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HARTWELL CORPORATION UC IRVINE

HARTWELL CORPORATION UC IRVINE. MAE 188 Engineering Design Industry Flush Handle Latch Assembly Redesign. Goal Statement. Redesign the H3414-33 flush handle latch assembly to reduce its manufacturing cost and improve its wearability. Flush Handle Latch Assembly H3414-33.

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HARTWELL CORPORATION UC IRVINE

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  1. HARTWELL CORPORATIONUC IRVINE MAE 188Engineering Design Industry Flush Handle Latch Assembly Redesign

  2. Goal Statement • Redesign the H3414-33 flush handle latch assembly to reduce its manufacturing cost and improve its wearability.

  3. Flush Handle Latch Assembly H3414-33 • H3414-33 has 92 parts per assembly • Customers • Canadair • Bombardier

  4. Specifications

  5. Cost Modified Cost Auditor Quote by TMC • Cost Analysis • Cost analysis is based on Cost Auditor Quote with quantity of 100 • Total manufacturing cost = $1,302.46 • Labor cost includes overhead rate factor of 4.03 (burdened labor) • 4 categories of manufacturing cost • Burdened Labor • Material • Outside Processing • Purchase Each

  6. Cost • Approach • 92 total parts • 13 most expensive parts make up 88.8% of the total manufacturing cost • 4 most expensive parts make up over 55% of the total manufacturing cost • Identify the 4 most expensive parts • 132797-600 Handle : $231.87 (22.5% TMC) • 117063-9 Housing : $168.35 (16.3% TMC) • 119922-3 Actuator : $ 98.58 ( 9.5% TMC) • 117067-5 Collar : $ 71.16 ( 6.9% TMC) • Individual cost analysis for these 4 parts • material • burdened labor • outside processing (O/P) • purchase cost of each (PurEa) • Redesign/replace the costly components with less expensive alternatives • Other candidates • H3414-33 : $70.22 (6.8% TMC) • 117068-3 : $56.91 (5.5% TMC)

  7. Cost

  8. Wearability Coating and paint chipping (132797-600) Wear on handle shaft (132797-600) Wear on inner of collar (117067-5) Wear on inner support (117065-1)

  9. Part Trouble Probable Cause Corrective Action (110B) (115B) (140A) Outside handle does not extend to operating position when trigger (115B) is pushed. Damaged or improper installation of spring trigger (140A). Check spring for deformation. Replace the damaged parts. (90) (110B) (315B) Excessive torque required to turn the outside handle assembly. Binding between the actuator fitting (90) and/or the housing (315B). Clean and check components for uneven or excessive wear and worm through areas in solid film lubricant. Repair or replace parts. (90) (220) Actuator does not turn the required angle. Damaged or improperly installed actuator fitting (90) or actuator (220) Check the components for damage. Repair or replace parts. (110B) (65A) Excessive force required to push the outside handle assembly (110B). Binding between the inner support (65A) and the rod (165B). Check the inner support and the rod for damage. Replace the damaged parts. (80) (160) Outside handle does not extend to operating position when trigger is pushed. Damaged springs (80 or 160). Check spring for deformation. Replace the damaged spring. (65A) (165B) Outside handle does not extend to operating position when trigger is pushed. Binding between the inner support (65A) and the rod (165B). Check the inner support and the rod for damage. Replace the damaged parts. (290) Outside handle does not extend to operating position when trigger is pushed. Bent pin (290) Replace the pin. Wearability Wear sensitive parts Hartwell Corporation, Components Maintenance Manual Part Number H3414. Fault isolation.

  10. Technical Issues • Materials • Manufacturing Process • Machining • Functional Design

  11. Materials • Coatings • Housing Cavity (Except Area of Prox Switches) and Inner Surfaces of Handle are coated with Emralon 310 PTFE • Electroless Nickel Plating • Handle Assembly • Painting • Customer Choice

  12. Manufacturing Processes • Current Processes • Alternatives • Roll forming • Metal • Shorter manufacturing time • Injection Molding • Requires plastic as material • Compression Molding • Requires plastic as material • Cost of Process • Tooling cost • Raw material cost

  13. Machining • Current Sequence • setting fixture  setting tooling  checking programs  inserting casted parts  remove finished parts  inspection  storage • Alternatives • net-shape forming AdvantagesDisadvantages virtually no material waste  lower energy product because material is Mold parts into high-precision finished parts diluted by the binding polymer lower manufacturing cost by saving machining  decreased corrosion resistance time  lack of high quality, reasonable-cost power Ideal for complex shapes price for general alloys average $40/pound • outside processing (O/P) in foreign countries Outside processing in foreign countries has several disadvantages:  present currency exchange rate between Europe and America limits the benefits  complexity of certain parts makes O/P impossible. Reliability and quality control becomes a problem.  instability of foreign work force • machining optimization • install software to provide a better integrated CNC production facility • change tooling and carbide brand and type • install high pressure coolant systems to increase production efficiency and extand tool life time

  14. Functional Design • Existing • A spring-loaded release lever that extends and rotates the outside handle assembly from inside the door. • A spring-loaded outside handle assembly that seats flush in the housing when stowed for flight, and extends under spring load for use when the trigger or release lever is pushed. • The flush handle latch assembly consists of one each: release lever, rod end, cover, actuator rod (not shown), outside handle assembly with integral spring-loaded trigger, trigger lift assembly actuator fitting, inner support, and a collar. • Components are secured by attaching hardware and pins retained by sealant. • Elastomer quad rings in the actuator assembly, inner support, and collar provide environmental and pressure seals. • Qualification

  15. Functional Design • Alternatives • fewer parts • simplified assembly • new materials • new manufacturing processes • Testing • Wearability

  16. Design Concepts 1. Materials 2. Manufacturing 3. Machining Optimizations 4. Functional Design

  17. Design Concept 1Materials • Victrex PEEKTM 150CA30, 30% Carbon Fiber Reinforced instead of aluminum alloy for collar and flush handle housing • Victrex PEEKTM 150CA30, 30% Carbon Fiber Reinforced • Cost • Victrex PEEKTM 150CA30, 30% Carbon Fiber Reinforced are packaged in 55.1 lb boxes 1 - 11 boxes - $ 40.75 /lb 12 - 23 boxes - $ 38.50 /lb 24 + boxes - $ 36.50 /lb • Advantages • Saving approximately $31 per collar ( 75 % material cost ) • Saving approximately $65 per housing ( 73% material cost ) • Lighter Weight • Disadvantages • Reducing the tensile strength in 20% • Brittleness • Temperature Range ( -85°F - 599 °F ) Collar Flush Handle Housing

  18. Design Concept 2Manufacturing • Advantages • No machining required • No surface finish required • No plating required • Lower material cost • Disadvantages • Material change required • Investment in tooling charge • Manufacturing Method • Change in manufacturing cost (quantity of 100 per year) • first year : • next year :

  19. Design Concept 3 Machining Optimizations Machining optimization: software  Integrated machining system for production facility from GE Fanuc  VisualDocs - Designed to replace paper and improve productivity on the shop floor, this software can provide operators with access to virtually any information on the floor, helping them tap into the combined operating knowledge of the company.  VisualMEM - Designed to help manufacturers gather machine performance information on the floor, VisualMEM (Machine Event Monitoring) records each event that takes place on a machine and places that information in a database for further analysis. 10% production improvement typical when implemented. VisualDocs • Machining optimization: hardware •  change tooling and insert type or brand •  For the machining of 17-4 PH stainless steel and A356.0 T61 Al alloy, two alternative • tooling inserts from Kennametal are suggested: • For 17-4 PH stainless steelFor A356.0 T61 Al alloy • insert geometry: MM-MR MS • recommended Grade: KC9025 KD100 • feed rate: 0.0255 in 0.0186 in • depth of cut: 0.2102 in 0.1046 in •  install EV2000 high pressure coolant system produced by chipblaster (unit price: $15,695) •  machining time and tool life time will increase 30% minimum •  cost saving study: - 8.477 hrs of machining labor per piece under regular coolant system • - overhead rate of 4.03 • - assume an average labor rate of $15.00/hr • - assume 30% production efficiency and tooling life gain by using high • pressure coolant system • (8.477*15*4.03) - (8.477*.70*15*4.03) = 153.73 ----------------------------- cost saving per piece • 15,695 / 153.73 = 102.09------------------------------ pay back after 103 units • 153.73*100 = 15,373------------------------------ machining labor saving per • 100 units Visual MEM EV 2000

  20. Design Concept 4Design • Design Alternatives • Trigger button • Trigger lift assembly • Flush handle • Housing (rivet inserts) • Collar (rivet inserts) • Advantages • 10 Fewer Parts • Cost Reduction $43.80 • Weight Reduction • Disadvantages • Testing • Modification Trigger Link Assembly

  21. Selection Matrix

  22. Recommendation • Replace collar and housing material with PEEK, 30% carbon reinforced • Redesign consistent with the material change to reduce the overall cost • Use injection molding instead of casting & machining • Remove link assembly (130331-5) • Due to qualification by similarity to H3412-1 in which the link assembly is not included* *Independent Testing Laboratories, Inc. Test Report No. TR9500

  23. Timeline 7th week 8th week 9th week 10th week final week

  24. Summary • Analyzed Cost Auditor Quote • Identified Four Most Expensive Parts • Housing, Handle, Collar, and Actuator • 55% of total manufacturing cost • Researched on: • Alternative Materials • PEEK (Polyetheretherketone) • PAEK (Polyaryletherketone) • NORYL • ULTEM • Alternative Manufacturing Processes • Injection molding • Roll forming • Compression molding • Alternative machining processes • Net-shape forming • Outside processing (O/P)_ • Machine optimization: hardware and software • Alternative designs • Down selection • Proposed design • Replace Aluminum Alloy with Victrex PEEKTM 150CA30, 30% Carbon Fiber Reinforced in housing and collar • Injection molding of collar and housing instead of casting and machining • Wearability good for the proposed design • Cost saving: ( $1,302.46 v.s. $1,071.45) • $231.01 decrease in total manufacturing cost

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