Cordless Screwdriver Reports

2.
875MechanicalAssemblyandItsRoleinProductDevelopment
TeamMembers:
AgusSudjianto
JaredClark
MilindOak
EiichiTanabe
_________________________________________________________________________________________________________
Originators: Sudjianto/Clark/Oak/Shukla/Tanabe Page 1 of 83 Date Initiated: September 29, 1999
fInal_report.doc Date Revised: December 5, 1999
2.875MechanicalAssemblyandItsRoleinProductDevelopment
GauravShukla
_________________________________________________________________________________________________________
PROBLEM STATEMENT............................................................................................................................4
3.6-VOLT SEARS/CRAFTSMAN CORDLESS SCREWDRIVER.......................................................4
1. REPORT #1: PRODUCT DESCRIPTION..............................................................................................5

1.1 PRODUCT ASSEMBLY DRAWING................................................................................................................6
1.2 TRANSMISSION ASSEMBLY.................................................................................................................. 7
1.3 EXPLODED VIEW OF TRANSMISSION ASSEMBLY....................................................................................8
1.4 CLEARANCE SPECIFICATION.............................................................................................................. 9
1.5 SCREWDRIVER COMPONENT BREAKDOWN.........................................................................................11
1.6 BILL OF MATERIALS....................................................................................................................... 12
1.7 ASSEMBLY TREE............................................................................................................................. 14
1.8 FUNCTIONAL FLOW MODEL............................................................................................................ 15
1.9 SYSTEM HIERARCHY BREAKDOWN....................................................................................................16
1.9.1 Battery Module System Breakdown............................................................................................16
1.9.2 Driver Mechanism System Breakdown.......................................................................................17
1.10 LIAISON DIAGRAMS OF PART MATING............................................................................................18
1.10.1 Product Main Assembly............................................................................................................18
1.10.2 Battery and Housing Assembly.................................................................................................18
1.10.3 Torque Limiter...........................................................................................................................18
1.10.4 Transmission.............................................................................................................................19
1.10.5 Motor Assembly.........................................................................................................................19
2. REPORT #2: DATUM FLOW CHAIN..................................................................................................20
2.1 OVERALL TRANSMISSION KEY CHARACTERISTICS...............................................................................20
2.2 FEATURE, MATE, AND CONTACT TABLE............................................................................................24
2.3 COMPLETE BILL OF MATERIALS...................................................................................................... 25
2.4. EXPLODED VIEW........................................................................................................................... 27
3. REPORT #3: ASSEMBLY SEQUENCE...............................................................................................28
3.1 REVISED LIAISON DIAGRAM............................................................................................................ 28
3.2 REVISED DATUM FLOW CHAIN........................................................................................................ 28
3.3 ALL POSSIBLE ASSEMBLY SEQUENCE................................................................................................29
3.4 THE MOST CONVENIENCEE ASSEMBLY SEQUENCE.............................................................................30
3.5 REQUIRED GROSS AND FINE MOTIONS............................................................................................ 31
3.6 FUTURES, CHAMFERS AND LEAD INS................................................................................................ 31
3.7 DIFFICULTIES & IDEAS IN ASSEMBLY................................................................................................ 33
3.8 FEATURE PARTS AND ASSOCIATED ASSEMBLY TOOL AND FIXTURES.....................................................34
3.9. FIXTURES AND TOOLS FOR ASSEMBLY..............................................................................................35
3.10 GEAR SET ARCHITECTURE REDESIGN.............................................................................................36
3.11 IMPROVEMENT HIGHLIGHT............................................................................................................. 37
4. REPORT #4: ASSEMBLY FLOOR LAYOUT ANALYSIS.................................................................38
4.1. ASSEMBLY SEQUENCE.................................................................................................................... 38
4.2 ASSEMBLY PROCESS TIME................................................................................................................ 39
4.3 ASSEMBLY LINE DESIGN AND ASSUMPTIONS......................................................................................41
4.3.1 Design Parameters......................................................................................................................42
4.3.2 Supplied Material.......................................................................................................................42
4.4 ASSEMBLY OPERATION STYLE............................................................................................................ 42
4.4.1 Assembly Line Design.................................................................................................................42
5. REPORT #5: WORKSTATION DESIGN.............................................................................................46
5.1 REQUIRED CYCLE TIME TO COMPLETE THE PLANNED OPERATIONS.......................................................46
5.1.1 Assembly Flow Diagram.............................................................................................................46
5.1.2 Final Assembly............................................................................................................................47
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5.1.3 Testing and Packaging................................................................................................................47

5.1.4 Transmission Assembly...............................................................................................................48
5.1.5 Grip Housing/Battery Assembly.................................................................................................48
5.2 STATION LAY OUT: IN AND OUT FLOWS OF ASSEMBLIES AND PARTS..........................................................50
5.3 REQUIRED MOTIONS OF EQUIPMENT AND PEOPLE.............................................................................51
5.4 NECESSARY INSPECTIONS OR TESTS..................................................................................................52
5.5 GANTT CHART OF REQUIRED TIME OF ACTIVITIES AND A COMPLETE CYCLE...........................................53
5.6 COST ESTIMATION OF WORKSTATIONS............................................................................................... 56
5.7 ESTIMATION OF THE COST OF PERFORMING ONE ASSEMBLY CYCLE.......................................................57
6. REPORT #6: ECONOMIC ANALYSIS AND ASSEMBLY LINE SIMULATION..........................59
6.1 ECONOMIC ANALYSIS OF THIS ASSEMBLY LAYOUT...............................................................................59
6.1.1 Estimated Manufacturing Cost...................................................................................................60
6.1.2 Inventory Cost and Distribution Cost.........................................................................................60
6.1.3 Development Cost.......................................................................................................................61
6.1.4 Unit Part Costs............................................................................................................................62
6.1.5 Economic Analysis......................................................................................................................63
6.2 DISCRETE EVENT SIMULATION OF ASSEMBLY LINE..............................................................................64
6.2.1 Discrete Event Simulation: Configuration Study.......................................................................64
6.2.2 Selection of Final Assembly Process..........................................................................................72
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ProblemStatement
3.6VoltSears/Craftsman CordlessScrewdriver
September29,1999
Clients:Dr.DanWhitney
ProjectTeam:
Name Email
AgusSudjianto asudjian@ford.com
JaredClark jclark15@ford.com
MilindOak moak@ford.com
GauravShukla Gaurav@mit.edu
EiichiTanabe eitanab@ibm.net
_________________________________________________________________________________________________________
TheteamdecidedtoanalyzeSears/Craftsman 3.6VoltCordlessScrewdriver.The
producthasdualpositionhandledesign:ingrippositiontoworkinconfinedareaswhich
canbeeasilyconvertedintopistolgripfornormalscrewdrivingtasks.
Thefollowingsaresomenotablefeaturesoftheproduct:
Twospeed,130and400RPM,with2speedgearboxtomatchtheneedfor
applicationsofhighspeedfastscrewdrivingandlowspeedhightorqueheavy
dutyscrewdriving.
Planetaryspurgearstoprovidethetorqueandpowerneeded.
Adjustabletorqueclutchtomatchdrivingtorquetask
Triggerswitchforreverseoffforwardcontrol.
Impactresistantglassfillednylonhousing.
in.hexcolletwithautomaticspindlelock.
3.6volt3cellrechargeablebatteries.
Powersupplytorechargethebatteries.
NOTE:
Thebatterychargersubsystemisexcludedfromthisstudy.
_________________________________________________________________________________________________________
1.Report#1:ProductDescription
In this report Sears/Craftsman 3.6VoltCordlessScrewdriver is described as follows,
Product Drawings
Product Assembly Drawing
TransmissionAssembly
ExplodedViewofTransmissionAssembly
Clearance Specification
Screwdriver Component Breakdown
Bill Of Material (Including Parts List, Function and Material)
AssemblyTree
FunctionalFlowModel
FunctionalSystemBreakdown
SystemHierarchyBreakdown
BatteryModuleSystemBreakdown
DriverMechanismSystemBreakdown
Liaison Diagrams of Part Mating
ProductMainAssembly
Battery and Housing Assembly
Torque Limiter
Transmission
Motor Assembly
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1.1 Product Assembly Drawing
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1.2 Transmission Assembly
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1.3 Exploded View of Transmission Assembly
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1.4 Clearance Specification
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_________________________________________________________________________________________________________
1.5 Screwdriver Component Breakdown
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1.6 Bill Of Materials

No Syst System Part Part Name Quantity Function Note Material
# Name #
1 1 Battery 1.1 Battery Charger 1 Charge Battery 6V DC Power supply N/A
Charger
2 2 Battery 2.1 Charger Contact 2 Contact Power Provide contact of battery SUS304
Closure Plates charger to battery
3 2.2 Battery Left 1 Enclose Battery Also function as hand grip Glass-filled
Housing nylon
4 2.3 Bettery Right 1 Enclose Battery Also function as hand grip Glass-filled
Housing nylon
5 2.4 Battery Cover 1 Enclose Battery Glass-filled
nylon
6 2.5 Baterry Housing 2 Hold battery N/A
Fasteners housing
7 3 Power 3.1 Rechargable 3 Store power Total of 3.6V battery N/A
Storage Batteries
8 3.2 Battery Cables 2 Transmit power Provide connection from battery N/A
to switch (+/-)
9 3.3 Battery Connectors 2 Connect cable Connecting cables to battery SUS304
10 3.4 Switch to Motor 2 Transmit power Provide connection from switch Polypropylene
Cables to
11 3.5 Crim Connectors 2 Hold cable Holding cable to motor SUS304
12 3.6 Shrink wrap 1 Hold batteries Polypropylene
13 3.7 Tape 1 Hold cable cellophane
14 3.8 Cable connectors 2 Connect cables to battery SUS304
15 4 Torque 4.1 Torque Limiter 1 Accept hand Accept hand control to push Polypropylene
Limiter Outer Cap needle bearing for torque limiter
16 4.2 Torque Limiter Inner 1 Accept outer cap PS
Cap (Polystyrene)
17 4.3 Torque Limiter Cap 1 Hold inner and outer caps SUS304
Clip
18 4.4 Needle Bearings 4 Push PG1 To adjust torque limiter N/A
internal gear
19 4.5 Ball Bearings 6 Allow internal gear PG1 slippage N/A
20 4.6 Bearing holder plate 1 Hold ball bearings SUS304
21 4.7 Torque Limiter 4 Hold bearing 4 springs to privide uniform flex SUS304
Springs holder plate suport
22 4.8 Torque Limiter Base 1 Support springs Nylon
Support
23 4.9 Torque Limiter 2 Hold base support to motor N/A
Fasteners
24 5 Drive 5.1 Drive Left Housing 1 Provide enclosure Also to isolate noise Glass-filled
Closure to drive nylon
25 5.2 Drive Right Housing 1 Provide enclosure Also to isolate noise Glass-filled
to drive nylon
26 5.3 Grip Locking Switch 1 Hold grip position Polypropylene
27 5.4 Grip Locking Spring 1 Support grip locking switch SUS304
28 5.5 Drive Housing Long 2 Hold housing N/A
Fasteners
29 5.6 Drive Housing 2 hold drive N/A
Medium Fasteners
30 5.7 Drive Housing Short 2 hold housing N/A
Fasteners
31 6 Power 6.1 DC Motor 1 Convert EE to Kinetic Energy N/A
generator
32 6.2 On/Off Button 1 Connect electric Polypropylene
power
33 6.3 On/Off Spring 1 Support On/Off SUS304
Button
# Name #
_________________________________________________________________________________________________________
34 6.4 F/R/S Lever 1 Provide control for rotation direction Polypropylene

35 6.5 F/R/S Switch 1 Control polarity connection to battery PS
Circuit (Polystyrene)
36 7 Bit Holder 7.1 Collet 1 Transmit torque Also to hold bit SUM
37 7.2 Bit Holder Housing 1 Provide housing to drive mechanism PS
(Polystyrene)
38 7.3 Direction Stopper 2 Hold PG3 carrier To allow counter rotation SUS304
Clips
39 7.4 Direction Stoppper 4 Hold stopper clips PS
Supports (Polystyrene)
40 7.5 Screwdriver bit 1 Act on screw SUM
41 8 Transmissi 8.1 Planetary Gear 1 1 Enclose pinion SUS304
on (PG1) Washer gears
42 8.2 PG1/PG3 Pinion 6 Increase torque SMF
Gears
43 8.3 PG1 Internal Gears 1 Coordinate pinion Allows all pinion gears to rotate SMF
gears along its internal gear
44 8.4 PG1 Carrier/PG2 1 Hold pinion gears Also transmit torque SUM
Sun Gear
45 8.5 PG1 Sun Gear 1 Transmit torque SMF
46 8.6 PG2 Pinion Gears 3 Reduce speed SMF
47 8.7 PG2 Washer 1 Enclose pinion SUS304
gears
48 8.8 PG2 Coupling Gear 1 Hold pinion gears PS
(Polystyrene)
49 8.9 PG2 Locking Gear 1 Hold PG2 system PS
(Polystyrene)
50 8.10 Hi/Lo Lever 1 Transmit control By shifting coupling gear SUS304
51 8.11 Hi/Lo Button 1 Accept Hi/Lo Polypropylene
control
52 8.12 Hi/Lo Fasteners 2 Hold Hi/Lo lever N?
53 8.13 PG2 Carrier/PG3 1 Hold pinion gears SUM
Sun Gear
gears
55 8.15 PG3 Internal 1 Coordinate pinion Allows all pinion gears to rotate SMF
Gear/Direction gears along its internal gear
Openner
56 8.16 PG3 Carrier 1 Hold pinion gears SUM
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1.7 Assembly Tree
3.6 V Dual Grip Craftmans Cordless Screwdriver
Battery Charger Module

Driver Module
Power Storage Module
Left Housing Fasteners Battery Cover
Left Housing Assembly
Label Batt.
Housing Housing Fasteners
Batt. Left Housing
Driver Assembly Housing
Charger Contact
RH Fasteners
F/R/S Lever
Hi/Lo Button
On/Off Switch
Grip Locking Button
Switch Spring
Spring
Batt. Right Housing
Transmission Motor Housing
Assembly Assembly Charger contact
Torque Adj. Assy.
RH Assembly Battery Assembly
Outer Cap As.
Label
Out cap
Housing Tape
Clip
Inner Cap
Ball Bearing Switch Module
Motor cables
PG1 Int. Gear Assy
Bearing Holder Batt. Cables
Internal Gear
Plate Connectors
Washer
Cables
PG1 pinions
Bearing Washer
PG1 carrier
Battery
PG2 washer
Torque Limiter Connectors
PG2 pinions
Springs Shrink Wrap
PG2 locking gear
Torque Limiter Batteries
Hi/Lo Fasteners
Torque Limiter Fasteners
Hi/Lo Lever
Base Support
PG2 Coupling Gear
Crim connectors
PG2 Carrier
Motor Assembly
PG3 Washer
Sun Gear
PG3 pinions
Motor
PG3 internal gear
Dir. Stop Support
Dir Stop Clip Bit Holder Assy.
Collet
Housing
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1.8 Functional Flow Model
Tight/loose screw
Hand Force Noise
Electricity Turn Vibration
Screw Heat
Bit Screw Worn bit
Control signal Damaged screw
Torque slip signal
Energy
Material
Information
3. Store
Electric Energy
(EE) Energy

EE
Hand Force
(HF) 1. HF
2. HF 4.
Accept Position Switch
Hand Grip Power

EE Torque/Speed
6.
5. ( 7.
Control
Convert Permit
Torque/
EE to KE Slippage

Speed

8.
9.
Prevent
Transmit
Reverse
Torque
Direction

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1.9 System Hierarchy Breakdown
Cordless Screwdriver
Battery Module Drive Mechanism
1.9.1 Battery Module System Breakdown
Battery Module
2. Closure 3. Power Storage
2.1. 2 Contact Plates 3.1. 3 Rechargables
2.2. Left 3.2. 2 Batt. Cables
2.3. Right 3.3. 2 Connectors
2.4. Cover 3.4. 2 Motor Cables
2.5. 2 Fasteners 3.5. 2 Crim Connectors
3.6. Shrink Wrap
3.7. Tape
3.8. Cable Connectors
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1.9.2 Driver Mechanism System Breakdown
Drive Mechanism
8. Transmission 5. Drive Closure
4. Torque Limiter Planetary Gear (PG) 1 5.1. Left Housing
5.2. Right Housing

4.1. Outer Cap 8.1. Washer 1
5.3. Grip Locking
4.2. Inner Cap 8.2. 3 Pinion Gears
5.4. Spring
4.3. Clip 8.3. Internal Gear
5.5.-5.7. 6 Fasteners (3 Types)
4.4. 4 Needle Bearing Pins 8.4. Carrier + Sun Gear for PG 2
4.5. 6 Ball Bearings 8.5. Sun Gear 6. Power Generator
4.6. Bearing Holder Plate

6.1. DC Motor
4.7. 4 Springs
Power Control
4.8. Base Support
4.9. 2 Fasteners On/Off Switch
Planetary Gear (PG) 2 Planetary Gear (PG) 3

6.2. Button
8.6. 3 Pinion Gears 8.2. 3 Pinion Gears 6.3. Spring
8.7. Washer 8.14. Washer Direction (F/R/S)
Hi/Lo Speed Control 8.15. Internal Gear + Direction Openner

6.4. Lever
8.16. Carrier
8.8. Coupling Gear 6.5. Switch Circuit
8.9. Locking Gear 7. Bit Holder

8.10. Lever
7.1. Collet
8.11. Interface Button
7.2. Housing
8.12. 2 Fasteners
Direction Stopper
8.13. Carrier and Sun Gear for PG 3
7.3. 2 Clips
7.4. 4 Supports
Screwdriver Bit
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1.10 Liaison Diagrams of Part Mating
1.10.1 Product Main Assembly
1.10.2 Battery and Housing Assembly
1.10.3 Torque Limiter
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1.10.4 Transmission
1.10.5 Motor Assembly
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2.Report#2:DATUMFLOWCHAIN
Transmission/Motor sub-assembly is selected for a detailed Datum Flow Chain (DFC)

analysis. The exploded view of this module is shown in Figure 7. Figure 1 shows the DFC
of overall sub-assembly. Detailed analysis of Hi/Lo speed conversion is presented in
Figures 2-6.
Datum Flow Chain for Transmission
4& 6: Torque Limiter & Power Generator
20
8.3: PG1 Internal Gears
18
KC#1 19 17 26 8.2: PG3 Pinion Gears
KC#2
8.1: Planetary Gear 1 Washer
16
8.10:Hi/Lo Lever
25 24 8.4: PG1 Carrier/PG2 Sun Gear
21
8.8: PG2 Coupling Gear 14
13
15 12 8.7: PG2 Washer
Alternative 8.6: PG2 Pinion Gears
8.9:PG2 Locking Gear
23 22
Alternative 9
8.13:PG2 Carrier/PG3 Sun Gear
11
10 8.14:PG3 Washer 8
4
7
8.15:PG3 Internal Gear 5
6 8.2: PG3 Pinion Gears
2
3
8.16 & 7.1:PG3 Carrier & Bit Holder
7.2: Bit Holder Housing 1
Figure1.DatumFlowChain(DFC)ofTransmission/MotorModule
2.1 Overall Transmission Key Characteristics
KC#1: Inorderforscrewdrivertofunctionproperly,BitHolderrotationaxismustbe
concentricwithPowerGeneratoraxis.Thusconcentricityisakeycharacteristic.
KC#2: The distance between PG3 Internal Gear & PG1 Internal Gear is important
becausethissubassemblyhastofitwithinthespaceprovidedbyTransmission/BitHolder
housing.SoStackuplengthisakeycharacteristic.
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KC#3#5:Hi/LowSpeedConfigurationandTheirKeyCharacteristics
The gear configurations for the high/low speeds and the transition are shown in the
following figure.
HighSpeed SpeedTransition LowSpeed
8.9 8.9 8.9

8.8 8.8 8.8
8.6 8.6 8.6
8.13 7.2 8.13 7.2 8.13 7.2
Figure2.Hi/Lospeedgearconfigurations.
Therearedistinctkeycharacteristicsforeachconfigurationasfollows.
HighSpeed:TheCouplingGearmustsuccessfullyengagetolockPG2Carrierand
PG2 Pinion Gears together so that they become an integral unit. Therefore, the
engagementofPG2CarrierandPinionGearsistheKC(KC#3).
8.10 Hi/Lo Lever
21
KC#3
8.8 PG2 Coupling Gear
22
8.13 PG2 Carrier
11 15
24 9
8.6 PG2 Pinion Gears
12 13
7.2 Bit housing
Figure3.DFCforHighSpeedcondition
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Transition:TheCouplingGearmustnotengagewitheitherPG2CarrierorLocking
Gear.Therefore,theKCisthegapbetweenPG2CarrierandLockingGear(KC#4).
8.10 Hi/Lo Lever
21
8.13 PG2 Carrier

11 15
24 9 KC#4
13
12
8.9 Locking Gear

7.2 Bit housing
Figure4.DFCfortransitioncondition
LowSpeed:TheCouplingGearandtheLockingGearmustbeproperlyengagedto
become an integral unit so that the Pinion Gear can rotate around the
Coupling/Locking Gear unit. The situation of the KC is shown in the following
figure.
h
8.9
8.8
g2 g1
8.6
8.13 7.2
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Figure5.Lowspeedcondition
If (g1 g2) < 2h then stress built up is occurring (over-constrained) and the
mechanism will fail. On the other hand, if (g1 g2) > 2h + , where is the acceptable
clearance, then wobbling problem is occurring. The former problem is more severe
than the later problem. Therefore, the KC (KC#5) is defined by the Pinion Gears and
the Locking Gear. The success of engagement between the Locking and Coupling
gear is a key condition to this mechanism. The Datum Flow Chains for the above
conditions are shown in the following figures.
8.10 Hi/Lo Lever
21

22
8.13 PG2 Carrier
11 15
24 9
12 13
KC#5
8.9 Locking Gear

7.2 Bit housing
Figure6.DFCforlowspeedcondition
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2.2 Feature, Mate, and Contact Table

Feature Part No. Part A Part No. Part B DOF MATE/ Comments
Number CONTACT
1 7.2 Bit Holder Housing 8.16 & Carrier & Bit Five Mate Peg & Hole
7.1 Holder
2 7.2 Bit Holder Housing 8.15 Internal Gear Five Mate Peg & Hole
3 8.16 & 7.1 Carrier & Bit Holder 8.2 Pinion Gears Five Mate 3 Peg & Holes for 3 pinions
4 8.2 Pinion Gears 8.13 PG2 Carrier/PG3 Five Mate Overconstrained Dofs, Clearance
Sun Gear
5 8.2 Pinion Gears 8.14 Washer Three Mate Overlap of 2 plates, OverCons. With #7
6 8.15 Internal Gear 8.2 Pinion Gears Four Mate Overconstrained Dofs, Clearance
7 8.15 Internal Gear 8.14 Washer Three Mate Overlap of 2 plates, OverCons. With #5
8 8.14 Washer 8.13 PG2 Carrier/PG3 Three Mate Overlap of two Plates
Sun Gear
9 8.13 PG2 Carrier/PG3 Sun 8.6 PG2 Pinion Gears Five Mate 3 Peg & Holes for 3 pinions
Gear
10 7.2 Bit Holder Housing 8.9 PG2 Locking Gear Five Mate Peg & Hole
11 7.2 Bit Holder Housing 8.1 Hi/Lo Lever Five Mate Peg & Hole
12 8.6 PG2 Pinion Gears 8.7 PG2 Washer Three Mate Overlap of 2 plates, OverCons. With #14
13 8.6 PG2 Pinion Gears 8.4 PG1 Carrier/PG2 Five Mate Overconstrained Dofs, Clearance
Sun Gear
14 8.7 PG2 Washer 8.4 PG1 Carrier/PG2 Three Mate Overlap of 2 plates, OverCons. With #12
Sun Gear
15 8.6 PG2 Pinion Gears 8.8 PG2 Coupling Five Mate Overconstrained Dofs, Clearance
Gear
16 8.4 PG1 Carrier/PG2 Sun 8.2 PG3 Pinion Gears Five Mate 3 Peg & Holes for 3 pinions
Gear
17 8.2 PG3 Pinion Gears 8.1 Pinion Gears 1 Three Mate Overlap of 2 plates
Washer
18 8.2 PG3 Pinion Gears 4 & 6 Torque Limiter & Five Mate Gear mate
Power Generator
19 8.1 Pinion Gears 1 Washer 8.3 PG1 Internal Gear Three Mate Overlap of 2 plates
20 8.3 PG1 Internal Gear 4 & 6 Torque Limiter & Three Mate Overlap of 2 plates
Power Generator
21 8.1 Hi/Lo Lever 8.8 PG2 Coupling One Mate
Gear
22 8.13 PG2 Carrier/PG3 Sun 8.8 PG2 Coupling Five Mate Gear mate
Gear Gear
23 8.9 PG2 Locking Gear 8.8 PG2 Coupling Six Mate Properly constrained
Gear
24 7.2 Bit Holder Housing 8.8 PG2 Coupling Three Mate Oversize hole
Gear
25 7.2 Bit Holder Housing 8.3 PG1 Internal Gear Three Mate Oversize hole
26 7.2 Bit Holder Housing 4 & 6 Torque Limiter & Six Mate Properly constrained
Power Generator
27 8.2 PG3 Pinion Gears 8.3 PG1 Internal Gear Five Mate Gear mate
_________________________________________________________________________________________________________
2.3 Complete Bill Of Materials

# Name #
1 1 Battery 1.1 Battery Charger 1 Charge Battery 6V DC Power supply N/A
Charger
2 2 Battery 2.1 Charger Contact 2 Contact Power Provide contact of battery SUS304
Closure Plates charger to battery
3 2.2 Battery Left 1 Enclose Battery Also function as hand grip Glass-filled
Housing nylon
4 2.3 Bettery Right 1 Enclose Battery Also function as hand grip Glass-filled
Housing nylon
5 2.4 Battery Cover 1 Enclose Battery Glass-filled
nylon
6 2.5 Baterry Housing 2 Hold battery N/A
Fasteners housing
7 3 Power 3.1 Rechargable 3 Store power Total of 3.6V battery N/A
Storage Batteries
8 3.2 Battery Cables 2 Transmit power Provide connection from battery N/A
to switch (+/-)
9 3.3 Battery Connectors 2 Connect cable Connecting cables to battery SUS304
10 3.4 Switch to Motor 2 Transmit power Provide connection from switch Polypropylene
Cables to
11 3.5 Crim Connectors 2 Hold cable Holding cable to motor SUS304
12 3.6 Shrink wrap 1 Hold batteries Polypropylene
13 3.7 Tape 1 Hold cable cellophane
14 3.8 Cable connectors 2 Connect cables to battery SUS304
15 4 Torque 4.1 Torque Limiter 1 Accept hand Accept hand control to push Polypropylene
Limiter Outer Cap needle bearing for torque limiter
16 4.2 Torque Limiter Inner 1 Accept outer cap PS
Cap (Polystyrene)
17 4.3 Torque Limiter Cap 1 Hold inner and outer caps SUS304
Clip
18 4.4 Needle Bearings 4 Push PG1 To adjust torque limiter N/A
internal gear
19 4.5 Ball Bearings 6 Allow internal gear PG1 slippage N/A
20 4.6 Bearing holder plate 1 Hold ball bearings SUS304
21 4.7 Torque Limiter 4 Hold bearing 4 springs to privide uniform flex SUS304
Springs holder plate suport
22 4.8 Torque Limiter Base 1 Support springs Nylon
Support
23 4.9 Torque Limiter 2 Hold base support to motor N/A
Fasteners
24 5 Drive 5.1 Drive Left Housing 1 Provide enclosure Also to isolate noise Glass-filled
Closure to drive nylon
25 5.2 Drive Right Housing 1 Provide enclosure Also to isolate noise Glass-filled
to drive nylon
26 5.3 Grip Locking Switch 1 Hold grip position Polypropylene
27 5.4 Grip Locking Spring 1 Support grip locking switch SUS304
28 5.5 Drive Housing Long 2 Hold housing N/A
Fasteners
29 5.6 Drive Housing 2 hold drive N/A
Medium Fasteners
30 5.7 Drive Housing Short 2 hold housing N/A
Fasteners
31 6 Power 6.1 DC Motor 1 Convert EE to Kinetic Energy N/A
generator
32 6.2 On/Off Button 1 Connect electric Polypropylene
power
33 6.3 On/Off Spring 1 Support On/Off SUS304
Button
# Name #
_________________________________________________________________________________________________________
34 6.4 F/R/S Lever 1 Provide control for rotation direction Polypropylene

35 6.5 F/R/S Switch 1 Control polarity connection to battery PS
Circuit (Polystyrene)
36 7 Bit Holder 7.1 Collet 1 Transmit torque Also to hold bit SUM
37 7.2 Bit Holder Housing 1 Provide housing to drive mechanism PS
(Polystyrene)
38 7.3 Direction Stopper 2 Hold PG3 carrier To allow counter rotation SUS304
Clips
39 7.4 Direction Stoppper 4 Hold stopper clips PS
Supports (Polystyrene)
40 7.5 Screwdriver bit 1 Act on screw SUM
41 8 Transmissi 8.1 Planetary Gear 1 1 Enclose pinion SUS304
on (PG1) Washer gears
42 8.2 PG1/PG3 Pinion 6 Increase torque SMF
Gears
43 8.3 PG1 Internal Gears 1 Coordinate pinion Allows all pinion gears to rotate SMF
gears along its internal gear
44 8.4 PG1 Carrier/PG2 1 Hold pinion gears Also transmit torque SUM
Sun Gear
46 8.5 PG2 Pinion Gears 3 Reduce speed SMF
gears
48 8.7 PG2 Coupling Gear 1 Hold pinion gears PS
(Polystyrene)
49 8.8 PG2 Locking Gear 1 Hold PG2 system PS
(Polystyrene)
50 8.9 Hi/Lo Lever 1 Transmit control By shifting coupling gear SUS304
51 8.10 Hi/Lo Button 1 Accept Hi/Lo Polypropylene
control
52 8.11 Hi/Lo Fasteners 2 Hold Hi/Lo lever N?
53 8.12 PG2 Carrier/PG3 1 Hold pinion gears SUM
Sun Gear
gears
55 8.14 PG3 Internal 1 Coordinate pinion Allows all pinion gears to rotate SMF
Gear/Direction gears along its internal gear
Openner
56 8.15 PG3 Carrier 1 Hold pinion gears SUM
_________________________________________________________________________________________________________
2.4. Exploded View
Figure7.ExplodedviewofTransmissionSubassembly.
_________________________________________________________________________________________________________
3.Report#3:AssemblySequence
3.1 Revised Liaison Diagram

6. Main Housing
1
6.1 Motor + PG1 Sun Gear
26 27
4
25 8.3 PG1 Ring Gear
8.9 Locking Gear 23
2
8.1 PG1 Washer 24
7 9 10 22
8.10 Hi/Lo Lever 8.7 PG2 Washer 21 8.4 PG1 Carrier
29 30 19
7.2 Gear Housing 20
6 11
8.8 Coupling Gear 12 18
5
8.15 PG3 Ring Gear
13 28 8.13 PG2 Carrier
8.14 PG3 Washer
17
14
3
16
8.16 PG3 Carrier
15
7.1 Shaft
3.2 Revised Datum Flow Chain

6. Main Housing
6
6.1 Motor + PG1 Sun Gear
3 4
6
5 8.3 PG1 Ring Gear
8.9 Locking Gear 4
6
8.1 PG1 Washer 3
6 3 5
6
8.10 Hi/Lo Lever 8.7 PG2 Washer 3 8.4 PG1 Carrier
1 4
5
7.2 Gear Housing 3
5 4
8.8 Coupling Gear 6 5
5
8.15 PG3 Ring Gear
3 3 8.13 PG2 Carrier
8.14 PG3 Washer
4
4
6
5
8.16 PG3 Carrier
7.1 Shaft
_________________________________________________________________________________________________________
3.3 All Possible Assembly Sequence

1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6
7 8 9 10 11 12 7 8 9 10 11 12 7 8 9 10 11 12 7 8 9 10 11 12
13 14 15 16 17 18 13 14 15 16 17 18 13 14 15 16 17 18 13 14 15 16 17 18
19 20 21 22 23 24 19 20 21 22 23 24 19 20 21 22 23 24 19 20 21 22 23 24
25 26 27 28 29 30 25 26 27 28 29 30 25 26 27 28 29 30 25 26 27 28 29 30
1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6
7 8 9 10 11 12 7 8 9 10 11 12 7 8 9 10 11 12 7 8 9 10 11 12
13 14 15 16 17 18 13 14 15 16 17 18 13 14 15 16 17 18 13 14 15 16 17 18
19 20 21 22 23 24 19 20 21 22 23 24 19 20 21 22 23 24 19 20 21 22 23 24
25 26 27 28 29 30 25 26 27 28 29 30 25 26 27 28 29 30 25 26 27 28 29 30
1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6
7 8 9 10 11 12 7 8 9 10 11 12 7 8 9 10 11 12 7 8 9 10 11 12
13 14 15 16 17 18 13 14 15 16 17 18 13 14 15 16 17 18 13 14 15 16 17 18
19 20 21 22 23 24 19 20 21 22 23 24 19 20 21 22 23 24 19 20 21 22 23 24
25 26 27 28 29 30 25 26 27 28 29 30 25 26 27 28 29 30 25 26 27 28 29 30
1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6
7 8 9 10 11 12 7 8 9 10 11 12 7 8 9 10 11 12 7 8 9 10 11 12
13 14 15 16 17 18 13 14 15 16 17 18 13 14 15 16 17 18 13 14 15 16 17 18
19 20 21 22 23 24 19 20 21 22 23 24 19 20 21 22 23 24 19 20 21 22 23 24
25 26 27 28 29 30 25 26 27 28 29 30 25 26 27 28 29 30 25 26 27 28 29 30
1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6
7 8 9 10 11 12 7 8 9 10 11 12 7 8 9 10 11 12
13 14 15 16 17 18 13 14 15 16 17 18 13 14 15 16 17 18
19 20 21 22 23 24 19 20 21 22 23 24 19 20 21 22 23 24
25 26 27 28 29 30 25 26 27 28 29 30 25 26 27 28 29 30
1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6
7 8 9 10 11 12 7 8 9 10 11 12 7 8 9 10 11 12
13 14 15 16 17 18 13 14 15 16 17 18 13 14 15 16 17 18
19 20 21 22 23 24 19 20 21 22 23 24 19 20 21 22 23 24
25 26 27 28 29 30 25 26 27 28 29 30 25 26 27 28 29 30
1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6
7 8 9 10 11 12 7 8 9 10 11 12 7 8 9 10 11 12
13 14 15 16 17 18 13 14 15 16 17 18 13 14 15 16 17 18
19 20 21 22 23 24 19 20 21 22 23 24 19 20 21 22 23 24
25 26 27 28 29 30 25 26 27 28 29 30 25 26 27 28 29 30
1 2 3 4 5 6 1 2 3 4 5 6
7 8 9 10 11 12 7 8 9 10 11 12
13 14 15 16 17 18 13 14 15 16 17 18
19 20 21 22 23 24 19 20 21 22 23 24
25 26 27 28 29 30 25 26 27 28 29 30
1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6
7 8 9 10 11 12 7 8 9 10 11 12 7 8 9 10 11 12 7 8 9 10 11 12
13 14 15 16 17 18 13 14 15 16 17 18 13 14 15 16 17 18 13 14 15 16 17 18
19 20 21 22 23 24 19 20 21 22 23 24 19 20 21 22 23 24 19 20 21 22 23 24
25 26 27 28 29 30 25 26 27 28 29 30 25 26 27 28 29 30 25 26 27 28 29 30
_________________________________________________________________________________________________________
3.4 The Most Conveniencee Assembly Sequence
Transmission/Motor Sub-assembly
R
R
R S F 6. Main Housing
8.12. Fastener for Hi/Lo Lever
8.10. Hi/Lo Lever
6.1. Motor Assembly
8.3. PG1 Ring Gear
8.1. PG1 Washer
Grease
8.2. PG1 Pinion Gears
8.4. PG1 Carrier/PG2 Sun Gear
8.7. PG2 Washer
Grease
8.9. PG2 Locking Gear F
8.8. PG2 Coupling Gear
8.14 PG3 Washer
Grease
F 8.15. PG3 Ring Gear
7.2. Bit Holder Housing

(Including 7.1. Shaft and 8.16. PG3 Carrier)
F: Fixture R: Reorient
S: Snap F: Remove Fixture
: Downward insertion : Horizontal insertion
_________________________________________________________________________________________________________
3.5 Required Gross and Fine Motions

TheGrossandFinemotionsareestimatedusingtheBoothroyd&DewhurstDFAtableas
follow.
1 2 3 4 5 6 7 9
Manual insertion time

Manual handling time
Number of times the
operation is carried
(sec.) = (2)*((4)+(6))
out consecutively
theoritical min. of
Operation time in
Two-digit manual
Two-digit manual
Part ID number
insertion code
handling code
estimation of
Figures for
Part Name
per part
per part
parts
No.
1 Bit Holder Housing (Including Shaft and PG3 Carrier) 7.2 1 03 1.95 03 2 3.95 1
2 PG3 Ring Gear 8.15 1 05 4 04 4.5 8.5 1
3 PG3 Pinion Gears 8.2 3 04 3.6 04 4.5 24.3 3
4 Grease 4 1 99 12 12 1
5 PG3 Washer 8.14 1 30 1.69 03 2 3.69 0
6 PG2 Carrier/PG3 Sun Gear 8.13 1 05 14 7.5 11.5 1
7 PG2 Pinion Gears 8.6 3 04 3.6 03 2 16.8 3
8 Fixture/Tool (for Hi/Lo lever) 1 00 1.13 03 2 3.13 0
9 PG2 Coupling Gear 8.8 1 05 4 03 2 6 1
10 PG2 Locking Gear 8.9 1 05 4 03 2 6 1
11 Grease 1 99 12 12 0
12 PG2 Washer 8.7 1 30 1.69 03 2 3.69 0
13 PG1 Carrier/PG2 Sun Gear 8.4 1 05 4 14 7.5 11.5 0
14 PG1 Pinion Gears 8.2 3 04 3.6 03 2 16.8 0
15 Grease 1 99 12 12 0
16 PG1 Washer 8.1 1 30 1.69 03 2 3.69 0
17 PG1 Ring Gear 8.3 1 05 4 13 5 9 0
18 Motor Assembly 6.1 1 00 1.13 14 7.5 8.63 0
19 Reorientation 2 80 9 18 0
20 Hi/Lo Lever 8.10 1 33 2.51 02 5.5 8.01 1
21 Snap fit 2 39 3.5 7 0
22 Fastners (for Hi/Lo lever) 8.12 2 24 4.35 83 6 20.7 0
Total 31 226.89 13
The Boothroyd and Dewhurst DFA suggest total assembly time of 226.89 seconds or 3
minutes and 46.89 seconds. The actual manual assembly experiments by us took about 4
minutes and 30 seconds without putting any grease.
3.6 Futures, Chamfers and Lead ins
Feature Part No. Part A Part No. Part B Chamfers and MATE/ Comments
Number Lead-ins CONTACT
1 7.2 Bit Holder Housing 8.16 & Carrier & Bit Not Applicable Mate(5) Peg & Hole
7.1 Holder
2 7.2 Bit Holder Housing 8.15 PG3 Ring Gear N. A. Mate(5) Peg & Hole
3 8.16 & 7.1 Carrier & Bit Holder 8.2 Pinion Gears N. A. Mate(5) 3 Peg & Holes for 3 pinions
4 8.2 Pinion Gears 8.13 PG2 Carrier/PG3 Chamfer and Lead- Mate(5) Over-constrained Dofs, Clearance
Sun Gear in on all 3 Pinion
Gears and on Sun
Gear
5 8.2 Pinion Gears 8.14 Washer N. A. Mate(3) Overlap of 2 plates, Over-Cons.
With #7
6 8.15 PG3 Ring Gear 8.2 Pinion Gears Chamfer and Lead- Mate(4) Over-constrained Dofs, Clearance
in on all 3 Pinion
Gears and on
_________________________________________________________________________________________________________
Internal Gear
7 8.15 PG3 Ring Gear 8.14 Washer N. A. Mate(3) Overlap of 2 plates, Over-Cons.
With #5
8 8.14 Washer 8.13 PG2 Carrier/PG3 N. A. Mate(3) Overlap of two Plates
Sun Gear
9 8.13 PG2 Carrier/PG3 Sun 8.6 PG2 Pinion Gears N. A. Mate(5) 3 Peg & Holes for 3 pinions
Gear
10 7.2 Bit Holder Housing 8.9 PG2 Locking Gear N. A. Mate(5) Peg & Hole
11 7.2 Bit Holder Housing 8.1 Hi/Lo Lever N. A. Mate(5) Peg & Hole
12 8.6 PG2 Pinion Gears 8.7 PG2 Washer N. A. Mate(3) Overlap of 2 plates, Over-Cons.
With #14
13 8.6 PG2 Pinion Gears 8.4 PG1 Carrier/PG2 Chamfer and Lead- Mate(5) Over-constrained Dofs, Clearance
Sun Gear in on all 3 Pinion
Gears and on Sun
Gear
14 8.7 PG2 Washer 8.4 PG1 Carrier/PG2 N. A. Mate(3) Overlap of 2 plates, Over-Cons.
Sun Gear With #12
15 8.6 PG2 Pinion Gears 8.8 PG2 Coupling Chamfer and Lead- Mate(5) Over-constrained Dofs, Clearance
Gear in on all 3 Pinion
Gears and on
Coupling Gear
16 8.4 PG1 Carrier/PG2 Sun 8.2 PG3 Pinion Gears N. A. Mate(5) 3 Peg & Holes for 3 pinions
Gear
17 8.2 PG3 Pinion Gears 8.1 Pinion Gears 1 N. A. Mate(3) Overlap of 2 plates
Washer
18 8.2 PG3 Pinion Gears 4 & 6 Torque Limiter & Chamfer and Lead- Mate(5) Gear mate
Power Generator in on all 3 Pinion
Gears and on Sun
Gear of Power
Generator
19 8.1 Pinion Gears 1 Washer 8.3 PG1 Ring Gear N. A. Mate(3) Overlap of 2 plates
20 8.3 PG1 Ring Gear 4 & 6 Torque Limiter & N. A. Mate(3) Overlap of 2 plates
Power Generator
21 8.1 Hi/Lo Lever 8.8 PG2 Coupling N. A. Mate(1)
Gear
22 8.13 PG2 Carrier/PG3 Sun 8.8 PG2 Coupling Chamfer and Lead- Mate(5) Gear mate
Gear Gear in on Sun Gear and
on Coupling Gear
23 8.9 PG2 Locking Gear 8.8 PG2 Coupling Chamfer and Lead- Mate(6) Properly constrained
Gear in on Locking Gear
and on Coupling
Gear
24 7.2 Bit Holder Housing 8.8 PG2 Coupling N. A. Mate(3) Oversize hole
Gear
25 7.2 Bit Holder Housing 8.3 PG1 Ring Gear N. A. Mate(3) Oversize hole
26 7.2 Bit Holder Housing 4 & 6 Torque Limiter & N. A. Mate(6) Properly constrained
Power Generator
27 8.2 PG3 Pinion Gears 8.3 PG1 Ring Gear Chamfer and Lead- Mate(5) Gear mate
in on all 3 Pinion
Gears and on
Internal Gear
DescriptionofChamfersandLeadinsonFeatures:
1. Pinion Gears and Sun Gear (Feature #04, #13, #18): Chamfers and Leadins are
provided on the Pinion Gears and Gun Gear in order to avoid jamming during
assembly.Oncetheassemblyoperationsareover,chamferplaysnorole.
2. Pinion Gears and Internal Gear (Feature #06, #27): Chamfers and Leadins are
provided on the Pinion Gears and Internal Gear to ensure the ease of assembly.
Chamferplaysnoroleduringtheactualoperationofmechanism.
_________________________________________________________________________________________________________
3. PinionGearsandCouplingGear(Feature#15): ChamfersandLeadinsavoidthe
jammingofthesetwopartsduringassembly.Theyplaynoroleaftertheproducthas
beenassembled.
4. Sun Gear and Coupling Gear (Feature #22): Here, Chamfers and Leadins have
functionalimportance.TheconnectionbetweenSunGearandCouplingGearisnot
permanent. It is established when the Coupling Gear is moved to achieve higher
speed.So,theproperchamferangleandleadinareveryimportant.Theyshouldbe
choseninsuchawaythattheconnectionbetweenSunGearandCouplinggearis
establishedirrespectiveoftheangularpositionofCouplingGearwithrespecttoSun
Gear.
5. CouplingGearandLockingGear(Feature#00):Hereagain,ChamfersandLeadins
have functional importance. The connection between Locking Gear and Coupling
Gear is established when the Coupling Gear is moved to achieve lower speed.
CouplingGearandLockingGeartogetherformtheInternalGearandtheyactasone
functionalunitinthissituation.So,theproperchamferangleandleadinarevery
important.TheyshouldbechoseninsuchawaythattheconnectionbetweenLocking
GearandCouplinggearisestablishedirrespectiveoftheangularpositionofCoupling
GearwithrespecttoLockingGear.
3.7 Difficulties & Ideas in Assembly

Ingeneral,thefollowingalternativesmightbeconsideredtoeliminatedifficultto
assembleparts:
Modifyassemblysequenceorarchitecturetoeliminatedifficulttoaccessassembly
steps.
Modifyassemblysequenceorarchitecturetoreducelengthyassemblytime.
Examplesoftheaboveapproachesmayleadtothefollowingchanges:
Modifythestackingofplanetarygearsets.Thissteprequiresarchitectural
changesasdiscussinthenextsection.
Commonizeandminimizefasteners.
Eliminatewashers.
Avoidtheuseoffixtures/toolsbyfindingassemblysequencealternatives.
Eliminatereorientationbychoosingassemblysequencethatrequireslessnumber
ofreorientations.
Eliminatemultiplegreasingsteps.
Thefollowingaresomeofthepossibleproblemsandresolutions.
Liaiso Part Par PossibleProblems/risks Possiblesolutions

n# A tB
16 8.2 8.1 Insertionindeepand Separate7.2BitHolderHousingtotwo
6 narrowhole,blind cylinders
operation Developgrippertoimproveoperation(see
fig#5)
18 8.6 8.1 Insertionindeepand Separate7.2BitHolderHousingtotwo
_________________________________________________________________________________________________________
3 narrowhole,blind cylinders
operation Developgrippertoimproveoperation(see
fig#5)
27 6.1 8.2 Needtojigglethemotor Changetheassemblysequencebymating
assemblytogetpropergear piniongearstomotorassemblyshaft.
mating,blindoperation
17 8.13 8.2 Needtojigglethemotor Changetheassemblysequencebymating
assemblytogetpropergear piniongearstomotorassemblyshaft.
mating
30 8.8 8.1 Mating8.10to8.8,because Usefixturetoconstrain8.8,Coupling
0 8.8issofreetobe gear.
positionedcorrectly,and
obstructedview
3.8 Feature Parts and Associated Assembly Tool and Fixtures
Theinsertiontool,T2, showninFigure5.aisusedforloadingmultiplepartintothe
transmissionhousing(7.2)duringthetransmissiongearassemblybuildsequence.The
grippertooldesigncanbeusedforloadingallpinioncarriergearsandringgears.
ThepartsinthefollowingtablewillloadedusingT2.
Subsystem P/N Description Grippingfeature

Transmission 8.3 PG1RingGears Insidediameter
Transmission 8.4 PG1Carrier 3pinionshafts
Transmission 8.8 PG2CouplingGear Insidediameter
Transmission 8.9 PG2LockingGear Insidediameter
Transmission 8.13 PG2Carrier 3pinionshafts
Transmission 8.15 PG3RingGear Insidediameter
TheT2grippingtoolisaspreaderdesign.Whentoolisinafree(ungripped)state,the
tipsofthetool,whichcontactthepart,areinaclosedposition(seeFigure5.a).This
positionismaintainedatfreestatebyaspringabovethetoolpivotpoint.
Whengrippingpiniongearcarriers,thetoolisplacedbetweenthe3piniongear
pinsandloadeduntilthetoolspreadstomakesufficientcontact(seeFigure5.a).
Whengrippingringgears,thetoolisplacedanywhereontheinsidediameterand
loadeduntiltoolspreadstomakesufficientcontact(seeFigure5.a).
ThePinionGearInsertionTool,T1,showninFigure5.b,isusedtoinsertpiniongears
intothetransmissionhousing(7.2).Thistoolisdesignedwithmagneticinsertsplacedat
_________________________________________________________________________________________________________
twodifferentdepthstoallowfordiametersandlengthscorrespondingtobothsizepinion
gears(8.2and8.6).Oncethepiniongearhasbeenloadedintothetoolandontoacarrier
pin,thebuttononthetopofthetoolispressedbytheoperatortoactuatetheejectorpin.
This motion extracts the pinion gear from the magnet, leaving it in final assembly
position.
Thetransmissionhousingholdingfixture,F1,showninFigure5.choldsandorients
thetransmissionhousing(7.2)duringtransmissionassemblybuildup.Thefixtureishard
mounted tothe tableinaworkcell infrontofthe operator.Theoperatormates the
housingtothefixturebypushingthecolletontoapinatthebaseofthefixture.Fixturing
thehousingpriortogearassemblybuildupallowstheoperatorfulluseofbothhandsfor
loadingpartsintohousing.
_________________________________________________________________________________________________________
3.9. Fixtures and Tools for Assembly
Figure5.b.ToolT1
Figure5.a.ToolT2
Figure5.c.FixtureF1
_________________________________________________________________________________________________________
3.10 Gear Set Architecture Redesign
OriginalArchitecture RedesignedArchitecture
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
3.11 Improvement highlight
Planetary gear sets are rearranged by moving the Planetary Gear Set #1 next to the
Planetary Gear Set #3. This new architecture results in significant part reduction and part
integration (function sharing, see item #4 below). The redesign also requires some feature
changes as described below.
1. IncreasingthelengthofPG3ringgear(8.15)tocontainsbothplanetarygear#1and
#3.Significantimprovementisachievedby:
EliminatingPG3washer(8.14)
Eliminatinglockinggear(8.9)byputtingitsfunctionalityintoPG2RingGear
(8.3)
2. FeaturemodificationofPG1carrier(8.4)tofitPG3planetarygearsandPG3Ring
gear.
3. Combiningthefunctionoflockinggear(8.9)into(8.3)
4. ModificationofsungearatthemotorshafttofitPG2planetarygears(8.6)
5. Shorteningthelengthofbitholderhousing(7.2)resultsthefollowingbenefits:
The assembly of the planetary gear sets #1 and #2 becomes much easier
(eliminatingdeepinsertions)
Eliminatingmultiplegreasingsteps.
Thenewarchitecturealsoprovidessignificantassemblycostbenefitby
Eliminatingspecialtoolsrequiredinthecurrentdesign.
Reductioninthetimerequiredassemblingthemodifiedproduct.
_________________________________________________________________________________________________________
4.Report#4:AssemblyFloorLayoutAnalysis
The following report steps through the analysis required to propose a feasible plant layout
to effectively perform operations necessary to assembly package and ship the Sears
Craftsman Screwdriver. The team broke the analysis into 3 primary tasks in order to
provide the necessary information for a viable operations solution. These analysis
activities are outlined in the report as follows:
Assembly Sequence
Assembly Process time
Assembly Line Design and Assumptions
4.1. Assembly Sequence

The assembly sequence chosen for the Sears Craftsman Screwdriver are shown in Figures
1 and 2. This sequence was chosen because it was conducive to an efficient flow of
assembly operations that were consistent with the overall operations strategy. The
sequence allowed for easily "chunking" assembly task into workcells that allowed for
optimal assembly line balance. This sequence also allowed the workcell subassemblies to
be robust against damage or loss of parts during transition to downstream operation.
Packed Box
Testing and Packaging
Manual
Testing
Screw Driver
Bits
Final Assembly
Charger Base
1.1:Battery Charger
Cardboard Bin
Drive Housing Fasteners
Box
5.2: Drive Right Housing
5.3: Grip Locking Switch

8.10: High/Lo Button
5.1: Drive Left

Housing
Wire Crimping
6: Motor Assembly
Grip Housing 4:Torque Limiter

Battery Assembly
8:Transmission assembly
Figure1AssemblySequenceTree
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
Transmission/Motor Sub-assembly
R
RSF
8.12. Fastener for Hi/Lo Lever
8.10. Hi/Lo Lever
8.3. PG1 Ring Gear

8.1. PG1 Washer
Grease
8.7. PG2 Washer
Grease
8.9. PG2 Locking Gear F
8.8. PG2 Coupling Gear
8.14 PG3 Washer
Grease
F 8.15. PG3 Ring Gear
7.2. Bit Holder Housing

(Including 7.1. Shaft and 8.16. PG3 Carrier)
F: Fixture R: Reorient
S: Snap F: Remove Fixture
: Downward insertion : Horizontal insertion
Figure2TransmissionSubAssemblySequenceTree
4.2 Assembly Process time
Assembly times were determined using Boothroyd & Dewhurst DFA tables (see Figures
3,4,&5). These techniques used associated times correlated to previously determined
manual insertion and handling codes. Once these times were determined, decisions were
made as to what workstations needed to be developed for an optimal work flow and
assembly line balancing. These decisions were also based on product architecture and
interfaces between subsystems, which allow easy and robust transfer to the downstream
workstation.
_________________________________________________________________________________________________________
2 3 4 5 6 7

Number of times the
(sec.) = (2)*((4)+(6))
out consecutively
Operation time in
Two-digit manual
Two-digit manual
insertion code
handling code
Part Name
per part
per part
No.
1 Box 1 00 1.13 30 31.13

2 Cardboard bin 1 03 1.95 00 1.5 3.45
3 Battery Charger 1 03 1.95 00 1.5 3.45
4 Charger Base 1 03 1.95 00 1.5 3.45
5 Bits 1 00 1.13 00 1.5 2.63
6 Screwdriver 1 03 1.95 00 1.5 3.45
7 Screwdriver testing 1 20 20
8 Manual 1 00 1.13 1.13
Total 8 68.69
Figure3TestingandPackaging
2 3 4 5 6 7

Number of times the
(sec.) = (2)*((4)+(6))
out consecutively
Operation time in
Two-digit manual
Two-digit manual
insertion code
handling code
Part Name
per part
per part
No.
1 Transmission Assembly 1 03 1.95 20 2.5 4.45

2 Torque Limiter 1 01 1.13 00 1.5 2.63
3 Grip Housing/Battery Assembly 1 03 1.95 03 2 3.95
4 Motor Assembly 1 00 1.13 1.13
5 Wire Crimping 2 39 3.5 7
6 Drive Left Housing 1 03 1.95 03 2 3.95
7 Hi/Low Button 1 13 2.25 03 2 4.25
8 Grip Locking Switch 1 13 2.25 03 2 4.25
9 Drive Right Housing 1 03 1.95 03 2 3.95
10 Drive Housing Fasteners 6 10 1.13 29 5 36.78
Total 16 72.34
Figure4FinalAssemblyProcessTime
_________________________________________________________________________________________________________
2 3 4 5 6 7

Number of times the
(sec.) = (2)*((4)+(6))
out consecutively
Operation time in
Two-digit manual
Two-digit manual
insertion code
handling code
Part Name
per part
per part
No.
1 Bit Holder Housing (Including Shaft and PG3 Carrier) 1 03 1.95 03 2 3.95
2 PG3 Ring Gear 1 05 4 04 4.5 8.5
3 PG3 Pinion Gears 3 04 3.6 04 4.5 24.3
4 Grease 1 99 12 12
5 PG3 Washer 1 30 1.69 03 2 3.69
6 PG2 Carrier/PG3 Sun Gear 1 05 14 7.5 11.5
7 PG2 Pinion Gears 3 04 3.6 03 2 16.8
8 Fixture/Tool (for Hi/Lo lever) 1 00 1.13 03 2 3.13
9 PG2 Coupling Gear 1 05 4 03 2 6
10 PG2 Locking Gear 1 05 4 03 2 6
11 Grease 1 99 12 12
12 PG2 Washer 1 30 1.69 03 2 3.69
13 PG1 Carrier/PG2 Sun Gear 1 05 4 14 7.5 11.5
14 PG1 Pinion Gears 3 04 3.6 03 2 16.8
15 Grease 1 99 12 12
16 PG1 Washer 1 30 1.69 03 2 3.69
17 PG1 Ring Gear 1 05 4 13 5 9
18 Reorientation 2 80 9 18
19 Hi/Lo Lever 1 33 2.51 02 5.5 8.01
20 Snap fit 2 39 3.5 7
21 Fastners (for Hi/Lo lever) 2 24 4.35 83 6 20.7
Total 30 218.26
Figure5TransmissionAssemblyProcessTime
It can be seen from the total assembly times found in the above tables that a total process
cycle time of approximately 60-70 seconds should be targeted. The grip housing assembly
process time, although not shown in this report, was calculated using the same method
and found to be approximately 70 seconds. With this information the workstations were
determined to be the following :
Grip Housing Assembly (1 workstation)

Transmission Assembly (3 workstations)
Final Assembly (1 workstation)
Testing and Packaging (1 workstation)
4.3 Assembly Line Design and Assumptions
Production Volumes were estimated by gathering information about the product

distribution network. This information was found from the Sears website. The table below
summarizes all retail outlets where the products are sold in the 2 key markets of U.S and
_________________________________________________________________________________________________________
Canada. Phone surveys were then conducted to gain a reasonable estimate of the average
number of units sold per month at these outlets.
Estimated Sales Amounts 8,358 /month

Estimated Production 379.9 /day (22 working days/month)
units/month/
SEARS Shops # of shops
shop
units/month
US Department stores 833 3 2499
Off-the-mall full-line stores 1,325 2 2650
Subr-lines in rural markets 1,384 1 1384
Canada Full-line stores 110 2.5 275
Catalog agent & dealers 1,550 1 1550
Total 8358
4.3.1 Design Parameters
Considering the estimated production size and the product packaging size, factory-out
distribution of this product will be less than once a day and the batch size should be
defined assembly process.
Parts supply: Parts for one day production are brought to the working area
by full-time worker, who is also responsible to other production
Batch: 95 units (4 batches/ day)
Set-up time 10 min./batch to carry parts from in-house inventory to each
workstation
Working time :7.5 hours/day (actual working time put off recesses)
Assumptive Cycle Time (temporary setting for designing)

Cycle time/ unit (7.5 hours/day) / (379.9 units/day ) = 71.1 sec.
Cycle time/ batch (Process time/ # of workers) * (95 units) + 10 min. <
71.1*95 sec.
(1 hours and 53 min., 4 batches/ day)
4.3.2 Supplied Material

It was estimated that supplied materials are all part level and all handicrafts are performed
in house because of following observations:
This product is made in China, in which labor cost is generally low.
Since this product is an integrated product, possible outside sub-assembles are Battery
Assembly and Grip Housing Assembly. However, if these are out-sourced, in
comparison, Transmission Assembly operation requires too long time, even if
separated to two workstation, and other assembly operations become too simple.
_________________________________________________________________________________________________________
4.4 Assembly operation style
Given that the annual production volumes were relatively low for a mass production
product and that the assembly operations are in China where labor cost is very low,
automated assembly operations were ruled out as a cost-effective means of assembly.
4.4.1 Assembly Line Design
Considering Assumptive Cycle Time, there is no need to organize highly sequential line,
however, too much individual workstations increase overheads. To balance minimizing
equipment cost and overhead cost, General Assembly Flow becomes as follows:
The production workflow starts with an inventory stockpile that supplies approximately 1
shift of production (see Figure 7 - A). Inventory is transferred manually by laborers to
supply all workcells during the shift. Enough inventory is transferred to workcells to
supply a batch size of 95 units. This is because the space for stocking inventory is limited
at the workcell tables. Also, this allows for the recirculation of the transmission housing
fixtures, which are limited in number to approx. 100 to minimize investment cost (see line
1 dotted). The details of these fixtures, T-1, are shown in project report #3.
Workcell B assembles the grip housing assembly concurrently with wokcells C,D&E
which assemble the transmissions. These 4 workcells are positioned around a common
conveyor system that feeds into a "pool" for use by the final assembly workcell (F). This
conveyor system consists of an inclined set of rollers or possibly a steel chute. It is
approximately 6 meters in length, so an automated transfer system is not necessary. It is
important to note that 3 workcells were used to assemble the transmissions to achieve
proper assembly line balancing. This strategy was needed because cycle time for
transmission assembly was 185 seconds (218 sec. without tool efficiency, see Figure 6). By
having 3 workcells the combined cycle time becomes 62 seconds. This is less than the 72
seconds required for final assembly, which will prevent build up of inventory.
Note: Holding fixtures are used to hold the transmission gear assembly vertical. These
fixture are placed on the conveyor along with assembled workpiece. After going through
final assembly, these fixtures are recirculated to workcells C,D, and E by a manual labor
head.
Workcell F is the place for final assembly. The transmission assembly is picked up and
motor is assembled with it. The grip housing assembly is picked up next and it is
assembled with it. Other part of the housing is snap fitted on to rest of the sub-assembly.
Workcell G stores the fixtures being used in the transmission assembly These fixtures are
sent back to the workcells C,D and E.
Workcell H is for packaging and testing. The fully assembled screwdrivers are picked from
workcell G and they are tested both in high speed and low speed operating conditions.
_________________________________________________________________________________________________________
Supplied Once a day In-house

Material
Inventory
Set-up Time: 10 min./Batch
Grip Housing Carried Once
Assembly a day
Testing & In-house Out-house
Final Assembly
Packaging Inventory Inventory
Transmission
Assembly
Cycle Time: about 62 sec. Cycle Time : about 72.34 sec. Cycle Time : about 68.69 sec.
1 worker for Grip Housing 1 worker 1 worker
3 workers for Transmission
(Process Time:218.26--> 185 sec. by 15% tool efficiency)
Figure6AssemblyFlowDiagram
Packaging & Testing
Final Assembly
H G
Storage for Parts Shelf F
Trans.
Parts Pallet Housing Table Parts Shelf
Fixture Tool
Table Grip Housing
Pool Slider Pool B Assembly
Once a day
In-house Inventory
by Forklift
for Final Assembly
(Pallet) J D
Transmission Table
C onveyor
Assembly-2
Parts Shelf
Parts Shelf
Transmission
Table Assembly-1
C
A
Once a day
In-house Material
by Forklift
Inventory
(Containers on Pallet)
E
Table
Parts Shelf Transmission

Assembly-3
Closer position for heavier parts
1 m2 Assembly Sequence
Material Supply
Figure7FloorLayout
_________________________________________________________________________________________________________
Materials are ordered Right to Left

along assembly sequence
Materials are supplied from rear side Tools & Grease-gun Hang Wall
Parts Shelf
Work Table
Small materials are

automatically supplied
on the table
Conveyer is located light-hand
Figure8WorkstationtableDesign
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
5.Report#5:WorkstationDesign
5.1 Required cycle time to complete the planned operations
FollowingAssemblyFlowDiagramshowscycletimeforalltheoperationsinvolvedin
screwdriversubassemblies,finalassemblyandtesting/packing.Formoredetailsplease
refertoindividualcharts.
5.1.1 Assembly Flow Diagram
Supplied Once a day In-house

Material
Inventory
Set-up Time: 10 min./Batch
Grip Housing Carried Once
Assembly a day
Testing & In-house Out-house
Final Assembly
Packaging Inventory Inventory
Transmission
Assembly
Cycle Time: about 62 sec. Cycle Time : about 72.34 sec. Cycle Time : about 68.69 sec.
1 worker for Grip Housing 1 worker 1 worker
3 workers for Transmission
(Process Time:218.26--> 185 sec. by 15% tool efficiency)
_________________________________________________________________________________________________________
5.1.2 Final Assembly
2 3 4 5 6 7

Number of times the
(sec.) = (2)*((4)+(6))
out consecutively
Operation time in
Two-digit manual
Two-digit manual
insertion code
handling code
Part Name
per part
per part
No.
1 Transmission Assembly 1 03 1.95 20 2.5 4.45

2 Torque Limiter 1 01 1.13 00 1.5 2.63
3 Grip Housing/Battery Assembly 1 03 1.95 03 2 3.95
4 Motor Assembly 1 00 1.13 1.13
5 Wire Crimping 2 39 3.5 7
6 Drive Left Housing 1 03 1.95 03 2 3.95
7 Hi/Low Button 1 13 2.25 03 2 4.25
8 Grip Locking Switch 1 13 2.25 03 2 4.25
9 Drive Right Housing 1 03 1.95 03 2 3.95
10 Drive Housing Fasteners 6 10 1.13 29 5 36.78
Total Time 16 72.34
5.1.3 Testing and Packaging
2 3 4 5 6 7

Number of times the
(sec.) = (2)*((4)+(6))
out consecutively
Operation time in
Two-digit manual
Two-digit manual
insertion code
handling code
Part Name
per part
per part
No.
1 Box 1 00 1.13 30 31.13

2 Cardboard bin 1 03 1.95 00 1.5 3.45
3 Battery Charger 1 03 1.95 00 1.5 3.45
4 Charger Base 1 03 1.95 00 1.5 3.45
5 Bits 1 00 1.13 00 1.5 2.63
6 Screwdriver 1 03 1.95 00 1.5 3.45
7 Screwdriver testing 1 20 20
8 Manual 1 00 1.13 1.13
Total Time 8 68.69
_________________________________________________________________________________________________________
5.1.4 Transmission Assembly
5.1.5 Grip Housing/Battery Assembly
_________________________________________________________________________________________________________
It can be seen from the total assembly times found in the above tables that a total process
cycle time of approximately 60-70 seconds should be targeted. With this information the
workstations were determined to be the following:
Grip Housing Assembly (1 workstation)

Transmission Assembly (3 workstations)
Final Assembly (1 workstation)
Testing and Packaging (1 workstation)
= (Analyzed assembly time

Tr1: Transmission Assembly Workstation #1: 218.26 sec.)
Tr2: Transmission Assembly Workstation #2: 61.84 sec. * (1 - tool efficiency 15%) /
Tr3: Transmission Assembly Workstation #3: (3 workstations)
Bat: Grip Housing/Battery Assembly Workstation:69.69 sec.
Fin: Final Assembly Workstation: 72.34 sec.
T&P: Testing and Packaging Workstation: 68.69 sec.
Inp: Input Component Inventory, Out: Finished Good Inventory
We have provided a small buffer (storage) between workstations to protect for process
uncertainties, therefore the cycle time of assembly line is directly obtained as a longest
cycle time among workstations.
Cycle Time of Assembly Line = 72.34 sec.
Critical Workstation is Final Assembly, which is located the second sequence
_________________________________________________________________________________________________________
5.2 Station lay out: in and out flows of assemblies and parts
Inthisreportwearefocusingon"Transmissionassembly".Theworkstationlayoutand
otherdetailsareshowninfollowingdiagrams.
WorkstationtableDesign
Materials are ordered Right to Left
along assembly sequence
Materials are supplied from rear side
Parts Shelf
Work Table
Small materials are

automatically supplied
on the table
Conveyer is located light-hand
_________________________________________________________________________________________________________
7.2 Bit Holder Housing

8.1 Planetary Gear 1 Washer Transmission Workstation
8.3 PG1 Internal Gears
8.4 PG1 Carrier
F-1 Stacked on spring loaded riser
8.7 PG2 Washer
8.8 PG2 Coupling Gear Fixtures enter onto Angled Chute
8.9 PG2 Locking Gear
8.8
8.13 PG2 Carrier 8.14 8.2 8.9 8.3 8.4
8.15
8.14 PG3 Washer 8.7
8.15 PG3 Internal Gear 8.1 8.6 8.13
Load stock here
Grease Gun
Operator Grabs parts
from here
Conveyor
T-1, Insertion Tool
T-2, Insertion Tool
7.2
1 sq. ft.
Operator
5.3 Required motions of equipment and people
Evaluation of required motions according to various criteria is very important in manual

assembly. The criteria can be summarized under following topics:
Right and left hand should be operative for the same amount of time.
Motions of right and left hand should be synchronized. I.e. the motions of right and left
hand should be in succession.
The arm movement should be minimized. The maximum movement of arm should be with
in the reach of operator.
The movement of the operator in the workstation area should be minimized.
Parts should be placed in bins in such a way that they can be picked by the operator in
correct orientation without any difficulty. I.e. parts should not entangle with themselves in
the bins.
These are some of the rules of motion and time study which have been given attention
while designing the transmission workstation. The slides show the configuration of the
workstation. Following is the brief summary of the hand motions:
The initial step for the operator is to place the transmission holding fixture (F-1) on the
tableinfrontofhimself.Thesefixtures aresuppliedfromtheothersideofthetable
_________________________________________________________________________________________________________
wheretheyareloadedontoaspringloadedriserthatfeedsthefixturesdownanangled
chute. These fixtures are continuously being circulated from the final assembly
workstationwherethefinishedtransmissionassemblyisremovedfromthefixture.
PickuptheBitHolderHousing(BHHousing7.2)fromrighthandandshiftittotheleft
hand.
PickuptheT1InsertionToolwithrighthand.
PickupPG1InternalGear(8.3)withthehelpofT1insertiontoolwithrighthandwhile
puttingtheBHHousing(7.2)intheFixturewithlefthand.
InsertthePG1InternalGear(8.3)intheBHHousing(7.2)withrighthand.
PuttheT1InsertionTooldownandpickT2InsertionToolinrighthand.
PickupthePG1PinionGears(8.2)withthehelpofT2Insertiontoolandinsertthem
onebyonewithrighthand.
PickuptheGreaseGuninthelefthandandputgreaseinthesubassembly.
PickupthePG1Washer(8.1)withlefthandanddropitintheBHHousing(7.2).
PickupthePG1Carrier(8.4)withthehelpofT2Insertiontoolwithrighthandand
insertit.
PickupPG2PinionGears(8.6)withthehelpofT2InsertionToolandinsertthemone
byone.
PickupPG2CouplingGear(8.8)withthelefthand,gripitwithT2InsertionTooland
insertit.
PickupPG2LockingGear(8.9)withtherighthand,gripitwithT2InsertionTooland
insertit.
PickuptheGreaseGuninthelefthandandputgreaseinthesubassembly.
PickupthePG2Carrier(8.13)withthehelpofT2InsertionToolwithrighthandand
insertit.
PickupPG3PinionGears(8.6)withthehelpofT2Insertiontoolandinsertthemoneby
one.
PickupthePG3InternalGearwithlefthandanddropitintheBHHousing(7.2).
Thesearethestepsrequiredfortheassemblyprocess.Bothofthehandshavebeenused
intermittently.Thissequencehasbeendevelopedbyassumingthattheoperatorisleft
handed.Ifthisisnotthecase,oneneedstosimplyshiftthebinsontherighttotheleft
andviceversa.Thejobsassignedtotherighthandwillthenbedonebylefthand.The
motion has beenkeptas synchronized as possible. Moreimportantly, thelocation of
feederbinscontainingthePinionGearshasbeendesignedveryclosetotherighthandof
theoperatorbecausethereareninepiniongearsintotalinthepart.
Finally,theoperatorneedstoputthefinishedsubassemblyalongwiththefixtureonthe
conveyor.
5.4 Necessary inspections or tests
_________________________________________________________________________________________________________
Screwdriver testing is done as a part of testing and packaging operation. We decided to

test fully assembled screwdriver at "Packaging" station in order to balance times on the
assembly line. The testing involves following steps:
Thefullyassembledscrewdriversarepickedfromworkcell
Testhighspeedandlowspeedoperatingconditions
TestForwardandReversefeature
TestAdjustableTorquefeature(TorqueLimiter)
Testdualpositionhandleandpistolgriplockfeature
Afterpassingthetesttheyareplacedincardboardbin(screwdriverswhichfailarekept
ina"rework"bin.
_________________________________________________________________________________________________________
5.5 Gantt chart of required time of activities and a complete cycle
Thecompleteassemblyprocessisshowninthefollowingdiagramwherethesequenceis
bottomup.Theassemblysequencewasthenbrokendownintospecificassembly
activitystepsanda"Gantt"chartswerecreated.
Packed Box
Testing and Packaging
Manual
Testing
Screw Driver
Bits
Final Assembly
Charger Base
1.1:Battery Charger
Cardboard Bin
Drive Housing Fasteners
Box
5.2: Drive Right Housing
5.3: Grip Locking Switch
8.10: High/Lo Button
5.1: Drive Left

Housing
Wire Crimping
6: Motor Assembly
Grip Housing 4:Torque Limiter

Battery Assembly
8:Transmission assembly
Assemblysequence
_________________________________________________________________________________________________________
Assemblyprocessdesignmainlyfollows1)requiredcycletime,whichisobtainedfrom
plannedproductionsize,2)modularity,themassofassemblysequencewhichisdifficult
tobeseparated,3)efficiencyinassemblymotionsandequipmentcost.
Inthiscase,wedesignedtheassemblyprocessfromfollowingobservations:
RequiredCycleTime
Asshowninthelastreport,plannedproductionsizeis8358units/month,therefore;
(7.5hours/day)/(379.9units/day)=71.1sec.
Modularity
Transmission Assembly is toughly integrated and hard to separate to two or more
workstations. Estimated assembly time for this module is 218 sec., which is
approximatelythreetimesofRequiredCycleTime.
Efficiency
OnethoughttosolvemodularityprobleminTransmissionAssemblyisorganizingthree
parallellinesallofwhichperformfullassemblesequence.
Inthiscase,estimatedimpactontheequipmentcostissmallsinceourassumptionofline
designingisfullhandcraftline.However,motionalefficiencymustbeworsesincesmall
motions,forexample,transmissionassembly,andlargemotions,forexample,packaging
andcarryingthepackagedproductstothestorage,arecombinedineachworkstation.
Finally,weusedfollowinglogictodesigntheassemblyprocess:
OrganizethreetransmissionassemblyworkstationstomeetRequiredCycleTime.
Organizepackagingworkstationtoseparatelargemotionsfromsmallassemblymotions.
OrganizeworkstationsgatheringotheractivitiestomeetRequiredCycleTime.
The designed assembly process logicisshowninthefollowingfigure.Forcycletime

calculationspleaserefertosection5.1.
Tr1
Tr2
Inp Tr2 Fin T&P Out
Bat
_________________________________________________________________________________________________________
ThetimingoftheprocessisshowninthefollowingGanttchart.
Transmission Assembly 1 2 3 4 5 6 7 8 9 10
Station 1 T1 T4 T7
Station 2 T2 T5 T8
Station 3 T3 T6 T9
Grip Housing/Battery Assembly B1 B2 B3 B4 B5 B6
Final Assembly F1(T1,B1) F2(T2,B2) F3(T3,B3) F4(T4,B4) F5(T5,B5) F6(T6,B6)
Testing and Packaging P1(F1) P2(F2) P3(F3) P4(F4) P5(F5) P6(F6)
Where
T1:TransmissionAssembly#1,T2:TransmissionAssembly#2,
B1:BatteryHousingAssembly#1,B2:BatteryAssembly#2,
F1:FinalAssembly#1,F2:FinalAssembly#2,
P1:Testingandpackaging#1,P2:Testingandpackaging#2,
WherethedetailedsubprocessesisshowninthefollowingGanttcharts.Thetimingscale
isshowninseconds.
FinalAssemblyTiming
ID Task Name 1 20 39 58 77 96 115 134

1 Build Final Assembly
2 Transmission Assembly
3 Torque Limiter
4 Grip Housing/Battery Assembly
5 Motor Assembly
6 Wire Crimping
7 Drive Left Housing
8 Hi/Low Button
9 Grip Locking Switch
10 Drive Right Housing
11 Drive Housing Fasteners
TestingandPackagingTiming
8:00 AM 9:00 AM 10:00 A

ID Task Name 1 20 39 58 77 96 115
1 Test and Package
2 Box
3 Cardboard bin
4 Battery Charger
5 Charger Base
6 Bits
7 Screwdriver
8 Screwdriver testing
9 Manual
_________________________________________________________________________________________________________
TransmissionAssemblyTiming
ID Task Name -6 24 53 82 111 140 169 198

1 Build Transmission Assembly
2 Bit Holder Housing
3 PG3 Ring Gear
4 PG3 Pinion Gears
5 Grease
6 PG3 Washer
7 PG2 Carrier/PG3 Sun Gear
8 PG2 Pinion Gears

9 Fixture/Tool (for Hi/Lo lever)
10 PG2 Coupling Gear
11 PG2 Locking Gear
12 Grease
13 PG2 Washer
14 PG1 Carrier/PG2 Sun Gear

15 PG1 Pinion Gears
16 Grease
17 PG1 Washer
18 PG1 Ring Gear

19 Reorientation
20 Hi/Lo Lever
21 Snap fit
22 Fasteners (for Hi/Lo lever)
GripHousing/BatteryAssemblyTiming
8:00 AM 9:00 AM
ID Task Name Duration 1 20 39 58 77 96
1 Grip Housing/Battery Assembly 69.8 mins
2 Left Housing 4 mins
3 Battery Package 2.6 mins
4 Switch circuit 3.5 mins
5 Wiring 36.5 mins

6 Switch button 3.8 mins
7 Right Housing 4 mins
8 Closure 3.1 mins

9 Fasteners 12.3 mins
ThetimingrepresentedintheaboveGanttchartisacquiredfrommotionandtimestudy
usingBoothroyd&Dewhurst'sDFAdatabaseasshowninthetablesinsection5.1.
_________________________________________________________________________________________________________
5.6 Cost estimation of workstations
The screwdriver assembly line consists of standard equipment except small parts cases.
The estimated purchase and installation costs are as follows:
_________________________________________________________________________________________________________
Purchase Making Cost Installing

# Equipment units Sub Total ($)
Cost ($) ($) Cost ($)
Transmission Workstation
1 Table 1 150 150
2 Side Desk 1 18 18
3 Chair 1 30 30
4 Parts Self 1 200 200
5 Parts Case 11 40 50 490
6 Insertion Tool (T-1) 1 80 80
8 Grease Gun 1 15 15
9 Housing Fixture 100 15 1500
Workstation Total 3 2563
3 Workstations Total 7689
Grip Housing Workstation
1 Table 1 150 150
2 Side Desk 1 18 18
3 Chair 1 30 30
5 Parts Case 12 40 50 530
6 Plier 1 3 3
7 Electoric Driver 1 40 40
Workstation Total 971
Final Assembly Workstation
1 Table 1 150 150
2 Side Desk 1 18 18
3 Chair 1 30 30
5 Parts Case 8 40 50 370
6 Plier 1 3 3
1 Table 1 150 150
2 Side Desk 1 18 18
3 Chair 1 30 30
Common
1 Conveyor 1 2000 2000
2 Slider 1 500 500
3 Pooling Table 3 15 45
4 Fixture Storage Box 1 20 20
6 Parts Carrier 2 30 60
5 Spare Tools 1set 160 160
Ground Total 13054
5.7 Estimation of the cost of performing one assembly cycle
Originalassemblycycletimeandcosttoperformoneassemblyareobtainedusing
followingformula:
_________________________________________________________________________________________________________
(TransmissionAT+GripHousingAT+FinalAT+Packaging&TestingAT)*Labor
Rate
= (218.26*85%+69.69+72.34+68.69)*(1/3600)*@1.3
= (396.24sec.)*(1/3600)*@1.3
= $0.143
where;
AT: AssemblingTime
1/3600: Secondstohourstranslation
85%: 15%toolefficiency
@1.3: $1.3/hourChineselaborrate
However,actualassemblingcostfollowsCycleTimeofAssemblyLine,anditsobtained
withfollowingformula:
(LongestCycleTime)*(#ofWorkers)*LaborRate
= (72.34)*6*(1/3600)*@1.3
= (434.04sec.)*(1/3600)*@1.3
= $0.157
Where,theoverheadofdesignedassemblylinetotheidealassemblyis9.5%.
=(434.04396.24)/396.24
_________________________________________________________________________________________________________
6.Report#6:EconomicAnalysisandAssemblyLineSimulation
6.1 Economic analysis of this assembly layout

As shown in following table this assembly line consists of standard equipment except small
parts cases. The estimated purchase and installation costs are as follows:
Transmission Workstation
1 Table 1 150 150
2 Side Desk 1 18 18
3 Chair 1 30 30
5 Parts Case 11 40 50 490
8 Grease Gun 1 15 15
9 Housing Fixture 100 15 1500
Workstation Total 3 2563
3 Workstations Total 7689
Grip Housing Workstation
1 Table 1 150 150
2 Side Desk 1 18 18
3 Chair 1 30 30
5 Parts Case 12 40 50 530
6 Plier 1 3 3
1 Table 1 150 150
2 Side Desk 1 18 18
3 Chair 1 30 30
5 Parts Case 8 40 50 370
6 Plier 1 3 3
1 Table 1 150 150
2 Side Desk 1 18 18
3 Chair 1 30 30
Common
1 Conveyor 1 2000 2000
2 Slider 1 500 500
3 Pooling Table 3 15 45
4 Fixture Storage Box 1 20 20
6 Parts Carrier 2 30 60
5 Spare Tools 1set 160 160
Total 13054
_________________________________________________________________________________________________________
(EquipmentandInstallationcosts)/(Productionamount:units/year)*(5years)
= $13,054/((6,490 units/month)*(12 months)*(5 years))
= $0.0202 per unit
*1: This 5 years is an assumptive lifecycle of this product, and means that this
equipment is used only for this product, even though many of equipment are
reusable to other products.
6.1.1 Estimated Manufacturing Cost
Assembling cost follows Cycle Time of Assembly Line and Setup Time, which is
needed for every batch to supply materials. This cost is calculated with following
formula:
((LongestCycleTime)*(#ofWorkers)+(SetupTime)/(Batchsize))*LaborRate
= (72.34)*6*(1/3600)*@1.3
= ((434.04sec.)*(1/3600)+((15min.)/(95units))*(1/60))*@$1.3
= $0.1601perunit
where;
1/3600: Secondstohourstranslation
1/60: minutestohourstranslation
@$1.3:$1.3/hourChineselaborrate
Addingonthis,weassumesuccess rate ofassemblylineto95%including specout

assembly,equipmentdowntime,andoperationaldelay.
Therefore,actualassemblycostis:
$0.1601/0.95
= $0.1685perunit
Furthermore,managingcostsareusuallyrequiredtodesigntheassemblylineandhandle
theproducts.Ifwesupposethat0.1manpower/day,whoselaborrateis$3.5,isrequired
inaverageforthisproduct,themanagingcostbecomesasfollows:
((Required managing manpower/day)*(Labor Rate)*(Working hours))

/(Dailyproductionamounts)
= ((0.1man/day)*@$3.5*6.93)/((6490units/month)/(22workingdays/month)
= $0.0157perunit
where;
workinghours=(72.34sec/unit)*(295units/day)+(15min)*(4batchs)=6.93
We dont include other costs such as land space cost or indirect stuff cost to the
manufacturing costs.
_________________________________________________________________________________________________________
6.1.2 Inventory Cost and Distribution Cost
As we mentioned in previous report, this manufacturing system includes in house

inventoriesformaterialsandfinishedproducts.
And,ofcourse,distributioncostisalsorequiredtosupplyproductstoSEARSshops.
Howeverwedirectlyassumethesecostsasfollowssinceitsquitedifficulttoestimateall
numbersrelatingtothesefactorsreasonably.
Materialinventorycost: $0.01perunit
Finishedproductinventorycost: $0.03perunit
Distributioncost: $0.60perunit(primarilyshippingcostfromChinatoU.S)
6.1.3 Development Cost
WeassumethatthisproductwasdesignedintheU.S.underthefollowingconditions:
Engineers: 2people
Engineeringlaborrate: $10,000/manmonth
Duration: 6month(includingfromconceptdesigningtodrawing)
Prototypemodelingcost: $3,000
Thedevelopmentcostperunitiscalculatedasfollows:
((2engineers)*(6month)*($10,000/manmonth)+$3,000)
/((6,490units/month)*(12months)*(5years))
= $0.3546perunit
We dont consider other costs as follows:

Designing equipment cost, including housing, energy, and devices such as CAD
Managing cost
Indirect stuff cost
Designing supply chain cost, such as negotiating with suppliers and establishing delivery
route
_________________________________________________________________________________________________________
6.1.4 Unit Part Costs

No. System # System Name Part # Part Name unit cost Qty. Total Function
1 0 Packaging 0.1 Box 0.075 1 0.075
2 0.2 Cardboard bin 0.01 1 0.01
3 0.3 Manual 0.02 1 0.02
4 1 Battery Charger 1.1 Battery Charger 0.4 1 0.4 Charge Battery
5 2 Battery Closure 2.1 Charger Contact Plates 0.005 2 0.01 Contact Power
6 2.2 Battery Left Housing 0.15 1 0.15 Enclose Battery
7 2.3 Bettery Right Housing 0.15 1 0.15 Enclose Battery
8 2.4 Battery Cover 0.05 1 0.05 Enclose Battery
9 2.5 Baterry Housing Fasteners 0.0025 2 0.005 Hold battery housing
10 3 Power Storage 3.1 Rechargable Batteries 0.3 3 0.9 Store power
11 3.2 Battery Cables 0.004 2 0.008 Transmit power
12 3.3 Battery Connectors 0.01 2 0.02 Connect cable
13 3.4 Switch to Motor Cables 0.1 2 0.2 Transmit power
14 3.5 Crim Connectors 0.01 2 0.02 Hold cable
15 3.6 Shrink wrap 0.0015 1 0.0015 Hold batteries
16 3.7 Tape 0.0015 1 0.0015 Hold cable
17 3.8 Cable connectors 0.015 2 0.03 Connect cables to battery
18 4 Torque Limiter 4.1 Torque Limiter Outer Cap 0.175 1 0.175 Accept hand
19 4.2 Torque Limiter Inner Cap 0.175 1 0.175 Accept outer cap
20 4.3 Torque Limiter Cap Clip 0.025 1 0.025 Hold inner and outer caps
21 4.4 Needle Bearings 0.015 4 0.06 Push PG1 internal gear
22 4.5 Ball Bearings 0.015 6 0.09 Allow internal gear PG1 slippage
23 4.6 Bearing holder plate 0.05 1 0.05 Hold ball bearings
24 4.7 Torque Limiter Springs 0.01 4 0.04 Hold bearing holder plate
25 4.8 Torque Limiter Base Support 0.09 1 0.09 Support springs
26 4.9 Torque Limiter Fasteners 0.005 2 0.01 Hold base support to motor
27 5 Drive Closure 5.1 Drive Left Housing 0.375 1 0.375 Provide enclosure to drive
28 5.2 Drive Right Housing 0.375 1 0.375 Provide enclosure to drive
29 5.3 Grip Locking Switch 0.1 1 0.1 Hold grip position
30 5.4 Grip Locking Spring 0.01 1 0.01 Support grip locking switch
31 5.5 Drive Housing Long Fasteners 0.01 2 0.02 Hold housing
32 5.6 Drive Housing Medium Fasteners 0.01 2 0.02 hold drive
33 5.7 Drive Housing Short Fasteners 0.01 2 0.02 hold housing
34 6 Power generator 6.1 DC Motor 1.25 1 1.25 Convert EE to Kinetic Energy
35 6.2 On/Off Button 0.09 1 0.09 Connect electric power
36 6.3 On/Off Spring 0.01 1 0.01 Support On/Off Button
37 6.4 F/R/S Lever 0.04 1 0.04 Provide control for rotation direction
38 6.5 F/R/S Switch Circuit 0.4 1 0.4 Control polarity connection to battery
39 7 Bit Holder 7.1 Collet 0.325 1 0.325 Transmit torque
40 7.2 Bit Holder Housing 0.4 1 0.4 Provide housing to drive mechanism
41 7.3 Direction Stopper Clips 0.025 2 0.05 Hold PG3 carrier
42 7.4 Direction Stoppper Supports 0.02 4 0.08 Hold stopper clips
43 7.5 Screwdriver bit 0.04 2 0.08 Act on screw
44 8 Transmission 8.1 Planetary Gear 1 (PG1) Washer 0.02 1 0.02 Enclose pinion gears
45 8.2 PG1/PG3 Pinion Gears 0.05 6 0.3 Increase torque
46 8.3 PG1 Internal Gears 0.1 1 0.1 Coordinate pinion gears
47 8.4 PG1 Carrier/PG2 Sun Gear 0.11 1 0.11 Hold pinion gears
48 8.5 PG2 Pinion Gears 0.06 3 0.18 Reduce speed
49 8.6 PG2 Washer 0.015 1 0.015 Enclose pinion gears
50 8.7 PG2 Coupling Gear 0.14 1 0.14 Hold pinion gears
51 8.8 PG2 Locking Gear 0.115 1 0.115 Hold PG2 system
52 8.9 Hi/Lo Lever 0.04 1 0.04 Transmit control
53 8.10 Hi/Lo Button 0.06 1 0.06 Accept Hi/Lo control
54 8.11 Hi/Lo Fasteners 0.01 2 0.02 Hold Hi/Lo lever
55 8.12 PG2 Carrier/PG3 Sun Gear 0.125 1 0.125 Hold pinion gears
56 8.13 PG3 Washer 0.02 1 0.02 Enclose pinion gears
57 8.14 PG3 Internal Gear/Direction Openner 0.225 1 0.225 Coordinate pinion gears
58 8.15 PG3 Carrier 0.175 1 0.175 Hold pinion gears
TOTAL = 8.056 $
_________________________________________________________________________________________________________
6.1.5 Economic Analysis

The engineering economic analysis for the payback period and Internal Rate of Return is
shown in the following table. Since the process is a manual operation with minimum initial
investment cost, the analysis indicates a very favorable result in terms of payback period
(9 months) and IRR (21.5%).
Production Volume = 6490 units/month
Product Life Cycle= 5 yrs Discount Rate= 15.00% apr IRR = 21.5%
Product Unit Price= 15 $ 1.2500% monthly rate Payback in 9 Months
NPV = 1,455,526 $
Fixed Cost Variable Discount
Fixed Costs Month (investment) Cost Revenue Net Cost Factor PV month Cumulitive
Tooling & Facilites 13054 1 -20000 -20000 0.9877 -19753.09 -19753.09
Prototype Modeling 3000 In 4th month 2 -20000 -20000 0.9755 -19509.22 -39262.31
3 -20000 -20000 0.9634 -19268.37 -58530.67
Development Costs (man-months, 6 mon PD cycle) 4 -23000 -23000 0.9515 -21885.06 -80415.73
Engineering Labor 20000 /month 5 -20000 -20000 0.9398 -18795.54 -99211.27
6 -33054 -57658.63 97350 6637 0.9282 6160.64 -93050.63
7 -57658.63 97350 39691 0.9167 36385.71 -56664.92
8 -57658.63 97350 39691 0.9054 35936.51 -20728.41
Variable Costs per unit 9 -57658.63 97350 39691 0.8942 35492.85 14764.43 Payback
Manufacturing(Labor) 0.168526 10 -57658.63 97350 39691 0.8832 35054.66 49819.09
Management (Labor) 0.0157 11 -57658.63 97350 39691 0.8723 34621.89 84440.98
Purchased Parts 8.06 12 -57658.63 97350 39691 0.8615 34194.46 118635.44
Raw Mat'l Inv 0.01 13 -57658.63 97350 39691 0.8509 33772.30 152407.74
Finished Product Inv 0.03 14 -57658.63 97350 39691 0.8404 33355.36 185763.10
Distribution 0.6 15 -57658.63 97350 39691 0.8300 32943.57 218706.67
Total 8.884226 16 -57658.63 97350 39691 0.8197 32536.86 251243.53
17 -57658.63 97350 39691 0.8096 32135.17 283378.70
18 -57658.63 97350 39691 0.7996 31738.44 315117.13
19 -57658.63 97350 39691 0.7898 31346.60 346463.74
20 -57658.63 97350 39691 0.7800 30959.61 377423.34
21 -57658.63 97350 39691 0.7704 30577.39 408000.74
22 -57658.63 97350 39691 0.7609 30199.89 438200.63
23 -57658.63 97350 39691 0.7515 29827.05 468027.68
24 -57658.63 97350 39691 0.7422 29458.82 497486.50
25 -57658.63 97350 39691 0.7330 29095.13 526581.63
26 -57658.63 97350 39691 0.7240 28735.93 555317.56
27 -57658.63 97350 39691 0.7150 28381.17 583698.73
28 -57658.63 97350 39691 0.7062 28030.78 611729.51
29 -57658.63 97350 39691 0.6975 27684.72 639414.23
30 -57658.63 97350 39691 0.6889 27342.94 666757.17
31 -57658.63 97350 39691 0.6804 27005.37 693762.54
32 -57658.63 97350 39691 0.6720 26671.97 720434.51
33 -57658.63 97350 39691 0.6637 26342.69 746777.19
34 -57658.63 97350 39691 0.6555 26017.47 772794.66
35 -57658.63 97350 39691 0.6474 25696.26 798490.93
36 -57658.63 97350 39691 0.6394 25379.03 823869.95
37 -57658.63 97350 39691 0.6315 25065.70 848935.66
38 -57658.63 97350 39691 0.6237 24756.25 873691.91
39 -57658.63 97350 39691 0.6160 24450.62 898142.53
40 -57658.63 97350 39691 0.6084 24148.76 922291.29
41 -57658.63 97350 39691 0.6009 23850.63 946141.91
42 -57658.63 97350 39691 0.5935 23556.17 969698.09
43 -57658.63 97350 39691 0.5862 23265.36 992963.45
44 -57658.63 97350 39691 0.5789 22978.13 1015941.58
45 -57658.63 97350 39691 0.5718 22694.45 1038636.03
46 -57658.63 97350 39691 0.5647 22414.27 1061050.30
47 -57658.63 97350 39691 0.5577 22137.55 1083187.85
48 -57658.63 97350 39691 0.5509 21864.25 1105052.10
49 -57658.63 97350 39691 0.5441 21594.32 1126646.42
50 -57658.63 97350 39691 0.5373 21327.72 1147974.15
51 -57658.63 97350 39691 0.5307 21064.42 1169038.56
52 -57658.63 97350 39691 0.5242 20804.36 1189842.93
53 -57658.63 97350 39691 0.5177 20547.52 1210390.45
54 -57658.63 97350 39691 0.5113 20293.85 1230684.30
55 -57658.63 97350 39691 0.5050 20043.31 1250727.60
56 -57658.63 97350 39691 0.4987 19795.86 1270523.46
57 -57658.63 97350 39691 0.4926 19551.46 1290074.92
58 -57658.63 97350 39691 0.4865 19310.09 1309385.01
59 -57658.63 97350 39691 0.4805 19071.69 1328456.70
60 -57658.63 97350 39691 0.4746 18836.24 1347292.94
_________________________________________________________________________________________________________
6.2 Discrete event simulation of assembly line
6.2.1 Discrete Event Simulation: Configuration Study
The simulation layout for the complete screwdriver assembly is shown in the following
figure.
Transmission
Assembly 1
In 1 Transmission
Buffer 1 Assembly 2 Buffer 3
Transmission
Assembly 3
Final Test & Out
Assembly Buffer 5 Packaging
In 2 Grip Housing
Buffer 2 Assembly Buffer 4
Buffer 6
Repair
From previous report, it is estimated that the required assembly cycle is about 70
second per assembly. Bot of the assembly speeds of "Grip Housing Assembly" and the
"Final Assembly" are about 70 seconds. To balance the assembly speed, the "Testing" and
"Packaging" stations are combined to reach assembly speed of 70 seconds. Because the
speed of assembling grip housing is three times the speed of assembling transmission
module, three "Transmission Assembly" stations are employed to balance the total
assembly speed.
The final assembly testing is done at the end of the assembly considering that the
sub-module testing impractical. That is, the transmission assembly and the grip housing
assembly cannot be tested separately. If the assembly is failed upon the testing, the
product is sent to the repair station. The repair station is going to "retest", "disassemble",
and "reassemble" the product. The repair results are sent back to the "Buffer 5" to be
packaged. It is assumed that 1 out of 100 final assembly will have to be repaired.
The statistics and capabilities of each station in the assembly process are
summarized in the following table. The capacity of the buffers were set according to the
required size from some simulation runs (see the histograms below).
_________________________________________________________________________________________________________
No. Name Process (seconds) Failure (seconds)1 Repair (seconds)2 Remark

1 In 1 (Inou_1) Constant rate = - - Transmission
80/s components
2 In 2 (Inou_2) Constant rate = - - Grip Housing
80/s components
5 Transmission Normal ( = 218, Normal ( = 7200, Log-Normal ( =
Assembly 1 = 21.8) = 900) 900, = 200)
(Mach_5)
Assembly 2 = 21.8) = 900) 900, = 200)
(Mach_6)
Assembly 3 = 21.8) = 900) 900, = 200)
(Mach_7)
8 Grip Housing Normal ( = 69.7, Normal ( = 7200, Log-Normal ( =
Assembly = 7) = 900) 900, = 200)
(Mach_8)
11 Final Assembly Normal ( = 72.7, Normal ( = 7200, Log-Normal ( =
(Mach_11) = 7.3) = 900) 900, = 200)
13 Testing & Normal ( = 68.7, Normal ( = 7200, Log-Normal ( =
Packaging = 6.9) = 900) 900, = 200)
(Mach_13)
15 Repair (Mach_15) Normal ( = 1200, Normal ( = 7200, Log-Normal ( =
= 300) = 900) 900, = 200)
3 Buffer 1 (Buff_3) Capacity = 24 Transmission
component buffer
4 Buffer 2 (Buff_4) Capacity = 30 Grip housing
component buffer
9 Buffer 3 (Buff_9) Capacity = 24 Finished
transmission
assembly buffer
10 Buffer 4 (Buff_10) Capacity = 30 Finished grip
housing assembly
buffer
screwdriver
assembly buffer
14 Buffer 6 (Buff_14) Capacity = 5 Repair buffer
1 Out (Inou_1) - - - Packaged
screwdrivers
Because the limitation of the student version of Taylor II software to allow only up to 15
elements, the "Out" element after the successful "Testing and Packaging" is combined with
the "Inp 1." The Taylor II layout model is shown in the following figure.
1
For all these manual operations, failure is the scheduled (allowed) break at about every 2 hours.
2
Repair means the length of allowable break for about 15 minutes. Log-normal distribution is assumed
because people tend to take a longer than a shorter break than allowed.
_________________________________________________________________________________________________________
An example of simulation run result is shown below.
screwd4TaylorIIElementreportDate:27111999Time:
22:30
=======================================================================
======
ClusterElnrElnameProducedAvgQueueUtilDown
01Inou_13601.00100.00
02Inou_23601.00100.00
03Buff_33495.54
04Buff_43564.13
05Mach_51160.9989.599.13
06Mach_61170.9789.298.21
07Mach_71130.9785.4611.27
08Mach_83550.9686.739.40
09Buff_93349.41
010Buff_1012.78
011Mach_113330.9483.8810.08
012Buff_123323.31
013Mach_133310.9079.0611.31
014Buff_1460.05
015Mach_1550.2623.429.61
_________________________________________________________________________________________________________
The queue utilization in each buffer is shown in the following histograms.
No. 3 - Buffer 1 No. 4 Buffer 2 No. 9 Buffer 3
No. 10 Buffer 4 No. 12 Buffer 5 No. 14 Buffer 6
At the beginning of operation when there is nobody taking a break, the buffers are almost
empty. The condition of high number of items in the buffers happened when the assembly
operators start taking breaks. The large size of buffers are the main concern for the
efficiency because in addition to taking space, buffers also mean a tight up capital because
the work-in-process inventory is sitting idle in the factory. The length of time that a work
in process inventory is sitting in a buffer is shown in the following waiting time
histograms.
_________________________________________________________________________________________________________
Therefore, it is preferable to minimize the amount of inventory and keeping the throughput
as high as possible. This can be done by some alternatives as follows:
To use the underutilized "Repair" person to do various tasks to substitute a person
that is taking a break. This simulation model of this situation is too complicated for
the student version to handle. Another alternative is described next.
Schedule the break at the same time. Therefore, during the break, the whole assembly
line is shut down so that nobody is accumulating work in progress inventory for the
next station. The duration of breaks are kept the same as the previous simulation
setting. That is, they are following Log-Normal distribution with mean of 15 minutes
and standard deviation of 200 seconds.
screwd5TaylorIIElementreportDate:28111999Time:
12:34
=======================================================================
======
01Inou_13601.00100.00
02Inou_23601.00100.00
03Buff_33505.83
04Buff_43555.45
05Mach_51150.9887.659.86
06Mach_61180.9788.348.30
07Mach_71140.9887.729.87
08Mach_83540.9786.3210.43
09Buff_93461.97
010Buff_104.31
011Mach_113450.9788.158.90
012Buff_123471.04
013Mach_133460.9383.0310.41
014Buff_146
015Mach_1560.2423.6111.14
The queue size of each buffer is shown in the following histogram.
_________________________________________________________________________________________________________
The corresponding waiting time in queue is shown in the following histogram.
Notice now that the required size of buffers 3, 4, 5, and 6 become much smaller than
before. The size of buffers 1 and 2 are still the same because we assume that a constant
stream of components are coming to these two buffers.
A more realistic situation can be simulated by assuming that the stream of

components from "In 1" and "In 2" also follow random pattern with "breaks" represented
by MTBF and MTTR. Negative exponential distributions are used for both the inputs to
represent a constant supply with random fluctuation. The following are the results of the
simulation with simulation parameters shown in the following table.
_________________________________________________________________________________________________________
No. Name Process (seconds) Failure (seconds)3 Repair (seconds)4 Remark

1 In 1 (Inou_1) Neg. exponential, Constant every Log-Normal ( = Transmission
= 80/s 7200 s 900, = 200) components
2 In 2 (Inou_2) Neg. exponential, Constant every Log-Normal ( = Grip Housing
= 80/s 7200 s 900, = 200) components
5 Transmission Normal ( = 218, Constant every Log-Normal ( =
Assembly 1 = 21.8) 7200 s 900, = 200)
(Mach_5)
Assembly 2 = 21.8) 7200 s 900, = 200)
(Mach_6)
Assembly 3 = 21.8) 7200 s 900, = 200)
(Mach_7)
8 Grip Housing Normal ( = 69.7, Constant every Log-Normal ( =
Assembly = 7) 7200 s 900, = 200)
(Mach_8)
11 Final Assembly Normal ( = 72.7, Constant every Log-Normal ( =
(Mach_11) = 7.3) 7200 s 900, = 200)
13 Testing & Normal ( = 68.7, Constant every Log-Normal ( =
Packaging = 6.9) 7200 s 900, = 200)
(Mach_13)
15 Repair (Mach_15) Normal ( = 1200, Constant every Log-Normal ( =
= 300) 7200 s 900, = 200)
3 Buffer 1 (Buff_3) Capacity = 20 Transmission
component buffer
4 Buffer 2 (Buff_4) Capacity = 15 Grip housing
component buffer
transmission
assembly buffer
10 Buffer 4 (Buff_10) Capacity = 10 Finished grip
housing assembly
buffer
screwdriver
assembly buffer
14 Buffer 6 (Buff_14) Capacity = 3 Repair buffer
1 Out (Inou_1) - - - Packaged
screwdrivers
screwd6 Taylor IIElement report Date:28111999 Time:

12:55
=======================================================================
=
01Inou_13171.0092.647.36
02Inou_23041.0090.349.66
03Buff_33172.65
04Buff_43041.95
3
For all these manual operations, failure is the scheduled (allowed) break at every 2 hours.
4
Repair means the length of allowable break for about 15 minutes. Log-normal distribution is assumed
because people tend to take a longer than a shorter break than allowed.
_________________________________________________________________________________________________________
05Mach_51100.9284.248.09
06Mach_61050.8478.189.14
07Mach_7990.7974.129.14
08Mach_83040.8373.069.81
09Buff_93047.46
010Buff_101.05
011Mach_113040.8576.928.03
012Buff_123091.21
013Mach_133080.8273.2510.38
014Buff_1450.03
015Mach_1550.2723.0411.40
The corresponding Queue size and waiting time histogram are shown in the following
figure.
Queue size hitogram
Waiting time histogram
_________________________________________________________________________________________________________
6.2.2 Selection of Final Assembly Process

To make more realistic condition, the "Input" elements "In 1" and "In 2" are
assumed to supply buffers 1 and 2 in batch sizes of 20 according to an exponential
distribution with rate of 900 seconds (15 minutes). This is the estimated time to move the
components to the buffers of "Transmission Assembly" and "Grip Housing Assembly"
stations. Using this assumption, an investigation was conducted to determine the proper
size of the rest of the buffers. The important buffers will be the buffers before the
bottleneck station: "Final Assembly" with the longest cycle time (72.7 seconds). The
results of the investigation are summarized in the following table.
No. Station Buffer size = Buffer size = Buffer size = Buffer size =
1 5 10 20
1 In 1 (Inou_1) 53.7 66.25 53.33 48.88
2 In 2 (Inou_2) 29.24 31.71 29.57 32.09
3 Buffer 1 (Buff_3)
4 Buffer 2 (Buff_4)
5 Transmission 59.9 73.98 76.62 77.24
Assembly 1 (Mach_5)
6 Transmission 61.72 70.22 77.94 77.16
Assembly 2 (Mach_6)
7 Transmission 62.14 71.77 75.54 77.75
Assembly 3 (Mach_7)
8 Grip Housing 58.25 69.74 75.12 74.83
Assembly (Mach_8)
9 Buffer 3 (Buff_9)
10 Buffer 4 (Buff_10)
11 Final Assembly 60.7 71.63 74.94 73.67
(Mach_11)
13 Testing & Packaging 57.88 69.98 72.85 70.82
(Mach_13)
15 Repair (Mach_15) 21.92 44.68 20 21.55
Finish Output 244 295 304 294
_________________________________________________________________________________________________________
Buffer size = 10 for the bottleneck station is selected because it is not as much different
from buffer size = 5 in terms of size requirement, but it provides higher utilization as well
as higher throughput. Buffer #5 and #6 are set equal to 1 (no buffer) because these are not
bottleneck stations. The queue and waiting time histograms for this selected setting are
shown below.
Queue Histograms
No. 3 Buffer 1 No. 4 Buffer 2
No.9 Buffer 3 No. 10 Buffer 4
_________________________________________________________________________________________________________
Waiting Time Histograms
No. 3 Buffer 1 No. 4 Buffer 2
No.9 Buffer 3 No. 10 Buffer 4
The statistics of this assembly operation is as follow.
screwd7 TaylorIIElementreport Date:29111999 Time:

19:55
=======================================================================
=
01Inou_13201.0053.3310.02
02Inou_23201.0029.579.82
03Buff_33078.77
04Buff_431310.84
05Mach_51020.8676.629.11
06Mach_61020.8477.946.48
07Mach_71000.8575.549.37
08Mach_83120.9875.129.06
09Buff_93021.55
010Buff_109.37
011Mach_113010.8574.949.33
012Buff_123050.21
013Mach_133040.8272.859.01
014Buff_1450.08
015Mach_1540.2820.0010.17
_________________________________________________________________________________________________________
In general, the utilization of the stations (around 75%) are considered appropriate for the
assembly workers. The Input stations (Inou_1 and Inou_2) and the repair station
(Mach_15) total utilization is about 100% (53.33% + 29.57% + 20%). These three tasks
are performed by 2 people instead of 3 people. That is, Inou_2 and repair are done by the
same person. A low utilization value of 50% is considered appropriate for these tasks as
these people need to walk around in between jobs to transfer the raw materials.
_________________________________________________________________________________________________________

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2.

3.6-VOLT SEARS/CRAFTSMAN CORDLESS SCREWDRIVER.......................................................4

1. REPORT #1: PRODUCT DESCRIPTION..............................................................................................5

5.1.3 Testing and Packaging................................................................................................................47

In this report Sears/Craftsman 3.6VoltCordlessScrewdriver is described as follows,

1.1 Product Assembly Drawing

1.2 Transmission Assembly

1.3 Exploded View of Transmission Assembly

1.4 Clearance Specification

1.5 Screwdriver Component Breakdown

1.6 Bill Of Materials

34 6.4 F/R/S Lever 1 Provide control for rotation direction Polypropylene

1.7 Assembly Tree

3.6 V Dual Grip Craftmans Cordless Screwdriver

Battery Charger Module

1.8 Functional Flow Model

1.9 System Hierarchy Breakdown

Battery Module Drive Mechanism

1.9.1 Battery Module System Breakdown

2. Closure 3. Power Storage

2.1. 2 Contact Plates 3.1. 3 Rechargables

2.2. Left 3.2. 2 Batt. Cables

2.3. Right 3.3. 2 Connectors

2.4. Cover 3.4. 2 Motor Cables

2.5. 2 Fasteners 3.5. 2 Crim Connectors

3.6. Shrink Wrap

3.8. Cable Connectors

1.9.2 Driver Mechanism System Breakdown

8. Transmission 5. Drive Closure

4. Torque Limiter Planetary Gear (PG) 1 5.1. Left Housing

5.2. Right Housing

4.5. 6 Ball Bearings 8.5. Sun Gear 6. Power Generator

4.6. Bearing Holder Plate

4.9. 2 Fasteners On/Off Switch

Planetary Gear (PG) 2 Planetary Gear (PG) 3

8.6. 3 Pinion Gears 8.2. 3 Pinion Gears 6.3. Spring

8.7. Washer 8.14. Washer Direction (F/R/S)

Hi/Lo Speed Control 8.15. Internal Gear + Direction Openner

8.9. Locking Gear 7. Bit Holder

1.10 Liaison Diagrams of Part Mating

1.10.1 Product Main Assembly

1.10.2 Battery and Housing Assembly

1.10.3 Torque Limiter

1.10.5 Motor Assembly

Transmission/Motor sub-assembly is selected for a detailed Datum Flow Chain (DFC)

Datum Flow Chain for Transmission

4& 6: Torque Limiter & Power Generator

2.1 Overall Transmission Key Characteristics

HighSpeed SpeedTransition LowSpeed

8.9 8.9 8.9

8.6 8.6 8.6

8.13 7.2 8.13 7.2 8.13 7.2

8.10 Hi/Lo Lever

7.2 Bit housing

8.10 Hi/Lo Lever

8.13 PG2 Carrier

8.9 Locking Gear

8.10 Hi/Lo Lever

8.8 PG2 Coupling Gear

8.9 Locking Gear

2.2 Feature, Mate, and Contact Table

2.3 Complete Bill Of Materials

34 6.4 F/R/S Lever 1 Provide control for rotation direction Polypropylene

2.4. Exploded View