1. Report #1: Product Description 7




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2.875 Mechanical Assembly and Its Role in Product Development



Team Members:

Agus Sudjianto

Jared Clark

Milind Oak

Eiichi Tanabe

Gaurav Shukla

Problem Statement 5

3.6-Volt Sears/Craftsman Cordless Screwdriver 5

1. Report #1: Product Description 7

1.1 Product Assembly Drawing 8

1.2 Transmission Assembly 9

1.3 Exploded View of Transmission Assembly 10

1.4 Clearance Specification 11

1.5 Screwdriver Component Breakdown 13

1.6 Bill Of Materials 14

1.7 Assembly Tree 16

1.8 Functional Flow Model 17

1.9 System Hierarchy Breakdown 18

1.9.1 Battery Module System Breakdown 18

1.9.2 Driver Mechanism System Breakdown 19

1.10 Liaison Diagrams of Part Mating 20

1.10.1 Product Main Assembly 20

1.10.2 Battery and Housing Assembly 20

1.10.3 Torque Limiter 20

1.10.4 Transmission 21

1.10.5 Motor Assembly 21

2. Report #2: DATUM FLOW CHAIN 22

2.1 Overall Transmission Key Characteristics 22

2.2 Feature, Mate, and Contact Table 26

2.3 Complete Bill Of Materials 27

2.4. Exploded View 29

3. Report #3: Assembly Sequence 30

3.1 Revised Liaison Diagram 30

3.2 Revised Datum Flow Chain 30

3.3 All Possible Assembly Sequence 31

3.4 The Most Conveniencee Assembly Sequence 32

3.5 Required Gross and Fine Motions 33

3.6 Futures, Chamfers and Lead ins 33

3.7 Difficulties & Ideas in Assembly 35

3.8 Feature Parts and Associated Assembly Tool and Fixtures 36

3.9. Fixtures and Tools for Assembly 38

3.10 Gear Set Architecture Redesign 39

3.11 Improvement highlight 41

4. Report #4: Assembly Floor Layout Analysis 42

4.1. Assembly Sequence 42

4.2 Assembly Process time 44

4.3 Assembly Line Design and Assumptions 46

4.3.1 Design Parameters 47

4.3.2 Supplied Material 47

4.4 Assembly operation style 48

4.4.1 Assembly Line Design 48

5. Report #5: Workstation Design 52

5.1 Required cycle time to complete the planned operations 52

5.1.1 Assembly Flow Diagram 52

5.1.2 Final Assembly 53

5.1.3 Testing and Packaging 53

5.1.4 Transmission Assembly 54

5.1.5 Grip Housing/Battery Assembly 54

5.2 Station lay out: in and out flows of assemblies and parts 56

5.3 Required motions of equipment and people 57

5.4 Necessary inspections or tests 58

5.5 Gantt chart of required time of activities and a complete cycle 60

5.6 Cost estimation of workstations 64

5.7 Estimation of the cost of performing one assembly cycle 65

6. Report #6: Economic Analysis and Assembly Line Simulation 67

6.1 Economic analysis of this assembly layout 67

6.1.1 Estimated Manufacturing Cost 68

6.1.2 Inventory Cost and Distribution Cost 69

6.1.3 Development Cost 69

6.1.4 Unit Part Costs 70

6.1.5 Economic Analysis 71

6.2 Discrete event simulation of assembly line 72

6.2.1 Discrete Event Simulation: Configuration Study 72

6.2.2 Selection of Final Assembly Process 80

Problem Statement

3.6-Volt Sears/Craftsman Cordless Screwdriver

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