MEC 2040 LAB PROJECT
COMPUTER AIDED TECHNOLOGY

VERMONT TECHNICAL COLLEGE

PROFESSOR PAUL JOHNSON

CUSTOMER SUPPORT DEVELOPMENT PROGRAM

GENERAL ELECTRIC AIRCRAFT ENGINES

RUTLAND OPERATIONS 

MAY 2003

The Matrix Organization Project

Overview

As part of our current course work in Computer Aided Technology, we are required to start a complex organization as our lab project.  This Matrix organization requires us to work as a team and start a profitable business.  This business will count as thirty-six hours of lab work.  We have been given a $200.00 to $500.00 budget from George Ambrose as start up money for our business.Our class project began on May 19, 2003 with a six-week time limit. 

This business will consist of design, development, marketing and sales.I was elected by the Customer Support Development Program students to act as the Project Manager.

Project management is used to help manage, plan, organize, schedule, monitor and control complex projects like this one. 

In order to help define our project, I have included the following list of team objectives:

üTeam building skills- learning to work within a team, taking on specific roles and working together to complete the project on time and within budget.

üDeveloping CNC Programming skills- learning to do simply programs for the CNC lathes and milling machines.Developing debugging skills for CNC programs. Using software linking CAD programs with CNC machines.

üDesign/Modeling- learning to design and model using Auto CAD and Mechanical Desktop 6, a product that can be produced on the available CNC machines at Stafford Technical Center.

üComplex Organization- learning the concepts behind successful marketing strategies, machine layout, manufacturing engineering process, material purchasing, budgeting, cost control, inventory, research & development and finance.

The class used brainstorming as the technique to develop our business plan, during which we discussed possible products, materials, and marketing strategies.We discussed the possibilities of using aluminum, bronze, brass, plastic and/or wood for our products.We discussed different product ideas such as candleholders, key chains, golf tees, business card holders, pocket bottle openers, letter openers and pen/pencil holders, along with the possibility of personalizing these products with the engraving software on the CNC lathe.

We also determined the necessary roles to manage our project.We determined that we would need to focus on marketing/sales, tooling, design, modeling and manufacturing flow as a complete team. We also determined that certain areas would need team leaders, these leaders would take on the responsibility of these areas:

·Research & Development-Lori Peer

·Finance-Thomas Desforge

·Purchasing/Inventory-Robert Gillespie

·      Industrial Engineer/layout-Justin Bishop

·Project Management-Louella Cyr

Our business will consist of design, development, marketing and selling of two different key chains.We decided on a jet engine bottle opener design and a patriotic theme design.We determined that any profits realized from this business objective would be returned to the community through Steve Jeski, in order, to further machine trades training at The Stafford Technical Center in Rutland.

Our marketing strategy consists of posters advertising the availability of our key chains throughout the community, along with access to a web-based catalog.We have requested through Glen Traverse, our program director, to be allowed to advertise our products at General Electric, through posters on the employee bulletin boards located at both plants.We specifically designed the jet engine bottle opener to be marketed to our fellow employees.The inclusion of our fellow employees in this project would allow for exposure and promotion of the Customer Support Development Program among fellow GEAE employees. 

PROJECT STATUS

May 29, 2003

I have been working on the development of the project.I contacted Glen Traverse about marketing within GE, which I did through e-mail and a written project overview.The CSDP council met and agreed to allow us to market our products inside the Rutland Operations of GE based on the information included in the overview that I provided to them.I also have been networking within the community looking at prospective marketing areas.

I have working on organizing and planning this project.I have been working on the timeline. I should have a schedule for the project by June 1, 2003.

June 2, 2003

I went to Mac Steel in Rutland and brought 2 material samples for prototype development. Also, I have been experimenting with the CNC lathe engraving software and the CNC lathe operating software.

The availability of tooling for the CNC machines is also something that needs to be addressed for this project. Tooling is going to be an issue for the jet engine project and I have been working with outside contacts, trying to address these tooling needs.I also have been working on a design for a nameplate on Mechanical Desktop 6.

June 5, 2003

I needed to address team members about their responsibility to the team when taking on specific roles within the project i.e. Materials availability.I wish I had been better prepared to handle this situation but with all considered it went well.Steve Bania will now handle the materials.I worked on my design.The packet of information given on line by line programming will allow me to complete a CNC program for my design, meeting the technical skills development portion of this project. I using the VTC library for the research paper due for this class.I worked with Steve Jeski to finalize the details for turning over the profits from this project.I committed to the sale of 50 USA key chains to the local VFW chapter and did some community networking on the marketing front. I have completed the timeline for this project, which I e-mailed to all of the team members.The projected timeline is included within this document.
 
Class Date
Where we need to be:
June 5, 2003
USA cutting Prototype, programming 

Jet-engine key chain programming

Card holder-programming, Prototype

Candle sticks-design, programming

Jaw Fixture-prototype programming

Golf Tee- design 

Materials- samples for prototypes available 

R & D fixtures for manufacturing products

June 9, 2003
Marketing Posters with USA design ready for distribution

Web page design begins

Jet-engine programming complete, begin prototype

Jaw Fixture complete

Card holder prototype complete

June 12, 2003
Web page up & running

Begin production of USA & Card holder

Jet-engine prototype finished

Cardholder engraving fixture? Before or after machining?

Candle stick prototype

Golf Tee prototype

June 16, 2003
Marketing push on running designs

Taking orders for products

Order stock for production to begin.

Produce sales samples

Tie up loose ends on designs are they going to make the cut for production and sales?

June 19
Begin production on orders 

Marketing push on other designs

Sales

June 23
Production, Production, Production

Marketing

Sales

June 26
End Marketing 

Complete orders for products

Production of products

June 30
End of Project

Finish up on production schedule 

Complete Budget

Release profits to VICA

Clean up and go home.

 

June 9, 2003

I continued to work on the design for the nameplate and also working with Justin on the prototype of the jet engine.Tooling issues were addressed with a .187 boring bar which I borrowed from an outside source.The available tooling at the Stafford Technical Center continues to be an issue for this project.

June 12, 2003

I worked with Steve Bania on a (fixture) stop to be used for the USA key chain as a stock stop for production.We brainstormed different ideas and looked through the shop for possible materials that could be used.One of the ideas was a shoulder bolt added to the custom jaws that Jason Patch designed.We decided on a custom stop that was fabricated out of aluminum.It is working great.I worked with Lori on deciding how the engraving would be done on the cardholder, before or after and discussed how she could get more machine time.The group is still having machine and tooling issues that are not being resolved.I have been trying to work with Kevin to get the software working on the mills, so that production can begin on the USA key chain.I completed my design for the toolbox tag using Mechanical desktop 6 and began writing a line-by-line program for the mill using the same custom vise jaws that Jason developed for USA.

June 16, 2003

I had the worse night ever in the lab.The mill that was being used for USA crashed. Kevin Norton was late. Bob needed measuring tools (calipers or mics) for his project and they were not available. The computers that were moved over went down and they do not print.The computers were not networked into the Internet, so we could not check e-mail or work on the research paper.I could not get my design for the toolbox tag to print. It was very frustrating! I worked on my line-by-line program for my design.I worked with Kevin on the PC for the mill.I worked with the team to come to an agreement to get more machine time for Lori Peer. I got into the machine shop and borrowed mics and calipers for Bob. I worked with Justin for a minute on the jet-engine body on the lathe.I need to get more machine time myself.I have committed to 50 USA key chains and am planning on working on the production of the product to get some time on the NC mill, if we can get one working. The project will continue through the last class.I am currently working to General Electric to allow us to use equipment at the plant.I believe that we will be able to do this, which will solve both the tooling issues that we have had throughout this project and the machine software issues.
 

 
NC MILL INFORMATION

COLLECTED ON MAY 12, 2003

STAFFORD TECHNICAL CENTER


 
A6P311001 

FAUNC CONTROLLED MILL

Max cutting circle diameter
22 mm sleeve 
Turning Tool
124 mm
Cutting Tool
140 mm
Max of 3 external tools can be clamped
10 mm max on internal tool shafts.
Feed speeds
0-2000 mm/min
Min travel slide path 
.5mm
Travel path longitudinal slide
236mm
Cross slide
48mm
Accessories
80 mm three jaw chuck

Collate chuck

Turning Tools
Side tool neutral with inserts
Tools
Plug in pivot
Tools
3 jaw 1-8 mm clamping chuck
Tooling
Center drills-assortment

Assortment of used twist drills

PC MILL 55 INFORMATION

MAY 12, 2003

190 mm
Y
125 mm
Z
190 mm
Clamping surface
420 mm L x 125 mm D

Max Load = 10 Kg

Normal Motor speed
1400 rpm

Range 100-3500 rpm

Machine dimensions
(LxDxH)840 x 865 x 816 mm
Chuck
2.5 in max jaw opening 

collet chuck .059 to .629 in

NC Programming Codes


 
G91
RELATIVE COORDINATES USED FOR REPEATED FEATURES
G90
ABSOLUTE COORDINATES
S
SPINDLE SPEED
M3
CLOCK WISE DIRECTION OF SPINDLE
M4
COUNTER CLOCK WISE (left hand cutter)
M5
STOP SPINDLE
M2
PROGRAM STOP
G0
RAPID
G1
FEED RATE SET
G2
CIRCLE ARC CUT (CLOCK WISE)
G3
CIRCLE (COUNTER CLOCK WISE)
T
TOOL
CLEAR PLANE
A SPOT ABOVE THE FIXTURE AND HEIGHT OF THE WORK PIECE.