Transcript Presentation of Phase 0 - University of Delaware

Presentation of Phase 3
Monday 12/11/2006
Nick DePompeo, Brian Hufe, Mike
Sacra, Ben Stuchlik
Southco
 Over the past 60 years, Southco has
grown through innovation, strategic
acquisitions and overseas investments into
a global leader in Engineered Access
Hardware.
 DZUS quarter-turn fasteners provide quick,
effortless access/fastening for military and
aerospace applications.
Project Scope Definition
 To accurately design and manufacture
an interface between an MTS machine
and required fasteners to produce an
efficient and safe testing process for
all required tests.
Current Process
 Utilizes 3 machines
 Utilizes compressed air
 Requires skilled, trained operator
 Tensile, shear and torsional tests are performed
Tensile/Shear
Fastener Testing
Torque
Fastener Testing
Tensile/Shear
Receptacle Testing
Why Change?





Three required machines to run tests
Extensive Testing time
Repetitive Testing Process
Testing process may be inaccurate
Southco has an MTS machine available
Customer Wants
 Decrease skill requirement of testing
procedure
 Decrease testing time
 Maintain testing safety standards
 Develop an interface with available
MTS Machine
 Increase repeatability and accuracy
Metrics





Number of machines
Testing time
Accuracy
Repeatability
Durability
Benchmark-Target Value Comparison
Benchmark Values
Target Values
1) 3 Machines
1) 1 Machine (MTS
Machine)
2) Approximately 8-9 hours
2) Less than 4 hours per lot
3) Unknown
3) 10% more accurate
than what is being tested
4) Unknown
4) 10% more repeatable than
current process
5) N/A
5) Operational for a minimum
of 10 years
Selected Concept:
 Single
interface
for all tests
 Reduced
setup time
between
tests
 Easily
allows for
“nesting”
feature
Key Pieces
1)
2)
3)
4)
Top U Piece
Bottom U Piece
Nesting
Rotator Pieces
1
4
2
3
Assembly Model
Nesting
 Nesting allows for adaptation. New
fasteners may be tested through the
use of new nesting pieces.
Locking/Unlocking Fastener
Shear to Tensile Test Re-Positioning
Design Schematic
Testing Procedure
1)
2)
3)
4)
Attach interface to MTS machine
Load TestWorks and initialize test
Calibrate machine
Performed 3 trials of testing for 3fastener lots using required testing
order
5) Record data and analyze results
Testing Results
 Interface works as intended.
 Testing time reduced to target value.
Test Validation- Ease of Use
Current System:
Requires three Machines
New System:
Requires 1 Machine
Test Validation- Testing Time
Current testing time take approximately 8 hours per lot
Testing Time has been reduced by approximately 4 hours
Test Validation- Accuracy
 Load Cell is much
more accurate than
the current
compressed air
system which can
have leaks.
 The new system is
calibrated every
time a new testing
shift begins.
Test Validation- Repeatability
 Testing showed a
high degree of
repeatability.
 Testing time had a low
std. deviation
Value to Southco
 Decreased testing time
 More lots can be tested in a given time.
 Set testing procedure
 Detailed step-by-step procedure
 Minimizes operator skill requirements
 Takes up less space
Project Costs
Implementation Plan
 Southco will be provided with the
interface and necessary
hardware/software.
 Southco will be provided with a
detailed operations manual, including
engineering drawings.
 Southco will be provided with a firsthand training session for operators.
Financial Payback
Skilled operator salary: $30/hr
Current Test Time:
8.5 hr
Tests per day:
1 test
=
$255.00 per test
Skilled operator salary: $30/hr
New Test Time:
4.5 hr
Tests per day:
1 test
=
$135.00 per test
Estimated Savings = $120.00 per test
At a total cost of $2410.85, it would take
Southco approximately 20 days of testing to
completely pay off the new testing system.
Questions?