NAME REG.

NO

AHMAD FAIQ IFWAT BIN AZMAM 24DTP20F1026

MUHD NAIM BIN OSMAN 24DTP20F1020

MUHAMMAD FIRDAUS BIN 24DTP20F1004

OTHMAN

MINI PROJECT 2
DJF51072: JIG AND FIXTURE DESIGN
SESSION 1 2022/2023

LECTURER’S NAME PN.ZALAIDA BINTI TALIB

 TABLE OF CONTENT

NO CONTENT PAGE
1.0 INTRODUCTION 3-4
1.1 OBJECTIVE PROJECT 4
2.0 METHODOLOGY 4-7
2.1 FLOWCHART 4-7
2.2 GANTT CHART 7
3.0 DRAWING 8 - 26
3.1 SKETCH DESIGN 8
3.2 DESIGN DETAIL 8 - 19
3.3 ASSEMBLY DESIGN 20 - 24
3.4 EXPLODED DESIGN 25 - 26
4.0 DISCUSSION 27 - 31
4.1 SUSTAINABILITY 27
4.2 ENVIRONMENTAL 28
4.3 THE PRINCIPLE OF FIXTURE 28 - 30
4.4 MAINTENANCE OF FIXTURE 31
5.0 CONCLUSION 32
6.0 REFERENCES 33
1.0 INTRODUCTION

A fixture is a work-holding or support device used in the manufacturing industry.

Fixtures are used to securely locate (position in a specific location or orientation) and
support the work, ensuring that all parts produced using the fixture will maintain
conformity and interchangeability. Using a fixture improves the economy of
production by allowing smooth operation and quick transition from part to part,
reducing the requirement for skilled labour by simplifying how workpieces are
mounted, and increasing conformity across a production run.

A fixture's primary purpose is to create a secure mounting point for a workpiece,

allowing for support during operation and increased accuracy, precision, reliability,
and interchangeability in the finished parts. It also serves to reduce working time by
allowing quick set-up, and by smoothing the transition from part to part. It frequently
reduces the complexity of a process, allowing for unskilled workers to perform it and
effectively transferring the skill of the tool maker to the unskilled worker. Fixtures also
allow for a higher degree of operator safety by reducing the concentration and effort
required to hold a piece steady.

Economically speaking the most valuable function of a fixture is to reduce labour

costs. Without a fixture, operating a machine or process may require two or more
operators; using a fixture can eliminate one of the operators by securing the
workpiece.

Fixtures should be designed with economics in mind; the purpose of these devices
is often to reduce costs, and so they should be designed in such a way that the cost
reduction outweighs the cost of implementing the fixture. It is usually better, from an
economic standpoint, for a fixture to result in a small cost reduction for a process in
constant use, than for a large cost reduction for a process used only occasionally.
 1.1 OBJECTIVES PROJECT

The objective of this project is:

I. To produce and design a suitable fixture based on the jig was designed from
previous project.

II. To securely locate, position in a specific location or orientation and support

the jig.

III. To create a simple but effective fixtures that have capacity to perform the
function and strong accommodating jig and its product.

IV. To make all the product achieve the required dimension for all manufacturing.

V. To create a productive fixture that can be used to do a production for a long

term.

2.0 METHODOLOGY

2.1 FLOWCHART

A flowchart is a formalized graphic representation of a logic sequence, work or

manufacturing process, organization chart, or similar formalized structure. The
purpose of a flow chart is to provide people with a common language or reference
point when dealing with a project or process. Flowcharts use simple geometric
symbols and arrows to define relationships.
Mini project brief

The starting of the mini project is started with a brief introduction about the
importance of Mini Project and presentation by lecturer.

Find group members

Find a group of member among classmates for mini project.

Planning

Planning stage is to focus more briefing the idea of the project. Plan the concept idea
of the design for jigs for mechanical application before started to sketch and dividing
task to team members.

Sketching

Sketching part is the part after know the problem to be solved. The sketching of the
project must have criteria or elements that always a jigs and fixtures need such as
clamping, locator, tool guiding and setting element. Then, develop the concept idea
to the purpose concept.

Checking

The product sketching need to be shown to the lecturer.A lecturer will decide
whether the product/parts can be accepted or not.If NO,a process will repeat at
planning stage.If YES, a process will continue to data analysis process.

Data Analysis

Data analysis is to analysis what kind of product that want to use. The process of
evaluating data using analytical and logical reasoning to examine each component of
the data provided. Data from various sources is gathered, reviewed, and then
analyzed to form some sort of finding or conclusion. There are a variety of specific
data analysis method, some of which include data mining, text analytics, business
intelligence, and data visualizations.

Design Outcome

Design that had been choose and proceed by a lecturer.

Final Design

Final design which is from design outcome that had been choose.
Technical Report

A report that records the procedure adopted and results obtained from a scientific or
technical activity or investigation. A report that include drawing details, objective of
the product and many more.

Presentation

Present our complete product to a lecturer.

2.2 GANTT CHART

A Gantt chart, commonly used in project management, is one of the most popular
and useful ways of showing activities (tasks or events) displayed against time. On
the left of the chart is a list of the activities and along the top is a suitable time scale.
Each activity is represented by a bar; the position and length of the bar reflects the
start date, duration and end date of the activity.

Task/Time Week 1 Week 2 Week 3

Mini project brief
Find group
members
Planning
Sketching
Checking
Data analysis
Design outcomes
Final design
Technical report
Presentation
3.0 DRAWING

3.1 SKETCH DESIGN

3.2 DESIGN DETAILS

 Parts Function Materials
Plate As a support of jig holder Mild steel
to base.
Base plate Acts as an interface Mild steel
between the
superstructure and the
foundation; thus,
completing the load path
into the foundation.
Jig holder To hold a jig and support Stainless steel
for clamping jig.
Hand wheel Enable movement of a jig Generic
and precise adjustment
when in working process.
Knob screw Tightening or Loosening Generic
which to lock movement
and adjustment of a jig
holder.
Clamp block Clamping parts where jig Mild steel
are attached to
Angle bracket To joint base and base Alloy steel
plate at 90 degree angle.
Nut Type of fastener that used Alloy steel
to fasten multiple parts
together.
Bolt 20mm Provide a clamp load or Alloy steel
preload
Bolt 30mm Provide a clamp load or Alloy steel
preload
 6 5 4 3 2 1

50,00
D D

100,00
TOP VIEW
( 1 : 10 )

n20,00
C C

ISO VIEW
( 1 : 10 )
1300,00

1300,00
B B

n20,00

50,00 100,00

Date Date
A Designed by Checked by Approved by
A
FRONT VIEW SIDE VIEW FAIQ IFWAT PN.ZALAIDA 28/10/2022

( 1 : 10 ) ( 1 : 10 ) PLATE DRAWING
POLITEKNIK BANTING SELANGOR Edition Sheet
FIXTURE PARTS 1/1
6 5 4 3 2 1
 6 5 4 3 2 1

740,00
D D
n20,00

50,00
50,00

TOP VIEW 30,00

(1:8)
50,00

C
ISO VIEW C
( 1 : 11 )
1200,00

B B

Date Date
A Designed by Checked by Approved by
A
FAIQ IFWAT PN.ZALAIDA 28/10/2022
FRONT VIEW SIDE VIEW BASE PLATE DRAWING
(1:8) (1:8) POLITEKNIK BANTING SELANGOR Edition Sheet
FIXTURE PARTS 1/1
6 5 4 3 2 1
 6 5 4 3 2 1

D n160,00 D

150,00

C C
TOP VIEW
(1:2) ISO VIEW
(1:2)

0
0,0
25,00

6
n1
B B
n30,00

n20,00

35,00
35,00

A FRONT VIEW SIDE VIEW Designed by Checked by Approved by Date Date

A
FAIQ IFWAT PN.ZALAIDA 28/10/2022
(1:2) (1:2) JIG HOLDER DRAWING
POLITEKNIK BANTING SELANGOR Edition Sheet
FIXTURE PARTS 1/1
6 5 4 3 2 1
 6 5 4 3 2 1

n2
90
,0 0

D D
00
R115,00 n8 5 ,

C TOP VIEW C
(1:4)

290,00
ISO VIEW
n50,00
(1:4)

30,00
20,00

B B
342,50

300,00
n30,00

A
FRONT VIEW SIDE VIEW Designed by
FAIQ IFWAT
Checked by

PN.ZALAIDA
Approved by Date Date

28/10/2022
A

(1:4) (1:4) HAND WHEEL DRAWING

POLITEKNIK BANTING SELANGOR Edition Sheet
FIXTURE PARTS 1/1
6 5 4 3 2 1
 6 5 4 3 2 1

D D

15,00 15,00
105,00
ISO VIEW
TOP VIEW (1:1)
C C
(1:1)

R1
5
00

,00
,
20
n

B B
n30,00

n20,00
45,61

FRONT VIEW SIDE VIEW

(1:1) (1:1)

Date Date
A Designed by Checked by Approved by
A
FAIQ IFWAT PN.ZALAIDA 28/10/2022

KNOB SCREW DRAWING

POLITEKNIK BANTING SELANGOR Edition Sheet
FIXTURE PARTS 1/1
6 5 4 3 2 1
 6 5 4 3 2 1
45,00

D D
30,00

TOP VIEW
C
(2:1) C
30,00

ISO VIEW
(2:1)
50,00

B B
n20,
00

5,00 15,00

FRONT VIEW SIDE VIEW

Date Date
A Designed by Checked by Approved by
A
(2:1) (2:1) FAIQ IFWAT PN.ZALAIDA 28/10/2022

CLAMP BLOCK DRAWING

POLITEKNIK BANTING SELANGOR Edition Sheet
FIXTURE PARTS 1/1
6 5 4 3 2 1
 6 5 4 3 2 1
50,00
120,00

D D
100,00

C C

TOP VIEW ISO VIEW

(1:1) (1:1)
0
2 0,0
n

B B

57,00

65,00
8,00
10,00 90,00
n20,00 n20,00

FRONT VIEW SIDE VIEW

Date Date
A Designed by
( 1 : 1 ) FAIQ IFWAT Checked by Approved by
A
(1:1) PN.ZALAIDA 28/10/2022

ANGLE BRACKET DRAWING

POLITEKNIK BANTING SELANGOR Edition Sheet
FIXTURE PARTS 1/1
6 5 4 3 2 1
 6 5 4 3 2 1

D D
43,30

C C
TOP VIEW
(2:1)

n3
ISO VIEW

0
,00
(2:1)

B B

30,00 43,30

Date Date
A SIDE VIEW
Designed by Checked by Approved by
A
FRONT VIEW FAIQ IFWAT PN.ZALAIDA 28/10/2022

(2:1) (2:1) NUT DRAWING

POLITEKNIK BANTING SELANGOR Edition Sheet
FIXTURE PARTS 1/1
6 5 4 3 2 1
 6 5 4 3 2 1

45,00

D 30,00 D

34,64
C C
TOP VIEW ISO VIEW
(2:1) (2:1)
20,00

B n20,00 B
n20,00
40,00

34,64

FRONT VIEW SIDE VIEW Date Date

A Designed by Checked by Approved by
A
(2:1) (2:1) FAIQ IFWAT PN.ZALAIDA 28/10/2022

BOLT 2OMM DRAWING

POLITEKNIK BANTING SELANGOR Edition Sheet
FIXTURE PARTS 1/1
6 5 4 3 2 1
 6 5 4 3 2 1

D D
165,00

150,00
34,64

C ISO VIEW C
(1:1)

TOP VIEW
34,64
(1:1)

n2
0 ,0
0
B B

n20,00
40,00

40,00
FRONT VIEW SIDE VIEW
(1:1) (1:1)

Date Date
A Designed by Checked by Approved by
A
AHMAD FAIQ PN.ZALAIDA 28/10/2022

BOLT 30MM
POLITEKNIK BANTING SELANGOR Edition Sheet
FIXTURE PARTS 1/1
6 5 4 3 2 1
 3.3 ASSEMBLY DESIGN

Assembly Fixture
Assembly Fixture with
Jig
Assembly Fixture with
Jig and Product
 6 5 4 3 2 1

7
8

D D
10

6
9 5

C C
4

2 1

B B

3
Date Date
A Designed by Checked by Approved by
A
FAIQ IFWAT MDM ZALAIDA 28/10/2022

FIXTURE BICYCLE FRAME ASSEMBLY

POLITEKNIK BANTING SELANGOR Edition Sheet
FIXTURE ASSEMBLY 1/1
6 5 4 3 2 1
 Part List

Item Quantity Parts Material

1 1 Base Plate Steel, mild

2 10 Bolt 20 mm Steel, alloy

3 2 Angle Steel, alloy

Bracket

4 1 Plate Steel, mild

5 1 Bolt 30mm Steel, alloy

6 2 Nut Steel, alloy

7 1 Jig Holder Stainless

Steel

8 2 Knob Screw Generic

9 1 Hand Wheel Generic

10 2 Clamp Block Steel, mild

 6 5 4 3 2 1

D D

C C

B B

PARTS LIST
ITEM QTY PART NUMBER DESCRIPTION
1 1 FIXTURE BICYCLE
FRAME
2 1 JIG BICYCLE FRAME
Date Date
A Designed by Checked by Approved by
A
FAIQ IFWAT PN.ZALAIDA 27/11/2022

ISO VIEW FIXTURE WITH JIG ASSEMBLY

POLITEKNIK BANTING SELANGOR
(1:7) FIXTURE WITH JIG
Edition Sheet
1/1
6 5 4 3 2 1
 6 5 4 3 2 1

D 1 D

C C

B B

PARTS LIST
ITEM QTY PART NUMBER DESCRIPTION
1 1 JIG BICYCLE FRAME
WITH PRODUCT
2 1 FIXTURE BICYCLE
FRAME
Date Date
A Designed by Checked by Approved by
A
FAIQ IFWAT PN.ZALAIDA 27/11/2022

ISO VIEW FIXTURE WITH JIG AND PRODUCT

(1:7) POLITEKNIK BANTING SELANGOR Edition Sheet
FIXTURE WITH JIG AND PRODUCT 1 / 1
6 5 4 3 2 1
 3.4 EXPLODED DESIGN

Part List
Item Quantity Parts Material
1 1 Base Plate Steel, mild
2 10 Bolt 20 mm Steel, alloy
3 2 Angle Steel, alloy
Bracket

4 1 Plate Steel, mild

5 1 Bolt 30mm Steel, alloy
6 2 Nut Steel, alloy
7 1 Jig Holder Stainless
Steel

8 2 Knob Screw Generic

9 1 Hand Wheel Generic
10 2 Clamp Block Steel, mild
 6 5 4 3 2 1

D 8 D

C 10 C
2

4
5
PARTS LIST
B B
ITEM QTY PART NUMBER MATERIAL
1 1 BASE PLATE Steel, Mild
2 10 BOLT 20MM Steel, Carbon
3 2 ANGLE BRACKET Steel, Carbon
4 1 PLATE Steel, Mild
5 1 BOLT 30MM Steel, Carbon
6 2 BOLT Steel, Cast
7 1 JIG HOLDER Stainless Steel
8 2 KNOB SCREW Generic
9 1 HAND WHEEL Generic
10 2 CLAMP BLOCK Leather, Dark Brown
1 3 Date Date
A Designed by Checked by Approved by
A
FAIQ IFWAT PN.ZALAIDA 27/11/2022

ISO VIEW FIXTURE BICYCLE FRAME EXPLODED

POLITEKNIK BANTING SELANGOR
(1:8) FIXTURE EXPLODED
Edition Sheet
1/1
6 5 4 3 2 1
4.0 DISCUSSION
4.1 SUSTAINABILITY

1. Reduced a cost of material

• We created a fixture design with another material that can be recycled so it
can reduce a cost of material and its still with a same efficiency as any fixture
in a marketplace.

2. Easy installation and handling

• A fixture designed are very easy to install from its part up to form a product
and don’t even need to use a heavy tools for the installation. The fixture also
can be held easily without a manual guide or high teaching stuff.

3. Reduced electricity consumption

• A fixture was designed without using electricity consumption. A fixture was not
attached to a machine. It was fully operated by human energy.

4. Accuracy and Efficiency of product

• A fixture can be used not only to produce a single product but can be used to
produce a product with a large quantity.

5. Stability of fixture design

• This fixture have a high support plate so it can’t be move of fall. The clamping
parts of fixture has a high grip which is a jig that placed on fixture also won’t
fall. This ensure that a productivity will increase.

6. Maintenance

• It is very easy to do maintenance on a fixture. Its only can be changed for a

certain parts of a fixture that found damages during working process.
Changing a certain parts are cheaper than changing all the parts.
 4.2 ENVIRONMENTAL

Noice Reduction
• The jig with its process are less produce a sound that can disrupting the
environment.

Zero Chemical Production

• It does not produce a chemicals in term of smoke that can harm humans life

4.3 THE PRINCIPLE OF FIXTURE

A fixture are assembled by parts.

Screw bolt that attached with clamp block at jig holder are loosened.

A jig are placed to its fixture at jig holder.

 Screw bolt at jig holder are tightened and clamping block will grip a jig
So that it does not move.

Process welding can be done. The function of hand wheel at the back of
fixture is to control movement or rotation of a jig so the welding process can
be done easily
 4.4 MAINTENANCE OF FIXTURE

• Cleaning stainless steel

Dirt deposits on stainless steel including dust, dirt, fingermarks, and

identification markings are easily removed. Frequently, warm or hot water with or
without detergent is sufficient. For slightly more aggressive cleaning, use
scouring powder with a small amount of vinegar. Rinsing in clean hot water
should always follow cleaning. When water is known to contain mineral solids,
which leave water spots, the surface must be dried with soft towels. Caution must
be used so the towels do not pick up abrasives and scratch the surface.
Oils can typically be removed using isopropyl alcohol or xylene. In cases where
these solvents don’t work, acetone, methyl or ethyl alcohol, toluene, and mineral
spirits will be more effective, but require some precautions. These solvents are
flammable and may leave behind a residue. It is important to remove all of the
contaminant and the residue by using a warm or hot water rinse or pressure
spray.
Adhesives are best removed using alcohol, xylene, or mineral spirits. It will often
leave streaking; therefore, should be followed with a glass cleaner or similar
cleaner that utilizes ammonia.

• Cleaning galvanized steel

Galvanizing may be cleaned using a water-based emulsifier, alkaline-based

cleaners with a pH of 12 or lower or organic solvents. Then rinse the area with
fresh water and simply wipe clean with a soft cloth.
For galvanizing product situated in a highly corrosive environment eg. coastal,
heavy industrial, etc it is recommended the product be rinsed with potable water
on a regular basis, particularly under sheltered conditions (i.e. not exposed to rain
and sun).

If there is physical damage to the galvanized coating of the product, it is

recommended that the damaged area be repaired in accordance with AS/NZS
4680.
5.0 CONCLUSION

Jigs and fixtures are manufacturing tools that are employed to produce
interchangeable and identical components. They are unique tool-guiding and work-
holding devices designed specifically for machining and assembling large number of
parts. They eliminate the need for a special set-up for every work-piece thereby
facilitating production and also ensuring that every work piece is manufactured within
a predetermined tolerance.

There are numerous advantages that are associated with the use of jigs and
fixtures, they include: production increase, low variability in dimension thereby
leading to consistent quality of manufactured products, manufacturing cost reduction,
interchangeability and high accuracy of parts, reduces the need for inspection and
quality control expenses, reduces accident as safety is improved, semi-skilled
machine operators can easily use them thereby saving the cost of manpower.

Other benefits are: the machine tool can be automated to an appreciable extent,
complex and heavy components can be easily machined, easy assembly operations
save labour, reduction of defective products, elimination of the need for measuring,
marking out, punching, positioning, alignments, and setting up for each work-piece
thereby reducing the cycle and set up time, increase technological capacities of
machine tools, setting of higher values of some operating conditions like depth of
cut, speed, and rate of feed can be attained because of the increased clamping
capability of jigs and fixtures.

As the conclusion, this project must achieve all the objectives above. From this
project, the design of the jig and fixtures of this mechanical application can rigid and
stable for support product during machining operation. This kind of jig and fixtures,
can make all product achieve the required dimension for all manufacturing process
because of the accuracy and economical of the jigs for this welding application. Also
can achieve less reject project and low cost of manufacturing because no rejection
during mass production.
6.0 REFERENCES

I. Wikipedia contributors. (2022a, February 10). Fixture (tool). Wikipedia.

https://en.wikipedia.org/wiki/Fixture_(tool)

II. Jigs and Fixtures CONCLUSION AND RECOMMENDATION 117. (n.d.).

https://text-id.123dok.com/document/ozlr339gz-jigs-and-fixtures-conclusion-and-

recommendation-117.html

III. Pocie, Z. (n.d.). jigs mini project.pdf. Scribd.

https://www.scribd.com/document/331690398/jigs-mini-project-pdf

IV. Wipulaguna, H. (n.d.). Introduction to jigs and fixtures.

https://www.slideshare.net/HasithaWipulaguna/introduction-to-jigs-and-fixtures-

69278551

V. Introduction To Jig & Fixture Design By Kempster [q6ngwwdrv6lv]. (n.d.).

https://idoc.pub/documents/introduction-to-jig-fixture-design-by-kempster-

q6ngwwdrv6lvWhy Cycling Makes Sense for Environmentally Sustainable Cities -

This Big City

VI. Sustainable Materials in Retail Fixture Design. (n.d.). Q20 Labs.

https://www.q20lab.com/sustainable-materials-in-retail-fixture-design