P 15665 GLEASON GEAR JAW METRICS PROBLEM DEFINITION

P 15665 GLEASON GEAR JAW METRICS PROBLEM DEFINITION REVIEW 9/11/14 KATIE BALDWIN JOSH SMITH DOUG PERRY EVAN MOLONY

AGENDA ➢Team Info ➢Stakeholders ➢Project Background and Problem Statement ➢Customer and Engineering Requirements ➢Benchmarking ➢Risk Analysis ➢Project Plan

THE TEAM MEMBER ROLE Katie Baldwin IE/Team Leader Josh Smith ME/Budget & Supplies Doug Perry ME Evan Molony ME/Documentation Tracking

STAKEHOLDERS ➢Gleason ❖ Gleason Operators ❖ Gleason Customers ➢MSD Group ➢Gerald Garavuso

PROJECT BACKGROUND A gear loader jaw assembly is responsible for holding a gear blank while being transferred in and out of the work chamber of the Gleason machine. This is typically part of an automation option for high production use at companies like Ford and GM. Currently Gleason inspects individual components of the gear jaws but doesn't inspect the final assemblies. This has led to machining errors at the customer level due to tolerance stacks and other factors.

PROJECT BACKGROUND

PROBLEM STATEMENT Detail Components of gear positioning assemblies are not adequately inspected or toleranced allowing out-of-spec assemblies to produce nonconforming gears

ASSUMPTIONS & UNKNOWNS ➢We only need to measure surfaces which contact the working part ➢We have not been provided with a list of jaws yet ➢Drawings will be provided before the device is tested ➢Images, models, or drawings of each component will be provided

CUSTOMER REQUIREMENTS Customer Rqmt. # Importance Description Comments/Status Why is This a Requirement? 1 1 Take accurate measurements of all surfaces which contact gear or arbor Top Priority This is the only way to ensure the gear jaws are within the expected tolerances relative to oneanother. 2 1 Secure positioning of the assembly Ensures assembly does not shift during measurement. 3 1 Conform to predefined budget The customer cannot exceed their spending limit without approval from an executive. 4 1 Pro-E files of all components The customer has specifically requested these for documentation and device replication purposes. 5 2 Safe to use The device can not be detrimental to operator health. 6 3 Portability The device will need to be transported between RIT and the facility and may need to be moved on the shop floor. The device should be movable by fewer than four people. 7 2 Easy to use Ease of use for the inspection operator will reduce necessary training and increase inspection efficiency thereby increasing customer profits and satisfaction. 8 3 Rapid positioning of the assembly Reduced inspection time increases profitability for the customer. 9 2 Digitally record measurements The customer needs a way to store and record the measurements 10 1 Output corrective actions to spreadsheet If parts do not conform, the customer needs to know how to fix them. 11 1 Accommodate three specific machines (GP 400, GP 300, 130/210) This was specifically requested and the device will not meet customer requirements without this functionality. The customer would also like additional space to accommodate future machines. 12 3 Rapid measurement Reduced inspection time increases profitability for the customer. 13 1 Device measures critical surfaces All arbor contact surface profile and position are critical to design intent. Based on customer feedback. 14 2 Device fits in available shop space The device will not meet Gleason's needs if it does not fit in their shop.

TOP PRIORITIES Customer Importance Rqmt. # Description Comments/Status 1 1 Take accurate measurements Top Priority 2 1 Secure positioning of the assembly 3 1 Conform to predefined budget 10 1 Output corrective actions to spreadsheet 11 1 Accommodate three specific machines (GP 400, GP 300, 130/210) 13 1 Device measures critical surfaces Why is This a Requirement? This is the only way to ensure the gear jaws are within the expected tolerances relative to oneanother. Ensures assembly does not shift during measurement. The customer cannot exceed their spending limit without approval from an executive. If parts do not conform, the customer needs to know how to fix them. This was specifically requested and the device will not meet customer requirements without this functionality. The customer would also like additional space to accommodate future machines. All arbor contact surface profiles and position are critical to design intent. Based on customer feedback.

ENGINEERING REQUIREMENTS Unit of Measure Marginal Value Ideal Value Test (how are you going to verify satisfaction) Gage Error From Ideal Over Full Measurement Envelope inches ± 0. 0002* 0 Gage Calibration Accuracy Rail Hole Position Tolerance inches ± 0. 0002* 0 Rig Calibration (CMM) CR 12 Efficiency Process Time minutes <20* <5 Stopwatch CR 6, 14 Size Device Footprint sq ft <16 <9 Tape Measure CR 3 Cost Prototype Cost $ <7000 <4000 Bill of Materials 2 CR 5, 6 Ergonomics Table Height 2 CR 6 Ergonomics Device Weight 8 3 CR 7 Efficiency Average Training Time Required by 90% of People Over the Age of 18 9 3 CR 1 Accuracy Number of Components in Measurement System (Excluding Gages and Fasteners) 10 1 CR 2 Accuracy Bolt Torque (Clamping Force) 11 2 CR 11, 12 Efficiency Number of Operators Able to Work Simultaneously 12 1 CR 12 Versatility 13 1 CR 1 Accuracy 14 1 CR 4 15 1 CR 1 Precision 16 2 CR 13 Accuracy rqmt. # Importance Source Function 1 1 CR 1 Accuracy 2 1 CR 1 3 3 4 2 5 1 6 7 Engr. Requirement (metric) ft ± 0. 050 3* Tape Measure Lbs <200* <120 Scale minutes <20* <10 Stopwatch units <10* <5 Bill of Materials In-Lbs (Lbs) ± 10 400* Torque Wrench units 2 3 Count Specified Machines Accommodated binary Yes Binary Measurement System & Output Error ** inches ± 0. 001 0 Rig Calibration (CMM) binary Yes Binary Measurement Results Repeatable inches ± 0. 001 0 Rig Calibration (CMM) Ability to Measure All Gear Contacting Surfaces on Existing Jaws binary Yes Binary Docmentation Designs Delivered in Pro-E Format

INITIAL SPEC

INITIAL SPEC

BENCHMARKING ➢Coordinate-Measuring Machine (CMM) ❖Automated or Manual ❖Five degrees of freedom ❖Can be very accurate ❖Large measurement envelope

BENCHMARKING CONT’D ➢ Mitutoyo Crysta-Apex EX 544 T CMM Benchmark Crysta-Apex EX Property 544 T Type Bridge X-axis 500 (19. 68) Range - mm (in) Y-axis 400 (15. 74) Z-axis 400 (15. 74) Resolution - mm (in) 1 x 10 -4 (4 x 10 -6) Guide Method Air bearing Degrees of Freedom 5 Cost $$$ Total Mass - kg (lbs) 536 (1181)

BENCHMARKING CONT’D ➢ Crysta-Apex Cons ❖ Expensive ❖ Heavy ❖ “overkill” for this application ➢Don’t need automation ➢Don’t need controller ➢ 0. 1 µm resolution not necessary

BENCHMARKING CONT’D ➢ Indicator Model Property LH-600 E/EG Resolution . 000001 m Accuracy Envelope Battery Life Crysta-Plus QM-Height M 443/574/710 Series 518 -221 6 Series 196. 00005 m . 000019 m (1. 1+0. 6 L/600)μ (. 00011+. 0002 L (3. 0+4. 0 L/1000) m /40)in μm. 972 m . 715 m 5 hours/charge 260 hours / ∞ . 4 x. 3 m N/A Degrees of Freedom 1 1 5 Cost $7, 630 $2, 701 ? Mass 24 kg 22 kg 360 kg

RISK ANALYSIS ID Risk Item Effect Cause Inaccurate 1 gauges The inspection measurements will not be accurate enough Failure to benchmark and research indicators that will work best for the application Station fails Customer will not Failure to 2 to support all be able to inspect receive machine all machine models drawings and models prints of all models and jaws. Unable to The inspection accurately measurements will 3 secure Jaws not be consistent enough Failure to secure rails onto inspection station. (regular assembly method will be employed for assembling jaws) Running out The customer will Poor planning not receive a and execution of 4 of time finished working project aspects part. and deliverables Likelihood Severity Importance 1 1 9 9 Action to Minimize Risk Owner 9 We will prevent and reduce this risk Katie, Evan, by putting in the time to properly Josh, Doug benchmark and research measurement instrumentation 9 We will reduce the risk by communicating to the customer project developments and needs Katie, Evan, Josh, Doug 3 9 27 This risk can only be reduced by locating the mounting rails as accurately as possible. 1 9 9 This risk will be prevented by the Katie, Evan, group following a strict schedule for Josh, Doug project deliverables

PROJECT PLAN Microsoft Project Schedule:

PROJECT PLAN Next Steps: ➢ Continue to update/meet with Richard ➢ Begin concept development ➢ Work on HOQ, making sure to adjust to any customer or engineering requirement changes ➢ Further explore benchmarking ideas ➢ Visit a nearby metrology lab