CHAPTER 1

INTRODUCTION 1.0 introduction about jig Mass production aims at high productivity to reduce unit cost and interchangeability to facilitate easy assembly. This necessitates production devices to increase the rate of manufacture and inspection device to the speedup inspection procedure. Jigs are special purpose tools which are used to facilitate production like machining, assembling and inspection operations. The mass production of the work-piece is based on the concept of interchangeability according to which every part produced within an established tolerance. Jigs provide a means of manufacturing interchangeable parts since they establish a relation with predetermined tolerances, between the work and the cutting tool. Once the jig is properly set up, any number of duplicate parts may be readily produced without additional setup. (Sharma, 1982) Jigs are used in drilling, reaming, tapping, milling and tapping. There are many Advantages for using jigs in production. Jigs eliminate individual making, positioning And frequent checking. This reduces operation time and increase productivity. There is no need for selective assembly. This chapter discussed about the project background to fabricate a jig and the more important to use jig in production. Problem statement, objectives and scopes for the project including in this chapter.

1.1Background

Over a decade ago, the manufacturing industry has grown rapidly and has achieved considerable progress in the field of manufacturing. Various parts can be produced more quickly and efficiently than before. This is due to the manufacturing revolution that facilitates manufacturing jobs where there is a new device technology, high niche tools and modern manufacturing processes. Although methods jigs and fixture have been developed, the basic principles still remain as clamping, holding and locate.

For large-scale production that success is dependent on the suitability and interchangeability easy to install and cost reduction. Large-scale production is also a quick and easy method is right for a certain industry. Thus, the concept of jig and fixture has been introduced and is widely used in large industries and for large-scale production.

This project is about innovation in the design and manufacture of jigs.. It will start from the review of existing designs. The project was undertaken in collaboration between University Kuala Lumpur Institute of Product Design and Manufacturing and ERECT PRESSWORKS ENGINEERING SDN BHD. ERECT PRESSWORKS ENGINEERING SDN BHD tense in Port Klang is a manufacturer of automotive engineered metal parts through stamping, pipe cutting & bending, robotic welding, spot welding, and sub & final assembly. During the complete development process jig, we 2

included conceptual design, manufacturing plan & approval process before manufacturing the product. The jig is the need for multiple products to produce a precise duplicate of mass production.

This chapter discussed about the project background to fabricate jig. This cooperation we have been assigned to innovate a jig for the bracket is a CVT. Bracket CVT for a national car at Malaysia (see figure 1.1a)

Figure 1.1a

1.1 Problem Statement

At ERECT ENGINEERING PRESSWORKS is currently having a problem for the spot-weld product. The product is a bracket CVT for a national car at Malaysia. It takes a longer time to set up the product to the machine. Average the time for setup one product is about 6 minutes. (See figure 1.2a)

Addition, the technician will also need to go from one machine to another machine to completion of the product. This machine is also far from each other that make it more difficult to complete. Average the time for a technician has to go one machine to another machine is about 5 minutes. So, it's a waste time to take a long time to this task. (See figure 1.2b)

Other than that, the technician should knock the product during set up and also ensure product in the right position at the jig (see figure 1.2c). So, it affects to the production line and takes a longer time to finish one product.

Besides that, the technician is difficult to determine the correct position to spotweld on the product. And this will cause the technician should take the time to determine the correct position. The current jig at the company is not flexible to use and operator must rotate the jigs to get the right position for weld.

Figure 1.2a

Figure 1.2b

Figure 1.2c

1.2 Objective 1.3.1 Group objectives

Summarizes the objectives will be achieved or what the goals of research or specific studies. The objective should be closely related to the statement of the problem or can determine from the research problem statement. Objective projects are: To improve the jig design for easier to use by the technician. The goal of this project is to improve the old design from the company to that they have required and it can be easily used by any operator to operate. To reduce time during the work for the spot welding. The goal of this project is to reduce the time as low as possible to the time spent it takes to set up spot-weld jigs for CVT bracket. To reduce the weight of the jig. The goal of this project is to minimize the weight of spot-weld jigs as much as possible. It is to ease the operator in handling the jigs.

1.3.2 Individual objectives

To prepare a process plan for fabricating a spot-welding jig for CVT bracket. When I prepare a process plan , my task will be organized in the matter of machine, tool, and software suitable, this will save much time once I start Fabricating my jig

1.3 Scope 1.4.1 What is project scope The project scope is the part of project planning that involves determining and documenting a list of specific project goals, deliverables, tasks, costs and deadlines.

The documentation of a project's scope, which is called a scope statement, terms of reference or statement of work, explains the boundaries of the project, establishes responsibilities for each team member and sets up procedures for how completed work will be verified and approved. During the project, this documentation helps the project team remain focused and on task. The scope statement also provides the project team with guidelines for making decisions about change requests during the project.

1.4.2 Group job scope This project only involves redesigning and manufacturing jigs for bracket CVT . This is because, engineered wood is much easier to obtain and lower in cost. It is natural for parts of a large project to change along the way, so the better the project has been "scoped" at the beginning, the better the project team will be able to manage change. When documenting a project's scope, stakeholders should be as specific as possible in order to avoid scope creep, a situation in which one or more parts of a project ends up requiring more work, time or effort because of poor planning or miscommunication. To facilitate my group is divided into three job scope.

The first scoop is producing the drawing. some of the elements Produce the drawing is about the drawing jig design. The second scope is to identify the material for making jig and to analyze jig design and the last job scope is to fabricate jig and to prepare a process plan

1.4.3 Individual job scope My job scope is fabricating spot-welding jig for cvt bracket. This spot-welding jig will be produced for automotive part manufacture by ERECT PRESSWORK ENGINEERING SDN BHD . Before making jigs, I have read about things related to the jig. The first thing I do is to plan ways to facilitate manufacturing jig. In the completion of the process plan, I have to choose software, machine and tool suitable for complete jigs. After completing the process plan, then I started making jigs, jigs and test the assembly jigs either work or not according to specification laid down by the process of the plan has been formulated.

1.4 Organization

This study consists 6 chapter. In the first chapter, the introduction of the study Were discussed. This chapter introduced briefly about the project and also provided the problem statement of the study. In this chapter also state about the objectives and scopes of the project. Chapter two consists of a literature review of fabricate jigs and definition of Important component in fabricating such as manufacturing principles common to jigs. This chapter also discussed about the advantages, disadvantages of the jig, and also type of jigs that already used today. The important of jigs discussed in this chapter. Chapter three discussed about the methodology used in this project from starting until completing this project. In methodology were discussed about the method and a tool that used in this project. In this chapter, the software which using master cam will be evaluated. It include choosing the best manufacture and suitable to the parts,

operational function and the problem or disadvantages of the product.

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