If you can remember seven
passwords to get into your
computer to do your job but
forget your second wedding
anniversary, you could be an
engineer.
Mei-Chuan S Haverkamp
Jim Haverkamp
Senior (Ancient) Mechanical Engineer
Disclaimer
 In this presentation I am going to mention some of the
things that has molded me into the engineer that I am.
 My mold is only one of many and just because you
don’t exactly fit in my mold does not mean that you
cannot become an outstanding engineer.
 Saying the word “engineer” is like saying vehicle, the
next question is usually “What kind?”
History
 From a young age I have always been intensely
interested in how things worked.
 I would get excited when thing broke
 This would extend to my toys
 This became such an obsession that I would actually
weigh the difference between having the toy and finding
out how it worked
 Finding out how it worked usually won
 I got to be good with the disassembly process
My mother labeled me the worlds most destructive kid
in the world!
Why Mechanical?
 Found in the basement as an old TV that was not
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working.
I plugged it in and confirmed that it, in fact, was not
working properly.
Before I did anything I unplugged to. “Can’t be too
careful, right?”
I took the back off and was immediately in heaven!
I discovered capacitance!
Cleaned up
United States Navy
 When in the Navy I was eventually assigned to R
division. R is for Repair.
 Take thing apart
 Put them back together
 The are supposed to work
 When on a ship at sea one cannot run to the local Osh
store.
 Have to make out own tools and I became very
interested in tool design and why.
 Leaving the navy I found work in the sheet metal
industries.
Education
 Chabot College (Los Positas) 1982 – 1986
 UC Berkeley 1986-1989
Digressing just a bit
 Part of the reason I left the
navy is that I objected to
being forced to wear a
uniform like everybody
else
 I went from this …..
To this …..
I think I lost that round
The following are sanitized slides from and actual project
that I ran
Phase 1 is to produce a conceptual design
 The first step is to clarify the objective
 What is causing the need? Some function that does not
meet a requirement.
 What is the scope of the problem?
 When is a solution needed?
 What is the budget?
 The second step is to create a specification that I will
design to.
 Finally I will come up with some conceptual designs
and demonstrate how they fulfill the specifications
 Product / Project Name / Date of Review / Name of Presenter

XXXXXXXX Window Pry tool, 3/7/13, Jim Haverkamp
 Objective of this Design Review

Obtain permission to purchase newly designed pry tool XXXXXXXXX and test fixture
 Identify EPL Item Driving This Activity

PR XXXXXXXX
 Problem statement
The XXXXXXX tool has two windows that stick together due to adhesion from the two O-rings.
A tool is needed to pull the windows apart.
 Previous tool does not fit well and requires the removal of several parts
 Earlier tool failed after 4 uses
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 Project Objective
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Specifications
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Pry the top window from the bottom window
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During the removal the gas distribution plenum with remain attached to the top window
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Material from the tool will not contaminate or damage either window
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Will not require the removal of the Plastic alignment brackets that are attached to the pinnacle
Cost - Targeting $1260
Time / Schedule

Design complete 2/28/13

Receive parts 3/11/13

Release 3/15/13
Success Criteria

Confirmation that will provide 2X the force or the XXXXX before failure on the upper window

Confirmation that it will perform equally as well as the XXXXX1 on the lower window
Scope

10 customers currently own a this tool including our lab. Potential need for the tool is between 20
and 30.
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This tool is not legacy, there is a potential for more customers
 Summary of Design Change
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Tool foot designed to fit into gap between the two windows
Material changed from polycarbonate to 40% glass filled polycarbonate
SS Helicoil changed to Nitronic 60 gall resistant Helicoil
An Aluminum plug insert is designed to provide support for the polycarbonate
Frame members were thickened to aid in managing the load
This is the part that I designed
The part in position
Addition specifications that I found
during the design process
Finite Element Analysis was used to confirm that the
part could match the forces
Example of a risk table
Phase 2 involves buying parts and breaking them!
Take notes and document lessons
learned
 During the breaking phase there is nearly always a
surprise or two that requires redesign.
 Question your results! In this case the Finite Element
Analysis was bit applicable
 Review and update risks
Phase 3 get it ready for a customer
 Lock down the design
 Create a Bill of Materials (BOM)
 Create instruction on how to use it or install it
 What to do with the old parts
 MONITOR CUSTOMER FEEDBACK!!!!! Be proactive!
 When the customer returns with positive feedback ….
After positive feedback
Go Kayaking
In that order!
and have a beer