P15665 GLEASON GEAR JAW METRICS

PROBLEM DEFINITION REVIEW9/11/14

KATIE BALDWIN

JOSH SMITH

DOUG PERRY

EVAN MOLONY

AGENDA

➢Team Info

➢Stakeholders

➢Project Background and Problem

Statement

➢Customer and Engineering Requirements

➢Benchmarking

➢Risk Analysis

➢Project Plan

THE TEAM

MEMBER ROLE

Katie Baldwin IE/Team Leader

Josh Smith ME/Budget & Supplies

Doug Perry ME

Evan MolonyME/Documentation

Tracking

STAKEHOLDERS

➢Gleason

❖ Gleason Operators

❖ Gleason Customers

➢MSD Group

➢Gerald Garavuso

PROJECT BACKGROUNDA gear loader jaw assembly is responsible for holding a gear blank while being transferred in and out of the work chamber of the Gleason machine. This is typically part of an automation option for high production use at companies like Ford and GM. Currently Gleason inspects individual components of the gear jaws but doesn't inspect the final assemblies. This has led to machining errors at the customer level due to tolerance stacks and other factors.

PROJECT BACKGROUND

PROBLEM STATEMENTDetail Components of gear positioning assemblies are not adequately inspected or toleranced allowing out-of-spec assemblies to produce non-conforming gears

ASSUMPTIONS & UNKNOWNS

➢We only need to measure surfaces which

contact the working part

➢We have not been provided with a list of

jaws yet

➢Drawings will be provided before the device

is tested

➢Images, models, or drawings of each

component will be provided

CUSTOMER REQUIREMENTSCustomer Rqmt. #

Importance Description Comments/Status Why is This a Requirement?

1 1Take accurate measurements of all surfaces

which contact gear or arborTop Priority

This is the only way to ensure the gear jaws are within the expected tolerances relative to oneanother.

2 1 Secure positioning of the assembly   Ensures assembly does not shift during measurement.

3 1 Conform to predefined budget  The customer cannot exceed their spending limit without approval from

an executive.

4 1 Pro-E files of all components  The customer has specifically requested these for documentation and

device replication purposes.

5 2 Safe to use   The device can not be detrimental to operator health.

6 3 Portability  The device will need to be transported between RIT and the facility and

may need to be moved on the shop floor. The device should be movable by fewer than four people.

7 2 Easy to use  Ease of use for the inspection operator will reduce necessary training and increase inspection efficiency thereby increasing customer profits

and satisfaction.

8 3 Rapid positioning of the assembly   Reduced inspection time increases profitability for the customer.

9 2 Digitally record measurements   The customer needs a way to store and record the measurements

10 1 Output corrective actions to spreadsheet   If parts do not conform, the customer needs to know how to fix them.

11 1Accommodate three specific machines (GP400,

GP300, 130/210) 

This was specifically requested and the device will not meet customer requirements without this functionality. The customer would also like

additional space to accommodate future machines.

12 3 Rapid measurement   Reduced inspection time increases profitability for the customer.

13 1 Device measures critical surfaces  All arbor contact surface profile and position are critical to design intent.

Based on customer feedback.

14 2 Device fits in available shop space   The device will not meet Gleason's needs if it does not fit in their shop.

TOP PRIORITIES

Customer Rqmt. #

Importance Description Comments/Status Why is This a Requirement?

1 1 Take accurate measurements Top PriorityThis is the only way to ensure the gear jaws are within the expected tolerances relative to oneanother.

2 1 Secure positioning of the assembly   Ensures assembly does not shift during measurement.

3 1 Conform to predefined budget  The customer cannot exceed their spending limit without approval from an executive.

10 1 Output corrective actions to spreadsheet  If parts do not conform, the customer needs to know how to fix them.

11 1Accommodate three specific machines (GP400, GP300, 130/210)

 This was specifically requested and the device will not meet customer requirements without this functionality. The customer would also like additional space to accommodate future machines.

13 1 Device measures critical surfaces 

All arbor contact surface profiles and position are critical to design intent. Based on customer feedback.

ENGINEERING REQUIREMENTS

rqmt. # Importance Source Function Engr. Requirement (metric)Unit of

MeasureMarginal

ValueIdeal Value

Test (how are you going to verify satisfaction)

1 1 CR 1 AccuracyGage Error From Ideal Over Full Measurement Envelope

inches ± 0.0002* 0 Gage Calibration

2 1 CR 1 Accuracy Rail Hole Position Tolerance inches ± 0.0002* 0 Rig Calibration (CMM)

3 3 CR 12 Efficiency Process Time minutes <20* <5 Stopwatch

4 2 CR 6, 14 Size Device Footprint sq ft <16 <9 Tape Measure

5 1 CR 3 Cost Prototype Cost $ <7000 <4000 Bill of Materials

6 2 CR 5, 6 Ergonomics Table Height ft ± 0.050 3* Tape Measure

7 2 CR 6 Ergonomics Device Weight Lbs <200* <120 Scale

8 3 CR 7 EfficiencyAverage Training Time Required by 90% of People Over the Age of 18

minutes <20* <10 Stopwatch

9 3 CR 1 AccuracyNumber of Components in Measurement System (Excluding Gages and Fasteners)

units <10* <5 Bill of Materials

10 1 CR 2 Accuracy Bolt Torque (Clamping Force) In-Lbs (Lbs) ±10 400* Torque Wrench

11 2 CR 11, 12 Efficiency Number of Operators Able to Work Simultaneously units 2 3 Count

12 1 CR 12 Versatility Specified Machines Accommodated binary Yes Yes Binary

13 1 CR 1 Accuracy Measurement System & Output Error ** inches ± 0.001 0 Rig Calibration (CMM)

14 1 CR 4 Docmentation Designs Delivered in Pro-E Format binary Yes Yes Binary

15 1 CR 1 Precision Measurement Results Repeatable inches ± 0.001 0 Rig Calibration (CMM)

16 2 CR 13 AccuracyAbility to Measure All Gear Contacting Surfaces on Existing Jaws

binary Yes Yes Binary

INITIAL SPEC

Need Priority Gag

e E

rror

Fro

m I

deal

Ove

r F

ull

Mea

sure

men

t E

nvel

ope

Rai

l Hol

e P

ositi

on T

oler

ance

Pro

cess

Tim

e

Dev

ice

Foo

tpri

nt

Pro

toty

pe C

ost

Tab

le H

eigh

t

Dev

ice

Wei

ght

Ave

rage

Tra

inin

g T

ime

Req

uire

d by

90%

of

Peo

ple

Ove

r th

e A

ge o

f 18

Num

ber

of C

ompo

nent

s in

Mea

sure

men

t S

yste

m (

Exc

ludi

ng G

ages

and

Fas

tene

rs)

Bol

t T

orqu

e (C

lam

ping

For

ce)

Num

ber

of O

pera

tors

Abl

e to

Wor

k S

imul

tane

ousl

y

Spe

cifie

d M

achi

nes

Acc

omm

odat

ed

Mea

sure

men

t S

yste

m &

Out

put

Err

or

Des

igns

Del

iver

ed in

Pro

-E F

orm

at

Mea

sure

men

t R

esul

ts R

epea

tabl

e

Abi

lity

to M

easu

re A

ll G

ear

Con

tact

ing

Sur

face

s on

Exi

stin

g Ja

ws

Take accurate measurements 1 x x x x xSecure positioning of the assembly 1 x xConform to predefined budget 1 xPro-E files of all components 2 xSafe to use 1 x xPortability 2 x xEasy to use 1 x xRapid positioning of the assembly 1 xDigitally record measurements 1 xOutput corrective actions to spreadsheet 2 xAccommodate three specific machines (GP400, GP300, 130/210)

3 x x

Rapid measurement 2 xDevice measures critical surfaces 3 xDevice fits in available shop space 1 x

Un

it o

f M

easu

rem

ent

Inch

es

Inch

es

Hou

rs

Fee

t

$

Fee

t

Pou

nds

Hou

rs

Uni

t

Lb-i

n (L

bs)

Uni

t

Bin

ary

Inch

es

Bin

ary

Inch

es

Bin

ary

INITIAL SPEC

Need Priority Gag

e E

rror

Fro

m I

deal

Ove

r F

ull

Mea

sure

men

t E

nvel

ope

Rai

l Hol

e P

ositi

on T

oler

ance

Pro

cess

Tim

e

Dev

ice

Foo

tpri

nt

Pro

toty

pe C

ost

Tab

le H

eigh

t

Dev

ice

Wei

ght

Ave

rage

Tra

inin

g T

ime

Req

uire

d by

90%

of

Peo

ple

Ove

r th

e A

ge o

f 18

Num

ber

of C

ompo

nent

s in

Mea

sure

men

t S

yste

m (

Exc

ludi

ng G

ages

and

Fas

tene

rs)

Bol

t T

orqu

e (C

lam

ping

For

ce)

Num

ber

of O

pera

tors

Abl

e to

Wor

k S

imul

tane

ousl

y

Spe

cifie

d M

achi

nes

Acc

omm

odat

ed

Mea

sure

men

t S

yste

m &

Out

put

Err

or

Des

igns

Del

iver

ed in

Pro

-E F

orm

at

Mea

sure

men

t R

esul

ts R

epea

tabl

e

Abi

lity

to M

easu

re A

ll G

ear

Con

tact

ing

Sur

face

s on

Exi

stin

g Ja

ws

Take accurate measurements 1 x x x x xSecure positioning of the assembly 1 x xConform to predefined budget 1 xPro-E files of all components 2 xSafe to use 1 x xPortability 2 x xEasy to use 2 x xRapid positioning of the assembly 2 xDigitally record measurements 2 xOutput corrective actions to spreadsheet 2 xAccommodate three specific machines (GP400, GP300, 130/210)

1 x x

Rapid measurement 2 xDevice measures critical surfaces 1 xDevice fits in available shop space 1 x

Un

it o

f M

easu

rem

ent

Inch

es

Inch

es

Hou

rs

Fee

t

$

Fee

t

Pou

nds

Hou

rs

Uni

t

Lb-i

n (L

bs)

Uni

t

Bin

ary

Inch

es

Bin

ary

Inch

es

Bin

ary

BENCHMARKING➢Coordinate-Measuring

Machine (CMM)

❖Automated or Manual

❖Five degrees of

freedom

❖Can be very accurate

❖Large measurement

envelope

BENCHMARKING CONT’D

➢ Mitutoyo Crysta-Apex EX 544TCMM Benchmark

Property Crysta-Apex EX 544T

Type Bridge

Range - mm (in)X-axis 500 (19.68)Y-axis 400 (15.74)Z-axis 400 (15.74)

Resolution - mm (in) 1x10-4 (4x10-6)Guide Method Air bearing

Degrees of Freedom 5Cost $$$

Total Mass - kg (lbs) 536 (1181)

BENCHMARKING CONT’D

➢ Crysta-Apex Cons

❖ Expensive

❖ Heavy

❖ “overkill” for this application

➢Don’t need automation

➢Don’t need controller

➢0.1 µm resolution not necessary

BENCHMARKING CONT’D

➢ Indicator

 

Indicator

Model

Property LH-600E/EG QM-Height Series 518-221

Crysta-Plus M443/574/710

6 Series 196

Resolution .000001 m .00005 m .000019 m

Accuracy (1.1+0.6L/600)μm

(.00011+.0002L/40)in

(3.0+4.0L/1000)μm

Envelope .972m .715m .4x.4x.3 m

Battery Life 5 hours/charge 260 hours / ∞ N/A

Degrees of Freedom 1 1 5

Cost $7,630 $2,701 ?

Mass 24 kg 22 kg 360 kg

RISK ANALYSISID Risk Item Effect Cause Likelihood Severity Importance Action to Minimize Risk Owner

1

Inaccurate gauges

The inspection measurements will not be accurate enough

Failure to benchmark and research indicators that will work best for the application

1 9 9

We will prevent and reduce this risk by putting in the time to properly benchmark and research measurement instrumentation

Katie, Evan, Josh, Doug

2

Station fails to support all machine models

Customer will not be able to inspect all machine models

Failure to receive drawings and prints of all models and jaws.

1 9 9

We will reduce the risk by communicating to the customer project developments and needs

Katie, Evan, Josh, Doug

3

Unable to accurately secure Jaws

The inspection measurements will not be consistent enough

Failure to secure rails onto inspection station.  (regular assembly method will be employed for assembling jaws)

3 9 27

This risk can only be reduced by locating the mounting rails as accurately as possible.

Katie, Evan, Josh, Doug

4

Running out of time

The customer will not receive a finished working part.

Poor planning and execution of project aspects and deliverables

1 9 9

This risk will be prevented by the group following a strict schedule for project deliverables

Katie, Evan, Josh, Doug

PROJECT PLANMicrosoft Project Schedule:

PROJECT PLAN

Next Steps:

➢ Continue to update/meet with Richard

➢ Begin concept development

➢ Work on HOQ, making sure to adjust to any

customer or engineering requirement

changes

➢ Further explore benchmarking ideas

➢ Visit a nearby metrology lab