This presentation encompasses three projects completed during my internship at the Master Lock Company.

1. ©2016 by Master Lock Company LLC. All rights reserved. No part of this document may be shared with third parties,
reproduced, transmitted or modified in any form or by any means without prior written permission of Master Lock Company LLC.AUTHOR I CHANNEL I FUNCTION I GEOGRAPHY
QUALITY ENGINEERING
August 16th, 2017
Milan Stojanovic
Quality Engineering Intern
University of Wisconsin
Milwaukee
Chris Ostram
Quality Lab Manager
Anthony Schaeve
Quality Engineering Intern
University of Wisconsin
Milwaukee

2. ©2016 by Master Lock Company LLC. All rights reserved. No part of this document may be shared with third parties,
reproduced, transmitted or modified in any form or by any means without prior written permission of Master Lock Company LLC.AUTHOR I CHANNEL I FUNCTION I GEOGRAPHY
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Presentation Overview
I. Quality Engineering
–Purpose
–Methods
–Importance
II. Projects
–Failure Investigation
–Drop Test Automation
–Robot Cycling
III. Conclusion
–Skill Development
–Collaboration
–Improvements to Lab

3. ©2016 by Master Lock Company LLC. All rights reserved. No part of this document may be shared with third parties,
reproduced, transmitted or modified in any form or by any means without prior written permission of Master Lock Company LLC.AUTHOR I CHANNEL I FUNCTION I GEOGRAPHY
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I. Quality Engineering
PURPOSE
– To design and perform
tests on new and
existing products to
ensure product reliability
METHODS
– Failure Investigation
– Test Design and
Automation
– Data collection and
recommendations
VALUE
– Find product issues
before market
availability
– Guarantee and maintain
reputation
A quality engineer works within a wider team of engineering focused professionals
with the overall aim of maintaining the quality of new and existing products.

4. ©2016 by Master Lock Company LLC. All rights reserved. No part of this document may be shared with third parties,
reproduced, transmitted or modified in any form or by any means without prior written permission of Master Lock Company LLC.AUTHOR I CHANNEL I FUNCTION I GEOGRAPHY
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A1100 Failure Investigation
Problem statement: According to
customer complaint, A1100 lock is
disassembling under normal working
conditions.
Proposed Solution: Investigate
A1100 lock using failure investigation
techniques and determined the root
cause of mechanical failure.

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reproduced, transmitted or modified in any form or by any means without prior written permission of Master Lock Company LLC.AUTHOR I CHANNEL I FUNCTION I GEOGRAPHY
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A1100 Failure Investigation
Determine Failure Scenarios
We know the point of failure, and
thus, the tests to replicate the failure.
Vibration & Rapping
Security Screw Torque
Security Screw
Trap Door

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reproduced, transmitted or modified in any form or by any means without prior written permission of Master Lock Company LLC.AUTHOR I CHANNEL I FUNCTION I GEOGRAPHY
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A1100 Cutaway
Thread Patch
A1100 Failure Investigation
Security screw is too short
Thread patch is not engaging properly
– Screw becomes prone to loosening
Why the product is failing
Lengthen the screw
Bigger thread patch
Proposed Solutions

7. ©2016 by Master Lock Company LLC. All rights reserved. No part of this document may be shared with third parties,
reproduced, transmitted or modified in any form or by any means without prior written permission of Master Lock Company LLC.AUTHOR I CHANNEL I FUNCTION I GEOGRAPHY
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Automated Drop Tester
Problem statement: Testing request
requires repetitive drops from multiple
heights.
Proposed Solution: Re-program
current setup and determine optimal
design configuration.

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reproduced, transmitted or modified in any form or by any means without prior written permission of Master Lock Company LLC.AUTHOR I CHANNEL I FUNCTION I GEOGRAPHY
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Purpose
Automates repetitive steps of testing
process.
Saves time and energy for the operator.
– Reduces strain on operator
– Safer
– More versatile
Automated Drop Tester

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reproduced, transmitted or modified in any form or by any means without prior written permission of Master Lock Company LLC.AUTHOR I CHANNEL I FUNCTION I GEOGRAPHY
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Automated Drop Tester
Controller Screen

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reproduced, transmitted or modified in any form or by any means without prior written permission of Master Lock Company LLC.AUTHOR I CHANNEL I FUNCTION I GEOGRAPHY
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Automated Drop Tester
Future Steps
• Installation of high impact plexiglass shielding
around the frame
• Upgrade to a larger step motor
• Recalibrate system for optimal performance

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reproduced, transmitted or modified in any form or by any means without prior written permission of Master Lock Company LLC.AUTHOR I CHANNEL I FUNCTION I GEOGRAPHY
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Automated Safe Cycler
NEW PRODUCT DEVELOPMENTEXISTING MODEL
Before a new product is shipped to market it must pass through an array of quality
control tests

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reproduced, transmitted or modified in any form or by any means without prior written permission of Master Lock Company LLC.AUTHOR I CHANNEL I FUNCTION I GEOGRAPHY
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Automated Safe Cycler
YASKAWA MOTOMAN EC 1700

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reproduced, transmitted or modified in any form or by any means without prior written permission of Master Lock Company LLC.AUTHOR I CHANNEL I FUNCTION I GEOGRAPHY
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Automated Safe Cycler
Problem statement: New product
design of a Sentry Safe is required to
be cycled 18000 times which is
normally done by hand
Proposed Solution: Program
Motoman to cycle new product designs

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reproduced, transmitted or modified in any form or by any means without prior written permission of Master Lock Company LLC.AUTHOR I CHANNEL I FUNCTION I GEOGRAPHY
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Automated Safe Cycler
Necessary Maintenance and Reboot
• Global Reboot of homing position
• Recalibrate entire system
• Calibrate sensors and tool
• Perform essential fluid exchange
• Recalibrate collision axis sensors
• Compile documentation

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reproduced, transmitted or modified in any form or by any means without prior written permission of Master Lock Company LLC.AUTHOR I CHANNEL I FUNCTION I GEOGRAPHY
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Automated Safe Cycler
Necessary Upgrades and Modifications
Design of New Fingers for the Pneumatic Head

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reproduced, transmitted or modified in any form or by any means without prior written permission of Master Lock Company LLC.AUTHOR I CHANNEL I FUNCTION I GEOGRAPHY
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Automated Safe Cycler

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reproduced, transmitted or modified in any form or by any means without prior written permission of Master Lock Company LLC.AUTHOR I CHANNEL I FUNCTION I GEOGRAPHY
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Automated Safe Cycler
Necessary Upgrades and Modifications
Design of New Adapter Plate for the Larger Pneumatic Head

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reproduced, transmitted or modified in any form or by any means without prior written permission of Master Lock Company LLC.AUTHOR I CHANNEL I FUNCTION I GEOGRAPHY
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Automated Safe Cycler

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reproduced, transmitted or modified in any form or by any means without prior written permission of Master Lock Company LLC.AUTHOR I CHANNEL I FUNCTION I GEOGRAPHY
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Automated Safe Cycler
Motoman EC 1700 Monitoring System
Web Login page:
https://app.hubbleconnected.com/#login
Username: mlock

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reproduced, transmitted or modified in any form or by any means without prior written permission of Master Lock Company LLC.AUTHOR I CHANNEL I FUNCTION I GEOGRAPHY
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Projects Reviewed
Problem statement: Testing request requires repetitive drops from multiple heights
Solution: Re-programed the setup and determined optimal design configuration
Problem statement: A1100 lock is disassembling under normal working conditions
Solution: Using failure investigation techniques, quality was able to determine the
root cause of mechanical failure
Problem statement: New product design of a Sentry Safe is required to be cycled
18000 times
Solution: Programed motorman to auto-cycle Sentry Safe

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reproduced, transmitted or modified in any form or by any means without prior written permission of Master Lock Company LLC.AUTHOR I CHANNEL I FUNCTION I GEOGRAPHY
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III. Conclusion
Quality Department: A Collaborative Effort
Engineering experience gained
– Data collection and analysis
– Experimental & mechanical design
Team work skills strengthened
– Project and task management
Overall efficiency of the Quality Lab has been improved
– Automated testing

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reproduced, transmitted or modified in any form or by any means without prior written permission of Master Lock Company LLC.AUTHOR I CHANNEL I FUNCTION I GEOGRAPHY
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Lab Roadmap
Improve test equipment and data collection
– Universal testing fixtures
– Built in sensors and data acquisition
Add remote capabilities to lab
– Monitor, operate, and view recorded data from
anywhere
– Automated notification system
III. Conclusion

23. ©2016 by Master Lock Company LLC. All rights reserved. No part of this document may be shared with third parties,
reproduced, transmitted or modified in any form or by any means without prior written permission of Master Lock Company LLC.AUTHOR I CHANNEL I FUNCTION I GEOGRAPHY
QUALITY ENGINEERING
August 16th, 2017
Milan Stojanovic
Quality Engineering Intern
University of Wisconsin
Milwaukee
Chris Ostram
Quality Lab Manager
Anthony Schaeve
Quality Engineering Intern
University of Wisconsin
Milwaukee