1. Report #1: Product Description 5

2.875 Mechanical Assembly and Its Role in Product Development

Problem Statement 4

3.6-Volt Sears/Craftsman Cordless Screwdriver 4

1. Report #1: Product Description 5

1.1 Product Assembly Drawing 6

1.2 Transmission Assembly 7

1.3 Exploded View of Transmission Assembly 8

1.4 Clearance Specification 9

1.5 Screwdriver Component Breakdown 11

1.6 Bill Of Materials 12

1.7 Assembly Tree 14

1.8 Functional Flow Model 15

1.9 System Hierarchy Breakdown 16

1.9.1 Battery Module System Breakdown 16

1.9.2 Driver Mechanism System Breakdown 17

1.10 Liaison Diagrams of Part Mating 18

1.10.1 Product Main Assembly 18

1.10.2 Battery and Housing Assembly 18

1.10.3 Torque Limiter 18

1.10.4 Transmission 19

1.10.5 Motor Assembly 19

2. Report #2: DATUM FLOW CHAIN 20

2.1 Overall Transmission Key Characteristics 20

2.2 Feature, Mate, and Contact Table 24

2.3 Complete Bill Of Materials 25

2.4. Exploded View 27

3. Report #3: Assembly Sequence 28

3.1 Revised Liaison Diagram 28

3.2 Revised Datum Flow Chain 28

3.3 All Possible Assembly Sequence 29

3.4 The Most Conveniencee Assembly Sequence 30

3.5 Required Gross and Fine Motions 31

3.6 Futures, Chamfers and Lead ins 31

3.7 Difficulties & Ideas in Assembly 33

3.8 Feature Parts and Associated Assembly Tool and Fixtures 34

3.9. Fixtures and Tools for Assembly 36

3.10 Gear Set Architecture Redesign 37

3.11 Improvement highlight 38

4. Report #4: Assembly Floor Layout Analysis 39

4.1. Assembly Sequence 39

4.2 Assembly Process time 41

4.3 Assembly Line Design and Assumptions 43

4.3.1 Design Parameters 44

4.3.2 Supplied Material 44

4.4 Assembly operation style 45

4.4.1 Assembly Line Design 45

5. Report #5: Workstation Design 49

5.1 Required cycle time to complete the planned operations 49

5.1.1 Assembly Flow Diagram 49

5.1.2 Final Assembly 50

5.1.3 Testing and Packaging 50

5.1.4 Transmission Assembly 51

5.1.5 Grip Housing/Battery Assembly 51

5.2 Station lay out: in and out flows of assemblies and parts 53

5.3 Required motions of equipment and people 54

5.4 Necessary inspections or tests 55

5.5 Gantt chart of required time of activities and a complete cycle 57

5.6 Cost estimation of workstations 61

5.7 Estimation of the cost of performing one assembly cycle 62

6. Report #6: Economic Analysis and Assembly Line Simulation 63

6.1 Economic analysis of this assembly layout 63

6.1.1 Estimated Manufacturing Cost 64

6.1.2 Inventory Cost and Distribution Cost 65

6.1.3 Development Cost 65

6.1.4 Unit Part Costs 66

6.1.5 Economic Analysis 67

6.2 Discrete event simulation of assembly line 68

6.2.1 Discrete Event Simulation: Configuration Study 68

6.2.2 Selection of Final Assembly Process 76