12/10/07 Mike Gilbert, Matt Williams, Tuan Huynh, Travis Pincoski

1. Team GORE 12/10/07 Mike Gilbert, Matt Williams, Tuan Huynh, Travis Pincoski

2. To design and fabricate a device or devices that will reduce the changeover time for the pleating machine. The designed solution must work for all CleanStream filter products and be integrated into the existing machines.

3. PleatHeight Pleat Assist Stripper Bar Bed Pleater Bed

5. 4 Critical Adjustments • Pleater bed • Stripper bar bed • Setting pleat height • Pleat assist • At Least: • 10 bolts • 7 different tools

6. Pleater Height (50%) • 2 sides • Iterative process • Must be accurate • Stripper Bar Bed (25%) • Hard to adjust (friction and weight) • Potential damage to other structures

8. Safety: Solution must keep operators and engineers out of harms way. Must also meet OSHA regulations. • Cost: Solution must fit within Gore’s budget for this project. • Machine Conditions: Solution must be able to fit on the current Chandler pleaters.

11. Approx. 1 hr per pleat height changeover • 170 changeovers per machine per year • 3 machines • 50% reduction = 255 production hours saved per year

12. Scissor Jack Automatic Blade Pleater • Popular tool (Automotive, aerospace, etc) • Proven reliability, durability and strength • Lightweight, cheap, etc. • Fully automatic pleating machine • High rate of production • Expensive

13. Not feasible with one concept • Cost • Time • Resources • Two Concepts • Moving both beds and holding the 1/8” gap • Setting pleat height

14. Adjustable Bolt Spacer Assortment of Custom Spacers Caliper Spacer

16. 3 = Best, 2 = Moderate, 1 = Worst

17. Caliper Spacer Design with slots for caliper

18. Calibration system Alignment system Locking system Caliper Spacer Design with slots for caliper

19. Designed to work with digital caliper • Tolerance due to slip fit of alignment system • Deformation due to loads are negligible

20. Scissor Jack Rack + Pinion Threaded Rod Design

22. 3 = Best, 2 = Moderate, 1 = Worst

24. Railing system Structural Mounts Bearing system Gearing system

25. Spacing of Railing Rods • ACME Thread Rod • Bearings Selection • Gearing

26. Bed Mover Spacer (x2) Total Cost = Under $2300

27. Custom Machine work • Low quantity • High precision • Adaptability • Off-the-Shelf Parts • Stock rods • Bearings (linear, roller) • ACME rod • Gearbox

28. Structure mounts and brackets • Linear and roller bearings pressed fit beforehand • Thread in ACME rod • Attach gearbox, crankshaft, and hand wheel

29. Changeover Time Test • 3 Team Members • Each Performed 3 Trials • Average time of 3rd trial will designate the new time of the changeover • One operator • Performed only one test due to time constraints • Results used to “bridge gap” between team tests to what Gore can expect • Basis for Comparison • Time of 62 minutes will be used as benchmark for time reduction

30. Target Time (31 Mins)

31. All 10 trials were well below target value of 31 mins. • 3rd Trial Times • Mike: 18:14 • Matt: 17:14 • Tuan: 18:35 • Team Average = 18:01 => 70% Reduction • Gore Operator had time of 18:10 • Times should improve as well, therefore Gore can expect roughly 70% improvement when system is fully implemented.

32. * Anticipated Value

33. Projected Percentage of Time Reduction: Approx. 56% Actual Tested Percentage of Time Reduction: 70% *Time in Minutes

34. Bed mover was removed from pleater after testing • Further testing required for manufacturing implementation • Additional time testing required • Additional alignment testing required • Solidworks drawings provided to Gore • Training materials created

35. Sponsor: Craig Livingston • Advisor: Dr. Michael Keefe • Engineers: Julia Levinson, Steve Stark • Operations: Mark Cotter, Dave Burnham • Machinists: Dave Pierce, Sebastian Giambanco, Brian Villanueva