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)

By

Sairizal bin Misri

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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 : ………..

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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

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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

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LIST OF FIGURES

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

3.6 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

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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

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

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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

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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

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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

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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

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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

Design Improvement On A Method Of Inflating The Inflatable Articles.

UNIVERSITI TEKNIKAL MALAYSIA MELAKA