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SafeKrackers: Coupler Redesign Project

A project to analyze and redesign faulty servo drive shaft couplers, aiming to reduce field failures. Includes FEA analysis, corrective actions, cost analysis, and implementation strategies. Comprehensive report structure with sections on introduction, appendices, and bibliography.

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SafeKrackers: Coupler Redesign Project

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  1. Phase II Manufacturing 327 Team: SafeKrackers Associate Name E-Mail Address Position Tracy D. Hille tracyh@epicturbo.comSr. Program Engr. George Pucci gpucci@lear.comFacilities Mgr. Mike Wheeler mwheeler@wollin.comProcess Engr. John Reddaway John.reddaway@tenneco-automotive.com Tech. Support Engr. Tim McIlrath Tim.mcilrath@tenneco-automotive.comSr. Design Engr. Eric Everman eeverman@lear.comQ.A. Engr. Slides will advance automatically

  2. Problem Statement • The number one field failure is related to the servo drive shaft coupler that connects the programmable servomotor to the vault combination knob.

  3. Project Objective • Develop Core Team. • Analyze Field Failures. • Determine Defective Coupler Cause. • Reevaluate Coupling Design. • Cost Analysis of Redesigned Coupling. • Implementation of New Couplings.

  4. Performance – Pareto Chart

  5. Finite Element Analysis - FEA Tension Torsion

  6. FEA – Red Stress Areas Tension Torsion

  7. Irreversible Corrective Action • Maintain Correct Rib Thickness (SPC Analysis Performed On-Line). • Radius Relief End of Each Slot (CNC Program Enhanced).

  8. Corrective Action Cost Analysis • Cycle Time - Original 5.04 minutes = $2.21 - New 5.34 minutes = $2.34 • Add SPC Analysis. • Reduce Cutter Life • Scale Back Final Torque Test from 100% to AQL.

  9. How To - Long Form SafeKrackers Long Form is broken down into four sections: 1 – Introduction 2 – Appendix A (SDA’s) 3 – Appendix B (RCA’s) 4 – Bibliography

  10. Long Form - Introduction The Introduction has links imbedded into the document. Simply mouse click on a blue link to jump to the corresponding form in the appendix. Press the blue arrow at the top of the page to jump back to the introduction.

  11. Long Form - Introduction The introduction details overviews of the Company, Customer, Product, Quality, and Process. It also details the Slot Cutting Process, along with Additional Process Improvements.

  12. Long Form – Appendix A This section includes all forms used during the objective of the project. These are referred to as Standard Dedicated Applications – SDA’s You will find them in the following order: Safety, Quality, Process, Finance, Planning.

  13. Long Form – Appendix B This section includes additional information gathered during the project. These are referred to as Regular Critique Assignments – RCA’s. RCA’s include: additional reading sources, team assessments, rotational matrix, and management review.

  14. Long Form – Bibliography This section details all sources used during the project.

  15. Company Goal Advance Relentlessly

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