Final Project:

Product Analysis Project

Assignment

Reverse-engineer a product with at least one

substantial and unique part for each team
member.
Design a factory and manufacturing system for
the product. Each team member contributes a
manufacturing process for their part.
Read and summarize a recent publication in the
manufacturing literature related to your part.
10 minute power point presentation.
Project in a binder that I need to keep (return a
copy graded)

Goals

Apply what you have learned about

materials, metal-casting, plastics and
composites processing, metal-forming,
and machining to the mass-production
of a real part.
Learn how to access and apply
manufacturing literature.

Team Product

Pick something that interests you.

Pick something with substantial and
unique parts for everyone.
One fastener or spring per team.
Pick something easily disassembled,
ideally something that does not have to
work again.

Your Part, 1: Reverse Engineering

Reverse engineer your part using a 3D

modeling program (Solid Edge or
equivalent).
Create a reasonably accurate 3D model
of each part, then a dimensioned
drawing. Dimension and tolerance the
main features of the part.
You may create a company title block.
Be sure to include material on the
drawing.

Your Part, 2: Manufacturing Process

Create a route sheet like Figure 2-6 for

each part.
The route sheet shall describe each
manufacturing operation you think is
required for your part, and the
equipment and tooling required.

Process Routing

FIGURE 2-6 Part drawing for a punch used in a

progressive die set (above) with the route sheet
(traveler) for making the punch. The route sheet
is used in the job shop to tell the material
handler (forklift truck driver) where to take the
containers of parts after each operation is
completed. The manufacturing engineer
designs the process plan or sequence of
operations to make the product.

Your Part, 2: Manufacturing Process

Create a process plan like Figure 2-7 for
each part.

The route sheet shall describe each

manufacturing step you think is required
for your part within an operation and the
equipment and tooling required.
Also include in-process quality control
operations.
Design the manufacturing process using
lean concepts (eliminate waste, 100%
quality, single-piece flow, u-shaped
cells).

You may not be able to give as much

detail as Figure 2-7 in the text; give your
best assumptions.

Process Plan

FIGURE 2-7 The manufacturing engineer

designs the process plan or sequence of
operations to make the product. (SHEET
MODIFIED FROM ONE IN TEXT)

NAME of PART:

PART NUMBER

QUANTITY:

REV:

PREPARED BY:

APPROVED BY:

Operation Number
10
20
30

Name of Operation

Machine
Tool

MATERIAL

Tooling Required

DATE

Inspection / Remarks

Your Part, 3: Manufacturing Literature

Use the library to find a recent (>= 2000)

article or book related to the
manufacture of your part.

Study the document.

Summarize the document in 3-4
paragraphs.

Write an additional paragraph describe

what you learned from finding and
reading this document.

Team Items

Product description
Make and Model (real world)
Price (real world)

Customers (real world)

Assumptions about making the product for this
assignment (materials, production quantities,
factory type and size, etc.)

Create a process flow chart like Figure 2-5

for your product. Note you may have
multiple subassemblies, and this should
include all parts in your product, not just the
ones you are analyzing.

Process Flow Chart

FIGURE 2-5 The process flow
chart for a personal computer
defines how the product comes
together.

Team Items

Create a block diagram like Figure 2-4

(simple shapes describing each station)
of your factory showing the part
manufacturing processes and the sub
and final assembly processes. Use arrows
to show part and product flow.

FIGURE 2-4 The block diagram provides information

for the material handler regarding the path the
container of parts takes through the job shop for the
manufacture of a punch.

Schedule
Wednesday, 11/19: Bring in your proposed product.
Friday, 12/3: Part drawings complete.
Monday 12/8: Part route sheets complete.
Friday 12/12: Factory layout complete.

Friday 12/12: Exam

12/15 Class Presentations - Class starts at

9:15 and ends at 11:30.