Melet Plastics utilizes an automated packaging machine to attach header cards to its injection molded egg holder product. However, the financial advantages of using automation have not manifested at Melet due to the high failure rate of the machine. This report was created by JAYS Mechanical Consulting to identify the machine failure modes, provide recommendations for modifications to reduce the occurrence of these failures, and provide detailed designs of these modifications. A failure modes and effects analysis (FMEA) conducted by JAYS Mechanical Consulting identified four failure modes associated with the machine. These four modes are: stapler misfire, misshapen staples, incorrect positioning of the staple, and incorrect positioning of the header card. The positioning failure modes have low variability and frequency. JAYS Mechanical recommends systematic set-up procedures to prevent positioning errors incurred during set-up, and modifications to the header card and card dispenser to prevent operator error during card reloading. The stapler misfire and misshapen staple failure modes were found to be a result of the stapler used in the machine. The main mechanisms of failure were interference of the egg holder handle on the stapling process and previous back plate modifications that prevent proper stapling. JAYS Mechanical Consulting is recommending two modification designs to deal with the stapling failure modes. The first design addresses these failure modes by applying modifications to the stapler currently used in the machine. Immobilization of the staple back plate and material removal from the bottom arm of the stapler are the key features of the first design. Immobilizing the back plate in its intended position ensures proper stapling and the material removal allows clearance for the handle preventing any interference with the stapling process. The estimated cost of this first design is $195.72, well below the allowable budget of $5000, and the design is quick to implement. The second design JAYS Mechanical Consulting recommends implements the Senior A16/L pneumatic stapler from Margreiter-Technik. The designed modifications are all based on making the stapling machine compatible with the Senior A16/L stapler. This stapler has the clearance necessary to prevent interference from the egg holder handle and […]