Group 19 - Ford F-150 Power Wheels: Gate 2

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Contents

Cause for Corrective Action

Introduction

This is an assessment of Group 19's work and management plans. In this section, Group 19 will review what went well according to the work and management plan. Challenges and difficulties encountered with the plan will also be assessed. A plan of action for unresolved challenges will be then be stated along with how Group 19 dealt with now resolved challenges.


Plan Successes

In the work proposal, Group 19's strengths and weaknesses were stated along with our expected challenges for dissection. Group 19 was able to exploit full potential due to the jobs that were assigned to each group member during Gate with the strengths and weaknesses as the main focal point. Dissection went well with no surprises. Like stated in our work proposal, a limited number of tools were used during the process and little human force was used to dis-attach certain parts. In the management proposal, a project timeline was proposed in order to finish Gate 1 effectively. As expected, Gate 1 was finished on time which made the process run smoothly into the start of Gate 2. The successes of our project management of Gate 1 allowed the plan to work in this sense thus far.


Plan Failures

The work proposal failed to state exact times that Group 19 would meet in order to dissect the product. Finding an ideal dissection time was a problem because it was difficult matching each group member's availability with the allotted lab time slots. The management proposal stated that work was supposed to be done in a uniform manner. A problem encountered was that individual part assignments were sent to the head wiki writer on the night before the Gate 1 due date. This was a challenge because minimal time was given to to writer to review and revise each part effectively in order for it to meet specifications and guidelines.


Challenge Resolution

To meet the challenge of scheduling dissection times, the group leader chose a dissection time for every week that was compatible with everyone's schedule. In order to meet the challenge of certain group members submitting their part of the assignment at the last minute, the group leader sent out an email to all the group members stating to improve their work and time management skills at the risk of involving the professor.


Unresolved Challenges

  • Uneven workload
  • Contact issues


To meet the unresolved challenge of an uneven workload, the lead of Group 19 has to decided to schedule more than one meeting per week. This allows all of the group members to come together and evenly distribute the work. By leaving individuals to do a portion of the work themselves, some group members may be putting more effort while others are putting in less effort. By taking on the workload together, it allows all the group members to meet the work and detail expectations of each other.

To deal with the challenge of contact issues, all the group members will give their cell phone numbers to each other. This was previously not the case in Gate 1, where the only communication was through e-mail. Communication through e-mail can sometimes be relatively slow due to the fact that some individuals to not check their inbox very often. By knowing each others' phone numbers, contact can be speedy and efficient. This would also allow the leader to schedule meetings in a more timely manner.


Future Challenges

If other challenges reveal themselves in the next project gates, Group 19 will try to effectively and efficiently deal with the situation as soon as possible. To do this, the group will look how past challenges were dealt with and try to deal with the new challenges in the same manner. The group leader will also try to the best of his ability to prevent future challenges before they actually occur.



Product Dissection

Introduction

This section describes the dissection of Group 19's product the Ford F-150 Power Wheels. In this section the parts list and step by step dissection procedure is listed. A thorough analysis of the subsystems is also discussed along with intention of disassembly and the factors that influence the assembly of the product.


Parts List

Part Number Part Name Quantity Image
1 Main Chassis 1
G19 Main Chassis.JPG
2 Cargo Bed 1
G19 Cargo Bed.JPG
3 Hubcap 2
G19 Hubcap.JPG
4 Steering Wheel 1
G19 Steering Wheel.JPG
5 Seat 1
G19 Seat.JPG
6 Steering Wheel Cover 1
G19 Steering Wheel Cover.JPG
7 Hood 1
G19 Hood.JPG
8 Long Seat Belt 1
G19 Long Seat Belt.JPG
9 Short Seat Belt 1
G19 Short Seat Belt.JPG
10 Rear Wheel 2
G19 Rear Wheel.JPG
11 Front Grille 1
G19 Front Grille.JPG
11a Grille Piece 1
G19 Grille Piece.JPG
11b Headlight Cover 2
G19 Headlight Cover.JPG
11c Headlight 2
G19 Headlight.JPG
11d Lower Headlight 2
G19 Lower Headlight.JPG
12 Grille Support 1
G19 Grille Support.JPG
13 Steering Column 1
G19 Steering Column.JPG
14 .25 x 2.85’’ Pin 1
G19 Pin.JPG
15 Steering Column Cap 1
G19 Steering Column Cap.JPG
16 12 Volt Battery Charger 1
G19 Charger.JPG
17 12 Volt Battery 1
G19 12 Volt Battery.JPG
18 Wire Clip 2
G19 Wire Clip.JPG
19 Side Skirt 2
G19 Sideskirt.JPG
20 Front Wheel 2
G19 Front Wheel.JPG
21 Side Mirror 2
G19 Side Mirror.JPG
22 Rear Axle 1
G19 Rear Axel.JPG
23 Gear Box 2
G19 Gearbox.JPG
23a Gear Box Inner Casing 1
G19 Gearbox Inner Casing.JPG
23b Gear Box Outer Casing 1
G19 Gearbox Outer Casing.JPG
23c Top Gear 1
G19 Gear 23 C.JPG
23d Middle Gear 1 1
G19 Gear 23 D.JPG
23e Middle Gear 2 1
G19 Gear 23 E.JPG
23f Bottom Gear 1
G19 Gear 23 F.JPG
Part Number Part Name Quantity Image
24 Wire Concealer 1
G19 Wire Concealer.JPG
25 Center Console Piece 1
G19 Center Console Piece.JPG
26 Gear Shifter 1
G19 Gear Shifter.JPG
26a Gear Shifter Top 1
G19 Gear Shifter Top.JPG
26b Gear Shifter Bottom 1
G19 Gear Shifter Bottom.JPG
27 Rear Motor 2
G19 Rear Motor.JPG
28 Battery Holder 1
G19 Battery Holder.JPG
29 Front Axle Assembly 1
G19 Front Axel Assembly.JPG
30 Pedal 1
G19 Pedal.JPG
31 Inner Cargo Bed Door 1
G19 Inner Cargo Bed Door.JPG
32 Outer Cargo Bed Door 1
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33 Windshield Frame 1
G19 Windshield Frame.JPG
34 Radio 1
G19 Radio.JPG
34a Radio Cover 1
G19 Radio Cover.JPG
34b Radio Middle 1
G19 Radio Middle.JPG
34c Radio Back 1
G19 Radio Back.JPG
34d Speaker Holder 1
G19 Speaker Holder.JPG
34e Speaker 1
G19 Speaker.JPG
34f Circuit Board Cover Front 1
G19 Circuit Board Cover.JPG
34g Circuit Board Cover Back 1
G19 Circuit Board.JPG
34h Circuit Board 1
G19 Circuit Board Focus.JPG
34i Radio Button Mount 1
G19 Radio Button Mount.JPG
34j Volume Knob 1
G19 Volume Knob.JPG
34k Refresh Button 1
G19 Refresh Button.JPG
34l Search Button 1
G19 Search Button.JPG
34m Reset Button 1
G19 Reset Button.JPG
34n Music Button 1
G19 Music Button.JPG
35 Battery Checker Box 1
G19 Battery Checker Box.JPG
36 Dashboard 1
G19 Dashboard.JPG
37 Seatback 2
G19 Seatback.JPG






















































































































































































































Binders

The Ford-150 Power Wheels contained 9 different types of screws. The most common one was a #8 by 3/4 inch screw, which Group 19 labeled [100] for Group 19's reference. The 8 other types of screws are listed and shown in the picture below.

Figure 1: Screws in order from left to right: [95],[96],[97],[98],[99],[100],[101],[102],[103]

Tools

Tools used in the dissection of the Ford-150 Power Wheels

Tool Name Image Usage
P1 Phillips Screwdriver
G19 P1 Screwdriver.JPG
The primary tool used for dissection. Used to do most of the unscrewing of the product beacause most of the fasteners are Phillips screws.
P2 Phillips Screwdriver
G19 P2 Screwdriver.JPG
Used with the larger sized Phillips screws of the product. Used rarely.
1/8 Flathead Screwdriver
G19 Flathead.jpg
Used for unscrewing slot screws and for prying out plastic components. Used moderately for force puporses.


Challenges

The disassembly of the Ford F-150 Power Wheels was relatively easy for Group 19 although there were some challenges that hindered the procedure.

  • Recorder keeping up with the disassemblers
  • Keeping track of the components and binders

The first challenge dealt with the recorder of the group. Group 19's recorder was on a laptop writing out all of the steps of the disassembly procedure on Microsoft Excel. The recorder often found it difficult to keep up with the disassemblers and type up everything that they were doing. Often times the disassemblers would get ahead of the recorder and the recorder would miss typing up a step. To resolve the challenge the group leader made sure that the disassemblers waited after each step to make sure the recorder could catch up and type up the required information.

The several components and binders of the Ford F-150 powers wheels made it challenging to keep track of all of them. Each component needed to be labeled a different number. Also the product used mostly one same screw except for the radio that used multiple different sizes of screws. This made it difficult to keep track of what screw went where, which would be very important for reassembly



Procedure

Part A: Main Chassis

Figure 2: Main Chassis
Step Part Taken Out Part # Off of Part Part # Notes Binders Quantity Tools Used Difficulty Picture
1 Seat 5 Main Chassis 1 Screws [100] 4 1
G19step44.jpg
2 Seatback 37 Seat 5 Took out 2 x headrests Screws [100] 6 2
G19step25.jpg
3 Hood 7 Main Chassis 1 Screws [100] 2 P2 Phillips Screwdriver 2
G19step45.jpg
4 Steering Column Cap 15 Dashboard 36 Screws [100] 1 P2 Phillips Screwdriver 2
G19step24.jpg
5 Dashboard 36 Main Chassis 1 Disconnected wire connecting Chassis and Dashboard Screws [100] 8 P2 Phillips Screwdriver 2
G19step43.jpg
6 Front Grille 11 Main Chassis 1 Had to reach in front of wheel, 2 screws under the car Screws [100] 8 2
G19step41.jpg
7 2 x Hubcaps 3 Rear Wheels 10 Took out by taking out 18. Wire Clips 1
G19step36.jpg
8 12 Volt Battery 17 Main Chassis 1 Popped off 28. Batter Holder 1
G19step40.jpg
9 Cargo Bed 2 Rear Wheels 1 Screws [100] 6 P2 Phillips Screwdriver 2
G19step39.jpg
10 2 x Sideskirt 19 Main Chassis 1 2 screws on each sideskirt Screws [100] 2 P2 Phillips Screwdriver 1
G19step38.jpg
11 2 x Side Mirror 21 Main Chassis 1 2 screws from each side Screws [100] 1 P2 Phillips Screwdriver 1
G19step37.jpg
12 Rear Wheel and Rear Axle 10&22 Main Chassis 1 Slide out 22 from Main Chassis; Gearboxes x2(23)slip off from Axle Popped out axle 1
G19step34.jpg
13 Wire Concealer 24 Main Chassis 1 1
G19step32.jpg
14 Center Console Piece 25 Main Chassis 1 Popped out with force using screwdriver 1/8 Flathead Screwdriver 1
G19step33.jpg
15 Gear Shifter 26 Main Chassis 1 Also popped out 2 x electric boxes Screws [100] 2 P2 Phillips Screwdriver 2
G19step31.jpg
16 Top of Gear Shifter 26a Bottom of Gear Shifter 26b Screws [100] 4 P2 Phillips Screwdriver 2
G19step30.jpg
17 Battery Holder 28 Front Axle Assembly 29 Screws [101] 2 P2 Phillips Screwdriver 2
G19step29.jpg
18 Front Axle Assembly 29 Main Chassis 1 Took out screw in front of center console which held the front axel assembly in place Screws [100] 2 P2 Phillips Screwdriver 2
G19step28.jpg
19 Pedal 30 Main Chassis 1 Snapped off Pedal from the Main Chassis 1
G19step27.jpg

Part B: Subsystem - Dashboard

Figure 3: Subsystem - Dashboard
Step Part Taken Out Part # Off of Part Part # Notes Binders Quantity Tools Used Difficulty Picture
21 Windshield Frame 33 Dashboard 36 Disconnected 4 clips with screwdriver Screws [100] 2 P2 Phillips Screwdriver 3
G19step42.jpg
22 Radio 34 Dashboard 36 Screws [100] with plastic clips 3 P2 Phillips Screwdriver 2
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23 Radio Cover 34a Radio 34 Screw came from the back of the radio Screws [102] 4 P1 Phillips Screwdriver 2
G19step18.jpg
24 Circuit Board Cover Front and Back 34f, 34g Radio Middle 34b Screws [97] 4 P1 Phillips Screwdriver 2
G19step17.jpg
25 Speaker Holder 34d Radio Back 34c Screws [98] 2 P1 Phillips Screwdriver 2
G19step16.jpg
26 Circuit Board Cover Front 34f Circuit Board Cover Back 34g Screws [96] 6 P1 Phillips Screwdriver 2
G19step15.jpg
27 Circuit Board 34h Circuit Board Cover 34f, 34g Popped off 1
G19step14.jpg
28 Radio Button Mount 34i Radio Middle 34b Screws [95] 6 P1 Phillips Screwdriver 2
G19step13.jpg
29 Volume Knob, Refesh Button, Search Button, Reset Button 34j, 34k, 34l, 34m Radio Middle 34b Popped off 1
G19step12.jpg
30 Battery Checker Box 35 Dashboard 90 Screws [99] 2 P1 Phillips Screwdriver 1
31 Steering Column, Steering Wheel, Steering Wheel Cover 13, 4, 6 Dashboard 90 Popped off with a flathead screwdriver 1/8 Flathead Screwdriver 1
G19step23.jpg
32 Steering Wheel Cover 6 Steering Wheel 4 Pryed off 1/8 Flathead Screwdriver 1
G19step22.jpg
33 Steering Wheel 4 Steering Column 13 Took out by taking out 14. Pin, The Pin was stuck through 18. Wire clips & 4. Steering Wheel, holding them together 1
G19step21.jpg

Part C: Subsystem - Cargo Bed

Figure 4: Subsystem - Cargo Bed
Step Part Taken Out Part # Off of Part Part # Notes Binders Quantity Tools Used Difficulty Picture
33 Cargo Bed Door Assembled Cargo Bed 2 The full cargo bed door was pulled off of the cargo bed using force 1
G19step2.jpg
34 Inner Cargo Bed Door 31 Outer Cargo Bed Door 32 Popped apart Screws [100] 8 P2 Phillips Screwdriver 1
G19step1.jpg

Part D: Subsystem - Front Grille

Figure 5: Subsystem - Front Grille
Step Part Taken Out Part # Off of Part Part # Notes Binders Quantity Tools Used Difficulty Picture
35 Grille Piece 11a Front Grille 11 Screws [100] 3 P1 Phillips Screwdriver 2
G19step8.jpg
36 2 x Headlight Cover, 2x Headlight 11b, 11c Front Grille 11 Screws [100] 1 P1 Phillips Screwdriver 1
G19step7.jpg
37 2 x Lower Headlight 11d Front Grille 11 Popped Off 1
G19step5.jpg
38 Grille Support 12 Front Grille 11 Used Extreme Force to Pop Off 3
G19step4.jpg

Part E: Subsystem - Left/Right Gearbox

Figure 6: Subsystem - Gearbox
Step Part Taken Out Part # Off of Part Part # Notes Binders Quantity Tools Used Difficulty Picture
39 Rear Motor 27 Gearbox 23 2 x flathead screwdriver on each side Flathead Screws 4 1/8 Flathead Screwdriver 2
G19step11.jpg
40 Gearbox Inner Casing 23a Gearbox Outer Casing 23b Popped apart 4 clips which held 23a. and 23b. together, both covered in grease Screws [103] 4 P2 Phillips Screwdriver 2
G19step10.jpg
41 Top Gear, Middle Gear 1, Middle Gear 2, Bottom Gear 23c, 23d, 23e, 23f Gearbox Inner Casing 23a All gears simply taken out of casing, all gears covered in grease 1
G19step9.jpg

Ease of Disassembly

Group 19 labeled each step in the procedure of the dissection with a difficulty scale of 1 through 5, with 1 being the most easy and 5 being the most difficult.


Difficulty Level Description Example
1 A difficulty rating of 1 implies a simple process. Only minimal human force was used to take apart a plastic connection. Documentation was also simple. Only one person was needed to perform the task Step 8: The battery was simply taken out of the front compartment and battery holder with minimal effort.
2 A difficulty rating of 2 implies a that the step was semi-simple. A screwdriver was needed to unscrew components from each other. Documentation of the step was relatively easy. One person could perform the task Step 23: The radio cover was simply unscrewed from the radio assembly with a P1 Phillips Screwdriver.
3 A difficulty rating of 3 implies a moderate difficulty. Moderate force and/or a screwdriver may have been used for the step. Documentation was not simple, but not complex. One or two people may have been needed. Also multiple tries were attempted. Step 38: A larger amount of force was needed to disattach the grille support from the front grille assembly. Multiple attempts were made before it finally popped out.
4 A difficulty rating of 4 implies a semi-diffult process. A large amount of force and multiple tools may have been required. Documentation was difficult because of the complexity of the process. More than one person was required to perform the step. No steps were deemed this difficult.
5 A difficulty rating of 5 implies the most extreme difficulty. Extreme force and several tools may have been used with multiple tries. Documentation was very difficult. Several people are needed to perform the task. No steps were deemed this difficult.



Intent of Disassembly

Mostly all of the parts on the Power Wheels are designed to be taken apart. A trained technician would not be required to put in/change a new part. The reason is that mostly all of the dissection steps use a Phillips screwdriver to unbind parts. A Philips screwdriver is a mandatory tool in any home, which makes it easily accessible to strip down certain parts in the Power Wheels if needed. There were some assemblies in the Power Wheels containing multiple parts in them that aren’t supposed to be taken apart by the user of the toy.

Looking at the consumer perspective of disassembly, almost none of this product is meant to be disassembled. The reason for this is because the product was designed for a small child to be a user. Due to safety concerns, the child should not be able to take apart any component of the vehicle at the risk of the vehicle not functioning correctly and injuring the user.



Front Axle Assembly

The Front Axle:
The front wheel-axle assembly containing the two front wheels, tie rod, axle, and a few other parts was believed to be a component not intended to be broken down by the user. The reason is that there are two metal end caps (one at the right and one at the left) locking everything together. No tool in an average person’s toolbox would be able to take the caps off the assembly, making this assembly non-dissectible unless a licensed person was called upon.









Rear Motor

The Rear Axle Motors:
The rear axle Motors were not intended to be taken apart by a novice. The reason is the motor is a complex part that requires heavy knowledge in understanding the concept of it. No average user would be available to fix a problem inside the motor. Fisher-Price makes sure the motor does not contain any average size screws in it, which warns people not to tamper with the part.









12 Volt Battery

The Lead Acid rechargeable 12-Volt Battery:
This part is not intended to be broken down any further because it contains harmful chemicals that could be dangerous to the user if handled incorrectly. Fisher-Price follows through in insuring that no unlicensed person should tamper with this part by putting warning labels directly on the Battery telling the user not to touch the part.








Connection of Subsystems

Figure 7: Connection of Subsystems


Figure 7 shows the subsystems acting together in the Power Wheels. To further understand Figure 1, it could be broken down into these subsystems: Steering, Pedal, Shifter, and Radio.

Steering:
In order for the F-150 to steer in the desired direction, Human Energy is the first input. The Human Energy is then converted to rotational energy in the Steering Wheel. With the steering wheel creating rotational energy the steering column is also rotated. With this rotation, the steering column which is directly connected to the Tie Rod changes the energy from Rotational Energy (in the steering column) to Translational Energy (in the Tie Rod). With the Tie Rod moving left to right (Translational Energy) it turns the wheels in the same direction the Tie Rod is moving, which is just a transfer of Translational Energy from the Tie rod to the Front Wheel.

Pedal:
In order for the F-150 move in a linear direction on the ground the Pedal subsystem is necessary because it’s responsible for moving the vehicle forward or reverse depending on the current location of the shifter. The primary input of Energy in this Sub-system is Human Energy. The Human Energy pushes the petal down which converts the Human Energy to Mechanical Energy. The Pedal signals the Mechanical Energy to the 12V Lead-Acid Battery through a wire. The Battery converts the Mechanical Energy to Electrical Energy which is sent via wire to the Motor. The Motor then converts the Electrical Energy received from the battery to rotational energy as an output. The Gear Box, which is connected directly to the Motor receives the Rotational Energy and Transfers the Energy to the Rear axle. The Rear axle outputs Rotational Energy, which is connected as one unit with the two rear wheels. The two Rear Wheels convert the rotational energy to Translational Energy when the product is on the ground and moving in a linear path. Shifter: This subsystem is linked heavily with the Pedal Subsystem. The Shifter’s responsibility is to give the desired linear output of the motion of the Ford F-150. The three available outputs of the motion are, Slow Gear in which the vehicle moves forward slowly at 2.5 mph, Fast Gear in which the vehicle moves forward at max speed 5 mph (which is only capable if the safety screw is removed on the shifter), and Reverse Gear which moves the vehicles in backwards at 2.5 mph. Same with this subsystem the primary input is Human Energy. Human Energy is converted to mechanical energy as it moves the shifter into the desired position. A signal of the position is sent to the Battery via a Wire. The Battery converts the Mechanical Energy to Electrical Energy which is sent via wire to the Motor. The Motor then converts the Electrical Energy received from the battery to rotational energy as an output. Note: The Speed and Direction of the Motor’s output is given by the position that the shifter is currently in. The Gear Box, which is connected directly to the Motor receives the Rotational Energy and transfers the energy to the Rear axle. The rear axle outputs Rotational Energy, which is connected as one unit with the two rear wheels. The two Rear Wheels convert the rotational energy to Translational Energy when the product is on the ground and moving in a linear path, either in reverse, slow, or fast.

Radio:
According to Figure 1 this subsystem is the only one out of the four that does not to be in working order for the F-150 Power Wheel to drive. Human Energy is first used to push a button or turn a knob on the radio interface. A signal is then sent to the circuit board directly underneath the interface. Note: Different signals may be sent from the buttons to the circuit board depending on which dial or button was push or rotated. This signal is then sent electrically from the circuit board to the battery by wires. Electrical Energy is then created by the batteries and the Electrical Energy is carried to the Radio Speaker. The Radio Speaker converts the Electrical Energy to Sound Energy which gives the desired output sound. All four of these subsystems are needed to be in a working order in order for the end goal; the car drives and plays the radio to occur.

The radio is the only subsystem that does not need to be in a working order for the F-150 to drive.

Connection Implementation

The Ford F-150 Power Wheels' subsystems are all connected by either threaded screws or simply attached together by plastic components. The connection of the subsystems are influenced by global, societal, economic, and environmental concerns. Performance of the product also influences the connections

Global Concerns:
Since the Ford F-150 Power Wheels is a child's product, global concerns do not really exist for the connection of subsystems. The only minor concern is using a screw that would be easy to be replaced in different regions of the world.

Societal Concerns:
The connection of subsystems is influenced by societal concerns due to safety issues. Since the product come partially disassembled, it must be relatively easy for the consumer to put it together. Also by initially putting a screw lock for the high speed gear, Fischer Price has taken another safety issue into account. Some parents may not want their child to drive the product at top speed due to the risk of injury to the child.

Economic Concerns:
The manufacturer most likely wanted to connect the products' subsystems in such a way that it would be the cheapest to produce. Minimal use of screws was probably implemented and replaced by connecting plastic components. Since the manufacturing cost would be lower, the cost to the consumer would also become lower.

Environmental Concerns:
The connection of subsystems is influenced by environmental concerns due to the use of materials in the connections. Since screws can not really be recycled effectively, the use of minimal screws for the product may be better for the environment in the long run.

Performance Concerns:
Performance influenced the connection type because the Ford F-150 Power Wheels was made and advertised to ride on rough terrains and environments. In order for the vehicle to be durable enough to not break when riding over bumps of a rough terrain, plastic connections were used. The plastic allows some deflection of the material that absorbs the force of off-road riding, causing the vehicle to stay intact.

References

[1] Fisher-Price. F-150 Power Wheels Manual Model K8285. 2007.