Mike Brody Phil Holcolme Adam Konneker Nick LaRocca Claire Ngengwe

1. Mike Brody Phil Holcolme Adam Konneker Nick LaRocca Claire Ngengwe Validation & Results Mission Statement The purpose of this project is to design a system which will improve manufacturing process of Boeing Business Jet auxiliary fuel tanks by making the process safer and reducing the time it takes to move the tanks. Prototype Current System Implementation Prototype and Implementation Cost Acknowledgements Concept • Target Metrics • Hold one BBJ (Boeing 737 Business Jet) auxiliary fuel tank (size and weight) plus two workers and equipment (approx. 1000 lbs) • Rotate tank through 360-degrees on one axis • Raise and lower tank 48 inches. • As safe as (or safer than) current process to tank and workers • Tests • Lift and rotate tank successfully 50 times • Minimize deflection between uprights (less than 1/2 in.) • Adequate winch and rotating hand wheel ergonomics • Overall safety Improvement to Auxiliary Fuel Tank Fabrication • Tanks Lifted by electric pulley • Rotating and clamping system • Removable side tables for workers to stand on while working • Simplified version of our concept • Detachable tables not included • Manual pulley system • Outer shell of tank is completed first • Installing inner components requires moving tank • Each tank is lifted and rotated multiple times during fabrication • All movement is done manually with 2+ workers • Tank is painted on one side and then flipped to be painted on the other side • Results • Lifting and rotating system 96% reliable – changes to final design will improve this • Average deflection between uprights is .15 in. which is acceptable • Good rotating hand wheel ergonomics • Winch gear ratio can be increased to reduce # of rotations because force required is only 1.32 lbf. • Safety training is necessary • Pinch points can be covered on pulley for final design • Frame • Steel Bar with Pulley System • Manual winch on both sides • 4 ft. stroke • Clamping/Rotation System • Hand wheel • Clamp with 4 Bolts • 360° Rotation • Polyethylene contact surfaces • Build final design • Train workers in use and safety • Implement into manufacturing process Problem Prototype Material and Machining $ 3,034.00 Implementation Material and Machining $ 6,000.00 Total cost $ 9,034.00 • Tanks can be damaged during movement which may result in scrapping part • Workers can be injured during lifting • Process needs improvement in order to better exhibit lean manufacturing The team would like to thank Dr. Hartman for his advisement, Matt Porter, Joe Reinhardt, and Caleb Janssen of PATS Aircraft, and Steve Beard for help in the machine shop.