Transcript Document

2.875
Mechanical Assembly and its Role in Product Development
Pencil Sharpener
Project Report No 3
November 14, 2001
Hernan Joglar
John Sharkey
Hernan Joglar
John Sharkey
Page 1
2.875 Mechanical Assembly
Fall 2001
Part list
Part No.
Part Name
Base Screws
2 Pencil guide
3 Battery compartment screw
4 Shavings receptacle
5 Sharpener base
6 Rubber foot (Underneath of base)
7 Sharpener case
8 Contacts on battery compartment cover
9 Battery compartment cover
10 Rubber foot (Underneath of battery comp. cover)
11 Battery Compartment housing
12 Contacts and rivets on battery compartment
13 Battery installation paper guide
14 Black wire
15 Gearbox housing
16 Output Gear
17 Intermediate Gear
18 Driven Gear
19 Gearbox cover screw
20 Electric motor
21 Safety lever
22 Lubrication (red jelly on gears)
23 Contacts and rivets on gearbox cover
24 Red wire
25 Blue wire
26 Gearbox cover
27 Blade nut and bolt
28 Blade
29 Blade holder
1
Hernan Joglar
John Sharkey
Page 2
Qty
2
1
1
1
1
1
1
2
1
1
1
3
1
1
1
1
1
1
1
1
1
1
3
1
1
1
1
1
1
2.875 Mechanical Assembly
Fall 2001
14
9
24
15
25
5
8
4
12
11
23
2
7
21
11
16
17
18 19 1
3 26
27 28
20
29
Figure 1. Pencil sharpener parts numbered as in the Part List
Hernan Joglar
John Sharkey
Page 3
2.875 Mechanical Assembly
Fall 2001
Safety lever pin
Input contact
Edge
Intermediate
contact
Output contact
Figure 2. Details of contacts and features in gearbox cover
Hernan Joglar
John Sharkey
Page 4
2.875 Mechanical Assembly
Fall 2001
Mating features
Electric in-out contacts
Red and black
electric wires
Electric contact
rivets
Figure 3. Details of contacts and features in battery compartment housing
Hernan Joglar
John Sharkey
Page 5
2.875 Mechanical Assembly
Fall 2001
Pencil Sharpener Indentured Parts List
Subassbly. Part #
sa1
1
2
3
4
7
sa2
5
6
sa3
8
9
10
sa4
11
12
13
sa5
14
15
16
17
18
19
20
21
22
sa6
23
24
25
26
sa7
27
28
29
Hernan Joglar
John Sharkey
Part Subassembly Name
Complete Asembly
Base Screws
Pencil guide
Battery compartment screw
Shavings receptacle
Sharpener case
Base Subassembly
Sharpener base
Rubber foot (Underneath of base)
Battery Compartment Cover Subassembly
Contacts on battery compartment cover
Battery compartment cover
Rubber foot (Underneath of battery comp. cover)
Battery Compartment Subassembly
Battery Compartment housing
Contacts and rivets on battery compartment
Battery installation paper guide
Motor/Gearbox Subassembly
Black wire
Gearbox housing
Output Gear
Intermediate Gear
Driven Gear
Gearbox cover screw
Electric motor
Safety lever
Lubrication (red jelly on gears)
Gearbox Cover Subassembly
Contacts and rivets on gearbox cover
Red wire
Blue wire
Gearbox cover
Cutter Unit Subassembly
Blade nut and bolt
Blade
Blade holder
Page 6
2.875 Mechanical Assembly
Fall 2001
Product Structure of Pencil Sharpener
sa1
p1
p7
sa5
p2
sa4
p12
p13
p3
p4
p11
p5
sa6
p14
p15
p16
p17
p18
p19
p20
p21
p22
sa2
p6
sa7
p8
p23
p24
p25
p26
Hernan Joglar
John Sharkey
p27
Page 7
sa3
p28
p9
p10
p29
2.875 Mechanical Assembly
Fall 2001
Part Liaisons and Mates in Pencil Sharpener
Mate No
1
2
Mated parts
Sharpener case/shavings receptacle
Battery compartment cover/sharpener base
Liaison/Mate Description
Snap fit of rim and slot.
Rim and slot in one end of the cover and rim and slot with snap fit in the other
end
Slot and rim along the contact edge and two peg and hole fits. The pegs
accommodate internal screws that keep the parts fastened.
Rim and slot plus sliding surface
Sliding surface
Peg and hole, rim and slot, and sliding surfaces
Two pegs and two holes
Two pegs and two holes
Peg and hole and sliding surface
Sliding surface on gear teeth
Square shaped peg and hole (pressed fit)
Alignment provided by two prongs and attachment is accomplished by nut
and bolt
Rim and slot
Circular rim and hole
Circular rim and slot
Peg and hole
Sliding surfaces
Sliding surfaces
Peg and hole
peg and hole
Peg and hole
Blade external surface with bolt head bottom surface
Permanent liaison thruogh adhesive
Permanent liaison thruogh adhesive
Permanent liason through rivets
3
Sharpener base/sharpener case
4
5
6
7
8
9
10
11
12
Gear and motor housing/ battery housing
Gearbox housing/ sharpener case
Battery compartment housing/ sharpener case
Electric motor/gearbox housing
Gearbox housing/gearbox cover
Driven gear/gearbox housing
Driven gear/electric motor
Cutter unit/output gear
Blade holder/blade
13
14
15
16
17
18
19
20
21
Pencil guide/sharpener case
Pencil guide/cutter unit
Electric motor/battery compartment
Safety lever/gearbox cover
Shavings Receptacle/Safety lever
Shavings receptacle/pencil guide
Safety lever/gearbox housing
Blade holder/blade nut and bolt
Blade/blade nut and bolt
22
23
24
sharpener base/rubber foot
Battery compartment cover/rubber foot
Battery compartment housing/battery comp
contacts
25
Battery compartment housing/battery paper guide Sliding surface
Hernan Joglar
John Sharkey
Page 8
2.875 Mechanical Assembly
Fall 2001
Part Liaisons and Mates in Pencil Sharpener (cont.)
Mate No
26
27
28
29
30
31
Liaison/Mate Description
Permanent liaison through soldering
Sliding surface on gear teeth
Sliding surface on gear teeth
Peg and hole and sliding surface
Peg and hole and sliding surface
Permanent liason through rivets
33
Mated parts
Battery comp. contacts/black wire
Driven gear/intermediate gear
Intermediate gear/output gear
Intermediate gear/gearbox housing
Output gear/gearbox housing
Battery compartment cover/contacts and rivets on
battery compartment cover
Gearbox cover/contacts and rivets on gearbox
cover
Contacts and rivets on gearbox cover/output gear
34
35
36
37
38
Contacts and rivets on gearbox cover/red wire
Contacts and rivets on gearbox cover/blue wire
Electric Motor/blue wire
Contacts on battery compartment /red wire
Electric Motor/black wire
Permanent liaison through soldering
Permanent liaison through soldering
Permanent liaison through soldering
Permanent liaison through soldering
Permanent liaison through soldering
32
Hernan Joglar
John Sharkey
Permanent liason through rivets
sliding surface
Page 9
2.875 Mechanical Assembly
Fall 2001
Pencil Sharpener Liaison Diagram and Fasteners Classification
p14
c26
p12
c24
c6
p11
p13
c25
c38
C37
p6
c15
c22
c1
p4
p20
c3
p7
p5
c5
c2
c18
c4
c23
p10
c31
p8
p9
c13
p2
c17
c10
c14
p29
c20
c21
c12
c7
p27
p28
p21
c16
c19
p15
c32
p23
c8
c35
p25
c11
c9
p18
p24
c34
p26
c33
c29
c27
c30
p17
c28
Permanent Liaisons
Rivets
p16
C36
Hernan Joglar
John Sharkey
Page 10
Liaisons Using
Threaded Features
Screws
Adhesive
Nut & Bolt
Soldering
Other mates
2.875 Mechanical Assembly
Fall 2001
Assembly Choreography
(Gross and fine motions, features where parts are gripped and
mated, lead-ins, and auxiliary operations)
1.
Create the Gearbox Cover Subassembly (sa6)
a. Solder the red wire (part 24) to the input contact.
b. Solder the blue wire (part 25) to the output contact.
c. Rivet gearbox cover contacts to the gearbox cover (parts 23 and 26)
2.
Create the Cutter Unit Subassembly (sa7)
a. Place the blade holder on a flat surface.
b. Put the blade on the blade holder with the cutter edge facing the slot. The blade
should fit into the space provided between the prongs so that the hole in the blade
gets aligned with the one in the blade holder.
c. Insert the bolt through the aligned holes. The bolt must be held with one finger
while the nut is grabbed with a tool and screwed from the other side.
d. For final tightening, hold the bolt with a Phillips head screwdriver while the nut is
tightened on the other side.
Hernan Joglar
John Sharkey
Page 11
2.875 Mechanical Assembly
Fall 2001
3.
Create the Battery Compartment Subassembly (sa4)
a. Rivet the contacts (part 12) to the battery compartment housing (part 11).
b. Install the battery installation paper guide inside the battery compartment. The
drawings must face the interior; the blank face should be at the side where the in/out
contacts are and the tabs must be folded to each side on top of the battery compartment
so that they are pressed between the battery compartment housing and the sharpener
base (part 5)once the latter is installed.
4. Create Motor/Gearbox Subassembly (sa5)
a. Place the gearbox housing (part 15) on a flat surface with the gear compartment facing
up.
b. Grab the output gear (part 16) from end of its shaft where the peg is not squared. Insert
the other end of the shaft in its hole in the gearbox housing so that the squared peg goes
into the hole.
c. Take the intermediate gear (part 17) by the input pinion teeth and insert it in the
intermediate gear pin that is attached to the gearbox so that the output pinion faces
down. Rotate the intermediate gear to ensure proper gear mesh.
d. Repeat this last operation with the driven gear (part 18).
e. Place lubrication (part 22) on all parts inside the gearbox.
Hernan Joglar
John Sharkey
Page 12
2.875 Mechanical Assembly
Fall 2001
f.
Insert the safety lever (part 21) on its pin in the gearbox housing. The safety lever must
be placed with its prong facing up. This prong must stay outside the gearbox cover
when that part is installed; therefore it is important at this point to observe that lever
positioning allows the right location of the prong.
g.
Place the gearbox cover (sa 6) on top of the gearbox housing. This is a difficult mate for
two reasons:
i. The safety lever must be held so that it doesn’t rotate about its pin.
ii. The ends of the blue and red wires must stay outside the gearbox.
In order to circumvent the above difficulties, the gearbox housing must be held with one
hand with the thumb finger holding the safety lever so that it doesn’t rotate. Then, the
gearbox cover must be grabbed with the other hand while pressing the wires against the
edges at the corresponding sides of the cover. It is very important for appropriate electrical
connection that the wires come out the gearbox at the same side where their corresponding
contacts are. Subsequently, the cover should be installed on the gearbox by first making
coincide the edges of both parts located at the end opposite to where the motor is. Once the
cover is installed, the wires must be slid around the edges until they reach the squared holes
that will be left for them to come out at both sides of the Motor/Gear Subassembly.
Hernan Joglar
John Sharkey
Page 13
2.875 Mechanical Assembly
Fall 2001
h.
i.
j.
k.
l.
m.
n.
o.
p.
Press the gearbox cover against the gearbox to make both parts fit and to enable the
intermediate electrical contact to store the tension that will let it keep pressing the
output gear.
Install the self threaded screw that attaches the gearbox cover to the gearbox (part 19).
Turn the gear housing upside down so that the cover is at the bottom and in contact
with a flat surface.
Take the Cutter Unit Subassembly and insert the square hole in the blade holder on the
square peg in the output gear shaft.
Test the circuit inside the gearbox by connecting the blue and red wires to a circuit
tester while pressing the safety lever and the cutter unit. The instrument should indicate
that the circuit is closed.
Solder the black wire (part 14) to the electric motor (+) terminal (part 20).
Solder the blue wire (part 25) to the electric motor (-) terminal.
Insert the electric motor in its compartment in the gearbox housing. Rotate the motor
until it fits the motor location pegs. The negative terminal must be placed at the same
side where the blue cable is coming out the gearbox housing. When that is
accomplished, the motor will not rotate any more. Its rim will then be inserted in the
motor location hole and the motor gear will engage the driven gear inside the gearbox.
Test the gear engagement by rotating the cutter unit and listening to the noise of the
motor rotating.
Note: the motor fixture described in DFC Project Report # 2 has been deleted in the above sequence.
Hernan Joglar
John Sharkey
Page 14
2.875 Mechanical Assembly
Fall 2001
5.
Create the Battery Compartment Cover Subassembly (sa3)
a. Rivet the contacts (Part 8) on the battery compartment cover (part 9).
b. Using an adhesive, place the rubber foot (part 10) on the battery compartment cover.
6.
Create the Base Subassembly (sa2)
a. Using an adhesive, place the rubber foot (part 6) on the sharpener base (part 5).
b. Attach the battery compartment cover subassembly to the sharpener base. First insert
the rims on the battery compartment cover in the corresponding slot on the sharpener
base. Then press both parts against each other on the opposite end until the snap fit
attaches both parts together.
7.
Complete assembly (sa1)
a. Grab the battery compartment housing, turn it upside down and place it on the
gear/motor subassembly. The rims on the battery compartment housing must be slid
inside the slots provided at both sides of the gearbox housing. When in its correct
position, the circular rim in the battery compartment housing is inserted in the circular
slot in the bottom of the electric motor.
b. Solder the black wire to the in/out contact in the battery compartment housing that is
located at the same side as the safety lever.
c. Solder the red wire to the remaining in/out contact in the battery compartment.
Hernan Joglar
John Sharkey
Page 15
2.875 Mechanical Assembly
Fall 2001
d.
Grab the sharpener case (part 7) in one hand and, with the other one, place inside it the
Battery Compartment Subassembly (sa 4) and the Motor/Gearbox Subassembly (sa 5),
so that the rims in the sharpener case fit the slots in the battery compartment housing
and the holes in both parts become aligned. To perform this action prongs are provided
in the interior of the sharpener case and the outside of the gearbox housing. These
prongs must slide against each other as the insertion is performed in order for the
assembly to be accomplished.
e.
Using a magnetic Phillips head screwdriver insert the battery compartment self
threaded screw (part 3) in the aligned hole and tighten it.
f.
Install the Base Subassembly so that both of its cylindrical screw guides are inserted in
the spaces provided on both sides of the gearbox housing. Once these guides reach their
position they act as holes and mate with pegs at the opposite side of the sharpener case.
This mate allows for the holes in the interior of both of the above features to become
aligned. Similarly, the above mate allows the insertion of the rim on the edges of the in
the slot on the edges of the sharpener case.
Hernan Joglar
John Sharkey
Page 16
2.875 Mechanical Assembly
Fall 2001
g.
Place and tighten the two self threaded screws that attach the base to the sharpener
case.
h.
Place and tighten the two self threaded screws that attach the base to the battery
compartment housing using a Phillips head screwdriver.
i.
Grab the pencil guide (part 2) with the chamfered rim for pencil guidance facing up.
Press the cutter unit down to allow room for the pencil guide to be inserted in the slot
between the sharpener case and the gearbox housing. The slot in the interior of the
sharpener case must fit the rim in the upper surface of the pencil guide. Release the
cutter unit to allow for its circular rim to fit in the hole at the bottom surface of the
pencil guide.
j.
Place the Shavings receptacle by inserting one of the lateral slots on the sharpener case
in one of the lateral slots in the receptacle and press on the opposite side to make the
snap fit attach both parts together.
Hernan Joglar
John Sharkey
Page 17
2.875 Mechanical Assembly
Fall 2001
Potential Problems and Risk Areas
Description
Probability
Impact
•
Reversed motor polarity wiring (black on +)
High
High
•
Reversed battery compartment wiring
High
High
•
Solder joint or wire breakage during gearbox insertion
Low
High
•
Solder joint or wire breakage during motor insertion
Low
High
•
Motor pinion clearance thru gearbox hole
High
Med
•
Loss of motor location during final assembly
High
Med
•
Improper location of battery compartment on gearbox
Med
Med
•
Part damage from shaver receptacle insertion (snap fit)
Med
Med
Hernan Joglar
John Sharkey
Page 18
2.875 Mechanical Assembly
Fall 2001
Suggested Design Improvements
Description
•
•
•
•
•
•
•
•
Impact
Reversed motor polarity wiring (black on +)
- Use wire connector instead of solder joint
Reversed battery compartment wiring (red on right)
- Imprint wiring polarity on battery compartment injection mold
Solder joint or wire breakage during gearbox insertion
- Use wire connector instead of solder joint
Solder joint or wire breakage during motor insertion
- Use wire connector instead of solder joint
Motor pinion clearance thru gearbox hole
Med
High
Med
Med
- Reduce and control gearbox manufacturing variance
Med
Loss of motor location during final assembly
- Include snap/fit feature between battery compartment and gearbox High
Improper location of battery compartment on gearbox
- Use wire connectors instead of solder joint
Part damage during shaver receptacle insertion (snap fit)
- Training, coupled with control of manufacturing variations
Hernan Joglar
John Sharkey
Page 19
Med
Low
2.875 Mechanical Assembly
Fall 2001
Fixtures and Special Tooling
Fixtures
• Riveting fixture. or special tooling, for battery compartment
• Riveting fixture, or special tooling, for gearbox cover
• Bending fixture for gearbox cover electrical contacts
• Bending fixture for battery cover electrical contacts
• Bending fixture for battery compartment electrical contacts (nice to have)
• Soldering station and fixture for electric motor (black and blue leads)
• Soldering station and fixture for battery compartment (black and red leads)
Standard Tools and Special Tooling
• Heat stake tooling for battery compartment electrical contacts
• Magnetic Phillips head screwdriver (4” length) for battery compartment screw
• Small wrench, or pliers, for blade screw and nut
• Wire strippers (22 gage)
• Wire tinning and pre-form bending
• Soldering station for gearbox cover
• Electrical test station for operation of motor/gearbox sub-assembly
• Lubrication dispenser gun
Hernan Joglar
John Sharkey
Page 20
2.875 Mechanical Assembly
Fall 2001
Assembly Time Analysis
•
Throughput requirement based on production volume
– 250,000 units/year @ 250 workdays/year = 1000 units/day
– 1000 units/day @ 8 hours/day = 125 units/hour = 2.08 mins/unit
•
Assembly time per Boothroyd Handling and Insertion Times
– Handling Time per unit
=
105.48 (sec/unit)
– Location Time per unit
=
47.50 (sec/unit)
– Reversible Fastening Time per unit
=
54.20 (sec/unit)
– Irreversible Fastening Time per unit
=
121.00 (sec/unit)
– Total predicted assembly time
=
328.18 (sec/unit)
207.18
(sec)
Note: does not include inspection and test time
•
•
Measured Handling, Location and Reversible Fastening Times
– Test#1
309 sec
– Test#2
222 sec
Assembly Efficiency
– Three “un-necessary parts: Sharpener case, paper guide, and pencil guide
–
Assem bly efficiency 
Hernan Joglar
John Sharkey
19 parts*3 sec/ part 
(total assem blytim e)
Page 21
57sec
 17.4%
328.18sec
2.875 Mechanical Assembly
Fall 2001
Example Assembly Process
SA 7
Cutter Unit
Assy
SA 7
Cutter Unit
Inspect
18.25 sec
5 sec
SA5
SA6
Gearbox Cover
Assy
SA 6
Gearbox Cover
Inspect
48.06 sec
5 sec
SA5a
Gearbox
Assy
SA5a
Gearbox
Solder
SA5a
Gearbox
Test
Motor/Gearbox Assy
87.30 + 30 sec
SA5
Battery Comp.
Assy
SA 5
Battery Comp.
Inspect
19.62 sec
SA1
Final
Assy
SA1
Final
Inspect
5 sec
101.83 sec
SA3
Battery Cover
Assy
SA 3
Battery Cover
Inspect
SA2
Base
Assy
19.62 sec
5 sec
33.5 sec
20 sec
Package
& Ship
30 sec
Note: Test, inspection and packaging times are SWAGS
Hernan Joglar
John Sharkey
Page 22
2.875 Mechanical Assembly
Fall 2001
Part Handling: Gross Motion
Order
P/N Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
29
28
27
SA7
26
23
24
25
SA6
15
22
16
17
18
22
SA6
21
SA6
19
sa5
20
14
25
20
SA7
SA5
Qty
Position blade holder
Locate blade
Locate and fasten blade screw and nut (tools: screwdriver & pliers)
Inspect & Release Cutter Sub-Assembly
Position Gearbox cover
Locate & rivet cover contacts
Solder red wire to cover
Solder blue wire to cover
Inspect & Release Gearbox Cover Sub-Assembly
Position gearbox housing (inverted)
Apply lubrication to axle stands
Locate output gear
Locate intermediate gear
Locate driven gear
Apply lubrication to gear surfaces and axles
Position gearbox cover sub-assembly
Locate safety lever on gearbox cover (retain with one hand)
Locate gearbox cover sub-assembly & safety lever (2 hand ops)
Locate and fasten gearbox cover screw (self-threading)
Invert & position partially complete gearbox sub-assembly
Position electric motor near gearbox
Solder blue wire to motor (2 hand ops)
Solder black wire to motor (2 hand ops)
Locate electric motor in gearbox
Locate cutter unit sub-assembly
Inspect, Test & Release Motor/Gearbox Sub-Assembly
Hernan Joglar
John Sharkey
Page 23
1
1
1
1
1
3
1
1
1
1
3
1
1
1
3
1
1
1
1
1
1
1
1
1
1
1
Size Thick
(mm) (mm)
35
21
9
35
65
18
130
111
65
58
6
0.5
1.5
6
1.9
0.2
1
1
1.9
50
25
21
21
2
5.8
5.8
65
11
65
15
65
43
111
86
43
35
65
1.9
6.1
1.9
3
50
23.6
1
1
23.6
6
50
G.M.
Code
Alpha Beta a + b Handling
(deg) (deg) (deg)
(sec)
10
13
03
180
180
180
180
180
0
360
360
180
10
13
03
03
10
10
00
03
00
00
00
00
85
85
00
00
10
03
03
85
80
180
180
180
360
360
540
0
0
1.50
2.06
1.69
5.25
1.50
2.06
1.69
1.69
180
180
180
180
180
0
180
180
180
180
180
180
0
0
0
0
0
270
0
0
0
360
180
180
45
90
360
0
180
180
180
0
180
450
180
180
180
540
0
0
225
270
1.50
1.13
1.69
1.13
1.13
1.13
1.13
5.00
5.00
1.13
1.13
1.50
1.69
1.69
5.00
4.10
2.875 Mechanical Assembly
Fall 2001
Part Handling: Gross Motion (con’t)
Order
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
P/N Description
9
8
SA3
11
19
12
SA4
5
SA3
11
SA2
SA5
SA4
25
24
7
SA4
SA5
3
SA2
3
1
13
sa1
2
4
SA1
Qty
Position battery compartment cover
Locate and rivet (plastic heat stake) battery cover contacts
Inspect & Release Battery Compartment Cover Sub-Assembly
Position battery compartment housing (inverted)
Contacts and rivets
Locate & rivet battery compartment contacts
Inspect & Release Battery Compartment Sub-Assembly
Position sharpener base
Locate battery compartment cover sub-assembly
Locate rubber feet on base and battery compartment cover
Inspect & Release Base Sub-Assembly
Position motor/gearbox sub-assembly
Locate battery compartment sub-assembly on motor/gearbox
Solder black wire to battery compartment
Solder red wire to battery compartment
Position sharpener case
1
2
Locate battery compartment & motor/gearbox in sharpener case
Locate and fasten battery compartment screw
Locate base sub-assembly in sharpener case
Locate and fasten battery compartment screws
Locate and fasten sharpener case screws
Install battery installation paper guide
Invert and reposition partially complete sharpener assembly
Locate pencil guide (tricky alignment)
Locate shavings receptacle (snap fit)
Inspect, Test & Release Pencil Sharpener Assembly
Hernan Joglar
John Sharkey
Page 24
Size Thick
(mm) (mm)
G.M.
Code
Alpha Beta a + b Handling
(deg) (deg) (deg)
(sec)
43
20
43
70
2.5
0.2
2.5
32
10
13
180
180
180
180
360
360
1.50
2.06
10
180
180
360
1.50
0.2
32
7
2.5
1.6
13
180
180
360
2.06
1
1
2
22
70
75
43
25
00
10
10
180
180
180
90
180
180
270
360
360
1.13
1.50
1.50
1
1
1
1
1
65
70
86
130
82
50
26
1
1
36
00
80
03
03
10
0
180
180
180
180
180
180
360
0
0
360
1.13
4.10
1.69
1.69
1.50
2
1
1
2
2
1
1
1
1
1
96
8
75
9
14
50
96
32
73
115
32
3
7
3
3
1
50
11.7
36
50
80
01
10
01
01
13
00
05
05
180
180
180
180
180
180
180
180
180
10
0
180
0
0
180
0
0
15
190
180
360
180
180
360
180
180
195
4.10
1.43
1.50
1.43
1.43
2.06
1.13
1.84
1.84
1
2
2.875 Mechanical Assembly
Fall 2001
Part Insertion: Fine Motion
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
P/N Description
29
28
27
SA7
26
23
24
25
SA6
15
22
16
17
18
22
SA6
21
SA6
19
sa5
20
14
25
20
SA7
SA5
9
8
SA3
Qty
Position blade holder
Locate blade
Locate and fasten blade screw and nut (tools: screwdriver & pliers)
Inspect & Release Cutter Sub-Assembly
Position Gearbox cover
Locate & rivet cover contacts
Solder red wire to cover
Solder blue wire to cover
Inspect & Release Gearbox Cover Sub-Assembly
Position gearbox housing (inverted)
Apply lubrication to axle stands
Locate output gear
Locate intermediate gear
Locate driven gear
Apply lubrication to gear surfaces and axles
Position gearbox cover sub-assembly
Locate safety lever on gearbox cover (retain with one hand)
Locate gearbox cover sub-assembly & safety lever (2 hand ops)
Locate and fasten gearbox cover screw (self-threading)
Invert & position partially complete gearbox sub-assembly
Position electric motor near gearbox
Solder blue wire to motor (2 hand ops)
Solder black wire to motor (2 hand ops)
Locate electric motor in gearbox
Locate cutter unit sub-assembly
Inspect, Test & Release Motor/Gearbox Sub-Assembly
Position battery compartment cover
Locate and rivet (plastic heat stake) battery cover contacts
Inspect & Release Battery Compartment Cover Sub-Assembly
Hernan Joglar
John Sharkey
Page 25
1
1
1
1
1
3
1
1
1
1
3
1
1
1
3
1
1
1
1
1
1
1
1
1
1
1
1
2
Size Thick
(mm) (mm)
35
21
9
35
65
18
130
111
65
58
6
0.5
1.5
6
1.9
0.2
1
1
1.9
50
25
21
21
2
5.8
5.8
65
11
65
15
65
43
111
86
43
35
65
43
20
43
1.9
6.1
1.9
3
50
23.6
1
1
23.6
6
50
2.5
0.2
2.5
F.M.
Code
00
40
48
Handling Insertion
(sec)
(sec)
0.00
4.50
8.50
00
35
95
95
1.50
2.06
1.69
5.25
1.50
2.06
1.69
1.69
00
99
00
00
00
99
00
00
06
38
00
00
95
95
11
30
1.50
1.13
1.69
1.13
1.13
1.13
1.13
5.00
5.00
1.13
1.13
1.50
1.69
1.69
5.00
4.10
0.00
1.20
1.50
1.50
1.50
1.20
0.00
1.50
5.50
6.00
0.00
0.00
8.00
8.00
5.00
2.00
00
35
1.50
2.06
0.00
7.00
0.00
7.00
8.00
8.00
Total
Time
1.50
6.56
10.19
18.25
1.50
27.18
9.69
9.69
48.06
1.50
6.99
3.19
2.63
2.63
6.99
1.13
6.50
10.50
7.13
1.13
1.50
9.69
9.69
10.00
6.10
87.30
1.50
18.12
19.62
2.875 Mechanical Assembly
Fall 2001
Part Insertion: Fine Motion (con’t)
Order
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
P/N Description
11
19
12
SA4
SA5
SA4
25
24
7
SA4
SA5
3
5
3
1
13
SA3
11
sa1
2
4
SA1
Qty
Size Thick
(mm) (mm)
F.M.
Code
Handling Insertion
(sec)
(sec)
Total
Time
Position battery compartment housing (inverted)
Contacts and rivets
Locate & rivet battery compartment contacts
Inspect & Release Battery Compartment Sub-Assembly
Position motor/gearbox sub-assembly
Locate battery compartment sub-assembly on motor/gearbox
Solder black wire to battery compartment
Solder red wire to battery compartment
Position sharpener case
1
70
32
00
1.50
0.00
1.50
2
0.2
32
50
26
1
1
36
35
2.06
7.00
1
1
1
1
1
22
70
65
70
86
130
82
00
02
95
95
00
1.13
4.10
1.69
1.69
1.50
0.00
2.50
8.00
8.00
0.00
18.12
19.62
1.13
6.60
9.69
9.69
1.50
Locate battery compartment & motor/gearbox in sharpener case
Locate and fasten battery compartment screw
Locate sharpener base in sharpener case
Locate and fasten battery compartment screws
Locate and fasten sharpener case screws
Install battery installation paper guide
Locate battery compartment cover sub-assembly
Locate rubber feet on base and battery compartment cover
Invert and reposition partially complete sharpener assembly
Locate pencil guide (tricky alignment)
Locate shavings receptacle (snap fit)
Inspect, Test & Release Pencil Sharpener Assembly
2
1
1
2
2
1
1
2
1
1
1
1
96
8
75
9
14
50
43
25
96
32
73
115
32
3
7
3
3
1
2.5
1.6
50
11.7
36
50
08
48
00
38
38
00
30
97
00
30
30
4.10
1.43
1.50
1.43
1.43
2.06
1.50
1.50
1.13
1.84
1.84
6.50
8.50
1.50
6.00
6.00
1.50
2.00
12.00
0.00
2.00
2.00
Assembly Total (sec) =
(min) =
Hernan Joglar
John Sharkey
Page 26
21.20
9.93
3.00
14.86
14.86
3.56
3.50
27.00
1.13
3.84
3.84
135.33
328.18
5.47
2.875 Mechanical Assembly
Fall 2001