2.875
Mechanical Assembly
and Its Role in Product Design
Pencil Sharpener Presentation#1
November 14, 2001
Hernan Joglar
John Sharkey
1
Presentation Contents
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Product Description
Company Background
CAD Exploded view
Parts and Material List
Photo of Product Disassembly
Product Structural Decomposition
Major Sub-Assemblies
Critical Mates and Clearances
Gearbox Key Characteristics and Datum Flow Chain
Assembly liaison diagram
Assembly Time Analysis
Example Assembly Process
Fixtures and Special Tooling
Potential Problems and Risks
Suggested Assembly Improvements
Backups
– DFA Gross Motions
– DFA Fine Motions
– Related Product Line
- Product Structural Decomposition
- Part Liaisons and Mates
2
Boston Stapler Product Description
• Battery Operated Pencil Sharpener: Model #16750 (black)
–
–
–
–
Referred to as a “razor spiral cutter” model
Operation activated by axial force of pencil insertion
Safety lockout feature prevents operation without receptacle
Features 1 year warranty
• No replaceable parts, Hunt simply replaces defective units
• Product Assembly Specifications:
– 29 identified parts, comprising 7 sub-assemblies
– 35 assembly features and liaisons
– Physical dimensions: 4.75” x 3.00” x 2.25” at 6.1 ounce weight
• Popular with graphic artists and designers
– provides clean, sharp pencil points for a wide range of pencil types,
including composite pencils
• Approximately 250,000 units sold last year
– Distributed through all major office supply retail stores
• Staples, Office Depot, Wal-Mart, Target, etc
– Typically sells for around $5.00
3
Hunt Manufacturing Corporation
• Founded in 1899 by George Bartol
• Went public in 1982 after a series of expansions and acquisitions.
• Corporate headquarters in Statesville, NC
• Donald L. Thompson became president and CEO in 1996
• Product design center located in Statesville, NC
• Outsources most manufacturing within the United States
• Boston Series of pencil sharpeners manufactured in China
• 1300 employees nationwide
• Sales revenue of $286M in 2000, 1.6% increase over 1999
• Main product lines is graphics equipment and office supplies
• A global leader in the pencil-sharpener market
• Boston family of pencil sharpeners and
staplers accounts for 40% of company sales
• Other significant products lines include:
• Exacto razor blades
• Conte crayons and pastels
• Bienfang paper, painter markers,
foam boards and laminates
• Seal imaging equipment
4
CAD Exploded View
5
[ Model developed using Autodesk Inventer Version 3.0 ]
Parts and Material List
P/N
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
Part Name
Base Screws
Pencil guide
Battery compartment screw
Shavings receptacle
Sharpener base
Rubber foot (Underneath of base)
Sharpener case
Contacts on battery compartment cover
Battery compartment cover
Rubber foot (Underneath of battery comp. cover)
Battery Compartment housing
Contacts and rivets on battery compartment
Battery installation paper guide
Blue wire
Gearbox housing
Output Gear
Intermediate Gear
Driven Gear
Gearbox cover screw
Electric motor
Safety lever
Lubrication
Contacts and rivets on gear housing cover
Red wire
Black wire
Gearbox cover
Blade screw and nut
Blade
Blade holder
Qty
2
1
1
1
1
1
1
2
1
1
1
3
1
1
1
1
1
1
1
1
1
1
3
1
1
1
1
1
1
Material Description
Self-threading steel screw
Injection molded plastic
Self-threading steel screw
Injection molded plastic
Injection molded plastic
black rubber
Injection molded plastic
stainless steel contacts with plastic rivets
Injection molded plastic
black rubber
Injection molded plastic
stainless steel contacts and brass rivets
white paper with black graphic print
22 gage aluminum braid wire
Injection molded plastic
Injection molded plastic
Injection molded plastic
Injection molded plastic
Self-threading steel screw
Brush commutated DC permament magnet motor
Injection molded plastic
red petroleum jelly on gears and motor
stainless steel contacts and brass rivets
22 gage aluminum braid wire
22 gage aluminum braid wire
Injection molded plastic
Machine screw and hex nut
Stainless steel razor blade
Injection molded plastic
6
Photo of Product Disassembly
14
9
24
15
25
5
8
4
12
11
23
2
7
21
11
16
17
18 19 1
3 26
27 28
20
29
7
Product Structural Decomposition
Complete Assembly
Pencil guide
Base screws
Motor Gearbox
Bat. Comp.
screws
Black wire
Gearbox
cover screw
Gearbox
housing
Electric
motor
Output gear
Safety lever
Intermediate
gear
Driven gear
Cutter
Unit
Blade nut
and bolt
Blade
Blade holder
Lubrication
Shavings
receptacle
Battery
Compartment
Sharpener
case
Bat. Comp.
housing
Bat. Comp.
contacts
Bat. install.
guide
Base
Sharpener
base
Rubber
foot
Battery
Comp. cover
Contacts battery
Comp. cover
Gearbox cover
Battery
Comp. cover
Gearbox cover
contacts
Rubber
foot
Red wire
Blue wire
Gearbox cover
General Assembly
Sub- Assembly
Part
8
Major Sub-Assemblies
Safety lever pin
Input contact
Edge
Gearbox Cover
Motor rim
Output gear
Driven
gear
Intermediate
contact
Motor
Output contact
Intermediate gear
Gearbox housing
Motor Gearbox Sub-Assembly
Gearbox cover Sub-Assembly
Mating
features
Blade holder
Blade
Bolt
Nut
Cutter Unit Sub-Assembly
Red and black
electric wires
Electric in-out
contacts
Electric contact
rivets
Battery Compartment Sub-Assembly
9
Critical Mate and Clearance Ratio #1
Slots
Shaver Receptacle to Shaver Case
clower 
1.990  2.019  0.014
2.019
1.713  1.792  0.044
cupper 
1.792
Rims
10
Critical Mate and Clearance Ratio #2
Base to Sharpener Case Edge Interface
c rimslot 
2.114  2.097   0.007
c peg hole#1 
0233  0.200  0.142
Holes
2.097
Slot along
edge
0.233
Slot
c peg hole# 2 
0229  0.200  0.127
0.229
Rim along
edge
Rim
Pegs
Note: Clearance ratio requires
Gearbox and battery compartment
sub-assemblies to be inserted.
Sliding
surfaces
11
Critical Mate and Clearance Ratio #3
Rim and
snap fit
c rimslot 
1.567  1.692  0.0798
1.597
Slots
Rims
Slot
12
Gearbox DFC and Key Characteristics
3
5
2
1
Z
6
4
13
17
1Driven gear stand
10
14
9
1Gear housing cover
2Driven gear block
3Intermediate gear block
4Output gear block
5Top lateral stopping peg
6Top central stopping peg
7Motor Location pegs
8Gear housing
9Motor gear
1Driven gear input pinion
1Driven gear output pinion
18
8
11
X
12
7
22
24
23
15
16
19
20
21
1 Driven gear pin
1 Intermediate gear input pinion
1Intermediate gear output pinion
1Intermediate gear stand and hole
1Intermediate gear pin
1Output gear
1Output gear stand
2Bottom lateral stopping peg
2Bottom central stopping peg
2Top part of motor compartment in gear housing
2Hole in gear housing for motor location
2Motor
13
z axis pre-load
Motor
Gearbox
Base
Flex
Contact
Bored
Stanchion
Output Gear
Upper Surface
Output Shaft
Center
Hole
Bored
Stanchion
Output Gear
Integrated
Datum Flow Chain
for Motor/Gearbox
Sub-Assembly
Outer Pitch Circle
Bored
Stanchion
Squared
Step
KC #3
Inner Pitch Circle
Outside
Perimeter
Thin
Stanchion
Center
Hole
Bored
Stanchion
Intermediate Gear
Outer Pitch Circle
5 dof
KC #2
Inner Pitch Circle
z , x , y
Hole &
Inside
Perimeter Low
Stand
x , y , z
Squared
Notch
Peg on
Stanchion
Thru Hole
5 dof
Driven Gear
5 dof
KC #1
Axle &
Med Stand
5 dof
Outer Pitch Circle
Pinion
& Rotor
Axle &
Tall Stand
Centering
Hole
Threaded
Stanchion
Safety Lever
Center
Hole
Cylindrical Base
With
Dimples
x,y
x , y , z , z
Top
Centering
Boss
5 dof
Base
Centering
Boss
Motor Case & Rotor
w/pinion gear
Top
Surface
W/Holes
Edge
Guides
Motor/Gearbox Housing
6 dof
Box
Guides
Note: 5 dof = { X , Y , Z, X , Y }
Base
Center
Hole
Assembly Fixture
14
Simplified Gearbox DFC: Driven to Intermediate Gear
Top surface
driven gear
input pinion
Co-planarity KC
Bottom surface
input pinion
Pitch circle
driven gear
output pinion
Intermediate
gear
Pitch circle input pinion
Gear hole
Tangency KC
Driven gear
Top surface
Gear hole
Bottom
surface
Top surface
Bottom
surface
Z , y , x
X ,Y
Z , y , x
Driven
gear
block
Intermediate
gear block
Top Stopping pegs
and contact end
Edges
Z , y , x
X , Y , z
Gear Housing cover
Intermediate Driven gear
gear pin
stand
Intermediate
gear stand
Bottom stopping pegs
and contact surface
X ,Y
Driven gear
pin
Gear
Housing
Rim
Pitch circle of
driven gear
Bottom Stopping
pegs
Gear pins
Rim
Gear stands
Pitch circle of
intermediate gear
Gears top surfaces
15
Pencil Sharpener Liaison Diagram and Fasteners Classification
p14
c26
p12
c24
c6
p11
p13
c25
c38
C37
p6
c15
c22
c1
p4
p20
c3
p7
p5
c5
c2
c18
c4
c23
p10
c31
p8
p9
c13
p2
c17
c10
c14
p29
c20
c21
c12
c7
p27
p28
p21
c16
c19
p15
c32
p23
c8
c35
p25
c11
c9
p18
p24
c34
p26
c33
c29
c27
c30
p17
c28
C36
p16
Permanent Liaisons
Rivets
Liaisons Using
Threaded Features
Screws
Adhesive
Nut & Bolt
Soldering
Other mates
16
Assembly Time Analysis
• Throughput requirement based on production volume
– 250,000 units/year @ 250 workdays/year = 1000 units/day
– 1000 units/day @ 8 hours/day = 125 units/hour = 2.08 mins/unit
• Assembly time per Boothroyd Handling and Insertion Times
–
–
–
–
–
Handling Time per unit
Location Time per unit
Reversible Fastening Time per unit
Irreversible Fastening Time per unit
Total predicted assembly time
=
=
=
=
=
106.98 (sec/unit)
47.50 (sec/unit)
54.20 (sec/unit)
121.00 (sec/unit)
329.68 (sec/unit)
207.18
(sec)
Note: does not include inspection and test time
• Measured Handling, Location and Reversible Fastening Times
– Test#1
– Test#2
– Test#3
309 sec
222 sec
198 sec
- Test#4
- Test#5
169 sec
153 sec
• Assembly Efficiency
– Three “un-necessary parts: Sharpener case, paper guide, and pencil guide


– Assembly efficiency  19 parts * 3 sec/ part 
(total assembly time)
57 sec
 17.3%
329.68 sec
17
Example Assembly Process
SA 7
Cutter Unit
Assy
SA 7
Cutter Unit
Inspect
18.25 sec
5 sec
SA5
SA6
Gearbox Cover
Assy
SA 6
Gearbox Cover
Inspect
48.06 sec
5 sec
SA5a
Gearbox
Assy
SA5a
Gearbox
Solder
SA5a
Gearbox
Test
Motor/Gearbox Assy
87.30 + 30 sec
SA5
Battery Comp.
Assy
19.62 sec
SA 5
Battery Comp.
Inspect
SA1
Final
Assy
SA1
Final
Inspect
5 sec
101.83 sec
SA3
Battery Cover
Assy
SA 3
Battery Cover
Inspect
SA2
Base
Assy
19.62 sec
5 sec
33.5 sec
Note: Test, inspection and packaging times are SWAGS
20 sec
Package
& Ship
30 sec
18
Fixtures and Special Tooling
Fixtures
•
•
•
•
•
•
•
Riveting fixture. or special tooling, for battery compartment
Riveting fixture, or special tooling, for gearbox cover
Bending fixture for gearbox cover electrical contacts
Bending fixture for battery cover electrical contacts
Bending fixture for battery compartment electrical contacts (nice to have)
Soldering station and fixture for electric motor (black and blue leads)
Soldering station and fixture for battery compartment (black and red leads)
Standard Tools and Special Tooling
•
•
•
•
•
•
•
•
Heat stake tooling for battery compartment electrical contacts
Magnetic Phillips head screwdriver (4” length) for battery compartment screw
Small wrench, or pliers, for blade screw and nut
Wire strippers (22 gage)
Wire tinning and pre-form bending
Soldering station for gearbox cover
Electrical test station for operation of motor/gearbox sub-assembly
Lubrication dispenser gun
19
Potential Problems and Risk Areas
Description
Probability
Impact
•
Personnel injury from razor blade
Med
High
•
Reversed motor polarity wiring (black on +)
High
High
•
Reversed battery compartment wiring (red on right)
High
High
•
Solder joint or wire breakage during gearbox insertion
Low
High
•
Solder joint or wire breakage during motor insertion
Low
High
•
Motor pinion clearance thru gearbox hole
High
Med
•
Loss of motor location during final assembly
High
Med
•
Improper location of battery compartment on gearbox
Med
Med
•
Part damage from shaver receptacle insertion (snap fit)
Med
Med
20
Suggested Design Improvements
•
•
•
•
•
•
•
•
Description
Impact
Reversed motor polarity wiring (black on +)
- Use wire connector instead of solder joint
Reversed battery compartment wiring (red on right)
Med
- Imprint wiring polarity on battery compartment injection mold
Solder joint or wire breakage during gearbox insertion
- Use wire connector instead of solder joint
Solder joint or wire breakage during motor insertion
- Use wire connector instead of solder joint
High
Med
Med
Motor pinion clearance thru gearbox hole
- Reduce and control gearbox manufacturing variance
Med
Loss of motor location during final assembly
- Include snap/fit feature between battery compartment and gearbox High
Improper location of battery compartment on gearbox
- Use wire connectors instead of solder joint
Part damage during shaver receptacle insertion (snap fit)
- Training, coupled with control of manufacturing variations
Med
Low
21
Backups
•
•
•
•
•
Part Handling: Gross Motion ( 2 slides)
Part Insertion: Fine Motions ( 2 slides)
Part Liaisons and Mates
Related Product Lines
Product Structural Decomposition
22
Part Handling: Gross Motion
Order P/N
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
29
28
27
SA7
26
23
24
25
SA6
15
22
16
17
18
22
SA6
21
SA6
19
sa5
20
14
25
20
SA7
SA5
Description
Position blade holder
Locate blade
Locate and fasten blade screw and nut (tools: screwdriver & pliers)
Inspect & Release Cutter Sub-Assembly
Position Gearbox cover
Locate & rivet cover contacts
Solder red wire to cover
Solder blue wire to cover
Inspect & Release Gearbox Cover Sub-Assembly
Position gearbox housing (inverted)
Apply lubrication to axle stands
Locate output gear
Locate intermediate gear
Locate driven gear
Apply lubrication to gear surfaces and axles
Position gearbox cover sub-assembly
Locate safety lever on gearbox cover (retain with one hand)
Locate gearbox cover sub-assembly & safety lever (2 hand ops)
Locate and fasten gearbox cover screw (self-threading)
Invert & position partially complete gearbox sub-assembly
Position electric motor near gearbox
Solder blue wire to motor (2 hand ops)
Solder black wire to motor (2 hand ops)
Locate electric motor in gearbox
Locate cutter unit sub-assembly
Inspect, Test & Release Motor/Gearbox Sub-Assembly
Qty
1
1
1
1
1
3
1
1
1
1
3
1
1
1
3
1
1
1
1
1
1
1
1
1
1
1
Size Thick G.M. Alpha Beta  Handling
(mm) (mm) Code (deg) (deg) (deg)
(sec)
35
21
9
35
65
18
130
111
65
58
6
0.5
1.5
6
1.9
0.2
1
1
1.9
50
25
21
21
2
5.8
5.8
65
11
65
15
65
43
111
86
43
35
65
1.9
6.1
1.9
3
50
23.6
1
1
23.6
6
50
10
13
03
180
180
180
180
180
0
360
360
180
10
13
03
03
10
10
00
03
00
00
00
00
85
85
00
00
10
03
03
85
80
180
180
180
360
360
540
0
0
1.50
2.06
1.69
5.25
1.50
2.06
1.69
1.69
180
180
180
180
180
0
180
180
180
180
180
180
0
0
0
0
0
270
0
0
0
360
180
180
45
90
360
0
180
180
180
0
180
450
180
180
180
540
0
0
225
270
1.50
1.13
1.69
1.13
1.13
1.13
1.13
5.00
5.00
1.13
1.13
1.50
1.69
1.69
5.00
4.10
23
Part Handling: Gross Motion (con’t)
Order P/N
Description
27
11 Position battery compartment housing (inverted)
28
12 Locate & rivet battery compartment contacts
29 SA4 Inspect & Release Battery Compartment Sub-Assembly
30
9 Position battery compartment cover
31
8 Locate and rivet (plastic heat stake) battery cover contacts
32 SA3 Inspect & Release Battery Compartment Cover Sub-Assembly
33
5 Position sharpener base
34 SA3 Locate battery compartment cover sub-assembly
35
11 Locate rubber feet on base and battery compartment cover
36 SA2 Inspect & Release Base Sub-Assembly
37 SA5 Position motor/gearbox sub-assembly
38 SA4 Locate battery compartment sub-assembly on motor/gearbox
39
25 Solder black wire to battery compartment
40
24 Solder red wire to battery compartment
41
7 Position sharpener case
42 SA4/ Locate battery compartment & motor/gearbox in sharpener case
43
3 Locate and fasten battery compartment screw
44 SA2 Locate base sub-assembly in sharpener case
45
3 Locate and fasten battery compartment screws
46
1 Locate and fasten sharpener case screws
47
13 Install battery installation paper guide
48 sa1 Invert and reposition partially complete sharpener assembly
49
2 Locate pencil guide (tricky alignment)
50
4 Locate shavings receptacle (snap fit)
SA1
Inspect, Test & Release Pencil Sharpener Assembly
51
Qty
1
2
1
2
1
1
2
1
1
1
1
1
1
2
1
1
2
2
1
1
1
1
1
Size Thick G.M. Alpha Beta  Handling
(mm) (mm) Code (deg) (deg) (deg)
(sec)
70
22
70
43
20
43
75
43
25
75
65
70
86
130
82
96
8
75
9
14
50
96
32
73
115
32
0.2
32
2.5
0.2
2.5
7
2.5
1.6
7
50
26
1
1
36
32
3
7
3
3
1
50
11.7
36
50
10
13
180
180
180
180
360
360
1.50
2.06
10
13
180
180
180
180
360
360
1.50
2.06
10
10
10
180
180
180
180
180
180
360
360
360
1.50
1.50
1.50
00
80
03
03
10
80
01
10
01
01
13
00
05
05
0
180
180
180
180
180
180
180
180
180
180
180
180
180
180
10
0
180
0
0
180
0
0
15
180
360
0
0
360
190
180
360
180
180
360
180
180
195
1.13
4.10
1.69
1.69
1.50
4.10
1.43
1.50
1.43
1.43
2.06
1.13
1.84
1.84
24
Part Insertion: Fine Motion
Order P/N
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
29
28
27
SA7
26
23
24
25
SA6
15
22
16
17
18
22
SA6
21
SA6
19
sa5
20
14
25
20
SA7
SA5
Description
Position blade holder
Locate blade
Locate and fasten blade screw and nut (tools: screwdriver & pliers)
Inspect & Release Cutter Sub-Assembly
Position Gearbox cover
Locate & rivet cover contacts
Solder red wire to cover
Solder blue wire to cover
Inspect & Release Gearbox Cover Sub-Assembly
Position gearbox housing (inverted)
Apply lubrication to axle stands
Locate output gear
Locate intermediate gear
Locate driven gear
Apply lubrication to gear surfaces and axles
Position gearbox cover sub-assembly
Locate safety lever on gearbox cover (retain with one hand)
Locate gearbox cover sub-assembly & safety lever (2 hand ops)
Locate and fasten gearbox cover screw (self-threading)
Invert & position partially complete gearbox sub-assembly
Position electric motor near gearbox
Solder blue wire to motor (2 hand ops)
Solder black wire to motor (2 hand ops)
Locate electric motor in gearbox
Locate cutter unit sub-assembly
Inspect, Test & Release Motor/Gearbox Sub-Assembly
Qty
1
1
1
1
1
3
1
1
1
1
3
1
1
1
3
1
1
1
1
1
1
1
1
1
1
1
Size Thick F.M. Handling Insertion
(mm) (mm) Code
(sec)
(sec)
35
21
9
35
65
18
130
111
65
58
6
0.5
1.5
6
1.9
0.2
1
1
1.9
50
25
21
21
2
5.8
5.8
65
11
65
15
65
43
111
86
43
35
65
1.9
6.1
1.9
3
50
23.6
1
1
23.6
6
50
00
40
48
0.00
4.50
8.50
00
35
95
95
1.50
2.06
1.69
5.25
1.50
2.06
1.69
1.69
00
99
00
00
00
99
00
00
06
38
00
00
95
95
11
30
1.50
1.13
1.69
1.13
1.13
1.13
1.13
5.00
5.00
1.13
1.13
1.50
1.69
1.69
5.00
4.10
0.00
1.20
1.50
1.50
1.50
1.20
0.00
1.50
5.50
6.00
0.00
0.00
8.00
8.00
5.00
2.00
0.00
7.00
8.00
8.00
Total
Time
1.50
6.56
10.19
18.25
1.50
27.18
9.69
9.69
48.06
1.50
6.99
3.19
2.63
2.63
6.99
1.13
6.50
10.50
7.13
1.13
1.50
9.69
9.69
10.00
6.10
87.30
25
Part Insertion: Fine Motion (con’t)
Order P/N
Description
27
11 Position battery compartment housing (inverted)
28
12 Locate & rivet battery compartment contacts
29 SA4 Inspect & Release Battery Compartment Sub-Assembly
30
9 Position battery compartment cover
31
8 Locate and rivet (plastic heat stake) battery cover contacts
32 SA3 Inspect & Release Battery Compartment Cover Sub-Assembly
33
5 Position sharpener base
34 SA3 Locate battery compartment cover sub-assembly
35
11 Locate rubber feet on base and battery compartment cover
36 SA2 Inspect & Release Base Sub-Assembly
37 SA5 Position motor/gearbox sub-assembly
38 SA4 Locate battery compartment sub-assembly on motor/gearbox
39
25 Solder black wire to battery compartment
40
24 Solder red wire to battery compartment
41
7 Position sharpener case
42 SA4/ Locate battery compartment & motor/gearbox in sharpener case
43
3 Locate and fasten battery compartment screw
44 SA2 Locate base sub-assembly in sharpener case
45
3 Locate and fasten battery compartment screws
46
1 Locate and fasten sharpener case screws
47
13 Install battery installation paper guide
48 sa1 Invert and reposition partially complete sharpener assembly
49
2 Locate pencil guide (tricky alignment)
50
4 Locate shavings receptacle (snap fit)
51 SA1 Inspect, Test & Release Pencil Sharpener Assembly
Qty
1
2
1
2
1
1
2
1
1
1
1
1
1
2
1
1
2
2
1
1
1
1
1
Size Thick F.M. Handling Insertion
(mm) (mm) Code
(sec)
(sec)
70
22
70
43
20
43
75
43
25
75
65
70
86
130
82
96
8
75
9
14
50
96
32
73
115
32
0.2
32
2.5
0.2
2.5
7
2.5
1.6
7
50
26
1
1
36
32
3
7
3
3
1
50
11.7
36
50
00
35
1.50
2.06
0.00
7.00
00
35
1.50
2.06
0.00
7.00
00
30
97
1.50
1.50
1.50
0.00
2.00
12.00
00
02
95
95
00
08
48
00
38
38
00
00
30
30
1.13
4.10
1.69
1.69
1.50
4.10
1.43
1.50
1.43
1.43
2.06
1.13
1.84
1.84
0.00
2.50
8.00
8.00
0.00
6.50
8.50
1.50
6.00
6.00
1.50
0.00
2.00
2.00
Assembly Total (sec) =
(min) =
Total
Time
1.50
18.12
19.62
1.50
18.12
19.62
1.50
3.50
27.00
32.00
1.13
6.60
9.69
9.69
1.50
21.20
9.93
3.00
14.86
14.86
3.56
1.13
3.84
3.84
104.83
329.68
5.49
26
Part Handling: Gross Motion (con’t)
Order
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
P/N Description
9
8
SA3
11
19
12
SA4
5
SA3
11
SA2
SA5
SA4
25
24
7
SA4
SA5
3
SA2
3
1
13
sa1
2
4
SA1
Qty
Position battery compartment cover
Locate and rivet (plastic heat stake) battery cover contacts
Inspect & Release Battery Compartment Cover Sub-Assembly
Position battery compartment housing (inverted)
Contacts and rivets
Locate & rivet battery compartment contacts
Inspect & Release Battery Compartment Sub-Assembly
Position sharpener base
Locate battery compartment cover sub-assembly
Locate rubber feet on base and battery compartment cover
Inspect & Release Base Sub-Assembly
Position motor/gearbox sub-assembly
Locate battery compartment sub-assembly on motor/gearbox
Solder black wire to battery compartment
Solder red wire to battery compartment
Position sharpener case
1
2
Locate battery compartment & motor/gearbox in sharpener case
Locate and fasten battery compartment screw
Locate base sub-assembly in sharpener case
Locate and fasten battery compartment screws
Locate and fasten sharpener case screws
Install battery installation paper guide
Invert and reposition partially complete sharpener assembly
Locate pencil guide (tricky alignment)
Locate shavings receptacle (snap fit)
Inspect, Test & Release Pencil Sharpener Assembly
Size Thick
(mm) (mm)
G.M.
Code
Alpha Beta  +  Handling
(deg) (deg) (deg)
(sec)
43
20
43
70
2.5
0.2
2.5
32
10
13
180
180
180
180
360
360
1.50
2.06
10
180
180
360
1.50
0.2
32
7
2.5
1.6
13
180
180
360
2.06
1
1
2
22
70
75
43
25
00
10
10
180
180
180
90
180
180
270
360
360
1.13
1.50
1.50
1
1
1
1
1
65
70
86
130
82
50
26
1
1
36
00
80
03
03
10
0
180
180
180
180
180
180
360
0
0
360
1.13
4.10
1.69
1.69
1.50
2
1
1
2
2
1
1
1
1
1
96
8
75
9
14
50
96
32
73
115
32
3
7
3
3
1
50
11.7
36
50
80
01
10
01
01
13
00
05
05
180
180
180
180
180
180
180
180
180
10
0
180
0
0
180
0
0
15
190
180
360
180
180
360
180
180
195
4.10
1.43
1.50
1.43
1.43
2.06
1.13
1.84
1.84
1
2
27
Part Liaisons and Mates in Pencil Sharpener
Mate No
1
2
Mated parts
Sharpener case/shavings receptacle
Battery compartment cover/sharpener base
Liaison/Mate Description
Snap fit of rim and slot.
Rim and slot in one end of the cover and rim and slot with snap fit in the other
end
Slot and rim along the contact edge and two peg and hole fits. The pegs
accommodate internal screws that keep the parts fastened.
Rim and slot plus sliding surface
Sliding surface
Peg and hole, rim and slot, and sliding surfaces
Two pegs and two holes
Two pegs and two holes
Peg and hole and sliding surface
Sliding surface on gear teeth
Square shaped peg and hole (pressed fit)
Alignment provided by two prongs and attachment is accomplished by nut
and bolt
Rim and slot
Circular rim and hole
Circular rim and slot ???
Peg and hole
Sliding surfaces
Sliding surfaces
Peg and hole
peg and hole
Peg and hole
Blade external surface with bolt head bottom surface
Permanent liaison thruogh adhesive
Permanent liaison thruogh adhesive
Permanent liason through rivets
3
Sharpener base/sharpener case
4
5
6
7
8
9
10
11
12
Gear and motor housing/ battery housing
Gearbox housing/ sharpener case
Battery compartment housing/ sharpener case
Electric motor/gearbox housing
Gearbox housing/gearbox cover
Driven gear/gearbox housing
Driven gear/electric motor
Cutter unit/output gear
Blade holder/blade
13
14
15
16
17
18
19
20
21
Pencil guide/sharpener case
Pencil guide/cutter unit
Electric motor/battery compartment
Safety lever/gearbox cover
Shavings Receptacle/Safety lever
Shavings receptacle/pencil guide
Safety lever/gearbox housing
Blade holder/blade nut and bolt
Blade/blade nut and bolt
22
23
24
sharpener base/rubber foot
Battery compartment cover/rubber foot
Battery compartment housing/battery comp
contacts
25
Battery compartment housing/battery paper guide Sliding surface
28
Part Liaisons and Mates in Pencil Sharpener (cont.)
Mate No
26
27
28
29
30
31
Liaison/Mate Description
Permanent liaison through soldering
Sliding surface on gear teeth
Sliding surface on gear teeth
Peg and hole and sliding surface
Peg and hole and sliding surface
Permanent liason through rivets
33
Mated parts
Battery comp. contacts/black wire
Driven gear/intermediate gear
Intermediate gear/output gear
Intermediate gear/gearbox housing
Output gear/gearbox housing
Battery compartment cover/contacts and rivets on
battery compartment cover
Gearbox cover/contacts and rivets on gearbox
cover
Contacts and rivets on gearbox cover/output gear
34
35
36
37
36
Contacts and rivets on gearbox cover/red wire
Contacts and rivets on gearbox cover/blue wire
Electric Motor/black wire
Battery compartment housing/blue wire
Electric Motor/red wire
Permanent liaison through soldering
Permanent liaison through soldering
Permanent liaison through soldering
Permanent liaison through soldering
Permanent liaison through soldering
32
Permanent liason through rivets
sliding surface
29
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Product Structural Decomposition
sa1
p1
p7
sa5
p2
sa4
p12
p13
p3
p4
p11
p5
sa6
p14
p15
p16
p17
p18
p19
p20
p21
p22
sa2
p6
sa7
p8
p23
p24
p25
p26
p27
sa3
p28
p9
p10
p29
31