Trolley Jack Report

Trolley Jack Manufacturing Report
ARMSTRONG M901
Hydraulic Trolley Jack
Manufacturing Report
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Introduction
This document includes information and documentation for creating a part of an automotive
trolley jack. The trolley jack to be examined is manufactured by Armstrong, Model number
M901. The intended use is for lifting vehicles up to a rated capacity of 2500Kg with a lifting
range of 133-483mm. Hydraulic jack oil is used and the jack is manufactured to AS/NZS
2615-1995 standards. Focus on the manufacture of the right side plate will identify various
processes that are based on cost and fitness for use.
Figure 1 Trolley Jack Dimensions
Figure 2 Right Side Plate of Jack
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Figure 3 Right Side Plate Engineering drawing

Parts Analysis
The trolley jack consists of seventy seven parts that are off the shelf, cast, machined or
pressed that are used in the manufacture.
Component manufacture classes
Cast Machined Pressed

Front wheel Cylinder Parallel link
Base Reservoir Left hand side plate
Handle fork Piston rod Right hand side plate
Lifting arm Pump piston Washer
Chart 1 Component Classes

Parts that are cut from one standard piece of raw material include:
 Parallel link
 Washer
 LH side plate assembly
 RH side plate assembly
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Off the shelf parts used in the manufacture include:

 Cotter pins
 Nuts
 Bolts
 Lock washers
 Return Spring
 Washers
 Bearings
 O’Rings
Side plate inspection

Closer inspection of the right side plate identifies numerous manufacturing processes
including casting, machining, press cutting and bending, straight cuts with the use of a
guillotine and oxy acetylene welding and cutting. The trolley jack is based around the $100
sale mark so manufacturing materials and processes must be cost effective.
Right side plate blueprints
Figure 4 Front Side Figure 5 Top Side Figure 6 Bottom Side
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Figure 7 Right Side

The right side plate is made from 6mm mild steel plate and is cut to size using a guillotine for
the straight edges and an oxy acetylene torch for cutting corners. 10mm (3), 20mm (1),
15mm (1), 26mm (1) and 30mm (1) diameter holes are cut into the plate using a press
punch. 32mm outside diameter mild steel pipe 15mm in width is chamfered at 45 degrees
(inside and out) at one end while the other end of oxy welded to the right side plate, lining
up with the 26mm diameter hole. Mild steel bar stock of diameter 30mm is bored out to
18mm diameter and threaded to M12 x 1.5 is pressed into a mild steel cast ring with 55mm
outside diameter and oxy welded together. The welded pieces are then welded to the right
side plate, lining up with the 30mm hole in the plate.
The wheel support bracket is made of 6mm mild steel plate and is cut to shape by guillotine
and oxy cutter. A hole is cut into the bracket using a press and then the bracket pressed into
shape with a shape bender. Mild steel cast bar stock of outside diameter 25mm is bored to
20mm diameter and oxy welded to the right side plate. A small piece of 6mm plate is cut
and oxy welded to the back inside of the right plate.
Note: All welded parts are preheated before welding.
Figure 7 Right Side Plate with Hole and Wheel Support Bracket Locations
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Figure 8 Shows Chamfered Edges, Welding and Internal Thread.
Figure 9 Wheel Support Pressed Component
Figure 10 Cast Wheel Support and Welding Locations
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Justification of materials and processes

Mild Steel in sheet and bar stock represents the best strength and lowest cost compared to
aluminium. Aluminium is more temperature sensitive which requires a more expensive
cutting process.
Oxyfuel cutting represents the best choice for making the right side plate. It requires low
cost equipment and has a wide range of uses including welding, heating and cutting. It’s
portable and cuts a wide range of thicknesses that is advantageous in high production runs.
However cutting is slower than other systems, not capable of tight tolerances and has a large
heat affected zone.
Other possible cutting processes include plasma arc cutting which is faster than oxyfuel but
costs more and leaves a large heat affected zone. Water jet systems produces a small heat
affected zone and suited to high performance metals. It cuts slower than both oxyfuel and
plasma and has a higher entry cost. Laser cutting is the best metal cutting system providing a
precise cut with the narrowest heat affected zone it’s also the most expensive and not
suitable for this application.
Sheet metal cutting in the form of a guillotine have the ability to make straight line cuts and
is the cheapest form of cutting. Other cutting systems include blanking, edge bending and
punching with the use of a press. These cutting systems other low capital investment and
offer a wide range of uses. Deciding which metal cutting system is best is based on the end
user. Edge cleanliness and tolerance don’t have a huge importance, low capital investment
and operating costs are important and play an important factor in what types of processes
are used. Based on these principles the use of mild steel, oxyfuel cutting and welding,
punching and shaping with the use of a press offer the best cost effective manufacturing
process.
Quality assurance
Hydraulic trolley jacks sold in Australia must conform to AS/NZS 2615-1995, meaning that
trolley jacks must meet all mandatory requirements for design and construction,
performance, testing, safety markings and instructions (ACCC, 2013). The Armstrong M901
conforms to all these standards as safety labels are shown on the jack and instructions are
supplied, these are just a few of the long list of requirements.
Estimation of manufacturing cost
The fluctuating price of mild steel and other metals impacts the stable overall price. The
time to produce trolley jack (based on a 10000 items) is calculated at $25 USD. The cost of
labour considers the all staff required to produce a completed item at $15. The cost of
machinery per item comes to $18.
Some solutions come from the use of single or very limited number of cost indicators such as
the time and they define a minimal cost per hour but other factors such as machinery
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consumables need to be considered and therefore do not provide an accurate

representation of the costs (Perry et el. 2004).
Conclusion
The Armstrong M901 hydraulic jack is AS/NZS 2615-1995 compliant. Focus on the
manufacture of the right side plate identified every process and how the cost effective
processes including the use of mild steel plate, oxyfuel cutting and welding, pressing and
punching with a press proved to be valuable across many processes. The alternatives were
considered and given reasoning why the cheaper options were chosen. Despite adhering to
strict standards, the manufacturing costs were able to restrict to a level where pricing can
remain competitive.
References
Australian Competition and Consumer Commission 2013, Trolley jacks: Supplier guide, to
AS/NZS 2615-1995, Australian Competition and Consumer Commission, Canberra.
Perry, N., Mauchand, M. & Bernard, A. 2004, ‘Cost models in design and manufacturing of
sand casting products’, integrated design and manufacturing in mechanical engineering, Vol.
24 no. 2, pp 1-10.
Acknowledgments
Figures 1, 2, 7, 8, 9 & 10 provided by Maheen Syed
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Trolley Jack Manufacturing Report

Hydraulic Trolley Jack

Figure 1 Trolley Jack Dimensions

Figure 2 Right Side Plate of Jack

Figure 3 Right Side Plate Engineering drawing

Cast Machined Pressed

Chart 1 Component Classes

Off the shelf parts used in the manufacture include:

Side plate inspection

Right side plate blueprints

Figure 4 Front Side Figure 5 Top Side Figure 6 Bottom Side

Figure 7 Right Side

Figure 8 Shows Chamfered Edges, Welding and Internal Thread.

Figure 9 Wheel Support Pressed Component

Figure 10 Cast Wheel Support and Welding Locations

Justification of materials and processes

Estimation of manufacturing cost

consumables need to be considered and therefore do not provide an accurate

Figures 1, 2, 7, 8, 9 & 10 provided by Maheen Syed

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