Ski rack
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= Bill of Materials = | = Bill of Materials = | ||
+ | == Bill of Materials == | ||
+ | |||
+ | [[Image:SkiRack_assembly.jpg]] | ||
+ | |||
+ | |||
+ | {| border="1" | ||
+ | |- | ||
+ | ! Assembly | ||
+ | ! Part | ||
+ | ! Quantity | ||
+ | ! Description | ||
+ | ! Material | ||
+ | ! Manufacturing process | ||
+ | ! Weight [grams] | ||
+ | ! Image | ||
+ | |- | ||
+ | | 1. Mounting Bracket | ||
+ | | | ||
+ | | 4 | ||
+ | | Mounts carrier to roof rack. | ||
+ | | | ||
+ | | | ||
+ | | | ||
+ | | [[Image:MountingBracket.JPG|100px]] | ||
+ | |- | ||
+ | | | ||
+ | | 1A. Base Screw | ||
+ | | 1 | ||
+ | | Connects bracket to rack. | ||
+ | | Steel | ||
+ | | | ||
+ | | 6 | ||
+ | | [[Image:SkiRack_longScrew_.jpg|100px]] | ||
+ | |- | ||
+ | | | ||
+ | | 1B. Slider Top | ||
+ | | 1 | ||
+ | | | ||
+ | | Molded Plastic | ||
+ | | Injection Molding | ||
+ | | 36 | ||
+ | | [[Image:SkiRack_sliderTop_.jpg|100px]] | ||
+ | |- | ||
+ | | | ||
+ | | 1C. Short Bail Screw | ||
+ | | 2 | ||
+ | | | ||
+ | | Steel | ||
+ | | | ||
+ | | 6 | ||
+ | | [[Image:SkiRack_shortScrew.JPG|100px]] | ||
+ | |- | ||
+ | | | ||
+ | | 1D. Long Bail Screw | ||
+ | | 2 | ||
+ | | | ||
+ | | Steel | ||
+ | | | ||
+ | | 9 | ||
+ | | [[Image:SkiRack_longScrew_.jpg|100px]] | ||
+ | |- | ||
+ | | | ||
+ | | 1E. Upper Bail | ||
+ | | 1 | ||
+ | | | ||
+ | | Molded Plastic | ||
+ | | Injection Molding | ||
+ | | 45 | ||
+ | | [[Image:SkiRack_upperBail_.jpg|100px]] | ||
+ | |- | ||
+ | | | ||
+ | | 1F. Square Nut | ||
+ | | 1 | ||
+ | | | ||
+ | | Brass | ||
+ | | | ||
+ | | 5 | ||
+ | | [[Image:SkiRack_squareNut.jpg|100px]] | ||
+ | |- | ||
+ | | | ||
+ | | 1G. Rubber Pad | ||
+ | | 1 | ||
+ | | | ||
+ | | Rubber | ||
+ | | | ||
+ | | 13 | ||
+ | | [[Image:SkiRack_rubberPad_.jpg|100px]] | ||
+ | |- | ||
+ | | | ||
+ | | 1H. Lower Bail | ||
+ | | 1 | ||
+ | | | ||
+ | | Molded Plastic | ||
+ | | Injection Molding | ||
+ | | 49 | ||
+ | | [[Image:LowerBail2.JPG|100px]] | ||
+ | |- | ||
+ | | | ||
+ | | 1I. Hex Nut | ||
+ | | 1 | ||
+ | | | ||
+ | | Brass | ||
+ | | | ||
+ | | 5 | ||
+ | | [[Image:HexNut.JPG|100px]] | ||
+ | |- | ||
+ | | 2. Hex Key | ||
+ | | | ||
+ | | 2 | ||
+ | | | ||
+ | | | ||
+ | | | ||
+ | | | ||
+ | | | ||
+ | |- | ||
+ | | | ||
+ | | 2A. Hex Key | ||
+ | | 1 | ||
+ | | | ||
+ | | Molded Plastic | ||
+ | | Injection Molding | ||
+ | | 6 | ||
+ | | [[Image:hexKey.JPG|100px]] | ||
+ | |- | ||
+ | | | ||
+ | | 2B. Hex Nut | ||
+ | | 1 | ||
+ | | | ||
+ | | Brass | ||
+ | | | ||
+ | | 5 | ||
+ | | [[Image:HexNut.JPG|100px]] | ||
+ | |- | ||
+ | | | ||
+ | | 2C. Bolt | ||
+ | | 1 | ||
+ | | | ||
+ | | Steel | ||
+ | | | ||
+ | | 12 | ||
+ | | [[Image:HexKeyBolt.JPG|100px]] | ||
+ | |- | ||
+ | | 3. Ski Lift | ||
+ | | | ||
+ | | 2 | ||
+ | | | ||
+ | | | ||
+ | | | ||
+ | | | ||
+ | | [[Image:SkiLiftAssembly_good.JPG|100px]] | ||
+ | |- | ||
+ | | | ||
+ | | 3A. Ski Lift | ||
+ | | 1 | ||
+ | | Raises up rack to provided additional clearance. | ||
+ | | Molded Plastic | ||
+ | | Injection Molding | ||
+ | | 25 | ||
+ | | [[Image:skiLift.JPG|100px]] | ||
+ | |- | ||
+ | | | ||
+ | | 3B. Hex Nut | ||
+ | | 1 | ||
+ | | Press fits into ski lift to provide secure purchase for mounting screws. | ||
+ | | Brass | ||
+ | | | ||
+ | | 5 | ||
+ | | [[Image:HexNut.JPG|100px]] | ||
+ | |- | ||
+ | | | ||
+ | | 3C. Button Head Screw | ||
+ | | 1 | ||
+ | | Holds ski lift together. | ||
+ | | Steel | ||
+ | | | ||
+ | | 11 | ||
+ | | [[Image:HexKeyBolt.JPG|100px]] | ||
+ | |- | ||
+ | | 4. Lock Assembly | ||
+ | | | ||
+ | | 2 | ||
+ | | | ||
+ | | | ||
+ | | | ||
+ | | | ||
+ | | | ||
+ | |- | ||
+ | | | ||
+ | | 4A. Lock Housing | ||
+ | | 1 | ||
+ | | Holds lock in place within release lever. | ||
+ | | Steel | ||
+ | | Casting | ||
+ | | | ||
+ | | | ||
+ | |- | ||
+ | | | ||
+ | | 4B. Lock | ||
+ | | 1 | ||
+ | | Preassembled lock. | ||
+ | | Steel | ||
+ | | | ||
+ | | 10 | ||
+ | | [[Image:SkiRack_lock_.jpg|100px]] | ||
+ | |- | ||
+ | | | ||
+ | | 4C. Lock Cap | ||
+ | | 1 | ||
+ | | Replaces optional lock | ||
+ | | Molded Plastic | ||
+ | | Injection Molding | ||
+ | | 0 | ||
+ | | | ||
+ | |- | ||
+ | | 5. Carrier Bottom | ||
+ | | | ||
+ | | 2 | ||
+ | | | ||
+ | | | ||
+ | | | ||
+ | | | ||
+ | | | ||
+ | |- | ||
+ | | | ||
+ | | 5A. Rivet | ||
+ | | 3 | ||
+ | | Holds rack together | ||
+ | | Aluminum | ||
+ | | | ||
+ | | 0 | ||
+ | | [[Image:Rivet2.JPG|100px]] | ||
+ | |- | ||
+ | | | ||
+ | | 5B. Hinge Spring | ||
+ | | 1 | ||
+ | | Opens rack. | ||
+ | | Brass | ||
+ | | | ||
+ | | 15 | ||
+ | | [[Image:SkiRack_hingeSpring_.jpg|100px]] | ||
+ | |- | ||
+ | | | ||
+ | | 5C. Lower Compression Pad | ||
+ | | 1 | ||
+ | | Compresses to firmly hold skis in place | ||
+ | | Rubber | ||
+ | | Extrusion | ||
+ | | 137 | ||
+ | | [[Image:SkiRack_bottomRubber.jpg|100px]] | ||
+ | |- | ||
+ | | | ||
+ | | 5D. Bottom Shell | ||
+ | | 1 | ||
+ | | Holds bottom compression pad in place. Mounts to mounting brackets. | ||
+ | | Steel | ||
+ | | Extrusion | ||
+ | | 198 | ||
+ | | [[Image:SkiRack_bottomSteelShell_.jpg|100px]] | ||
+ | |- | ||
+ | | | ||
+ | | 5E. Latch (Bottom Half) | ||
+ | | 1 | ||
+ | | Provides something for upper half of latch to secure to. | ||
+ | | Molded Plastic | ||
+ | | Injection Molding | ||
+ | | 20 | ||
+ | | [[Image:SkiRack_bottomLatch.jpg|100px]] | ||
+ | |- | ||
+ | | 6. Latch | ||
+ | | | ||
+ | | 2 | ||
+ | | | ||
+ | | | ||
+ | | | ||
+ | | | ||
+ | | | ||
+ | |- | ||
+ | | | ||
+ | | 6A. Latch Housing | ||
+ | | 1 | ||
+ | | Contains the latch mechanisms. | ||
+ | | Molded Plastic | ||
+ | | Injection Molding | ||
+ | | 52 | ||
+ | | [[Image:LatchCasing.JPG|100px]] | ||
+ | |- | ||
+ | | | ||
+ | | 6B. Release Lever | ||
+ | | 1 | ||
+ | | Releases the latch when pressed. | ||
+ | | Molded Plastic | ||
+ | | Injection Molding | ||
+ | | 45 | ||
+ | | [[Image:SkiRack_latchHandle_.jpg|100px]] | ||
+ | |- | ||
+ | | | ||
+ | | 6C. Lock Back | ||
+ | | 1 | ||
+ | | Interfaces between the lock and locking tab. | ||
+ | | Steel | ||
+ | | Casting | ||
+ | | 5 | ||
+ | | [[Image:SkiRack_lockBack_.jpg|100px]] | ||
+ | |- | ||
+ | | | ||
+ | | 6D. Locking Tab | ||
+ | | 1 | ||
+ | | Rotates when rack is locked to hold the rack shut. | ||
+ | | Steel | ||
+ | | Punching | ||
+ | | 0 | ||
+ | | [[Image:SkiRack_lockingTab_.jpg|100px]] | ||
+ | |- | ||
+ | | | ||
+ | | 6E. Spring | ||
+ | | 1 | ||
+ | | Returns the latch release lever to its closed position | ||
+ | | Brass | ||
+ | | | ||
+ | | 4 | ||
+ | | [[Image:SkiRack_latchSpring_.jpg|100px]] | ||
+ | |- | ||
+ | | | ||
+ | | 6F. Lock Washer | ||
+ | | 1 | ||
+ | | Holds the locking mechanism together. | ||
+ | | Steel | ||
+ | | | ||
+ | | 0 | ||
+ | | Missing | ||
+ | |- | ||
+ | | 7. Carrier Top | ||
+ | | | ||
+ | | 2 | ||
+ | | | ||
+ | | | ||
+ | | | ||
+ | | | ||
+ | | [[Image:Top Bar Assembly.JPG|100px]] | ||
+ | |- | ||
+ | | | ||
+ | | 7A. Upper Horizontal Shell | ||
+ | | 1 | ||
+ | | Holds the rubber compression pad in place. | ||
+ | | Rubber | ||
+ | | Extrusion | ||
+ | | 206 | ||
+ | | [[Image:SkiRack_horizontalSteelTop_.jpg|100px]] | ||
+ | |- | ||
+ | | | ||
+ | | 7B. Upper Compression Pad | ||
+ | | 1 | ||
+ | | Compression pad to hold the skis firmly in place | ||
+ | | Rubber | ||
+ | | Extrusion | ||
+ | | 127 | ||
+ | | [[Image:TopRubber_sideview.JPG|100px]] | ||
+ | |- | ||
+ | | | ||
+ | | 7C. Rivet | ||
+ | | 2 | ||
+ | | | ||
+ | | Aluminum | ||
+ | | | ||
+ | | 0 | ||
+ | | [[Image:Rivet2.JPG|100px]] | ||
+ | |- | ||
+ | | | ||
+ | | 7D. Hinge Shell | ||
+ | | 1 | ||
+ | | Connects the top and bottom parts together and acts as a hinge. | ||
+ | | Molded Plastic | ||
+ | | Injection Molding | ||
+ | | 67 | ||
+ | | [[Image:skiRack_hingeShell_.jpg|100px]] | ||
+ | |} | ||
= Design for Manufacture and Assembly = | = Design for Manufacture and Assembly = |
Revision as of 17:21, 7 February 2011
Hello
Ski Rack Bill of Materials
Ski Rack DFMA
Ski Rack FMEA
Ski Rack DFE
Contents |
Bill of Materials
Bill of Materials
Design for Manufacture and Assembly
Failure Mode and Effects Analysis
Ski Rack FMEA
Assembly | Function | Potential Mode of Failure | Potential Effect of Failure | Sev | Potential Cause of Failure | Occurance | Detection Controls | Detection | RPN |
---|---|---|---|---|---|---|---|---|---|
Bracket | Hold the rack onto the crossbars | Plastic Cracks | Rack Unstable | 5 | Cold | 2 | Material Choice | 1 | 10 |
Bracket | Hold the rack onto the crossbars | Plastic Cracks | Rack Unstable | 5 | Poor Manufacturing | 4 | N/A | 6 | 120 |
Bracket | Hold the rack onto the crossbars | Plastic Cracks | Rack Unstable | 5 | Vehicle Crash | 4 | N/A | 10 | 200 |
Bracket | Hold the rack onto the crossbars | Plastic Cracks | Rack Unstable | 5 | Overtorque | 4 | Allen Key Size | 7 | 140 |
Bracket | Hold the rack onto the crossbars | Bolt Shears | Rack Unstable | 5 | Vehicle Crash | 4 | N/A | 10 | 200 |
Bracket | Hold the rack onto the crossbars | Bolt Shears | Rack Unstable | 5 | Rust | 7 | Use Stainless Steel | 5 | 175 |
Bracket | Hold the rack onto the crossbars | Bolt Shears | Rack Unstable | 5 | User Bolt - Not Factory | 3 | Specific Shape and Thread | 10 | 150 |
Bracket | Hold the rack onto the crossbars | Bolt Shears | Rack Unstable | 5 | Overtorque | 4 | Allen Key Size | 7 | 140 |
Bracket | Hold the rack onto the crossbars | Bolt Shears | Rack Unstable | 5 | Undertorque | 3 | Allen Key Size | 7 | 105 |
Bracket | Hold the rack onto the crossbars | Mounting Grooves Wear | Rack Unstable | 5 | Vibrations | 3 | Material Choice | 5 | 75 |
Latch | Open and Close the Ski Rack on Request | Will Not Open | Cannot go skiing | 7 | Frozen | 5 | Material Choice | 8 | 280 |
Latch | Open and Close the Ski Rack on Request | Will Not Open | Cannot go skiing | 7 | Deformation | 6 | Material Choice | 8 | 280 |
Latch | Open and Close the Ski Rack on Request | Will Not Open | Cannot go skiing | 7 | Lost / Broken Key | 4 | Extra Key | 1 | 28 |
Latch | Open and Close the Ski Rack on Request | Will Not Open | Cannot go skiing | 7 | Broken Rivet | 2 | Material Thickness | 6 | 84 |
Latch | Open and Close the Ski Rack on Request | Will Not Close | Cannot go skiing | 7 | Broken Latch | 5 | Material Choice | 2 | 70 |
Latch | Open and Close the Ski Rack on Request | Will Not Close | Cannot go skiing | 7 | Deformation | 6 | Material Choice | 4 | 168 |
Latch | Open and Close the Ski Rack on Request | Will Not Close | Cannot go skiing | 7 | Lock Frozen Locked | 4 | Seal Lock to prevent moisture from entering | 4 | 112 |
Latch | Open and Close the Ski Rack on Request | Will Not Close | Cannot go skiing | 7 | Broken / Worn Spring | 3 | Spring Choice | 5 | 105 |
Latch | Open and Close the Ski Rack on Request | Will Not Close | Cannot go skiing | 7 | Broken Rivet | 2 | Material Choice | 6 | 84 |
Latch | Open and Close the Ski Rack on Request | Opens on its own | Loss of Skis, Potentially Fatal Accidents | 9 | Deformation | 6 | Material Choice | 4 | 216 |
Latch | Open and Close the Ski Rack on Request | Opens on its own | Loss of Skis, Potentially Fatal Accidents | 9 | Weakened Plastic | 7 | Material Choice | 6 | 378 |
Latch | Open and Close the Ski Rack on Request | Opens on its own | Loss of Skis, Potentially Fatal Accidents | 9 | Driving Forces Break Latch | 3 | Minimize Forces, Material Choice | 10 | 270 |
Latch | Open and Close the Ski Rack on Request | Opens on its own | Loss of Skis, Potentially Fatal Accidents | 9 | Ratchet Tooth Failure | 4 | Avoid Use of Ratchet Teeth | 8 | 288 |
Latch | Open and Close the Ski Rack on Request | Opens on its own | Loss of Skis, Potentially Fatal Accidents | 9 | Broken / Worn Spring | 3 | Spring Choice | 5 | 135 |
Latch | Open and Close the Ski Rack on Request | Opens on its own | Loss of Skis, Potentially Fatal Accidents | 9 | Broken Rivet | 2 | Material Thickness | 6 | 108 |
Latch | Open and Close the Ski Rack on Request | Not Fully Closed | Chance of Opening leading to loss of skis, potentially fatal accidents | 9 | Ratchet Tooth Barely Engaged | 6 | Color Notification | 2 | 108 |
Latch | Open and Close the Ski Rack on Request | Not Fully Closed | Chance of Opening leading to loss of skis, potentially fatal accidents | 9 | Debris in the Way | 8 | Color Notification | 2 | 144 |
Latch | Open and Close the Ski Rack on Request | Not Fully Closed | Chance of Opening leading to loss of skis, potentially fatal accidents | 9 | Too much in the rack | 6 | Color Notification | 2 | 144 |
Latch | Open and Close the Ski Rack on Request | User Forgets to Close | Loss of skis, potentially fatal accidents | 9 | Distracted User | 4 | Warning System | 6 | 216 |
Latch | Open and Close the Ski Rack on Request | User Forgets to Close | Loss of skis, potentially fatal accidents | 9 | Cannot See Open Rack | 2 | Visual Aide | 7 | 126 |
Crossbars | Holds the Skis Securely in Place | Does not hold the skis with sufficient force | Loss of skis, potentially fatal accidents | 9 | Different height of skis | 5 | Individually sliced rubber | 1 | 45 |
Crossbars | Holds the Skis Securely in Place | Does not hold the skis with sufficient force | Loss of skis, potentially fatal accidents | 9 | Bent Crossbars | 2 | Material Choice | 1 | 18 |
Crossbars | Holds the Skis Securely in Place | Does not hold the skis with sufficient force | Loss of skis, potentially fatal accidents | 9 | Unevenly worn rubber | 3 | Individually sliced rubber | 1 | 27 |
Crossbars | Holds the Skis Securely in Place | Holds the skis too tightly | Damage to skis | 6 | Too thick of a ski | 4 | More space between crossbars, taller rubber | 1 | 24 |
Crossbars | Holds the Skis Securely in Place | Holds the skis too tightly | Damage to skis | 6 | Bent Crossbars | 2 | Material Choice | 1 | 12 |
Crossbars | Holds the Skis Securely in Place | Holds the skis too tightly | Damage to skis | 6 | Rubber too hard | 3 | Material Choice | 3 | 54 |
Crossbars | Holds the Skis Securely in Place | Does not apply uniform pressure | Loss of skis, potentially fatal accidents | 9 | Different height of skis | 5 | Individually sliced rubber | 1 | 45 |
Crossbars | Holds the Skis Securely in Place | Does not apply uniform pressure | Loss of skis, potentially fatal accidents | 9 | Bent crossbars | 2 | Material | 1 | 18 |
Crossbars | Holds the Skis Securely in Place | Does not apply uniform pressure | Loss of skis, potentially fatal accidents | 9 | Unevenly worn rubber | 3 | Individually sliced rubber | 1 | 27 |
Crossbars | Holds the Skis Securely in Place | Does not keep skis from sliding | Loss of skis, potentially fatal accidents | 9 | Not enough friction | 1 | Material choice | 1 | 9 |
Crossbars | Holds the Skis Securely in Place | Does not keep skis from sliding | Loss of skis, potentially fatal accidents | 9 | Rubber too soft | 1 | Material choice | 3 | 27 |
Crossbars | Holds the Skis Securely in Place | Improperly loaded | Loss of skis, potentially fatal accidents, Damage to rack | 9 | Attempt to load over the binding | 4 | Less space between crossbars | 2 | 72 |
Crossbars | Holds the Skis Securely in Place | Improperly loaded | Loss of skis, potentially fatal accidents, Damage to rack | 9 | Attempt to load non-skis | 5 | Less space between crossbars | 4 | 180 |
Inside hinge | Align the crossbars as it closes | Does not align properly | Rack will not close | 7 | Crossbars bent | 2 | Material choice | 1 | 14 |
Inside hinge | Align the crossbars as it closes | Does not align properly | Rack will not close | 7 | Plastic | 6 | Material choice | 4 | 168 |
Inside hinge | Align the crossbars as it closes | Does not align properly | Rack will not close | 7 | Rivet broken | 2 | Material thickness | 6 | 84 |
Inside hinge | Align the crossbars as it closes | Does not fully open | Crossbars will not stay open | 3 | Customer cannot open it far enough | 4 | Create an easier way to open the rack | 2 | 24 |
Inside hinge | Align the crossbars as it closes | Does not fully open | Crossbars will not stay open | 3 | Plastic deformed | 6 | Material choice | 4 | 72 |
Inside hinge | Align the crossbars as it closes | Does not fully close | Cannot go skiing | 7 | Spring worn or broken | 3 | Spring choice | 5 | 105 |
Inside hinge | Align the crossbars as it closes | Does not fully close | Cannot go skiing | 7 | Plastic | 6 | Material | 4 | 168 |
Inside hinge | Align the crossbars as it closes | Does not hold the top and bottom crossbars together | Cannot go skiing | 7 | Rivet broken | 2 | Material thickness | 6 | 84 |
Inside hinge | Align the crossbars as it closes | Does not hold the top and bottom crossbars together | Cannot go skiing | 7 | Broken plastic | 4 | Material choice | 1 | 28 |
Riser | Increase clearance | Binding still does not clear roof | Vehicle gets scratched and dented | 3 | Not enough of a lift in design | 1 | Better design | 1 | 3 |
Riser | Increase clearance | Mount does not attach properly | Cannot go skiing | 7 | Rivet breaks | 2 | Material thickness | 6 | 84 |
Riser | Increase clearance | Mount does not attach properly | Cannot go skiing | 7 | Plastic breaks | 4 | Material choice | 1 | 28 |