BRIGGS & STRATTON

Auburn University Design ProjectCorporation 2 & Corporation 3

V-Twin Sump Sub-Assembly Production Line Improvements

Corporation Members

§ Bradley Cordell

§ Marie Craig§ Ben Daniel

§ Marcus Drain

§ Brad Fickett§ Adam Frey

§ Scott Frishman

§ Ben Garner

§ Jason Garrette§ Paul Geldmeier

§ Chris Gregson

§ Jon Hammett§ Spencer Harris

§ Chris Walker

Existing Assembly Process

§ Station 1• Ball, Spring, and Cap• Oil Tube

§ Station 2• Screen• Oil Nipple

§ Station 3• Bushing• Drain Plug

§ Station 4• Check Valve• Governor and E-clips• Governor seal

The Production Problem

The current assembly of the sump does not meet future production rate

requirements.

§Current Assembly Line Time Study

Current Assembly Line Time Study

# Element Description Time #1 Time #2 Time #3 Time #4 Time #5 Time #6 Time #7 Time #8 Average Station 1 24.8 1/10 Arrange sumps/insert oil tube 71.65 83.28 93.28 8.273667 Retrieve sump 2.46 2.56 2.78 2.78 2.59 2.78 5.15 3.53 3.07875 Ball, spring, plug installed, oil tube align 7.37 5.43 7.46 9.00 5.03 4.93 11.53 6.31 7.1325 Cycle Machine 4.03 3.50 3.21 3.40 3.65 3.40 3.31 3.34 3.48 Remove sump & set aside 3.12 3.09 2.71 2.56 3.02 2.46 2.87 3.18 2.87625 Station 2 25.4 Retrieve part, place in fixture 2.53 2.12 3.71 1.59 4.90 2.21 3.43 2.87 2.92 Put screen in press 1.84 1.81 5.84 2.65 5.21 2.25 3.28 2.81 3.21125 Screw in oil nipple 3.50 4.59 3.81 2.34 4.06 2.46 4.56 8.59 4.23875 Cycle machine 10.12 10.93 10.28 13.43 10.46 14.46 16.00 16.00 12.71 Remove and set aside 2.34 2.43 2.06 2.09 2.18 2.35 2.40 2.87 2.34 Station 3 33.5 Retrieve and place in fixture 5.40 4.09 4.96 2.50 2.96 4.71 5.00 4.53 4.26875 Assemble plug & bushing to press 6.00 5.50 6.00 5.21 7.96 7.53 12.78 22.68 9.2075 Cycle machine 2.96 3.59 2.37 3.56 3.62 5.90 6.75 2.84 3.94875 Remove oil filter from carton, dip install 9.96 12.37 11.93 9.28 11.75 24.34 17.81 17.12 14.32 Remove sump & set aside 1.00 1.50 2.84 1.76 1.75 1.84 1.63 2.00 1.79 Station 4 41.5 Retrieve sump & torque oil press C.V. 8.21 13.75 7.53 4.81 7.06 6.84 6.34 7.12 7.7075 Position governor & install E-clips 15.96 14.93 20.81 14.03 22.06 15.34 13.21 22.93 17.40875 Assemble governor seal to sump 10.28 6.21 6.46 8.62 6.03 6.87 9.40 7.75 7.7025 1/3 Assemble washer and bushings 22.78 27.28 21.28 32.78 24.87 30.71 24.65 24.84 8.71625

Current Assembly Line Time Study

24.8 25.4

33.5

41.5

0

5

10

15

20

25

30

35

40

45

Tim

e (s

ec)

1 2 3 4

Station Number

The Production Problem

The current assembly of the sump does not meet future production rate

requirements.

§Current Assembly Line Time Study

§Current Assembly Line Production Capability

Ø 650 sumps per each 7 ½ hour shift

Design Goal

Our goal is to increase the efficiency of the assembly line in order to produce

1000 sumps per shift.

V-Twin Sump Assembly Design Proposal

New Assembly Line Layout

Station 1 - Layout

Station 1 - Operations

§ Arrange sumps in bin as needed§ Insert oil tubes into sumps as needed

§ Retrieve sump and place in fixture§ Insert ball and spring into sump§ Place bushing and cap into presses

§ Align oil tube§ Cycle machine using opti-touch buttons§ Remove sump and set aside

Station 1 - Table Design

Station 1 - Table Design

Station 1 - Bill of Materials

Quantity Description SourceManufacturer Part Number

Price

Spacers and Brackets

Southern Tool & Steel $300

1 Bushing Ram Parker 06.00KC2AU14A14A4.00 $916.20

1 Oil Tube StakeColumbia Marking

Tools Inc.751-OC-2.5 $844

1 Cap Press Parker 06.00KC2AU14A14A6.500 $963.602 Clamps Bannel Clamp H 30 200045 $2252 Light Curtains Banner Light $291.071 Pallet Southern Tool & Steel $100

Miscellaneous Expenses

$500

$4,655.94TOTAL

Station 2 - Layout

Station 2 - Operations

§ Retrieve sump and place in fixture§ Insert drain plug into gun socket

§ Insert oil nipple into gun socket§ Place screen in press§ Cycle machines using opti-touch buttons

§ Remove sump from fixture§ Install check valve with hand gun§ Set sump aside

Station 2 - Table Design

Station 2 - Oil Nipple DesignThe oil nipple will be redesigned with a hexagon interior. This will allow for faster loading times and the use of a non reversing gun. This design change will add $0.16 to the total cost of each sump.

Station 2 - Bill of Materials

1 Pneumatic Cylinder Motion IndustriesBimba -TA-MS1D-6X5-

HLC2-KK2$570

2 Linear Thrusters Motion Industries ¾ Bore $190

2Pneumatic Cylinder (for

securing sump)Motion Industries Bimba $50

1Fixtured Cleomatic

NutrunnerCooper Tools 88MA5-R5-3/8 $2,022

1Fixtured Cleomatic

NutrunnerCooper Tools 45MA2-R8-3/8 $1,297

1 Light Curtain Banner Light $291.07Sheet Metal for

BracketsSouthern Tool & Steel $100

1 Pallet Southern Tool & Steel $200 Miscellaneous

Expenses$500

$5,460.07

Price

TOTAL

Quantity Description SourceManufacturer Part Number

Station 3 - Layout

Station 3 - Operations

§ Retrieve sump and place in fixture§ Position governor in sump

§ Spread bushings on governor shaft§ Cycle e-clip press using opti-touch buttons§ Remove sump from fixture

§ Assemble oil seal to governor§ Set sump aside

Station 3 - E-clip Press

Station 3 - E-clip Press Head

Station 3 - Press Stand

Station 3 - Table Design

Station 3 - Bill of Materials

E-Clip Press Stand Materials

Southern Tool & Steel A-6036 sheet $200

2 Clamps Bannel Clamp H 30 200045 $225

1 Pneumatic Press Motion IndustriesBimba TA-MX2-1 ½ x12

1" Rod 3/4 - 16 Rod Thread$213.29

1 Pallet Southern Tool & Steel $100 Bolts $75

E-Clip Head Materials

Southern Tool & Steel $150

Miscellaneous Expenses

$350

$1,538.29

PriceQuantity Description Source Manufacturer Part Number

TOTAL

Intermediate Tables

Intermediate Table Design

Table Foot DesignThe main station tables will be bolted to the floor.

The intermediate tables will be free standing.

Pneumatics

Pneumatics

Controls

§ Brief control explanation for each station§ Sample Control Sequence

§ Bill of Materials for Controls

Station 1 - Controls

Station 2 - Controls

Station 3 - Controls

Sample Control Sequence - Station 3

1. Operator presses the opti-touch push buttons. PB 31 (INPUT)2. Sump clamped into pallet. FWD SOL (OUTPUT)3. Is E-clip press fully retracted? PROX 31 (INPUT)4. E-clips in press? PROX 32 (INPUT)

IF 1-4, THEN 5-6 (5-6 start simultaneously)

5. E-clips pressed into sump. FWD SOL (OUTPUT)

6. Is E-clip press fully extended? PROX 33 (INPUT)

IF 5-6, THEN 7-8 (7-8 start simultaneously)

7. E-clip press is retracted. REV SOL (OUTPUT)8. Sump is unclamped from pallet. REV SOL (OUTPUT)

Note: After 1. if the light curtain in front of the station is broken then all operations pause, and will resume by pressing PB 31.

Bill of Materials for Controls

Quantity Description SourceManufacturer Part Number

Price

1 SLC 500 Allen Bradley 1747-L514 $5401 Rack Allen Bradley 1746-A7 $3301 Power Supply Allen Bradley 1746-P1 $3152 Input Module (16 inputs) 1746-IA16 $3054 Output Module (8 inputs) 1746-OX8 $2651 Main Panel Hoffman A363010LP $4793 Push Button Enclosures Hoffman $1501 Inner Panel Wiring $2001 Miscellaneous Wiring Allen Bradley $2001 Main Panel Disconnect $1505 Photoelectric Sensors Allen Bradley $10013 Inductive Prox Switches Allen Bradley $1003 Light Curtains Allen Bradley $4009 Push Buttons Allen Bradley $60

$7,874Total

Total Assembly Layout

Total Draft Layout

Top View

Total Assembly Layout

Top View

Total Assembly Layout

Side View

New Assembly Line Time StudyElement Description Estimated TimeStation 1 22.7 secRetrieve sump, insert oil tube, place in fixture 8.0Ball, spring, cap installed; Oil tube aligned; Bushing placed in press 9.2Cycle machine 3.5Remove sump & set aside 2.0 Station 2 24.5 secRetrieve sump, place in fixture 3.0Put screen in press; Drain plug placed in gun 5.0Insert oil nipple into gun tip 3.0Cycle machine 5.0Remove sump from fixture 1.6Install check valve with hand gun 5.4Set sump aside 1.5 Station 3 24.3 secRetrieve sump, place in fixture 3.0Position governor in sump and spread bushings 6.5Cycle machine for e-clip installation 4.0Remove sump from fixture 1.6Assemble seal to governor 7.7Set sump aside 1.5

New Assembly Line Time Study

22.724.5 24.3

0

5

10

15

20

25

30T

ime

(sec

)

1 2 3

Station Number

Time Comparison

0

5

10

15

20

25

30

35

40

45

Tim

e (s

ec)

1 2 3 4

Station Number

Existing Process

New Process

Total Time Comparison

125.2

71.5

0

20

40

60

80

100

120

140

Tota

l Tim

e (s

ec)

43 % Total Time Reduction

Design Results

§Current Assembly Line Production Capability

Ø 650 sumps per each 7 ½ hour shift

§ New Assembly Line Production Capability

Ø 1102 sumps per each 7 ½ hour shift

452 Sump Increase Per Shift452 Sump Increase Per Shift

Complete Bill of Materials (1)

E-Clip Press Stand Materials

Southern Tool & Steel A-6036 sheet $200

E-Clip Head Materials Southern Tool & Steel $150 4 Clamps Bannel Clamp H 30 200045 $225

1 Pneumatic Cylinder Motion IndustriesBimba -TA-MS1D-6X5-

HLC2-KK2$570

1 Pneumatic Press Motion IndustriesBimba TA-MX2-1 ½ x12

1" Rod 3/4 - 16 Rod Thread

$213.29

2Pneumatic Cylinder (for securing sump)

Motion Industries Bimba $50

1 Bushing Ram Parker 06.00KC2AU14A14A4.00 $916.201 Cap Press Parker 06.00KC2AU14A14A6.500 $963.60

1 Oil Tube StakeColumbia Marking

Tools Inc.751-OC-2.5 $844

1Fixtured Cleomatic

NutrunnerCooper Tools 88MA5-R5-3/8 $2,022

1Fixtured Cleomatic

NutrunnerCooper Tools 45MA2-R8-3/8 $1,297

2 Linear Thrusters Motion Industries ¾ Bore $190 1 Pallet Southern Tool & Steel $200 2 Pallet Southern Tool & Steel $100

Bolts $75 Sheet Metal for

Spacers and BracketsSouthern Tool & Steel $400

PriceQuantity Description Source Manufacturer Part Number

Complete Bill of Materials (2)

5 Rubber Mats Southern Tool & Steel $1503 Main Tables R&D Metal Fabrication $5002 Transport Tables R&D Metal Fabrication $3003 Light Curtains Banner Light $291.073 Light Curtains Allen Bradley $4001 SLC 500 Allen Bradley 1747-L514 $5401 Rack Allen Bradley 1746-A7 $3301 Power Supply Allen Bradley 1746-P1 $315

2 Input Module(16 inputs)

1746-IA16 $305

4 Output Module(8 inputs)

1746-OX8 $265

1 Main panel Hoffman A363010LP $479

3Push Button Enclosures

Hoffman $150

1 Inner Panel Wiring $2001 Miscellaneous Wiring Allen Bradley $2001 Main Panel Disconnect $1505 Photoelectric Sensors Allen Bradley $100

13 Inductive Prox Switches

Allen Bradley $100

9 Push Buttons Allen Bradley $60Miscellaneous

Expenses $1,350

$22,378.30

Price

TOTAL

Quantity Description Source Manufacturer Part Number

Economic Analysis

§ Cost of sump = $26.11§ Sales mark up = 15%§ Profit per sump = 0.15 * $26.11 = $3.92§ Oil nipple cost adjustmentà

$3.92 - $0.16 = $3.76§ $3.76/sump * 452 sumps/shift * 1 shift/day *

5 days/week * 48 weeks/year =

Estimated profit increase due to new production

$407,885 / year

Economic Analysis

§ Existing assembly layout requires 6 people/day to meet production capability

§ The new layout requires 3 people/day to meet production goals§ Labor Savingsà

$9.05/hr * 8 hrs/day * 5 days/week * 48 weeks/yr * 3 people =

Estimated labor savings due to new production

$52,128 / year

Economic Analysis

§ $22,378.30 / $3.76 profit per sump = 5,952 sumps

§ 5,952 sumps / 452 extra sumps per shift = 14 shifts

Estimated payback period from new production profit

The profit from the new assembly production will pay for all expenses in 14 shifts. (0% interest)

Questions