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Hydraulic Fan Motors: Design, Efficiency, and Optimization

This project focuses on the design, efficiency, and optimization of hydraulic fan motors. The team aims to improve production, safety, and quality, while reducing downtime and implementing preventative maintenance. Data collection, analysis, and adherence to industrial standards are key components of this project.

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Hydraulic Fan Motors: Design, Efficiency, and Optimization

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  1. Team Valeo Team Members Stefan Enjem – ISE Joe Van Hofwegen - ISE Young Lee - ISE Joe Pecht - ME Walter Freitag - ME Jason Zion - ME Luis Garcia - EE

  2. Hydraulic Fan Motors • Who uses them? • Why are they used? • How are they built?

  3. Needs Assessment • QPH (9) • 4 to 6% Increase in Production • 2 year payback • Safety and Quality

  4. Organization • Scope and Resource Distribution • Work Breakdown Structure • Scheduling • Gantt Chart • Communication • Yahoo Web Group

  5. Deliverables • Standardized Procedures • Preventative Maintenance • Set Production Guidelines • Fix Problematic Stations • End of Line Tester Efficiency • Identify improved system configurations

  6. Organizational Structure

  7. Data Collection and Analysis • Data Collection • Motor Counters • EOLT Data Sheets • Cycle Time • Historical Data

  8. Bottleneck Identification • Histogram shows major sources of backup

  9. Micro-stop • Micro stop = Downtime of less than 5 minutes

  10. Industrial Standards • Clean Room • Certified Class 100,000 • QS 9000 • Quality standard TS 16949 • Valeo Union Standard • 423 minutes per shift • Ergonomic Guidelines

  11. Detailed Procedures • Standard Procedures • Worker Rotation • Failure Response Plan

  12. Manual Stations Station 90 Station 160 • Current Problems • Concept for Improvements • Expected Improvements

  13. Preventative Maintenance • Creation of a Preventative Maintenance Schedule

  14. Station 210 • Current Problems Camera for Optical Test Leak Test Connectors

  15. Station 210 • Concepts for Improvement • Mirror • PM on Rubber Connectors Rubber Connectors • Expected Improvements • Reduction in Downtime

  16. End of Line Tester • Function • Current Problems • Feasibility of Concepts

  17. Mounting Concept • Linear Slide Mount

  18. Mating Concept • Modified Assembly Cell Balancer

  19. Technical Analysis • FEA • Air Cylinder Sizing • Expected Improvements

  20. Arena Simulation – Our Test Plan • Analyze system as a whole • Identify optimal system configuration and alternatives • Using pallets, conveyor speed, queue sizes • Justify Improvements

  21. Cost Analysis of Total System • Estimated Cost Analysis • Net Present Value

  22. Future of Project • Engineering Models • Head start • Simulation • Stations • Detailed Design • Meet the Goal

  23. Backup - Bill of Materials

  24. Backup - Regression

  25. Backup – Bottleneck Rank

  26. Backup - WBS

  27. Backup –Gantt Chart

  28. Backup – Counter Data

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