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Engineering 470 Project. Redesign proposal for the 1999 Mercury Cougar (SW-164) exterior mirrors. By John Uken. “Introvert”. The ‘99 Cougar Ext. Mirror. North American and European designs RHD and LHD Convex glass Heated mirror glass Breakaway design Dual pivot Spring-loaded.
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Engineering 470 Project • Redesign proposal for the 1999 Mercury Cougar (SW-164) exterior mirrors By John Uken “Introvert”
The ‘99 Cougar Ext. Mirror • North American and European designs • RHD and LHD • Convex glass • Heated mirror glass • Breakaway design • Dual pivot • Spring-loaded
Current Problems • Vertical force • Breakaway • Failure • Car wash test • Failure at Ford’s Belgium car wash • Assembly • 11 Screws • 5 Re-orientations
Proposed Redesign • 1994 Ford Mondeo Mirror (European) • Robust dual pivot breakaway design • Diecast brackets • Redesign • Incorporate Mondeo- like brackets into current housing and base
Design Photographs Electrical Components
Design Photographs Current Housing Subassembly
Design Photographs Current Base with Hinge, Hinge Plate and Screws
Design Photographs Redesign Brackets with Current Actuator
Design for Assembly • Design for assembly (DFA) analysis • Current design • Redesign
Conclusion • Design feasibility • Cost • Quality • Final decision based on: • Cost • Quality • Reputation
My Personal Conclusion • Proceed with redesign • Save reputation with Ford • Encourage further business • Improve current relationship • Produce only quality parts • Reduce warranty costs • A product you can be proud of