Causes For Corrective Action
The product in scope is the engine belonging to a 1994 Honda CB-R 600 motorbike. The group has completed the disassembly of the combustion components of the engine. The group is currently analyzing the disassembly and documenting all aspects including specifics. Many different issues arose during disassembly, which slowed down the process and generated new challenges. Now moving to specific examples:
“The actual disassembly of the engine will not take as long as similar car engine would. This is because the engine is already out of the bike, all of the components connecting to the engine are gone and the engine is relatively small in size. It should take approximately 3 hours to disassemble the entire engine, including the internal components.” -Work proposal
Visual inspection prior to disassembly led to the prediction that it would take approximately three hours to disassemble. Engines are designed to be disassembled with fair ease for maintenance. The group was able to complete disassembly within two hours. By completing disassembly slightly ahead of schedule, the group was able to devote more time to analysis. However, a few problems arose causing slight delays in the disassembly.
The first issue that arose was the other group working on the engine began disassembly without our knowledge and did not label the parts. This may complicate the reassembly of the engine. An email has been sent to the other group consulting this issue. Proper disassembly consists of detailed logs of the process, which became an issue when the group began disassembly without our group’s knowledge. We plan to consult with the other group to inquire some logging information on components, which might be useful to our group’s disassembly.
“By initial observation, some of the tools that we would need to disassemble the engine are a drill (electric), a socket set, Torx bit, Phillips head bit and Allen wrenches. Due to further observation it appears that other tools that would most likely be necessary are a wrench, flathead screwdriver and some needle nose pliers. These excess tools would be used to loosen other components of the engine including screws.” -Work Proposal
The group’s unfamiliarity with the tools and their location in the tool set also delayed the disassembly of the engine. The group also came across other tool issues during disassembly. The proper size Allen wrench could not be found, which limited the depth of our disassembly. The bolts were located directly under the space between the two camshafts. Because the proper size Allen wrench could not be located, disassembly of the intake and exhaust valves were limited. According to the work proposal, an electric drill was needed for disassembly, however the group was able to complete disassembly without it.
Due to wear and tear, some components of the engine were difficult to remove; some could not be removed at all. Some screws were completely stripped, which also limited the depth of our disassembly. This issue occurred during the disassembly of carburetor. Specifically, the two middle screws were stripped, only allowing further disassembly of the two outer carburetors. The group decided to work around it by only detaching one of the outer carburetors and dissecting it individually.
The disassembly also had to be done on a strict time constraint in the presence of a TA. The group had much difficulty working under the time constraint of the lab hours and other classes. Due to inadequate planning in the management stage, the group was unable to establish an efficient schedule, which delayed the disassembly process. The group has addressed the problem and has established a weekly schedule, which satisfies all group members. Along with weekly lab visits, the group also established a weekly meeting time where issues and progress can be discussed. Along with proper scheduling, effective communication has been a past issue. The group agreed to keep each other better updated with meeting times through emails and phone calls.
Future Group Collaboration
Effective collaboration with the other group working on the engine is required to reassemble the engine in a reasonable time. Our group plans to address this issue with frequent emails updating one another on disassembly issue and any possible reassembly issues. Good communication between both groups throughout the project will allow reassembly to be done effectively in a timely manner.