Group 3 - Homelite Fluid Pump (Gasoline Powered) - Project Planning

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Contents

Work Proposal

Creating a well-developed plan is a crucial step to take in preparation for the dissection of a mechanically complex product like the Homelite fluid pump. This section is focused on laying the framework for such a plan by proposing a generalized approach to disassembly & assembly, specific challenges & requirements, and evaluating group members\' strengths & weaknesses.

Disassembly & Assembly

The processes of disassembly and assembly will be addressed with the same order in which they will be encountered for this project.

Disassembly

The disassembly process will involve the handling of many parts (perhaps hundreds) ranging in physical size from the as small as a paperclip (throttle linkages & tiny fasteners) to the nearly the same size of the product (engine & pump housings). In order to accomplish this task with order and efficiency, a cohesive generalized model has been conceived \'\'(Figure 1)\'\'.

Figure 1 - Generalized Disassembly Procedure (Iterative Model)‎

\'\'\'Figure 1 Explained\'\'\'

  • Identify the Next Part to be Removed
    Decide which part is the next logical part to be removed. Begin with the largest systems and then recursively dissect the contained subsystems and assemblies.
  • Preparation for Removal
    Includes identifying the required tools, considering special techniques that may be required (for seized connections or fragile components), and assigning a part number.
  • Part Removal
    Includes the removal of the part, and also documenting the process in writing.
  • Part Cataloging
    Includes cleaning, photographing, and labeling of the part.

Upon initial investigation of the proposed model it\'s apparent that the first step is to identify the next part to be removed. However, its iterative (cyclic) nature is intended to be exploited. We expect to find that as we become more experienced with working together as a team, it will be possible for more than one step to be executed simultaneously.


Assembly

The Assembly process is expected to be executed in the reverse order of disassembly according to the same model with just a few differences to clarify. In similar fashion to the presentation of the disassembly process, Figure 2 depicts the proposed \'\'Generalized Assembly Procedure\'\' and discussion follows.


Figure 2 - Generalized Assembly Procedure


\'\'\'Figure 2 Explained\'\'\'

  • Identify the Next Part to be Assembled
    Reference documentation to determine which part is the next part to be assembled. Retrieve the part from storage by part number.
  • Preparation for Assembly
    Includes identifying the required tools, considering special techniques that may be required (torque specifications, lubrication requirements, and/or thread sealant/thread-locking treatments), and referencing pre-disassembly photos.
  • Part Assembly
    Includes the assembly of the part.
  • Validation of Proper Assembly
    Refer to pre-disassembly photos for visual validation, and inspect assembly for proper functionality.

Specific Challenges & Requirements

Any well-thought plan is susceptible to the misfortune of encountering unforeseen challenges and requirements that can impede progress. This section\'s focus is to specifically identify such challenges and requirements.

Challenges

Through an initial inspection of the Homelite fluid pump, we identified challenges of two different classifications. There are general challenges that would be present in the dissection of products with similar mechanical complexity, and there are also particular challenges that will be faced in the dissection of our product specifically.

In general, with any product of similar mechanical complexity, there are many challenges that result from the gross quantity of parts incorporated in the product\'s design. Merely looking at the product externally, more than 50 fasteners and more than 20 parts can be identified. Both group members who have previous hands-on experience with mechanics (Alex and Mark) agree that this external visual inspection is only showing us the "tip of the iceberg" pertaining to the total number of parts involved in this product.

The high number of parts involved presents challenges in dissection that will test the group\'s operational efficiency and organizational skills. Efficient disassembly and assembly of the product will necessitate optimal coordination of the group members\' tasks in real-time. Without this efficiency, much time can be wasted, and time will be one of the group\'s most valuable resources in completing the project -- especially when posed with other challenges.

In particular, the Homelite fluid pump that is the subject of dissection, presents another challenge. Because it is not a brand-new product, it is dirty, rusty, and some parts appear to be worn-out and/or slightly damaged. Explanations of these challenges follow.

Dirty Parts
Built-up dirt and oily grime can visually impede the disassembly of the product by masking the appearance of the assembly. In some instances, parts may not be visible at all, and in other cases, unique parts may appear to be the same part if seams are covered by grime.
Rusty Parts
Rust is clearly evident in the base of the fluid pump. Other corrosion may also exist. Rust can contribute to the same challenges mentioned above for Dirty Parts, but also comes with its own subset of nuances. Rust and corrosion can weaken material, leaving parts prone to breaking, and also corrosion can "weld" mating parts together, making them difficult to separate.
Worn Parts
Some fasteners appear to be very worn. A potential challenge in removing worn fasteners is the potential for the head to strip. This must be considered when removing all fasteners.
Slightly Damaged Parts
For slighly damaged parts like a bent throttle linkage, the removal of such parts may not be routine. Removing a bent linkage may require bending the linkage back into its intended shape before removal is possible.

Requirements

Many materials will be required for dissection. This section clarifies these requirements by the categories \'\'Disassembly\'\' and \'\'Documentation\'\' in the following tables.

Disassembly Supplies
Item Details Purpose


Work Table
  • 3ft x 8ft area
  • Waist-Height
  • Sturdy and Stable
  • Comfortable platform to support the product.
Bench Vise
  • 4in jaw
  • Holding unwieldy parts and assemblies
Flat-Head Screwdrivers
  • 1/8in
  • 3/16in
  • 1/4in
  • 5/16 in
  • 1/2in
  • Removing fasteners
  • Use as a prying tool
Phillips-Head Screwdrivers
  • #1
  • #2
  • #3
  • Removing fasteners
Sockets (General)
  • 6-point & 12-point Hex
    • Metric sizes: 4mm - 21mm
    • Standard Sizes: 3/16in - 1in
  • 6-point Allen
    • Metric Sizes: 2mm - 10mm
    • Standard Sizes: 1/8in - 3/8in
  • Removing various fasteners
Sockets (Specialty)
  • 5/8in Sparkplug
  • Removing the Sparkplug
Socket Wrenches
  • 1/4in, 3/8in & 1/2in Square Drive
  • Use to drive sockets
Combination Wrenches
  • Boxed end / Open end
    • Metric Sizes: 6mm - 21mm
    • Standard Sizes: 1/4in - 7/8in
  • Removing fasteners with limited clearance for socket wrench


Plyers
  • Needlenosed
  • Visegrip (locking)
  • Handling tiny parts like springs/wire linkages
  • General use
Materials to aid in removal of stubborn fasteners
  • PB Blaster
  • CRC Freeze-out
  • Loosen seized fasteners
Tools to aid in removal of broken fasteners
  • Stud Removal Tool
  • Easy-Out Bits
  • Remove bolts if the head breaks off and the shank is protruding
  • Remove screws when the head strips or has broken off flush
Cleaning Supplies
  • Parts Cleaner
  • Rags
  • Wire Brush
  • Used for cleaning components before, during, and after disassembly
Documentation Supplies
Item Details Purpose
3-Ring Binder
  • Including loose-leaf paper
  • Contain all documentation literature in one organized location
Digital Camera
  • Sd Card for storage
  • Good Batteries
  • Visual Documentation
Masking Tape
  • High-Quality adhesive
  • Attach to parts to serve as a label tag
Permanent Markers
  • High Quality
  • Writing part numbers on labels
Index Cards
  • 3in x 5in
  • Easy Part identification in photographs
    • For each part, its part number will be written on a card, and the card will be photographed with the part

Group Member Evaluation

It is very important to assess the status of individual group members\' strengths and weaknesses in order to appropriately utilized the group\'s human assets and identify personal attributes that may require special attention for growth and improvement. The following table presents these strengths and weaknesses.


Group Member Strengths & Weaknesses
Group Member Strengths Weaknesses
Abner Bogan
  • Hard-Working
  • Good people-skills
    • Can serve to maintain positive relationships between group members
  • Sometimes lacks punctuality
  • Susceptible to distractions
Alex Keller
  • Time Management
  • Hands-on Mechanical Experience
  • Understanding of Engine Systems
  • Proficiency with Solid Modeling (Creo/ProE)
  • Sometimes lacks patience.
  • Can be unorganized
  • Technical Writing
  • Maintaining balance with coursework
Alberto Santiago
  • Intrinsically motivated to succeed
  • Easy-going personality (easy to work with)
  • Punctual and Reliable
  • Weak engineering analysis skills
  • Susceptible to distractions
  • Written Communication
Hamlet Spencer
  • Detail Oriented
  • Ability to manage data.
  • Artistic (Keen eye for visual aesthetics)
  • Has ambition to learn
  • Written and Oral Communication
  • Theoretical Analysis
Mark Tomaszewski
  • Time Management
  • Responsible & Diligent Worker
  • Good Written & Verbal Communication Skills
  • Experience with:
    • Mechanics (hands-on)
    • Solid Modeling
    • Print Design
    • Web Design
  • Has difficulty depending upon others to accomplish tasks
  • Strives for perfection
    • Sometimes set unachievable goals
    • Imposed workload can be overbearing


Management Proposal

In order to accomplish the many tasks that Group 3 will encounter throughout the duration of this project, a protocol that outlines certain aspects of group management has been created. The facets of this protocol include the assignment of a Point of Contact for the group, a group productivity model & meeting schedule, the assignment of group member roles, and group conflict handling.

Point of Contact

\'\'\'Mark Tomaszewski\'\'\' \'\'(Communication Liaison)\'\' :
\'\'\'Telephone:\'\'\' (716)541-8630
\'\'\'E-mail:\'\'\' marktoma@buffalo.edu

Productivity Model & Meeting Schedule

The most important aspects to being successful as a group in accomplishing time-sensitive goals include thorough communication, clarification of expectations, and peer review with feedback. These are the key aspects to maximizing the productivity of the group such that the project gates can be completed within given time constraints.

Through regularly scheduled group meetings the group can assess its current status with respect to the project requirements, and in doing such, group members can cooperatively build a strategy by which to maintain productivity according to the above-mentioned key aspect of productivity.

Mandatory group meetings are periodically scheduled to take place every Monday and Wednesday immediately following MAE 277 Lecture. Group members should plan to dedicate at least one hour of time to these group meetings. The meetings will take place on the ground floor of the Silverman Library in Capen Hall.

Other meetings may be necessary from time to time and it\'s expected that in most cases it will be possible to schedule an auxiliary meeting while the group members are in attendance of a mandatory meeting. However, in some instances this may not be possible, and in those cases the group will arrange an auxiliary meeting through telephone communication.

In addition to these objectives in completing specific tasks, the group has also created the following timeline for completion of the project\'s 5 gates.

Project Timeline

Group Member Roles

Upon Compiling a list of the group members\' strengths and weaknesses in the Work Proposal, it became clearly evident ho to assign dutiful roles to the group members for this project. The following table presents the Roles assigned and Description of Duties for each group member.

Group Member Roles
Group Member Roles Decription of Duties
Abner Bogan
  • \'\'\'Documentation Expert\'\'\'
  • Document the dissection process in detailed written format
  • Responsible for consistency in part number labeling
  • Work directly with the Communication Liaison to provide documentation for reports
Alex Keller
  • \'\'\'Technical Expert\'\'\'
  • \'\'\'Solid Modeler\'\'\'
  • Lead the hands-on product dissection process with disassembly & assembly
    • Put Safety First!
  • Work directly with the Documentation Expert to provide him with detailed information and commentary regarding product dissection
Alberto Santiago
  • \'\'\'Project Manager\'\'\'
  • Influence the group\'s productivity with:
    • Achieving prioritized objectives (long-term)
    • Organizing group meetings (short-term)
    • Addressing conflict (immediate)
  • Maintain open lines of communication with (and between) all group members
  • Serves as reinforcement for any group member who needs help with his own duties
Hamlet Spencer
  • \'\'\'Visual Media Expert\'\'\'
  • Document the dissection process in visual format
    • Label each part
    • Photograph each part
  • Visually catalog all parts
  • Source and/or create visual media for reports
  • Work directly with the Communication Liaison to provide him with an organized batch of visual content for reports
Mark Tomaszewski
  • \'\'\'Communication Liaison\'\'\'
  • \'\'\'Technical Assistant\'\'\'
  • Update the Group\'s Wiki page
    • Work directly with the Documentation Expert and the Visual Media Expert to compile data and compose reports
  • Maintain professionalism in the group\'s communication
    • Edit all published reports
  • Backup the Technical Expert with his duties

Conflict Handling

In the event that group conflict occurs, it will be the duty of the group\'s Project Manager, Alberto Santiago, to address the conflict in a group setting and arbitrate a solution to the conflict. The group\'s first method of choice for reaching a resolution to conflict is to compromise within reason. If a simple compromise cannot be reached, then the group will rely upon a majority vote to resolve conflict.