Ski rack

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= Bill of Materials =
= Bill of Materials =
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== Bill of Materials ==
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[[Image:SkiRack_assembly.jpg]]
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{| border="1"
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|-
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! Assembly
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! Part
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! Quantity
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! Description
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! Material
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! Manufacturing process
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! Weight [grams]
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! Image
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|-
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| 1. Mounting Bracket
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|
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| 4
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| Mounts carrier to roof rack.
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|
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|
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|
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| [[Image:MountingBracket.JPG|100px]]
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|-
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|
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| 1A. Base Screw
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| 1
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| Connects bracket to rack.
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| Steel
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|
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| 6
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| [[Image:SkiRack_longScrew_.jpg|100px]]
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|-
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|
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| 1B. Slider Top
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| 1
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|
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| Molded Plastic
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| Injection Molding
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| 36
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| [[Image:SkiRack_sliderTop_.jpg|100px]]
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|-
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|
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| 1C. Short Bail Screw
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| 2
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|
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| Steel
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|
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| 6
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| [[Image:SkiRack_shortScrew.JPG|100px]]
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|-
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|
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| 1D. Long Bail Screw
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| 2
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|
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| Steel
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|
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| 9
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| [[Image:SkiRack_longScrew_.jpg|100px]]
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|-
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|
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| 1E. Upper Bail
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| 1
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|
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| Molded Plastic
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| Injection Molding
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| 45
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| [[Image:SkiRack_upperBail_.jpg|100px]]
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|-
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|
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| 1F. Square Nut
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| 1
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|
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| Brass
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|
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| 5
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| [[Image:SkiRack_squareNut.jpg|100px]]
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|-
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|
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| 1G. Rubber Pad
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| 1
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|
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| Rubber
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|
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| 13
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| [[Image:SkiRack_rubberPad_.jpg|100px]]
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|-
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|
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| 1H. Lower Bail
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| 1
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|
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| Molded Plastic
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| Injection Molding
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| 49
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| [[Image:LowerBail2.JPG|100px]]
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|-
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|
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| 1I. Hex Nut
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| 1
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|
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| Brass
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|
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| 5
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| [[Image:HexNut.JPG|100px]]
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|-
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| 2. Hex Key
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|
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| 2
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|
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|
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|
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|
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|
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|-
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|
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| 2A. Hex Key
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| 1
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|
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| Molded Plastic
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| Injection Molding
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| 6
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| [[Image:hexKey.JPG|100px]]
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|-
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|
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| 2B. Hex Nut
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| 1
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|
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| Brass
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|
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| 5
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| [[Image:HexNut.JPG|100px]]
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|-
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|
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| 2C. Bolt
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| 1
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|
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| Steel
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|
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| 12
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| [[Image:HexKeyBolt.JPG|100px]]
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|-
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| 3. Ski Lift
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|
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| 2
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|
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|
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|
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|
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| [[Image:SkiLiftAssembly_good.JPG|100px]]
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|-
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|
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| 3A. Ski Lift
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| 1
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| Raises up rack to provided additional clearance.
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| Molded Plastic
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| Injection Molding
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| 25
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| [[Image:skiLift.JPG|100px]]
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|-
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|
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| 3B. Hex Nut
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| 1
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| Press fits into ski lift to provide secure purchase for mounting screws.
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| Brass
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|
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| 5
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| [[Image:HexNut.JPG|100px]]
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|-
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|
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| 3C. Button Head Screw
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| 1
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| Holds ski lift together.
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| Steel
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|
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| 11
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| [[Image:HexKeyBolt.JPG|100px]]
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|-
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| 4. Lock Assembly
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|
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| 2
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|
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|
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|
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|
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|
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|-
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|
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| 4A. Lock Housing
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| 1
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| Holds lock in place within release lever.
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| Steel
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| Casting
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|
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|
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|-
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|
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| 4B. Lock
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| 1
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| Preassembled lock. 
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| Steel
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|
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| 10
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| [[Image:SkiRack_lock_.jpg|100px]]
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|-
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|
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| 4C. Lock Cap
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| 1
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| Replaces optional lock
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| Molded Plastic
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| Injection Molding
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| 0
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|
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|-
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| 5. Carrier Bottom
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|
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| 2
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|
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|
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|
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|
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|
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|-
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|
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| 5A. Rivet
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| 3
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| Holds rack together
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| Aluminum
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|
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| 0
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| [[Image:Rivet2.JPG|100px]]
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|-
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|
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| 5B. Hinge Spring
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| 1
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| Opens rack.
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| Brass
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|
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| 15
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| [[Image:SkiRack_hingeSpring_.jpg|100px]]
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|-
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|
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| 5C. Lower Compression Pad
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| 1
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| Compresses to firmly hold skis in place
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| Rubber
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| Extrusion
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| 137
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| [[Image:SkiRack_bottomRubber.jpg|100px]]
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|-
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|
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| 5D. Bottom Shell
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| 1
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| Holds bottom compression pad in place.  Mounts to mounting brackets.
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| Steel
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| Extrusion
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| 198
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| [[Image:SkiRack_bottomSteelShell_.jpg|100px]]
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|-
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|
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| 5E. Latch (Bottom Half)
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| 1
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| Provides something for upper half of latch to secure to.
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| Molded Plastic
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| Injection Molding
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| 20
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| [[Image:SkiRack_bottomLatch.jpg|100px]]
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|-
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| 6. Latch
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|
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| 2
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|
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|
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|
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|
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|
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|-
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|
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| 6A. Latch Housing
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| 1
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| Contains the latch mechanisms.
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| Molded Plastic
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| Injection Molding
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| 52
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| [[Image:LatchCasing.JPG|100px]]
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|-
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|
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| 6B. Release Lever
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| 1
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| Releases the latch when pressed.
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| Molded Plastic
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| Injection Molding
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| 45
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| [[Image:SkiRack_latchHandle_.jpg|100px]]
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|-
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|
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| 6C. Lock Back
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| 1
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| Interfaces between the lock and locking tab.
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| Steel
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| Casting
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| 5
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| [[Image:SkiRack_lockBack_.jpg|100px]]
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|-
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|
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| 6D. Locking Tab
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| 1
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| Rotates when rack is locked to hold the rack shut.
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| Steel
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| Punching
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| 0
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| [[Image:SkiRack_lockingTab_.jpg|100px]]
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|-
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|
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| 6E. Spring
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| 1
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| Returns the latch release lever to its closed position
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| Brass
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|
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| 4
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| [[Image:SkiRack_latchSpring_.jpg|100px]]
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|-
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|
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| 6F. Lock Washer
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| 1
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| Holds the locking mechanism together.
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| Steel
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|
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| 0
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| Missing
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|-
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| 7. Carrier Top
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|
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| 2
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|
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|
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|
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|
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| [[Image:Top Bar Assembly.JPG|100px]]
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|-
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|
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| 7A. Upper Horizontal Shell
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| 1
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| Holds the rubber compression pad in place. 
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| Rubber
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| Extrusion
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| 206
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| [[Image:SkiRack_horizontalSteelTop_.jpg|100px]]
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|-
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|
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| 7B. Upper Compression Pad
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| 1
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| Compression pad to hold the skis firmly in place
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| Rubber
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| Extrusion
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| 127
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| [[Image:TopRubber_sideview.JPG|100px]]
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|-
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|
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| 7C. Rivet
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| 2
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|
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| Aluminum
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|
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| 0
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| [[Image:Rivet2.JPG|100px]]
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|-
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|
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| 7D. Hinge Shell
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| 1
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| Connects the top and bottom parts together and acts as a hinge.
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| Molded Plastic
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| Injection Molding
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| 67
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| [[Image:skiRack_hingeShell_.jpg|100px]]
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|}
= 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

Image:SkiRack_assembly.jpg


Assembly Part Quantity Description Material Manufacturing process Weight [grams] Image
1. Mounting Bracket 4 Mounts carrier to roof rack.
1A. Base Screw 1 Connects bracket to rack. Steel 6
1B. Slider Top 1 Molded Plastic Injection Molding 36
1C. Short Bail Screw 2 Steel 6
1D. Long Bail Screw 2 Steel 9
1E. Upper Bail 1 Molded Plastic Injection Molding 45
1F. Square Nut 1 Brass 5
1G. Rubber Pad 1 Rubber 13
1H. Lower Bail 1 Molded Plastic Injection Molding 49
1I. Hex Nut 1 Brass 5
2. Hex Key 2
2A. Hex Key 1 Molded Plastic Injection Molding 6
2B. Hex Nut 1 Brass 5
2C. Bolt 1 Steel 12
3. Ski Lift 2
3A. Ski Lift 1 Raises up rack to provided additional clearance. Molded Plastic Injection Molding 25
3B. Hex Nut 1 Press fits into ski lift to provide secure purchase for mounting screws. Brass 5
3C. Button Head Screw 1 Holds ski lift together. Steel 11
4. Lock Assembly 2
4A. Lock Housing 1 Holds lock in place within release lever. Steel Casting
4B. Lock 1 Preassembled lock. Steel 10
4C. Lock Cap 1 Replaces optional lock Molded Plastic Injection Molding 0
5. Carrier Bottom 2
5A. Rivet 3 Holds rack together Aluminum 0
5B. Hinge Spring 1 Opens rack. Brass 15
5C. Lower Compression Pad 1 Compresses to firmly hold skis in place Rubber Extrusion 137
5D. Bottom Shell 1 Holds bottom compression pad in place. Mounts to mounting brackets. Steel Extrusion 198
5E. Latch (Bottom Half) 1 Provides something for upper half of latch to secure to. Molded Plastic Injection Molding 20
6. Latch 2
6A. Latch Housing 1 Contains the latch mechanisms. Molded Plastic Injection Molding 52
6B. Release Lever 1 Releases the latch when pressed. Molded Plastic Injection Molding 45
6C. Lock Back 1 Interfaces between the lock and locking tab. Steel Casting 5
6D. Locking Tab 1 Rotates when rack is locked to hold the rack shut. Steel Punching 0
6E. Spring 1 Returns the latch release lever to its closed position Brass 4
6F. Lock Washer 1 Holds the locking mechanism together. Steel 0 Missing
7. Carrier Top 2
7A. Upper Horizontal Shell 1 Holds the rubber compression pad in place. Rubber Extrusion 206
7B. Upper Compression Pad 1 Compression pad to hold the skis firmly in place Rubber Extrusion 127
7C. Rivet 2 Aluminum 0
7D. Hinge Shell 1 Connects the top and bottom parts together and acts as a hinge. Molded Plastic Injection Molding 67

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

Design for Environment

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