Windshield wiper assembly 2
From DDL Wiki
Contents |
Report 1 - Product Analysis: Competitor Study
Executive Summary
Major Post-Production Stakeholders
A list of the major stakeholders of the competitors product was generated as long as a listing of their primary concerns with regard to the product. The benefit of this process is the expansion it has on our own awareness of the product since the redesign will be focused on benefiting these stakeholders and addressing their concerns in the most effective manner. Additional stakeholders or stakeholder concerns, along with a more quantitative understanding of the importance of these concerns, will be generated after more market research has been completed.
- User
- Resistance to corrosion
- Unobtrusive
- Effective
- Cheap to replace
- Long lasting blades
- Long lasting structure
- Safety
- Doesn't damage the car
- Aesthetics
- Cleans heavy snow
- Cleans entire windshield
- Doesn't streak
- Doesn't ice over
- EZ to store blades
- Wider fluid dispersal
- Car retailer
- Cheap to manufacture
- Appeals to the user
- Shop workers
- Standardized
- Difficult to replace
- EZ to repair
- Modular
- Safety
- Car manufacturer
- Cheap to manufacture
- Safety, No VOC
- Easy to assemble/install
- Parking Police
- EZ to put ticket under
- Wiper Retailer
- Standardized
- Low Cost
- Other Cars on the road
- Effective
- Cleans entire window
Product Usability Study
Assembly
Product Operation
Dissection Exercise
Dissection Write Up
Dissection Table
Bill of Materials | ||||||||
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Part Number | Sub-Assembly | Part Name | Quantity | Weight (in g) | Function | Manufacturing Process | Material | Image |
Base Structure |
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1 | Driver Side Wiper Casing | 1 | 111 | Protect Arm 3 (driver side) wiper mount linkage | Cast | Aluminum | Image:.jpg
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2 | Passenger Side Wiper Casing | 1 | 212 | Protect Arm 3 (passenger side) wiper mount linkage | Cast | Aluminum | Image:.jpg | |
3 | U-Shaped Connection Bar | 1 | 259 | Connect driver and passenger side wiper mount casings | Stamping | Steel | Image:.jpg | |
Vibration Mount (large) | ||||||||
4 | Metal Grommet Insert (large) | 2 | Stabilizes vibration mount by holding onto chassis | Extended and expanded | Steel | Image:.jpg | ||
5 | Rubber Mount (large) | 2 | Vibration dampening | Molding | Rubber | Image:.jpg | ||
Vibration Mount (small) |
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6 | Metal Grommet Insert (small) | 1 | Stabilizes vibration mount by holding onto chassis | Extended and expanded | Steel | Image:.jpg
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7 | Rubber Mount (small) | 1 | Vibration dampening | Molding | Rubber | Image:.jpg
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Arm 1 |
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8 | Arm 1 Linkage (w/ plastic ball-in-socket joint) | 1 | 53 | Transfers drivetrain's rotational motion 90 degrees to linkage mechanism's plane | Steel tube crushed and welded. Hole drilled, ball-in-socket joint stamped in. | Steel | Image:.jpg
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9 | Lock Washer | 1 | 2 | Distribute nut pressure | Steel | Image:.jpg
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10 | Nut | 1 | 3 | Attach Arm 1 to drivetrain | Tapping | Steel | Image:.jpg
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Arm 2 | ||||||||
11 | Arm 2 Linkage (w/ plastic ball-in-socket joint) | 1 | 149 | Transfer motion | Steel tube crushed and welded. Hole drilled, ball-in-socket joint stamped in. | Steel | Image:.jpg
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Arm 3 |
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12 | Arm 3 linkage (w/ plastic ball-in-socket-joint) | 2 | Transfer motion | Steel | Image:.jpg | |||
13 | Wiper Mount Pin | 2 | Transfer motion | Steel | Image:.jpg
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14 | Plastic Cover | 2 | 2 | Prevent fluid from seeping into linkage area | Injection Mold | Plastic | Image:.jpg
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15 | Screw-On Cap | 2 | 11 | Protect Wiper Mount Pin | Cast and Threaded Die | Steel | Image:.jpg
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Arm 4 |
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16 | Arm 4 linkage [Length: 20.5" (52 cm) | 1 | 177 | Transfer motion | Image:.jpg
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Other |
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17 | Top Washer | 1 | 1 | Steel | Image:.jpg
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Gear Casing |
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18 | Gear Casing Cover Screws | 4 | <1 | Attach cover to casing | Die | Steel | Image:.jpg
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19 | Drivetrain Mounting Bolts | 3 | 5 | Mount drivetrain to base | Die | Steel | Image:.jpg | |
Motor |
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20 | Motor Mounting Bolts (w/ Lock Washer) | 4 | 5 | Mount motor to base | Die | Steel | Image:.jpg
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21 | Motor Mounting Nuts | 4 | 3 | Mount motor to base | Tapping | Steel | Image:.jpg
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22 | Motor | 1 | Convert electric current via EMF to rotation of a linear worm gear | Standard purchased part | Image:.jpg
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Windshield Wiper |
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23 | Wiper | 2 | Rotate about pin and sweep across windshield | Plastic | Image:.jpg
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24 | Blade | 2 | Remove water or other debris from windshield | Rubber | Image:.jpg |
DFMA
Manufacturing
Design for Manufacturing | |
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Guideline | Comments |
Minimize Part Count Eliminate fasteners, part consolidation | One motor Remove extra bolts
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Standardize Components Take advantage of economies of scale & known component properties | Different bolt sizes Different sized grommets that performed similar functions Adjustable length for use in range of vehicle models Standardized C-channel and tube size, standardized motor Standardized cast housing |
Commonize Product Line Economies of scale and minimum training and equipment | |
Standardize Design Feature Common dimensions for fewer tools and setups | |
Keep Designs Simple Simplest way to achieve needed functionality | |
Multifunctional Parts e.g.: fingernail clipper | |
Ease of Fabrication Choose materials easy to work with | |
Avoid Tight Tolerances Causes exponential cost increases | |
Minimize Secondary & Finishing Operations Only where needed | |
Take Advantage of Special Process Properties e.g.: color in injection molding |
Assembly
Design for Assembly | |
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Guideline | Comments |
Minimize Part Count Eliminate fasteners, part consolidation | One motor Remove extra bolts
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Minimize Assembly Surfaces and sequence them | Different bolt sizes Different sized grommets that performed similar functions Adjustable length for use in range of vehicle models Standardized C-channel and tube size, standardized motor Standardized cast housing |
Use Subassemblies can be assembled and tested separately, can be outsourced | |
Mistake-Proof unambiguous, unique assembly orientation | |
Minimize Fasteners snap fits and part consolidation | |
Minimize Handling position for insertion or joining is easy to achieve | |
Minimize Assembly Direction ideal - add each component from top to base | |
Provide Unobstructed Access consider assembly path (e.g.: oil filter) | |
Maximize Assembly Compliance chamfers and radii help assemble parts with variance | |
Features for Assembly Features that have no functionality in use but support assembly |
FMEA
Failure Mode and Effects Analysis | |||||||||
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Item & Function | Failure Mode | Effects of Failure | S | Causes of Failure | O | Design Controls | D | RPN | Recommended Actions |
Gearbox | Stripped teeth | Costly repair Temporarily inoperable | 7 | Extra stress Obstruction on arm | 1 | Durability Tests | 2 | 14 | |
Linkages | Misalignment Shearing | Costly repair Temporarily inoperable | 7 | Improper installation Environmental degredation | 2 | Durability Tests Easily repairable | 1 | 14 | |
Ball Joints | Ball becomes detached from joint Ball seizes in joint | Costly repair Temporarily inoperable | 7 | Debris Linkage misalignment Random forces | 2 | Sheleltered | 2 | 28 | |
Wiper Arm | Deformation | Reduced effectiveness | 5 | Impact from flying debris User error Weather Damage from carwash | 4 | Recess arm beneath car hood Increase plastic strength | 4 | 80 | |
Mounting Assembly | Loosening from body Grommet failiure | Damage to other components in the engine bay Reduced effectiveness | 8 | Loosened from body vibrations Bad installation Corrosion | 1 | Specify correct materials Durability Tests Allow for maintainance Electrical sensor Progressive, controlled failure | 4 | 24 | |
Wiper Blades | Tearing | Reduced Effectiveness | 5 | Material failure | 5 | Second blade Easily replaced | 1 | 25 | |
Wiper Arm Spring |
DFE
Team Member Roles (Report I)
For Report 1, the team member roles were assigned as follows:
Role | Team Member |
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Team Leader | Justin Whaley |
DFMA Lead | Mike Lin |
FMEA Lead | Max Gustafson |
DFE Lead | Andrew Socha |
The roles were assigned based on preference and expertise in an area. Each team member was present for the usability study, the dissection, and the in-class exercises. While the write-ups for the analysis sections of the report were contributed by the individual analysis leads, the team leader completed the write-ups for the usability study, the conclusions from the dissection exercise, compiled the Powerpoint presentation, and scheduled weekly team meetings.