A-Level Physics Project Provides Plant Savings

A-Level Physics Project Provides Plant Savings Project leads to the design of an automated process for chamfering a specific type of ball bearing manufactured at the Schaeffler plant. By designing a new automated process for chamfering bearing components, a team of A Level physics students from Wales will help save GBP 32,000 per year at an automotive component manufacturing plant in Llanelli. By automating the process of chamfering a new high volume ball bearing, a team of young engineers from Ysgol Gyfun Gwyr School in Wales will help a UK-based manufacturing plant save more than GBP 32,000 per year. The engineering project was so successful that it was recently awarded the Best Innovative Solution at this year's EESW (Engineering Education Scheme Wales) Work of Excellence exhibition. The team comprised seven sixth form A-Level physics students and their teacher David Wheeler, working in close partnership with engineers at Schaeffler UK's manufacturing plant in Bynea, Llanelli. Schaeffler UK develops and manufactures precision ball bearings, linear guidance systems and automotive components.The objective of the project was to design an automated process for chamfering a specific type of ball bearing manufactured at the Schaeffler plant.The existing process at Bynea was a manual one, with one operator dedicated to the operation. The team's brief was to create a machine that would automate this task, therefore saving Schaeffler money by making the operation faster and more efficient. Factors the students had to consider included cost, productivity, health and safety, quality, reliability and process efficiency.The final model, presented to a panel of Schaeffler staff, consisted of sloped tracks of low friction material, so that gravity could be used to move the components to a pre-determined point, where a pneumatic cylinder was then used to move the parts individually into the correct location for chamfering. To align the part, therefore ensuring that the chamfer tool locates correctly, a wheel-type mechanism was then used to rotate the component. During the rotation process, two-location dowels were raised by a spring in order to lock the part in the correct position, before chamfering the hole perfectly. The solution was not only very efficient - reducing the time taken for chamfering by 20% - but was also projected to save the plant more than GBP 32,000 per year.Schaeffler UK was so impressed that a full-scale construction of the model is currently being manufactured at the Bynea plant. The students chose the solution because it had low running costs (based on a low power input) and a 10 to 20% reduction in operation time.Payback time for the machine was expected to be just two months. During their presentation to Schaeffler staff, the students also suggested further ways of improving the automated process. These included using two rollers instead of a V-block; using a ripple plate-sliding surface that would reduce friction; and incorporating a single circular finger location.These further improvements were expected to reduce processing times by more than 40%, increase productivity (parts per hour) by around 70%, and to cut payback from two months to one month. Jeff Guest, Maintenance/Development Manager at Schaeffler UK was involved in supporting the students throughout the project.He says: 'We had to point the students in the right direction on a couple of occasions and ensure that they didn't over-engineer the solution'. 'But we were particularly pleased to see how the students tackled the engineering problems they were faced with'.'Their enthusiasm, interest and overall willingness to learn new skills was a delight to see and should serve them all well in their future careers'. David Wheeler comments: 'I am extremely proud of the students'.'They have worked diligently over the last few months, giving up their spare time and lunch times in order to work on this project'.'This was their first attempt to compete at a national level'.'Even though there were more than 100 experienced teams competing, they won the most lucrative award'. 'I would like to thank Schaeffler UK for its time, expertise and dedication over the last few months in helping the pupils achieve their goal'.'Not only did the students win the award, but they also gained new skills and it has opened up engineering as a career prospect'.