Lean Manufacturing ME410

Tyler, Nathan, Waleed, Mark

Block Project Deliverables
5/24 /17
 Manufacturing Procedures Discussion

Our first draft of the manufacturing plans for each part changed throughout the lab. We noticed

there were more efficient ways to do each step and quicker methods of operations that could speed up

the overall time. Once we had familiarity with the machining setup and operation we were able to move

more efficiently on each part. One method to improve the procedure setup time would be to include a

dial gauge mounted to the side of the lathe for zeroing the run-out. By having an arm with a dial gauge

that swings out from the side of the lathe we would be able to cut the time in half it takes to zero the

part. This could save an additional 10 minutes, which adds up quickly to help lean the process of

manufacturing. Another way to increase efficiency would be to have a set of separate drill bits for each

lathe machine. In addition, checking the tool sharpness before making the cut saves time that would

require us to take the tool back out and replace it with another. Lastly, on the female lathe part we

could have used a larger diameter drill bit, then switched to the boring method to reduce cutting time.

Delegating tasks out beforehand would have been a lot more helpful. Instead of having each

person run through the same operation on the same part, we could have decided on one person to

machine each part individually. Then this would allow one person to take notes for the lab, and allow

another student to help out with calculations and setup. Furthermore, being able to use the dial calipers

and micrometers effectively and getting readings quicker would have reduced production time for each

part. Finally, to make the process more efficient we could have also divided each of the parts between

the groups. That way we wouldn't lose time between changing tools.
Mark, Waleed, Nathan, Tyler

Fit:

Most of the parts fit with the other groups. The majority of the tolerance problems we are

running into with the other teams pieces are the female and male lathe parts as well as the pin. Our

Female lathe part fit with each of the male parts. Additionally, our top block was within tolerance of the

other groups pieces. In the end, our top and bottom block pieces were very snug but within tolerance.

Finish:

We still need to finish sanding on the round lathe parts in order to make them fit better since

they are so close to tolerance. This will take off approximately one thousandth of an inch. The majority

of the finishing on the parts we made was the result of having the machine auto feed within a couple

thousandths of an inch. Our final finish of each part were

Tolerancing:

On most of our parts we focused a lot on tolerance and this might have hindered our ability to

stay on schedule. But, most of the other groups had issues with making parts fit and some had to redo

pieces. During manufacturing, the dimension that was the hardest to achieve was the inside diameter

of the female lathe part. Because we had to constantly check with an inside mic, the total time to finish

the machine part was exceedingly longer than the other pieces. This process is something we were

always constantly checking and rechecking in order remain within tolerances.

 Two strengths:

Communication has been outstanding. Our mentality to make the part right the first time instead of
having to start over.

Two improvements:

Delegating and deciding beforehand which process each person is supposed to do before going out to
the machine the part. Meeting beforehand continuously to go over manufacturing plans.

One strength and one improvement for block project itself:

We gained a lot of experience with each machine and the tools used to make the block project. Having a
little more class time that taught us the basics beforehand, such as setting up the lathe or mill.
 Manufacturing Process

Bottom Block 2-01 (center milling)

Bottom block (tapping process)

 Top Block 2-02

Female Lathe 1-01

Final product:

Bottom Block 2-01

 Top Block (2-02)

Female Lathe 1-01

Male Lathe 1-02

Lathe pin 1-04