Ski rack
From DDL Wiki
(Difference between revisions)
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= Bill of Materials = | = Bill of Materials = | ||
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[[Image:SkiRack_assembly.jpg]] | [[Image:SkiRack_assembly.jpg]] | ||
Line 42: | Line 41: | ||
| Connects bracket to rack. | | Connects bracket to rack. | ||
| Steel | | Steel | ||
- | | | + | | Cold Heading and Thread Rolling |
| 6 | | 6 | ||
| [[Image:SkiRack_longScrew_.jpg|100px]] | | [[Image:SkiRack_longScrew_.jpg|100px]] | ||
Line 49: | Line 48: | ||
| 1B. Slider Top | | 1B. Slider Top | ||
| 1 | | 1 | ||
- | | | + | | Connects the bails to the lower horizontal cross bar. |
| Molded Plastic | | Molded Plastic | ||
| Injection Molding | | Injection Molding | ||
Line 58: | Line 57: | ||
| 1C. Short Bail Screw | | 1C. Short Bail Screw | ||
| 2 | | 2 | ||
- | | | + | | Holds the bails together |
| Steel | | Steel | ||
- | | | + | | Cold Heading and Thread Rolling |
| 6 | | 6 | ||
| [[Image:SkiRack_shortScrew.JPG|100px]] | | [[Image:SkiRack_shortScrew.JPG|100px]] | ||
Line 67: | Line 66: | ||
| 1D. Long Bail Screw | | 1D. Long Bail Screw | ||
| 2 | | 2 | ||
- | | | + | | Holds the bails together |
| Steel | | Steel | ||
- | | | + | | Cold Heading and Thread Rolling |
| 9 | | 9 | ||
| [[Image:SkiRack_longScrew_.jpg|100px]] | | [[Image:SkiRack_longScrew_.jpg|100px]] | ||
Line 76: | Line 75: | ||
| 1E. Upper Bail | | 1E. Upper Bail | ||
| 1 | | 1 | ||
- | | | + | | Clamps over roof rack cross bar. |
| Molded Plastic | | Molded Plastic | ||
| Injection Molding | | Injection Molding | ||
Line 85: | Line 84: | ||
| 1F. Square Nut | | 1F. Square Nut | ||
| 1 | | 1 | ||
- | | | + | | Provides purchase for the base screw withing the slider top. |
| Brass | | Brass | ||
- | | | + | | Forging and tapping |
| 5 | | 5 | ||
| [[Image:SkiRack_squareNut.jpg|100px]] | | [[Image:SkiRack_squareNut.jpg|100px]] | ||
Line 94: | Line 93: | ||
| 1G. Rubber Pad | | 1G. Rubber Pad | ||
| 1 | | 1 | ||
- | | | + | | Provides grip to the bails. |
| Rubber | | Rubber | ||
- | | | + | | Casting |
| 13 | | 13 | ||
| [[Image:SkiRack_rubberPad_.jpg|100px]] | | [[Image:SkiRack_rubberPad_.jpg|100px]] | ||
Line 103: | Line 102: | ||
| 1H. Lower Bail | | 1H. Lower Bail | ||
| 1 | | 1 | ||
- | | | + | | Clamps under roof rack cross bar. |
| Molded Plastic | | Molded Plastic | ||
| Injection Molding | | Injection Molding | ||
Line 112: | Line 111: | ||
| 1I. Hex Nut | | 1I. Hex Nut | ||
| 1 | | 1 | ||
- | | | + | | Provides purchase for the bail screws within the lower bail. |
| Brass | | Brass | ||
- | | | + | | Forging and tapping |
| 5 | | 5 | ||
| [[Image:HexNut.JPG|100px]] | | [[Image:HexNut.JPG|100px]] | ||
Line 121: | Line 120: | ||
| | | | ||
| 2 | | 2 | ||
- | | | + | | Attaches the ski lift to the ski rack. |
| | | | ||
| | | | ||
Line 130: | Line 129: | ||
| 2A. Hex Key | | 2A. Hex Key | ||
| 1 | | 1 | ||
- | | | + | | Holds the ski lift in place. |
| Molded Plastic | | Molded Plastic | ||
| Injection Molding | | Injection Molding | ||
Line 139: | Line 138: | ||
| 2B. Hex Nut | | 2B. Hex Nut | ||
| 1 | | 1 | ||
- | | | + | | Provides purchase for the bold within the hex key. |
| Brass | | Brass | ||
- | | | + | | Forging and tapping |
| 5 | | 5 | ||
| [[Image:HexNut.JPG|100px]] | | [[Image:HexNut.JPG|100px]] | ||
Line 148: | Line 147: | ||
| 2C. Bolt | | 2C. Bolt | ||
| 1 | | 1 | ||
- | | | + | | Connects with the hex key through the ski lift to attached the ski lift |
| Steel | | Steel | ||
- | | | + | | Cold Heading and Thread Rolling |
| 12 | | 12 | ||
| [[Image:HexKeyBolt.JPG|100px]] | | [[Image:HexKeyBolt.JPG|100px]] | ||
Line 177: | Line 176: | ||
| Press fits into ski lift to provide secure purchase for mounting screws. | | Press fits into ski lift to provide secure purchase for mounting screws. | ||
| Brass | | Brass | ||
- | | | + | | Forging and tapping |
| 5 | | 5 | ||
| [[Image:HexNut.JPG|100px]] | | [[Image:HexNut.JPG|100px]] | ||
Line 186: | Line 185: | ||
| Holds ski lift together. | | Holds ski lift together. | ||
| Steel | | Steel | ||
- | | | + | | Cold Heading and Thread Rolling |
| 11 | | 11 | ||
| [[Image:HexKeyBolt.JPG|100px]] | | [[Image:HexKeyBolt.JPG|100px]] | ||
Line 206: | Line 205: | ||
| Casting | | Casting | ||
| | | | ||
- | | | + | | [[Image:SkiRack_lockHousing.jpg|100px]] |
|- | |- | ||
| | | | ||
Line 213: | Line 212: | ||
| Preassembled lock. | | Preassembled lock. | ||
| Steel | | Steel | ||
- | | | + | | Unknown multi-part assembly process. |
| 10 | | 10 | ||
| [[Image:SkiRack_lock_.jpg|100px]] | | [[Image:SkiRack_lock_.jpg|100px]] | ||
Line 224: | Line 223: | ||
| Injection Molding | | Injection Molding | ||
| 0 | | 0 | ||
- | | | + | | [[Image:SkiRack_lockCap.jpg|100px]] |
|- | |- | ||
| 5. Carrier Bottom | | 5. Carrier Bottom | ||
Line 240: | Line 239: | ||
| Holds rack together | | Holds rack together | ||
| Aluminum | | Aluminum | ||
- | | | + | | |
| 0 | | 0 | ||
| [[Image:Rivet2.JPG|100px]] | | [[Image:Rivet2.JPG|100px]] | ||
Line 249: | Line 248: | ||
| Opens rack. | | Opens rack. | ||
| Brass | | Brass | ||
- | | | + | | Coiling |
| 15 | | 15 | ||
| [[Image:SkiRack_hingeSpring_.jpg|100px]] | | [[Image:SkiRack_hingeSpring_.jpg|100px]] | ||
Line 287: | Line 286: | ||
| | | | ||
| | | | ||
- | | | + | | [[Image:SkiRack_latchAssembly.jpg|100px]] |
|- | |- | ||
| | | | ||
Line 330: | Line 329: | ||
| Returns the latch release lever to its closed position | | Returns the latch release lever to its closed position | ||
| Brass | | Brass | ||
- | | | + | | Coiling |
| 4 | | 4 | ||
| [[Image:SkiRack_latchSpring_.jpg|100px]] | | [[Image:SkiRack_latchSpring_.jpg|100px]] | ||
Line 388: | Line 387: | ||
| [[Image:skiRack_hingeShell_.jpg|100px]] | | [[Image:skiRack_hingeShell_.jpg|100px]] | ||
|} | |} | ||
+ | |||
+ | [[Ski rack]] | ||
= Design for Manufacture and Assembly = | = Design for Manufacture and Assembly = |
Revision as of 17:48, 7 February 2011
Hello
Ski Rack Bill of Materials
Ski Rack DFMA
Ski Rack FMEA
Ski Rack DFE
Contents |
Usage
Bill of Materials
Ski rack
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 |