillips head screwdriver (4” length) for battery compartment screw
•   Small wrench, or pliers, for blade screw and nut
•   Wire strippers (22 gage)
•   Wire tinning and pre-form bending
•   Soldering station for gearbox cover
•   Electrical test station for operation of motor/gearbox sub-assembly
•   Lubrication dispenser gun
                                                                                   19
                     Potential Problems and Risk Areas

    Description                                               Probability   Impact

•   Personnel injury from razor blade                         Med           High

•   Reversed motor polarity wiring (black on +)                High         High

•   Reversed battery compartment wiring (red on right)         High         High

•   Solder joint or wire breakage during gearbox insertion     Low          High

•   Solder joint or wire breakage during motor insertion       Low          High

•   Motor pinion clearance thru gearbox hole                   High         Med

•   Loss of motor location during final assembly               High         Med

•   Improper location of battery compartment on gearbox        Med          Med

•   Part damage from shaver receptacle insertion (snap fit)    Med          Med
                                                                                     20
               Suggested Design Improvements
    Description                                                           Impact
•   Reversed motor polarity wiring (black on +)
     - Use wire connector instead of solder joint                         Med
•   Reversed battery compartment wiring (red on right)
     - Imprint wiring polarity on battery compartment injection mold      High
•   Solder joint or wire breakage during gearbox insertion
     - Use wire connector instead of solder joint                         Med
•   Solder joint or wire breakage during motor insertion
     - Use wire connector instead of solder joint                         Med
•   Motor pinion clearance thru gearbox hole
     - Reduce and control gearbox manufacturing variance                  Med
•   Loss of motor location during final assembly
     - Include snap/fit feature between battery compartment and gearbox   High
•   Improper location of battery compartment on gearbox
     - Use wire connectors instead of solder joint                        Med
•   Part damage during shaver receptacle insertion (snap fit)
     - Training, coupled with control of manufacturing variations         Low      21
                               Backups
•   Part Handling: Gross Motion ( 2 slides)
•   Part Insertion: Fine Motions ( 2 slides)
•   Part Liaisons and Mates
•   Related Product Lines
•   Product Structural Decomposition




                                               22
                       Part Handling: Gross Motion
                                                                                         Size Thick G.M. Alpha Beta  Handling
Order P/N    Description                                                           Qty   (mm) (mm) Code (deg) (deg) (deg)     (sec)
   1    29   Position blade holder                                                  1      35      6    10   180   180   360     1.50
   2    28   Locate blade                                                           1      21    0.5    13   180   180   360     2.06
   3    27   Locate and fasten blade screw and nut (tools: screwdriver & pliers)    1       9    1.5    03   180     0   180     1.69
   4   SA7   Inspect & Release Cutter Sub-Assembly                                  1      35      6                             5.25
   5    26   Position Gearbox cover                                                 1      65    1.9    10   180   180   360     1.50
   6    23   Locate & rivet cover contacts                                          3      18    0.2    13   180   360   540     2.06
   7    24   Solder red wire to cover                                               1     130      1    03                 0     1.69
   8    25   Solder blue wire to cover                                              1     111      1    03                 0     1.69
   9   SA6   Inspect & Release Gearbox Cover Sub-Assembly                           1      65    1.9    10
  10    15   Position gearbox housing (inverted)                                    1      58     50    10   180   180   360     1.50
  11    22   Apply lubrication to axle stands                                       3                   00                 0     1.13
  12    16   Locate output gear                                                     1      25      2    03   180     0   180     1.69
  13    17   Locate intermediate gear                                               1      21    5.8    00   180     0   180     1.13
  14    18   Locate driven gear                                                     1      21    5.8    00   180     0   180     1.13
  15    22   Apply lubrication to gear surfaces and axles                           3                   00     0     0     0     1.13
  16   SA6   Position gearbox cover sub-assembly                                    1      65    1.9    00   180     0   180     1.13
  17    21   Locate safety lever on gearbox cover (retain with one hand)            1      11    6.1    85   180   270   450     5.00
  18   SA6   Locate gearbox cover sub-assembly & safety lever (2 hand ops)          1      65    1.9    85   180     0   180     5.00
  19    19   Locate and fasten gearbox cover screw (self-threading)                 1      15      3    00   180     0   180     1.13
  20   sa5   Invert & position partially complete gearbox sub-assembly              1      65     50    00   180     0   180     1.13
  21    20   Position electric motor near gearbox                                   1      43   23.6    10   180   360   540     1.50
  22    14   Solder blue wire to motor (2 hand ops)                                 1     111      1    03                 0     1.69
  23    25   Solder black wire to motor (2 hand ops)                                1      86      1    03                 0     1.69
  24    20   Locate electric motor in gearbox                                       1      43   23.6    85   180    45   225     5.00
  25   SA7   Locate cutter unit sub-assembly                                        1      35      6    80   180    90   270     4.10
  26   SA5   Inspect, Test & Release Motor/Gearbox Sub-Assembly                     1      65     50



                                                                                                                                        23
            Part Handling: Gross Motion (con’t)
                                                                               Size Thick G.M. Alpha Beta  Handling
Order P/N   Description                                                  Qty   (mm) (mm) Code (deg) (deg) (deg)     (sec)
  27   11 Position battery compartment housing (inverted)                 1      70     32    10   180   180   360     1.50
  28   12 Locate & rivet battery compartment contacts                     2      22    0.2    13   180   180   360     2.06
  29 SA4 Inspect & Release Battery Compartment Sub-Assembly                      70     32
  30    9 Position battery compartment cover                              1      43    2.5    10   180   180   360     1.50
  31    8 Locate and rivet (plastic heat stake) battery cover contacts    2      20    0.2    13   180   180   360     2.06
  32 SA3 Inspect & Release Battery Compartment Cover Sub-Assembly                43    2.5
  33    5 Position sharpener base                                         1      75      7    10   180   180   360     1.50
  34 SA3 Locate battery compartment cover sub-assembly                    1      43    2.5    10   180   180   360     1.50
  35   11 Locate rubber feet on base and battery compartment cover        2      25    1.6    10   180   180   360     1.50
  36 SA2 Inspect & Release Base Sub-Assembly                              1      75      7
  37 SA5 Position motor/gearbox sub-assembly                              1      65     50    00     0   180   180     1.13
  38 SA4 Locate battery compartment sub-assembly on motor/gearbox         1      70     26    80   180   180   360     4.10
  39   25 Solder black wire to battery compartment                        1      86      1    03                 0     1.69
  40   24 Solder red wire to battery compartment                          1     130      1    03                 0     1.69
  41    7 Position sharpener case                                         1      82     36    10   180   180   360     1.50
  42 SA4/ Locate battery compartment & motor/gearbox in sharpener case    2      96     32    80   180    10   190     4.10
  43    3 Locate and fasten battery compartment screw                     1       8      3    01   180     0   180     1.43
  44 SA2 Locate base sub-assembly in sharpener case                       1      75      7    10   180   180   360     1.50
  45    3 Locate and fasten battery compartment screws                    2       9      3    01   180     0   180     1.43
  46    1 Locate and fasten sharpener case screws                         2      14      3    01   180     0   180     1.43
  47   13 Install battery installation paper guide                        1      50      1    13   180   180   360     2.06
  48 sa1 Invert and reposition partially complete sharpener assembly      1      96     50    00   180     0   180     1.13
  49    2 Locate pencil guide (tricky alignment)                          1      32   11.7    05   180     0   180     1.84
  50    4 Locate shavings receptacle (snap fit)                           1      73     36    05   180    15   195     1.84
  51 SA1 Inspect, Test & Release Pencil Sharpener Assembly                1     115     50




                                                                                                                              24
                            Part Insertion: Fine Motion
                                                                                         Size Thick F.M. Handling Insertion   Total
Order P/N    Description                                                           Qty   (mm) (mm) Code   (sec)     (sec)     Time
   1    29   Position blade holder                                                  1      35      6   00     1.50     0.00     1.50
   2    28   Locate blade                                                           1      21    0.5   40     2.06     4.50     6.56
   3    27   Locate and fasten blade screw and nut (tools: screwdriver & pliers)    1       9    1.5   48     1.69     8.50    10.19
   4   SA7   Inspect & Release Cutter Sub-Assembly                                  1      35      6          5.25             18.25
   5    26   Position Gearbox cover                                                 1      65    1.9   00     1.50     0.00     1.50
   6    23   Locate & rivet cover contacts                                          3      18    0.2   35     2.06     7.00    27.18
   7    24   Solder red wire to cover                                               1     130      1   95     1.69     8.00     9.69
   8    25   Solder blue wire to cover                                              1     111      1   95     1.69     8.00     9.69
   9   SA6   Inspect & Release Gearbox Cover Sub-Assembly                           1      65    1.9                           48.06
  10    15   Position gearbox housing (inverted)                                    1      58     50   00     1.50     0.00     1.50
  11    22   Apply lubrication to axle stands                                       3                  99     1.13     1.20     6.99
  12    16   Locate output gear                                                     1      25      2   00     1.69     1.50     3.19
  13    17   Locate intermediate gear                                               1      21    5.8   00     1.13     1.50     2.63
  14    18   Locate driven gear                                                     1      21    5.8   00     1.13     1.50     2.63
  15    22   Apply lubrication to gear surfaces and axles                           3                  99     1.13     1.20     6.99
  16   SA6   Position gearbox cover sub-assembly                                    1      65    1.9   00     1.13     0.00     1.13
  17    21   Locate safety lever on gearbox cover (retain with one hand)            1      11    6.1   00     5.00     1.50     6.50
  18   SA6   Locate gearbox cover sub-assembly & safety lever (2 hand ops)          1      65    1.9   06     5.00     5.50    10.50
  19    19   Locate and fasten gearbox cover screw (self-threading)                 1      15      3   38     1.13     6.00     7.13
  20   sa5   Invert & position partially complete gearbox sub-assembly              1      65     50   00     1.13     0.00     1.13
  21    20   Position electric motor near gearbox                                   1      43   23.6   00     1.50     0.00     1.50
  22    14   Solder blue wire to motor (2 hand ops)                                 1     111      1   95     1.69     8.00     9.69
  23    25   Solder black wire to motor (2 hand ops)                                1      86      1   95     1.69     8.00     9.69
  24    20   Locate electric motor in gearbox                                       1      43   23.6   11     5.00     5.00    10.00
  25   SA7   Locate cutter unit sub-assembly                                        1      35      6   30     4.10     2.00     6.10
  26   SA5   Inspect, Test & Release Motor/Gearbox Sub-Assembly                     1      65     50                           87.30




                                                                                                                                       25
               Part Insertion: Fine Motion (con’t)
                                                                               Size Thick F.M. Handling Insertion     Total
Order P/N   Description                                                  Qty   (mm) (mm) Code   (sec)     (sec)       Time
  27   11 Position battery compartment housing (inverted)                 1      70     32    00     1.50      0.00     1.50
  28   12 Locate & rivet battery compartment contacts                     2      22    0.2    35     2.06      7.00    18.12
  29 SA4 Inspect & Release Battery Compartment Sub-Assembly                      70     32                             19.62
  30    9 Position battery compartment cover                              1      43    2.5    00     1.50      0.00     1.50
  31    8 Locate and rivet (plastic heat stake) battery cover contacts    2      20    0.2    35     2.06      7.00    18.12
  32 SA3 Inspect & Release Battery Compartment Cover Sub-Assembly                43    2.5                             19.62
  33    5 Position sharpener base                                         1      75      7    00     1.50      0.00     1.50
  34 SA3 Locate battery compartment cover sub-assembly                    1      43    2.5    30     1.50      2.00     3.50
  35   11 Locate rubber feet on base and battery compartment cover        2      25    1.6    97     1.50     12.00    27.00
  36 SA2 Inspect & Release Base Sub-Assembly                              1      75      7                             32.00
  37 SA5 Position motor/gearbox sub-assembly                              1      65     50    00     1.13      0.00     1.13
  38 SA4 Locate battery compartment sub-assembly on motor/gearbox         1      70     26    02     4.10      2.50     6.60
  39   25 Solder black wire to battery compartment                        1      86      1    95     1.69      8.00     9.69
  40   24 Solder red wire to battery compartment                          1     130      1    95     1.69      8.00     9.69
  41    7 Position sharpener case                                         1      82     36    00     1.50      0.00     1.50
  42 SA4/ Locate battery compartment & motor/gearbox in sharpener case    2      96     32    08     4.10      6.50    21.20
  43    3 Locate and fasten battery compartment screw                     1       8      3    48     1.43      8.50     9.93
  44 SA2 Locate base sub-assembly in sharpener case                       1      75      7    00     1.50      1.50     3.00
  45    3 Locate and fasten battery compartment screws                    2       9      3    38     1.43      6.00    14.86
  46    1 Locate and fasten sharpener case screws                         2      14      3    38     1.43      6.00    14.86
  47   13 Install battery installation paper guide                        1      50      1    00     2.06      1.50     3.56
  48 sa1 Invert and reposition partially complete sharpener assembly      1      96     50    00     1.13      0.00     1.13
  49    2 Locate pencil guide (tricky alignment)                          1      32   11.7    30     1.84      2.00     3.84
  50    4 Locate shavings receptacle (snap fit)                           1      73     36    30     1.84      2.00     3.84
  51 SA1 Inspect, Test & Release Pencil Sharpener Assembly                1     115     50                            104.83
                                                                                             Assembly Total (sec) =   329.68
                                                                                                            (min) =     5.49




                                                                                                                               26
                          Part Handling: Gross Motion (con’t)

                                                                                   Size Thick    G.M.    Alpha Beta  +  Handling
Order   P/N Description                                                      Qty   (mm) (mm)     Code    (deg) (deg) (deg)  (sec)
   27     9   Position battery compartment cover                              1      43    2.5      10     180   180   360     1.50
   28     8   Locate and rivet (plastic heat stake) battery cover contacts    2      20    0.2      13     180   180   360     2.06
   29   SA3   Inspect & Release Battery Compartment Cover Sub-Assembly               43    2.5
   30    11   Position battery compartment housing (inverted)                 1      70     32      10     180   180   360     1.50
   31    19   Contacts and rivets
   32    12   Locate & rivet battery compartment contacts                     2      22    0.2      13     180   180   360     2.06
   33   SA4   Inspect & Release Battery Compartment Sub-Assembly                     70     32
   34     5   Position sharpener base                                         1      75      7      00     180    90   270     1.13
   35   SA3   Locate battery compartment cover sub-assembly                   1      43    2.5      10     180   180   360     1.50
   36    11   Locate rubber feet on base and battery compartment cover        2      25    1.6      10     180   180   360     1.50
   37   SA2   Inspect & Release Base Sub-Assembly
   38   SA5   Position motor/gearbox sub-assembly                             1      65    50       00       0   180   180     1.13
   39   SA4   Locate battery compartment sub-assembly on motor/gearbox        1      70    26       80     180   180   360     4.10
   40    25   Solder black wire to battery compartment                        1      86     1       03                   0     1.69
   41    24   Solder red wire to battery compartment                          1     130     1       03                   0     1.69
   42     7   Position sharpener case                                         1      82    36       10     180   180   360     1.50
        SA4
   43   SA5   Locate battery compartment & motor/gearbox in sharpener case    2      96     32      80     180    10   190     4.10
   44     3   Locate and fasten battery compartment screw                     1       8      3      01     180     0   180     1.43
   45   SA2   Locate base sub-assembly in sharpener case                      1      75      7      10     180   180   360     1.50
   46     3   Locate and fasten battery compartment screws                    2       9      3      01     180     0   180     1.43
   47     1   Locate and fasten sharpener case screws                         2      14      3      01     180     0   180     1.43
   48    13   Install battery installation paper guide                        1      50      1      13     180   180   360     2.06
   49   sa1   Invert and reposition partially complete sharpener assembly     1      96     50      00     180     0   180     1.13
   50     2   Locate pencil guide (tricky alignment)                          1      32   11.7      05     180     0   180     1.84
   51     4   Locate shavings receptacle (snap fit)                           1      73     36      05     180    15   195     1.84
   52   SA1   Inspect, Test & Release Pencil Sharpener Assembly               1     115     50



                                                                                                                                      27
                           Part Liaisons and Mates in Pencil Sharpener
Mate No                    Mated parts                                              Liaison/Mate Description
   1      Sharpener case/shavings receptacle              Snap fit of rim and slot.
   2      Battery compartment cover/sharpener base        Rim and slot in one end of the cover and rim and slot with snap fit in the other
                                                          end
   3      Sharpener base/sharpener case                   Slot and rim along the contact edge and two peg and hole fits. The pegs
                                                          accommodate internal screws that keep the parts fastened.
   4      Gear and motor housing/ battery housing         Rim and slot plus sliding surface
   5      Gearbox housing/ sharpener case                 Sliding surface
   6      Battery compartment housing/ sharpener case     Peg and hole, rim and slot, and sliding surfaces
   7      Electric motor/gearbox housing                  Two pegs and two holes
   8      Gearbox housing/gearbox cover                   Two pegs and two holes
   9      Driven gear/gearbox housing                     Peg and hole and sliding surface
  10      Driven gear/electric motor                      Sliding surface on gear teeth
  11      Cutter unit/output gear                         Square shaped peg and hole (pressed fit)
  12      Blade holder/blade                              Alignment provided by two prongs and attachment is accomplished by nut
                                                          and bolt
  13      Pencil guide/sharpener case                     Rim and slot
  14      Pencil guide/cutter unit                        Circular rim and hole
  15      Electric motor/battery compartment              Circular rim and slot ???
  16      Safety lever/gearbox cover                      Peg and hole
  17      Shavings Receptacle/Safety lever                Sliding surfaces
  18      Shavings receptacle/pencil guide                Sliding surfaces
  19      Safety lever/gearbox housing                    Peg and hole
  20      Blade holder/blade nut and bolt                 peg and hole
  21      Blade/blade nut and bolt                        Peg and hole
                                                          Blade external surface with bolt head bottom surface
  22      sharpener base/rubber foot                      Permanent liaison thruogh adhesive
  23      Battery compartment cover/rubber foot           Permanent liaison thruogh adhesive
  24      Battery compartment housing/battery comp        Permanent liason through rivets
          contacts
  25      Battery compartment housing/battery paper guide Sliding surface



                                                                                                                                             28
                     Part Liaisons and Mates in Pencil Sharpener (cont.)


Mate No                      Mated parts                                               Liaison/Mate Description
  26      Battery comp. contacts/black wire                  Permanent liaison through soldering
  27      Driven gear/intermediate gear                      Sliding surface on gear teeth
  28      Intermediate gear/output gear                      Sliding surface on gear teeth
  29      Intermediate gear/gearbox housing                  Peg and hole and sliding surface
  30      Output gear/gearbox housing                        Peg and hole and sliding surface
  31      Battery compartment cover/contacts and rivets on   Permanent liason through rivets
          battery compartment cover
  32      Gearbox cover/contacts and rivets on gearbox       Permanent liason through rivets
          cover
  33      Contacts and rivets on gearbox cover/output gear   sliding surface

  34      Contacts and rivets on gearbox cover/red wire      Permanent liaison through soldering
  35      Contacts and rivets on gearbox cover/blue wire     Permanent liaison through soldering
  36      Electric Motor/black wire                          Permanent liaison through soldering
  37      Battery compartment housing/blue wire              Permanent liaison through soldering
  36      Electric Motor/red wire                            Permanent liaison through soldering




                                                                                                                  29
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                                                                                                                         30
                          Product Structural Decomposition



                                                                                              sa1




                                              sa5         p7         p1     p2          sa4         p3          p4    sa2


                                                                                  p12     p13       p11
                                                                                                                 p5   p6     sa3


            sa6     p14     p15   p16   p17         p18        p19    p20   p21         p22     sa7
                                                                                                                        p8   p9    p10


p23   p24         p25     p26                                                           p27     p28       p29




                                                                                                                                         31

								
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