Design Improvement On A Method Of Inflating The Inflatable Articles.

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UNIVERSITI TEKNIKAL MALAYSIA MELAKA

Design Improvement on a Method of Inflating the

Inflatable Articles

Thesis submitted in accordance with the partial requirements of the Universiti Teknikal Malaysia Melaka for the

Bachelor of Manufacturing Engineering (Robotic and Automation)

Sairizal bin Misri

Faculty of Manufacturing Engineering April 2007

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APPROVAL

This thesis submitted to the senate of UTeM and has been accepted as partial fulfillment of the requirements for the degree of Bachelor of Manufacturing Engineering (Manufacturing Robotic and Automation). The members of the supervisory committee

are as follow:

………. Supervisor

En Nik Mohd Farid Che Zainal Abidin Faculty of Manufacturing Engineering

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DECLARATION

I hereby, declare this thesis entitled “Design Improvement on a Method of Inflating the Inflatable Articles” is the results of my own research

except as cited in the reference.

Signature : ……….. Author’s Name : ……….. Date : ………..

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ABSTRACT

In this thesis have to develop design assembly product using Autodesk Inventor and analyze the data manufacture and costing in production using TeamSET software. In making the several designs, it focuses on current design and analysis it and then decides the final design. In decide the final design analysis the result for machining and the process in make each part component like manual machining, auto machining, CNC machines and investment casting. This all type machining define from graph between the component cost and annual production quantity. In this thesis also analyses the assembly analysis, design efficiency, handling analysis and analysis limits. Beside that, it have to design for assembly and manufacturing analysis (DFA/MA) Summary to get the data about how many part, A parts, Design Efficiency, Handling Time, Assembly Time, Total time, Labor Time and design of assembly option. This also define the result for design to cost (DTC) Summary about cost for the product design efficiency, production quantity, production cost, cost pr production, tooling cost, total cost, target cost and variance. Finally from the all result, it shows the improvement for the product between current assembly design and final assembly design from machining selection, material selection and design efficiency. It also defines the ergonomic design for the product concept for the human in using it.

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DEDICATION

1 dedicate this PSM thesis to my beloved parents, Sopiah Konting and Solehen Misri, my beloved brothers, Mohd Safie Misri and Ahmad Ismail Misri,

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ACKNOWLEDGEMENTS

Bismillahirrahmanirrahim. Alhamdullillah, with the helps and blessings from Allah S.W.T., 1 had managed to complete this project successfully. First of all, I would like to thank my parents, for their concern and support, all over the time. Not forgotten my brothers and sister, who had helps me a lot supporting me physically and morally.

I also want to thank Mr. Nik Mohd Farid Che Zainal Abidin from Faculty of Manufacturing Engineering, Universiti Teknikal Malaysia Melaka, for supervised me all along this project, and provide helps, guidance, ideas, and suggestions to accomplish this project. All the supports and motivation that been given to me are greatly appreciated.

Also not forgotten, Mr. Najib Manan as leader for this project has giving a permission to conduct the design improvement assembly parts.

With a deep sense of gratitude, I would also like to express my sincere thanks to my colleague, Nor Afandi Shafrif, MuslimWan Harun, Muhammad Zhafran and Wan Shahrulnizat for the helps and supports that been shown by them.

Finally, last but not least, thanks to all my friends who had helped me directly or indirectly in completing this project and thesis in time.

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Abstract ………. ……… i

Dedication…...……… ii

Acknowledgement…………. ……… iii

Table of Contents……. ..……… iv

List of Figures ……… vii

List of Tables………. ……… ix

Sign and Symbols………..………….……… x

List of Appendices……….. xii

1. INTRODUCTION……. …..……… 1

1.1 Introduction………. ……… 1

1.2 Problem Statement………... ……… 2

1.3 Objectives……… ……… 2

1.4 Scopes…………. ……… 3

1.5 Project Planning………. 4

1.6 Summary………...4

2. LITERATURES REVIEW……… ………. 6

2.1 Introduction ………….………. 6

2.2 Internal Combustion Engine……….. 7

2.3 Two Stroke Engine………... 8

2.4 Four Stroke Engine………... 10

2.5 Introduction Sparkplug……….. 12

2.5.1 The Parts of the Spark Plug………. 14

2.6 Location Spark plug at Motorcycle………...18

2.6.1 Motorcycle 2 Stroke Engine……….. ……… 18

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2.7 Thermal Properties……….22

2.7.1 Introduction……… ………. 22

2.7.2 Heat Capacity………. .. 22

2.7.3 Thermal Expansion………... 24

2.7.4 Thermal Conductivity……… 24

2.7.5 Thermal Stresses……….……….. 25

2.8 Design Manufacturing and Assembly (DFMA)………26

2.8.1 The design for manufacture………..……… 26

2.8.2 The design for assembly………... 29

2.8.3 Product Design Manual Assembly………. 30

2.8.4 T he Lucas DMA Evaluation………. 40

2.9 Summary……….45

3. METHODOLOGY ………..…. 46

3.1 Introduction……….……… 46

3.2 Define the Air Pressure Plug Problem……….. 49

3.3 Literature Review Design Manufacturing Assembly and Location Sparkplug……….….. 49

3.4 Identify the Air Pressure Plug………. 50

3.5 Design the Current Product and Component Using Autodesk Inventor……… 50

3.6 Study the TeamSET Software………. 52

3.7 Analysis the Current Design Using TeamSET……….. …. 56

3.8 Development Concept……….……… 56

3.8.1 Brainstorming………..…. 57

3.8.2 Concept Selection……… .58

3.8.3 Air Pressure Plug Method……… 58

3.9 Choose the Final Design Product………. 59

3.10 Embodiment Design………. 60

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3.10.1.1 Material Selection for Air Pressure Plug………..61

3.11 Analysis the Final Product……… 61

3.12 Discuss the Analysis Product……… 62

3.13 Conclusion and Discussion………... 62

3.14 Summary………...…63

4. PRODUCT CASE STUDY ………..…... 63

4.1 Introduction………...………64

4.2 Concept Current Air Pressure Plug………....………..65

4.2.1 How to use the Air Pressure Plug………..…..65

4.2.2 Advantages of the Product……… …………...66

4.2.3 Current Design for Air Pressure Plug………...68

4.2.4 Product Structure and Parts Quantity………...68

4.2.5 Assembly Drawing………...70

4.2.6 Exploded Drawing………...70

4.2.7 Bill of Materials………...71

4.2.8 Part Functions………...73

4.2.9 TeamSET Analysis………...77

4.3 Development Concept………...80

4.3.1 Brainstorming ………...80

4.3.2 Concepts Design Evaluation………82

4.3.3.1 First Concept………82

4.3.3.2 Second Concept………83

4.3.3.3 Third Concept………...84

4.3.3.4 Forth Concept………...85

4.3.3.5 Fifth Concept………86

4.3.3.6 Sixth Concept………...87

4.3.3.7 Seventh Concept………...88

4.3.3 Concept Selection………89

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4.3.3.2 Concept Evaluation………91

4.3.4 Design Assembly Development…………...92

4.4 Summary………...95

5. RESULT ………... 96

5.0 Introduction………...………...96

5.1 Final Design Air Pressure Plug……….………97

5.1.2 Products Structure and Parts Quantity ………..…………...98

5.1.3 Exploded Drawing ………..…….………...99

5.1.4 Bill of Material ………..………...………100

5.1.5 Parts Function………..……….……….101

5.1.6 Function for Final Design Air Pressure Plug ……….……..104

5.2 Calculation System……….……….…... 106

5.2.1 Introduction ………..………....…106

5.2.2 Calculation System Air Pressure Plug ...……..…………...…….….106

5.3 The Simulation Analysis ……….………...108

5.4 TeamSET Analysis ……… ………....109

5.4.1 Introduction………..………...………..109

5.4.2 Result for Final Design ……….………...109

5.5 Material and Process Selection ………...111

5.6 Process and Material Cost Selection ………...……....………...112

5.7 Summary………118

6. DISCUSSIONS ………...119

6.1 Introduction………...…119

6.2 Discussion………...120

6.3 Summary………124

7. CONCLUSION & RECOMMENDATION……….…...125

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7.2 Conclusion………..126

7.3 Recommendation………127

REFERENCES……….………128

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LIST OF FIGURES

2.1 Two Stroke Engine 8

2.2 Four Stroke Engine 10

2.3 The Process Spark Plug 12

2.4 The Spark in Spark Plug 13

2.5 Electrode in Spark Plug 13

2.6 Parts in Spark Plug 14

2.7 Yamaha 125 Motorcycle 18

2.8 Yamaha RXZ Motorcycle 18

2.9 RG Sport Suzuki Motorcycle 19

2.10 Suzuki Motorcycle 19

2.11 EX5 Honda Motorcycle 20

2.12 Kriss Modenas Motorcycle 20 2.13 Lagenda Yamaha Motorcycle 20

2.14 Wave Honda Motorcycle 21

2.15 Kristar Modenas Motorcycle 21 2.16 Formula Thermal Conductive 24 2.17 Compatibility Matrix between Process and Material 28 2.18 Shape General Capabilities of Process 29 2.19 Geometrical Features Affect Part Handling 31 2.20 Some other features affect Part Handling 32

2.21 Incorrect Geometry 32

2.22 Provision of Air-relief passages to Improve Insertion into Blind Hole 32 2.23 Design of Ease of Insertion assembly of long stepped bushing

into counter bored Holes 33

2.24 Provision of Chamfer to Allow Easy Insertion 33

2.25 Standardize Parts 33

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2.27 Provision of self location features to avoid holding down and alignment 34

2.28 Designs to Aid Insertion 35

2.29 Common Fastening Method 35 2.30 Insertion from Opposite Direction Requires reposition of assembly 35

2.31 Control Assembly 37

2.32 Completed Worksheet Analysis for the Control Assembly 37 2.33 Conceptual Redesign of the Controller Assembly 38 2.34 Completed Analysis for the Controller Assembly Redesign 39

2.35 The Lucas DFMA 41

2.36 Assembly Sequence Flow chart Example 43

2.37 Redesign Example 44

3.1 Summary of Method for the First Semester 47 3.2 Summary of Method for the First Semester 48 3.3 Screens in Autodesk Inventor 51

3.4 The Design for Assembly 53

3.5 The Function Analysis 53

3.6 Manufacturing Analysis 54

3.7 Volume Calculation 54

3.8 Shape Legend 55

3.9 Manual Handling Analysis 55

3.10 Insertion Process 55

4.1 Following Step in Fitting the Product in Motorcycle 66

4.2 Type Pump 67

4.3 Current Pump 68

4.4 Product Structure Air Pressure Plug 69

4.5 An Assembly Drawing 70

4.6 Exploded Drawing of the Product 3 71 4.7 TeamSET assembly Report for Current Design 78

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4.8 Design Cost for Current Design 79 4.9 First Concept Air Pressure Plug 80 4.10 Design for Valve Assembly 80 4.11 Design for Second Valve Assembly 81 4.12 Design for Coupling Assembly 81 4.13 Design for Normally Closed Valve Assembly 81 4.14 First Concept Air Pressure Plug 82 4.15 Second Concept Air Pressure Plug 83 4.16 Third Concept Air Pressure Plug 84 4.17 Ford Concept Air Pressure Plug 85 4.18 Five Concept Air Pressure Plug 86 4.19 Six Concept Air Pressure Plug 87 4.20 Seven Concept Air Pressure Plug 88

4.21 Concept Evaluation 91

4.22 Design Development 1 92

4.23 Design Development 2 93

4.24 Design Development 3 93

4.25 Design Development 4 94

4.26 Insulator before 94

4.27 Insulator after 94

5.1 The Final Design Assembly 97 5.2 The Air Pressure Plug Final Design 97 5.3 Product Structure of Air Pressure Plug Final Design 98 5.4 Exploded Drawing for the Final Design 99

5.5 Parts Function 103

5.6 The Cross Section Final Design Show the Pressure Flow 104 5.7 The Cross Section Final Design show the Section Parts 104 5.8 Show the Location Product at Engine Motorcycle 105 5.9 The Section Pressure Flow from Combustion Engine 106

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5.10 The Result for the Maximum Yield Strength 108 5.11 TeamSET assembly Report 110

5.12 The Graph for Ball Part 112

5.13 The Graph for Bush Part 113 5.14 The Graph for Handle Part 114 5.15 The Graph for Housing Part 115 5.16 The Graph for Shaft Part 116 5.17 The Graph for Fitting Body Part 117

6.1 Location Air Pressure Plug 122

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LIST OF TABLES

2.1 Tabulation of the Thermal Properties for a Variety of Material 23 2.2 Design for Assembly Worksheet 36 2.3 Design Change and Associated Savings for the Controller Assembly 38

4.1 Bill of the Material for the Current Product 72 4.2 Parts Function and Critics 76

5.1 Bill of Material for the Final Design 100

5.2 Material Selected 111

5.3 The Cost for Ball Part 112

5.4 The Cost for Bush Part 113

5.5 The Cost for Handle Part 114 5.6 The Cost for Housing Part 115

5.7 The Cost for Shaft Part 116

5.8 The Cost for Fitting Body Part 117

6.1 The Result from TeamSET software for the comparison between Current Design

and Final Design 121

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SIGN AND SYMBOLS

PSM1 - Projek Sarjana Muda 1 PSM2 - Projek Sarjana Muda 2

UTem - Universiti Teknikal Malaysia Melaka H - Height

Dh - Height different Dt - Time different

G - Gravity acceleration/force = 9.81 ms-2 K - Parameter used for gain in calculation J - Inertia

ε - Epsilon parameter = 8.8541-12

AEM - Assembly Evaluation Method CA - Conformability Analysis DFA - Design for Assembly DFM - Design for Manufacture

DFMA - Design for Manufacture and Assembly DFQ - Design for Quality

FMEA - Failure Mode and Effects Analysis ISO - International Organization of Standards MA - Manufacturing Analysis

PDS - Product Design Specification PIM - Product Introduction Management QFD - Quality Function Deployment ap - Additional assembly process risk

Cp - Process capability index (centered distributions) Cpk - Process capability index (shifted distributions) C, - Coefficient of variation

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LIST OF APPENDICES

Appendix A: Detail drawing for current design

A1: Detail drawing air pressure plug current design A2: Detail drawing 3D air pressure plugs current design A3: Assembly air pressure plug current design

Appendix B: Detail drawing for final design

B1: Detail drawing air pressure plug final design B2: Detail drawing 3D air pressure plugs final design B3: Detail drawing for housing part

B4: Detail drawing for insulator part

B5: Assembly 3D air pressure plug final design B6: Assembly air pressure plug final design

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CHAPTER 1 INTRODUCTION

1.1 Introduction

Design Improvement Air Pressure Plug on a method of Inflate in a Flatting Articles. This title is corresponding to the improvement of air pressure plug. Generally this product or prototype is an air pump for the motorcyclist. The function of this product is just like an ordinary pump in the market now which used to inflate the tire when the tire punctured or less of air. But with this product it will gives more benefit and functionality to the user. The most advantage of this product compare to the ordinary pump is save energy, time and mobile.

That designers should give more attention to possible manufacturing problems has been advocated for the product. The idea was that a competent designer should be familiar with manufacturing processes to avoid adding unnecessarily to manufacturing costs during design. This is the aspect of product design mainly considered.

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1.2 Problem Statement

Air pressure plug in current design have some problem when using it, the problem that detected is;

1. The product are used on several type of motorcycle because the size to large. 2. It take a along time to make the product, just for one product.

3. It cannot filter the residue oil in the air pressure plug when the pressures flow on it to pump the tire.

4. To assembly the component it to simple and easy to leak when the air pressure plug function.

5. It not safe for human to touch it when it function because it to hot and take a time to reduce the temperature.

So from this problem, redesign the product and assembly it. Than analysis using the TeamSET software that calculated the data in analysis the fitting, assembly and estimate cost.

1.3 Objective of the Research

1) Reducing the number of parts

2) Design product to get the improvement result in assembles and manufacture for production.

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1.4 Scopes

In order to design improvement product, scopes are required to assist and guide the development of the project. The scope should be identified and planned to achieve the objective of the project successfully on the time.

The scopes for this project are such as below.

a. Collect Data

Collect necessary data on the current air pressure plug and assembly design by conducting case studies. From the case studies, current problem, material and manufacture of the product are identified.

b. Analysis the Assembly Design.

Analysis for the assembly design and develop the result for design efficiency, material cost and machining cost were developed by the aid of TeamSET software.

c. Create the Final Design

Create a final design that development from many concept and show the improvement analysis.

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1.5 Project Planning

This is the schedule in planning the project, before we start. In here we follow the direction way when we beginning the project and ending the project. The Project 1 schedule show the planning project for semester 1 and the project 2 schedule show the planning project for semester 2.

1.6 Summary

This section is about, the introduction about the product and project, then it defines the problem statement for current design and makes the objective to be the main point and focus product. Next the scopes that must be follow in research and develop it and lastly the planning from the beginning to the end in making this product.

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CHAPTER 2 LITERATURE REVIEW

2.1 Introduction

In literature review have list about information that related with the project. So the information that has been taken is about combustion engine such as two strokes and four strokes. The plug location for each type engine motorcycle also include for this project. It also inform about thermal properties because the project related on higher temperature when in operation.

In main objective is to design improvement air pressure plug on a method of inflate in a flatting articles so in make improvement, it use the design for manufacturing and assembly (DFMA). In making the design for manufacturing and assembly, it using TeamSET software in this project, in other software that also have a same function such as Boothroyd Dewhurst DFMA Software.

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CHAPTER 1

INTRODUCTION