Old Main Group

Design Issues There are no changes to the overall Design It will remain the way it is The Attachment Issue is resolved Going to screw on the tower to the flat part of the roof. The other parts of the roof will be fastened with “metal strips” and a pin.

Production Plan FAME Lab will be used for majority of work. Currently finalizing fixtures, and programs Machines to be used are: CNC Milling Centers and CNC Lathes Going to utilize Skytop Machine Shop to make precise cuts on some components. Final Machine Time per Old Main: 100 min. Total Time to Complete 20: 33 Hrs, 15 min.

Front Face Front Face Process Plan

Front Face (cont.) More Detailed Front Face Process Plans

Side Faces Side Face Process Plan

Side Faces (cont.) More Detailed Side Process Plans

Flat Roof Top Plate of Roof Begin with one 5”x6’x0.5” plate of 6061 Al Cut down to lengths of ” to machine After machining, cut-off sections at 2.625” Each set up will produce 8 top roofs Will need to perform 3 set-ups to produce 24 top roofs

Flat Roof (cont) Process Plans for Top Plate of Roof Set Up No. Operation Description Machine Tool Description 10Cut-Off a 5” x 0.5” cross section of 6061 Al plate to a length of ” ±.005” Cut-Off Saw 20Face Mill Surface Cut down edges 3 axis vertical machining center 3” Face Mill Concave Radius Cutter 30Cut-Off each plate to a length of 2.625” ±.005” Cut-Off Saw

Flat Roof (cont) Bottom Plate of Roof Begin with two 4”x6’x0.5” plates of 6061 Al Cut down to lengths of ” and a width of 3.125” to machine Machine one side before flipping plate to machine the other Each set up will produce 4 bottom roofs Will need to perform 5 set-ups to produce 20 bottom roofs

Flat Roof (cont) Process Plans for Bottom Plate of Roof Set Up No. Operation Description Machine Tool Description 10 Cut-Off a 4” x 0.5” cross section of 6061 Al plate to a length of ” ±.005” Cut-Off Saw 20End Mill the plate to a width of 3.125” ±.005” 3 axis vertical machining center 1” End Mill 30Face Mill Surface Cut down edges 3 axis vertical machining center 3” Face Mill Concave Radius Cutter 40 Flip Plate Face Mill Surface End Mill a width of 1.5” to a depth of.250” ±.005” Spot Drill Edges End Mill to a depth of.125” for column insertions 3 axis vertical machining center 3” Face Mill 1” End Mill.5” Spot Drill 5/16” End Mill 50Cut-Off each plate to a length of 5.5” ±.005” Cut-Off Saw

Triangular Roof Sections

Material Ordered- 11/13/01 Outsourcing to SkyTop Machine & Tool, Inc. Water Jet Cutting Contract written Meeting for contract review First roof delivery/inspection All roofs delivered within 1 week of approval

Outsourcing Reasons In-house production difficulties Fixturing triangular stock Many operations- Difficulty maintaining required tolerances Not time efficient Water jet cutting can meet required tolerances and specifications Cost Effective

Base & Middle of Tower Fixture bars at a 45° angle in the specialty jaws and end mill the flat on each corner (4) Fixture on parallels and end mill steps (2) On the middle, pocket hole for clock mounting Base Process Plan Part 1

Top of Tower Drill hole 3 in center of stock for hollow portion of tower End mill flats and archway; rotate 45° and end mill flats plus ball mill columns (4) Contour dome and cutoff on lathe Top Process Plan Part 3

Current Status Material – Still waiting on material for front/backs and the triangular roof, as well as wood for bases. Fixturing – Constructing fixtures is complete. Tooling – All required tooling is available.

Schedule

Delivery Schedule Dates when components will be complete: Bases: Dec. 1 Front/Backs: Nov. 30 Sides: Nov. 30 Flat Roof: Dec. 4 Triangular Roof: Dec. 3 Tower: Dec. 5 Assembly including Clock Faces: Dec. 5-7 Complete Product by December 7

Final Income Statement

Conclusion Making a total of 20 6 Given away to the professors and 5 given away to the group Sell 9 The cost per Old Main is $ Sell at $250, still make a profit Questions/Comments