Problem Description:

At times part mixing occurs causing jams in grinding machinery. These jams stop the automated line and the down time costs money. If the part mixing is severe enough, meaning having tubs of more than one part then we will sort. Currently one employee sorts by hand 8 hours a day. This is a very tedious and slow practice which can be improved upon, and by automating this process the sorting associate can be assigned to a higher value-added task.

We would like a machine or other means to automate this sorting process. This process should require a human to load the device and require very little human supervision during operation.

Constraints & Criteria:

Must be safe (accounting for covers for moving parts, stable, etc) Must sort tapered rollers for both O.D. & Length Must sort atleast 1 tub in an 8 hour period (one tub contains 30-60,000 parts) Must be able to separate small piece of unforged wire that we call “headed blanks” Must be able to sort all rollers within reason and versatile enough to sort rollers we may

use in the future. Must be able to easily dispense sorted rollers into tubs that we currently have. Should fit into a similar size area already alotted to sorting area currently in use Should require no change over Should use a hopper Should be able to sort parts that have excessive forging flash Should utilize parts already in use at the plant if possible….such as motors, electrical

components, etc. Should use parts made from preferred companies if possible

Team requirements:

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Confidentiality and safety: On the first plant visit, the team must go through brief safety training and sign non-disclosure agreements. They will be considered private contractors for the duration of the project, and must meet the same expectations as other contractors that work in the plant.

Weekly meetings: can be held in person or by conference call. After the project is started, we will try to set a regular recurring time based on scheduling availability. At least 50% of the team needs to be involved every week. No member can go more than three weeks without being involved. Weekly meeting minutes need to be recorded by a team member.

Hourly requirements: There is no set number of hours required, as long as reasonable weekly goals are met.

Plant visits: We do not want traveling to the plant to be a burden, but every member must be in the plant at least once a month, within reason. The entire group does not have to be present for every visit, but over the course of the month every member needs to visit the plant.

For the first semester, they must be with a Koyo engineer or assigned associate. They can come before or after business hours, provided it is communicated before hand and a Koyo associate is available to assist the team or team members.

All expenses should be recorded by the team for a budget summary at the end of the year.

Machining time budget: We will allow 100 hours of machining time, including programming and setup. Materials will be accounted for in the budget, even if it is material we already have on hand.

Project justification: So the team is involved in multiple aspects of manufacturing, the team will justify the project by forecasting the improvement effect the project is supposed to have. The advising engineer will provide production history/scrap data/etc. for the team to base their forecast on.

Prototypes will be assembled by team members under supervision of the advising engineer. Light machining and fabrication will be performed by team members under supervision of the advising engineer and/or technician.

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