AGI Westfield 35' Flight Forming

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Rempel Boschman, Michael
Liu, Wenbin
Tehlan, Bhumit
Thind, Resham
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AGI Westfield currently produces 25' flights, which is the critical component of an auger that helps farmers to transfer grain into grain bins. The flight is the helicoid section of the grain auger. AGI Westfield would like to produce 35' flights. Due to limited space in the facility, team 9 must find a solution to produce the 35' flights in the same footprint of the 25' flight production facility. The final solution features the design of new standoffs that secure the tube on the red helicoid forming table, which changes the current design from producing the helicoid then sliding the tube into the helicoid to forming the helicoid directly around the tube in one step. This reduces the total required length of the manufacturing footprint and allows AGI Westfield to produce 35' flights without expanding the areas. In order to accomplish forming the helicoid around the tube, the tube preparation station goes in tandem to the red helicoid forming machine to allow the tubes to be dropped off into the red helicoid forming machine. To ensure that the tubes can still slide into the helicoids once the helicoids are formed, the tube preparation station is longitudinally aligned with the welding station. Other features of the design include the various types of coupler inserts on the welder to accommodate various diameter flights. The new material flow map was demonstrated in detail on how parts are transported and stored during the new proposed production streams. Furthermore, the failure mode and effect analysis was completed to help clients prevent any risks that could undermine project goals. Most risks were identified from the red helicoid forming phase. Changing the layout of the facility and forming the helicoid around the tube allows the cycle time per foot to decrease from 45.88 seconds/foot to 38.84 seconds/foot. The cost estimation of parts designed for integrating the new solution was determined as $3,586.80 USD. The final design provides automation recommendations, such as a hydraulic system to push flights, which will reduce the potential strain on the workers that could cause safety hazards.
Mechanical Engineering