If you can remember seven passwords to get into your

computer to do your job but forget your second wedding anniversary, you could be an

engineer.Mei-Chuan S Haverkamp

Chabot College Presentation11/19/13

Jim HaverkampSenior (Ancient) Mechanical Engineer

DisclaimerIn this presentation I am going to mention

some of the things that has molded me into the engineer that I am.

My mold is only one of many and just because you don’t exactly fit in my mold does not mean that you cannot become an outstanding engineer.

Saying the word “engineer” is like saying vehicle, the next question is usually “What kind?”

HistoryFrom a young age I have always been

intensely interested in how things worked.I would get excited when thing brokeThis would extend to my toysThis became such an obsession that I would

actually weigh the difference between having the toy and finding out how it worked

Finding out how it worked usually wonI got to be good with the disassembly process

My mother labeled me the worlds most destructive kid in the world!

Why Mechanical?Found in the basement as an old TV that was

not working. I plugged it in and confirmed that it, in fact,

was not working properly.Before I did anything I unplugged to. “Can’t

be too careful, right?”I took the back off and was immediately in

heaven! I discovered capacitance! Cleaned up

United States NavyWhen in the Navy I was eventually assigned to

R division. R is for Repair.Take thing apartPut them back togetherThe are supposed to work

When on a ship at sea one cannot run to the local Osh store.

Have to make out own tools and I became very interested in tool design and why.

Leaving the navy I found work in the sheet metal industries.

EducationChabot College (Los Positas) 1982 – 1986

UC Berkeley 1986-1989

Digressing just a bitPart of the reason I

left the navy is that I objected to being forced to wear a uniform like everybody else

I went from this …..

To this …..I think I lost that round

The following are sanitized slides from and actual project that I ranPhase 1 is to produce a conceptual design The first step is to clarify the objective

What is causing the need? Some function that does not meet a requirement.

What is the scope of the problem?When is a solution needed?What is the budget?

The second step is to create a specification that I will design to.

Finally I will come up with some conceptual designs and demonstrate how they fulfill the specifications

Product / Project Name / Date of Review / Name of Presenter XXXXXXXX Window Pry tool, 3/7/13, Jim Haverkamp

Objective of this Design Review Obtain permission to purchase newly designed pry tool XXXXXXXXX and test

fixture

Identify EPL Item Driving This Activity PR XXXXXXXX

Problem statement The XXXXXXX tool has two windows that stick together due to adhesion from the

two O-rings. A tool is needed to pull the windows apart. Previous tool does not fit well and requires the removal of several parts Earlier tool failed after 4 uses

Project Objective Specifications

Pry the top window from the bottom window During the removal the gas distribution plenum with remain attached to the top

window Material from the tool will not contaminate or damage either window Will not require the removal of the Plastic alignment brackets that are attached to the

pinnacle Cost - Targeting $1260 Time / Schedule

Design complete 2/28/13 Receive parts 3/11/13 Release 3/15/13

Success Criteria Confirmation that will provide 2X the force or the XXXXX before failure on the upper

window Confirmation that it will perform equally as well as the XXXXX1 on the lower window

Scope 10 customers currently own a this tool including our lab. Potential need for the tool is

between 20 and 30. This tool is not legacy, there is a potential for more customers

Summary of Design Change Tool foot designed to fit into gap between the two windows Material changed from polycarbonate to 40% glass filled polycarbonate SS Helicoil changed to Nitronic 60 gall resistant Helicoil An Aluminum plug insert is designed to provide support for the polycarbonate Frame members were thickened to aid in managing the load

This is the part that I designed

The part in position

Addition specifications that I found during the design process

Finite Element Analysis was used to confirm that the part could match the forces

Example of a risk table

Phase 2 involves buying parts and breaking them!

Take notes and document lessons learnedDuring the breaking phase there is nearly

always a surprise or two that requires redesign.

Question your results! In this case the Finite Element Analysis was bit applicable

Review and update risks

Phase 3 get it ready for a customerLock down the designCreate a Bill of Materials (BOM)Create instruction on how to use it or install

itWhat to do with the old partsMONITOR CUSTOMER FEEDBACK!!!!! Be

proactive!When the customer returns with positive

feedback ….

After positive feedbackGo Kayaking and have a beer

In that order!