Windshield wiper assembly 2

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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
    1. Resistance to corrosion
    2. Unobtrusive
    3. Effective
    4. Cheap to replace
    5. Long lasting blades
    6. Long lasting structure
    7. Safety
    8. Doesn't damage the car
    9. Aesthetics
    10. Cleans heavy snow
    11. Cleans entire windshield
    12. Doesn't streak
    13. Doesn't ice over
    14. EZ to store blades
    15. Wider fluid dispersal
  • Car retailer
    1. Cheap to manufacture
    2. Appeals to the user
  • Shop workers
    1. Standardized
    2. Difficult to replace
    3. EZ to repair
    4. Modular
    5. Safety
  • Car manufacturer
    1. Cheap to manufacture
    2. Safety, No VOC
    3. Easy to assemble/install
  • Parking Police
    1. EZ to put ticket under
  • Wiper Retailer
    1. Standardized
    2. Low Cost
  • Other Cars on the road
    1. Effective
    2. Cleans entire window

Product Usability Study

Assembly

Product Operation

Dissection Exercise

Dissection Write Up

Dissection Table

Bill of Materials
Part Number Sub-Assembly Part Name Quantity Weight (in g) Function Manufacturing Process Material Image
Base Structure


1 Driver Side Wiper Casing 1 111 Protect Arm 3 (driver side) wiper mount linkage Cast Aluminum Image:.jpg


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)


6 Metal Grommet Insert (small) 1 Stabilizes vibration mount by holding onto chassis Extended and expanded Steel Image:.jpg


7 Rubber Mount (small) 1 Vibration dampening Molding Rubber Image:.jpg


Arm 1


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


9 Lock Washer 1 2 Distribute nut pressure Steel Image:.jpg


10 Nut 1 3 Attach Arm 1 to drivetrain Tapping Steel Image:.jpg


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


Arm 3


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


14 Plastic Cover 2 2 Prevent fluid from seeping into linkage area Injection Mold Plastic Image:.jpg


15 Screw-On Cap 2 11 Protect Wiper Mount Pin Cast and Threaded Die Steel Image:.jpg


Arm 4


16 Arm 4 linkage [Length: 20.5" (52 cm) 1 177 Transfer motion Image:.jpg


Other


17 Top Washer 1 1 Steel Image:.jpg


Gear Casing


18 Gear Casing Cover Screws 4 <1 Attach cover to casing Die Steel Image:.jpg


19 Drivetrain Mounting Bolts 3 5 Mount drivetrain to base Die Steel Image:.jpg
Motor


20 Motor Mounting Bolts (w/ Lock Washer) 4 5 Mount motor to base Die Steel Image:.jpg


21 Motor Mounting Nuts 4 3 Mount motor to base Tapping Steel Image:.jpg


22 Motor 1 Convert electric current via EMF to rotation of a linear worm gear Standard purchased part Image:.jpg


Windshield Wiper


23 Wiper 2 Rotate about pin and sweep across windshield Plastic Image:.jpg


24 Blade 2 Remove water or other debris from windshield Rubber Image:.jpg

DFMA

Manufacturing

Design for Manufacturing
Guideline Comments
Minimize Part Count
Eliminate fasteners, part consolidation
One motor
Remove extra bolts


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
Guideline Comments
Minimize Part Count
Eliminate fasteners, part consolidation
One motor
Remove extra bolts


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
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
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.

References

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