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

Team GORE

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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.

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Pleat Height

Pleater Bed

Pleat AssistStripper Bar

Bed

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Gore Confidential

4 Critical Adjustments◦ Pleater bed◦ Stripper bar bed◦ Setting pleat height◦ Pleat assist

At Least:◦ 10 bolts◦ 7 different tools

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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

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Customer Wants

Operators

More controlled adjustmentsLess tools requiredSafer*Easier access to adjustment sitesTurn two adjustments into oneImprove product accuracy

Engineers

Low MaintenanceReliability and durabilityImproved accuracyLess scrapAvailability of parts

Business LeadersImproved efficiencyReasonable cost/benefitsSafer*

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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.

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Gore Confidential

Rank MetricTarget Value

1 Decrease in Changeover Time 50%2 Increase of Filters Per Day +1753 Number of Hard to Move Parts 2

4Number of Awkward Adjustment Sites 1

5Number of Maintenances Per Year 1

6 Number of Tools Needed 4 to 5

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

saved per year

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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

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Not feasible with one concept◦ Cost◦ Time◦ Resources

Two Concepts1.Moving both beds and holding the 1/8” gap2.Setting pleat height

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Adjustable Bolt Spacer

Assortment of Custom Spacers

Caliper Spacer

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Gore Confidential

Metric Importance Multiplier Custom Spacer Bolt Spacer Caliper SpacerReduce Changeover Time 1 1 3 1 2Less Adjustments 2 0.5 3 1 2Cost 3 0.4 1 2 3Reduce Number of Tools 4 0.35 1 2 3Minimize Required Force 5 0.3 N/A N/A N/A

Less Maintenances 6 0.25 2 1 3

SCORE: 5.75 3.25 6

3 = Best, 2 = Moderate, 1 = Worst

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Caliper Spacer Design with slots for caliper

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Caliper Spacer Design with slots for caliper

Locking system

Alignment system

Calibration system

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

Components Material

Alignment system Tool Steel

Calibrated Brackets Tool Steel

Locking system Steel

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Rack + Pinion

Scissor Jack

Threaded Rod Design

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Gore Confidential

3 = Best, 2 = Moderate, 1 = Worst

Metric Importance Multiplier Scissor Jack Threaded Rod Rack/PinionReduce Changeover Time 1 1 1 2 3Less Adjustments 2 0.5 2 3 1Cost 3 0.4 1 2 3Reduce Number of Tools 4 0.35 2 3 1Minimize Required Force 5 0.3 2 3 1

Less Maintenances 6 0.25 2 3 1

SCORE: 4.2 7 5.6

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Gore Confidential

Gearing system

Bearing system

Structural Mounts

Railing system

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Spacing of Railing Rods ACME Thread Rod Bearings Selection Gearing

Components Material

Railing system Wear-resistant Steel

Threaded Rod Steel

Structural Brackets and mounts Wear-resistant Steel

Hardware Stainless Steel

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Item Description Quantity Price TotalThreaded rod Precision ACME threaded rod 1"-10 1 $ 150.00 $150.00 Acme tap Straight Flute cut tap 1"-10 1 $ 165.00 $165.00Steel Rods Wear-Resistant 4150 Alloy Steel 1" 2 $ 67.00 $134.00 Stripper bar bracket 1018 Carbon Steel 1 $165.00 $165.00Gear Box Slide-Rite 2:1 Standard Series Right Hand 1 $330.00 $330.00Bearing Frelon Lined Linear bearing for rail system 4 $50.00 $200.00Miscellaneous Bearings, hardware, etc - - $350.00Labor/Fabrication Cost 8 $50.00 $400.00

TOTAL ~$1800.00

Item Description Quantity Price Total

Metal Plate 4142 Alloy Steel Hardened (1” by 6” by 6”) 2 $75.00 $150.00

Miscellaneous - 20.00 $20.00

Labor/Fabrication Cost Machine custom components 5 $50.00 $250.00

TOTAL ~$450.00

Total Cost = Under $2300

Bed M

over

Space

r (x

2)

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Custom Machine work◦ Low quantity◦ High precision◦ Adaptability

Off-the-Shelf Parts◦ Stock rods◦ Bearings (linear, roller)◦ ACME rod◦ Gearbox

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1. Structure mounts and brackets Linear and roller bearings pressed fit beforehand

2. Thread in ACME rod3. Attach gearbox, crankshaft, and hand wheel

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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

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Target Time (31 Mins)

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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.

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Rank MetricTarget Value

Testing Value

1 Decrease in Changeover Time 50% 70%2 Increase of Filters Per Day +175 +245*3 Number of Hard to Move Parts 2 0

4Number of Awkward Adjustment Sites 1 1

5Number of Maintenances Per Year 1

Unknown

6 Number of Tools Needed 4 to 5 5* Anticipated Value

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Projected Percentage of Time Reduction: Approx. 56%Actual Tested Percentage of Time Reduction: 70%

*Time in Minutes

Step # Adjustment Comments Original Time Projected Time New Time1 Loosen Set Screws 2:00 0:00 1:452 Loosen Lock Nut NEW 0:00 1:00 0:113 Loosen Pleat Assist 2:00 2:00 1:504 Move Beds 15:00-20:00 3:00-5:00 0:495 Set Pleat Assist Gap ELIMINATED 5:00 0:00 0:006 Set Pleat Assist 5:00 5:00 4:467 Tighten Pleat Assist 2:00 2:00 2:018 Secure Lock Nut NEW 0:00 1:00 0:209 Tighten Set Screws 2:00 0:00 1:46

10 Loosen Pusher Bar 2:00 2:00 0:4211 Set Pusher Bar 20:00-25:00 8:00-12:00 2:0712 Tighten Pusher Bar 2:00 2:00 1:44

Totals: 57:00 - 67:00 26:00-32:00 18:01

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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

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

Giambanco, Brian Villanueva