1. Co-op Final Presentation
Name: Andrew Littlejohn
Department: ALDC
Supervisor: Rick Niekamp
Mentors: John Pletcher, Jason Oldiges
University: Edison Community College & Miami University 2+2
Academic Level: Senior
Expected Graduation Date: May 2016
Major: Electro-Mechanical Engineering Technology
Co-op Term: Second within HAM
Project Summary:
1.)Implement New Model Die Confirmation CMM
Laser Scan Programs for cylinder blocks and heads
5. Implement New Model Laser Scan Programs for Cylinder Heads & Blocks
Current Situation
Objectives
New Idea/Concept/Improvement
Planning/Testing/Implementation
Impact/Benefit/Result
Develop and implement scan and inspection programs
utilizing the existing SurfaceMeasure 610 Line Laser
Probe to scan, measure, and evaluate parts
•New model head and block dies are confirmed with CMM touch
points and sent through machining
•Machined die confirmation parts are scrapped
•Blocks are not heat treated
•Blocks have steel sleeves and cannot are not currently remelted
•Lower blocks are mated parts that are scrapped with the block
•Only a small percentage of the part surface is measured (<50%)
•New Model die confirmation takes 3+ hrs
•Reduce die confirmation scrap cost to $0
•Increase percentage of surface measured to 90%
•Decrease time to complete die confirmation
•Increase new model laser scan die confirmation capability to
100%
•Fixtures designed with Catia CAD software
•Drawings sent to MTS for manufacture
•Scan path and inspection macroinstructions written
•Associates trained to scan and inspect parts
•Program implemented without interfering with daily
quality CMM checks or die confirmations
•Worked with associates to troubleshoot problems
•Part surface scanned and measured increased from 50% to 80%
•Die confirmation scrap cost decreased from $37,250 per year to $0
•Die confirmation time decreased from 3 hrs to 1 hr
•New model die confirmation capability increased from 47% to 100%
+
6. Current situation
Scrapped block-$97
•5 parts per week are used for die confirmation
•New Model Blocks are measured with CMM touch point inspections and sent through machining
•Block cast with steel sleeves
•Block pulled for die confirmation before heat treat
•Measured by CMM
•Block painted orange
•Blocks are sent through machining
•Picked up after final inspection
•Block is checked for machining stock defects and machining clearance (less than 50% of part)
•Process takes 3+ hrs to complete
•Parts are not currently remelted in house
•Raw material and machining cost is approximately $149 per block
Block with Lower Block -$149
5 Blocks/Week-$745
50 weeks/Year-$37,250
Scrapped lower block-$52
7. Implement New Model Laser Scan Programs for Cylinder Heads & Blocks
Current Situation
Objectives
New Idea/Concept/Improvement
Planning/Testing/Implementation
Impact/Benefit/Result
Develop and implement scan and inspection programs
utilizing the existing SurfaceMeasure 610 Line Laser
Probe to scan, measure, and evaluate parts
•New model head and block dies are confirmed with CMM touch
points and sent through machining
•Machined die confirmation parts are scrapped
•Blocks are not heat treated
•Blocks have steel sleeves and cannot are not currently remelted
•Lower blocks are mated parts that are scrapped with the block
•Only a small percentage of the part surface is measured (<50%)
•New Model die confirmation takes 3+ hrs
•Reduce die confirmation scrap cost to $0
•Decrease time to complete die confirmation
•Increase percentage of surface measured to 90%
•Increase new model laser scan die confirmation capability to
100%
•Fixtures designed with Catia CAD software
•Drawings sent to MTS for manufacture
•Scan path and inspection macroinstructions written
•Associates trained to scan and inspect parts
•Program implemented without interfering with daily
quality CMM checks or die confirmations
•Worked with associates to troubleshoot problems
•Part surface scanned and measured increased from 50% to 80%
•Die confirmation scrap cost decreased from $37,250 per year to $0
•Die confirmation time decreased from 3 hrs to 1 hr
•New model die confirmation capability increased from 47% to 100%
+
Block with Lower Block -$149
5 Blocks/Week-$745
50 weeks/Year-$37,250
8. CMM SYSTEM
Mitutoyo Crysta-Apex S9168
PH10MQ/TP200 Probe System
MCOSMOS- CMM software
SurfaceMeasure 610 Laser Probe
MSURF S-Scan software
MSURF I- Inspection software
CMM Touch Probes Line Laser Scanner
Coordinate Measuring Machine (CMM)
•A machine that measures the physical geometrical characteristics of an object
•May be manually or computer controlled
•Measurements are taken by a probe and plotted in the machines coordinate system
•Probes may be mechanical, optical, laser, or white light, amongst others
9. PH10MQ/TP200 Probe System
RPY-Fixed Die PrintRPY-Fixed Die CMM
Points plotted in machine
generated coordinate system
Probe tree with multiple
touch probes
•CMM measurement programs are written in MCOSMOS
•Points are measured and evaluated automatically by the software using part specific programs
•Measured data is exported to an Excel spreadsheet for further evaluation
•Part measurement programs are 30 minutes or less
10. New Die Confirmation Method
Part on CMM table
CMM touch point
probe
Laser scan
•Block cast with steel sleeves
•Block pulled for die confirmation before heat treat
•Block inspected with CMM touch points and laser scan
•Machining stock and exterior cast surfaces checked for defects (75-80% of part)
•Process takes 1 hr to complete
•Parts are not scrapped after inspection is complete
•5 parts per week used for die confirmation
•After inspection blocks go back into production
11. Implement New Model Laser Scan Programs for Cylinder Heads & Blocks
Current Situation
Objectives
New Idea/Concept/Improvement
Planning/Testing/Implementation
Impact/Benefit/Result
Develop and implement scan and inspection programs
utilizing the existing SurfaceMeasure 610 Line Laser
Probe to scan, measure, and evaluate parts
•New model head and block dies are confirmed with CMM touch
points and sent through machining
•Machined die confirmation parts are scrapped
•Blocks are not heat treated
•Blocks have steel sleeves and cannot are not currently remelted
•Lower blocks are mated parts that are scrapped with the block
•Only a small percentage of the part surface is measured (<50%)
•New Model die confirmation takes 3+ hrs
•Reduce die confirmation scrap cost to $0
•Decrease time to complete die confirmation
•Increase percentage of surface measured to 90%
•Increase new model laser scan die confirmation capability to
100%
•Fixtures designed with Catia CAD software
•Drawings sent to MTS for manufacture
•Scan path and inspection macroinstructions written
•Associates trained to scan and inspect parts
•Program implemented without interfering with daily
quality CMM checks or die confirmations
•Worked with associates to troubleshoot problems
•Part surface scanned and measured increased from 50% to 80%
•Die confirmation scrap cost decreased from $37,250 per year to $0
•Die confirmation time decreased from 3 hrs to 1 hr
•New model die confirmation capability increased from 47% to 100%
+
Block with Lower Block -$149
5 Blocks/Week-$745
50 weeks/Year-$37,250
12. •Utilize existing fixtures for parts
•Design and modify fixtures for part scan using Catia CAD software
8hrs
Implementation: Fixtures
13. Implementation: Scan Software (MSURF-S)
•Scan paths are programmed using MSURF-S software
•Manually program scan paths via joystick for 6 core faces
1hr
•Surface scan information is saved as a point cloud and converted into a scan mesh for inspection
•2A Optimize scanned data (remove scan overlap and non-part data)
•2B Utilize established software to generate scan mesh geometry
•2C export mesh to inspection software
8hr
•Macroinstruction created to automate program for regular use
•Part scanning, mesh generation, and file export is done by a programmed macroinstruction
2hr
14. Implementation: Inspection Software (MSURF-I)
•Add reference geometry to 3D model from EGA
1hr
•Scan meshes are compared to a 3D model and discrepancies are calculated
•Import modified 3D model
•Import Scan meshes
•Manually define reference geometry on scan meshes
•Geometrically align meshes and 3D model
•Calculate discrepancies between the scan meshes and 3D model
•Generate color map to make discrepancies visible
•Generate Excel based reports
3hrs
•Macroinstruction created to automate the Inspection process
•140 commands per inspection program
•2500 controlled parameters per program
2hrs
•Testing and troubleshooting program
40 hrs
•Train associates
10 hrs
15. Implement New Model Laser Scan Programs for Cylinder Heads & Blocks
Current Situation
Objectives
New Idea/Concept/Improvement
Planning/Testing/Implementation
Impact/Benefit/Result
Develop and implement scan and inspection programs
utilizing the existing SurfaceMeasure 610 Line Laser
Probe to scan, measure, and evaluate parts
•New model head and block dies are confirmed with CMM touch
points and sent through machining
•Machined die confirmation parts are scrapped
•Blocks are not heat treated
•Blocks have steel sleeves and cannot are not currently remelted
•Lower blocks are mated parts that are scrapped with the block
•Only a small percentage of the part surface is measured (<50%)
•New Model die confirmation takes 3+ hrs
•Reduce die confirmation scrap cost to $0
•Decrease time to complete die confirmation
•Increase percentage of surface measured to 90%
•Increase new model laser scan die confirmation capability to
100%
•Fixtures designed with Catia CAD software
•Drawings sent to MTS for manufacture
•Scan path and inspection macroinstructions written
•Associates trained to scan and inspect parts
•Program implemented without interfering with daily
quality CMM checks or die confirmations
•Worked with associates to troubleshoot problems
•Part surface scanned and measured increased from 50% to 80%
•Die confirmation scrap cost decreased from $37,250 per year to $0
•Die confirmation time decreased from 3 hrs to 1 hr
•New model die confirmation capability increased from 47% to 100%
+
Block with Lower Block -$149
5 Blocks/Week-$745
50 weeks/Year-$37,250
16. Machining CMM Touch Points CMM Laser Scan
Scrap Produced YES NO NO
Time to Complete 3+ hours 30 minutes 30 minutes
Features Evaluated Machine stock
features only
Touch points
limited by
probe size
Line of sight
features only*
Measurement
Rate
NA 20 points/min 4.5 Million
points/min
Die Confirmation Methods
Touch points and laser scans can be done
together to evaluate 80+% of Part.
Machining parts
only evaluates
machine stock
(less than 50%).
17. Number of associates trained to program scanner 3
RPY Block 59B Block 5A2 Block RPY Head 59B Head RDF Head
Scan Paths 0 of 2 0 of 2 2 of 2 0 of 2 0 of 2 2 of 2
Inspection 0 of 1 0 of 1 1 of 1 0 of 1 0 of 1 1 of 1
Fixture 1 of 2 2 of 2 1 of 2 1 of 2 2 of 2 2 of 2
Total 1 of 5 2 of 5 3 of 5 1 of 5 2 of 5 5 of 5 47%
RPY Block 59B Block 5A2 Block RPY Head 59B Head RDF Head
Scan Paths 2 of 2 2 of 2 2 of 2 2 of 2 2 of 2 2 of 2
Inspection 1 of 1 1 of 1 1 of 1 1 of 1 1 of 1 1 of 1
Fixture 2 of 2 2 of 2 2 of 2 2 of 2 2 of 2 2 of 2
Total 5 of 5 5 of 5 5 of 5 5 of 5 5 of 5 5 of 5 100%
Program Completion Beginning of Term vs. Present
Laser Die Confirmation Project Completion at Co-op term start
Laser Die Confirmation Project Completion at present
-Not started
-Started, but not finished/needs modification
-Finished/ready for mass production
Number of associates trained to program scanner 4*
18. Implement New Model Laser Scan Programs for Cylinder Heads & Blocks
Current Situation
Objectives
New Idea/Concept/Improvement
Planning/Testing/Implementation
Impact/Benefit/Result
Develop and implement scan and inspection programs
utilizing the existing SurfaceMeasure 610 Line Laser
Probe to scan, measure, and evaluate parts
•New model head and block dies are confirmed with CMM touch
points and sent through machining
•Machined die confirmation parts are scrapped
•Blocks are not heat treated
•Blocks have steel sleeves and cannot are not currently remelted
•Lower blocks are mated parts that are scrapped with the block
•Only a small percentage of the part surface is measured (<50%)
•New Model die confirmation takes 3+ hrs
•Reduce die confirmation scrap cost to $0
•Decrease time to complete die confirmation
•Increase percentage of surface measured to 90%
•Increase new model laser scan die confirmation capability to
100%
•Fixtures designed with Catia CAD software
•Drawings sent to MTS for manufacture
•Scan path and inspection macroinstructions written
•Associates trained to scan and inspect parts
•Program implemented without interfering with daily
quality CMM checks or die confirmations
•Worked with associates to troubleshoot problems
•Part surface scanned and measured increased from 50% to 80%
•Die confirmation scrap cost decreased from $37,250 per year to $0
•Die confirmation time decreased from 3 hrs to 1 hr
•New model die confirmation capability increased from 47% to 100%
+
Block with Lower Block -$149
5 Blocks/Week-$745
50 weeks/Year-$37,250
$0
19. Summary of Co-op Experience:
Lessons Learned:
Future Career Interest/Plans:
•Honda policies and procedures
•Safe Practices when dealing with Molten Aluminum
•High pressure die cast processes
•Troubleshooting problems
•Time management and scheduling
•Working with production associates to ensure project was finished without interfering with daily checks
•Designing and modifying fixtures using Catia CAD software (2d part drawing, 3d part models, 3D assemblies)
•Working with fabrication shop (MTS) to make fixtures and parts
•Testing fixtures for daily use for implementation into mass production
•Manually modifying fixtures (grinding, drilling, tapping, filing)
•Operating Mitutoyo coordinate measuring machines
•Developing new and modifying existing CMM programs in MCOSMOS and MSURF software
•Converting point clouds into meshes for die confirmation part vs. 3d model analysis
• Utilization of MSURF software (creating part meshes from point clouds coordinates in virtual space, writing
macroinstructions, testing and troubleshooting the program for errors)
•Mitsubishi PLC programming using GX Works2 software
•Evolution from first co-op
•Finish my Bachelors in Electro-Mechanical Engineering Technology.
•I would consider Honda as a potential future employer if the opportunity presents itself.
•If hired after graduation, I’d like to be considered for the Engineering Development Program.
Special Thanks:
•John Pletcher for his guidance and support
•Associates for the time spent showing me the different casting processes
•ALDC Management for giving me this opportunity and allowing me to modify my work schedule for school
