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EPOCs Kangaroo paw sheet metal FA inspection
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Description

This is the first time we have received these parts from EPOCS, so we will want to FAI them

(done, passed) PP-FP0171 bed plate revB
(done, failed on case mounting inserts callout #61) PP-MP0258 bottom plate revA (grounds to reject)
(done, failed on dims 17, 51, 70) PP-FP0167 case revB (probably want to concede if there are no fitment issues) (drawing has been updated for silk screen issue)
(done, failed on powdercoat thickness) PP-FP0170 left side revA (probably want to concede if there are no fitment issues)
(done, passed) PP-FP0169 right side revIR
(done, passed) PP-FP0168 top plate rev IR

PO32225

Event Timeline

kent created this task.Aug 15 2019, 8:19 AM
kent triaged this task as Normal priority.
kent created this object with edit policy "Restricted Project (Project)".

@kent do you have the 167 and 168? I do not see where they were received.

kent added a comment.Aug 15 2019, 9:53 AM

@sherylb No I don't have them. I guess they are yet-to-be-delivered.

kent edited subscribers, added: AOJAS; removed: jlively.Aug 15 2019, 9:54 AM

Ok I have a note out to Andrew at Epocs.

kent moved this task from Restricted Project Column to Restricted Project Column on the Restricted Project board.Aug 23 2019, 9:04 AM

kent moved this task from Restricted Project Column to Restricted Project Column on the Restricted Project board.Aug 23 2019, 9:07 AM

kent moved this task from Restricted Project Column to Restricted Project Column on the Restricted Project board.Aug 23 2019, 9:10 AM
kent reassigned this task from kent to AOJAS.

@AOJAS can you take and record measurments of the dimensions listed on the inspection forms?

I have some pressing production buffer and supplier issues I'm working on this week, but if @sherylb will sign off on it, I could have Will do FA's on some of the less complex parts over the week, such as PP-FP0168, PP-FP0169, and PP-FP0171.

@AOJAS what supplier issues are you having? These need to be communicated to Kent and purchasing as well. Will can certainly do FAI's on parts once you give him the inspection forms and walk through some with him.

kent added a subscriber: stanback.Aug 29 2019, 7:36 AM
kent added a subscriber: tomc.Aug 29 2019, 8:07 AM
kent raised the priority of this task from Normal to High.Sep 3 2019, 2:22 PM
kent added a comment.EditedSep 3 2019, 3:23 PM

T9938 related

kent added a comment.Sep 4 2019, 1:38 PM

Here are the reports for the bed plate, right side, and top plate.

kent updated the task description. (Show Details)Sep 4 2019, 1:40 PM

Kent please let us know where we are on these as we need to order materials this week for these printers.

kent added a comment.Sep 4 2019, 3:13 PM

We have 3 reports generated out of the 6 parts. I am under the impression that the remainder of these are in-progress by Justin since this ticket is assigned to him. If I need to work on these inspections, please assign this ticket to me.

It appears there are issues with the PP-FP0170 Left Side. Will is still working on the the FA for it. I thought Kent was going to be working on the PP-FP0167 Electronics Case and PP-MP0258 Bottom Plate.

Kent please confirm what you have done and what needs to be done, this is a hot item today. Thank you

kent added a comment.Sep 5 2019, 9:12 AM

Probably in the future, we should split these tickets up into individual parts so they can be independently assigned. That's how I did it originally, but someone (I don't remember who) asked to put them all in one ticket.

I can definitely do the inspection on the PP-FP0167 and PP-MP0258. I did already update the annotated drawing and inspection form for these parts, which is somwhat time consuming, so @AOJAS you're not wrong to think I was working on them.

kent added a comment.Sep 5 2019, 9:13 AM

@sherylb calling you now...

kent added a comment.Sep 5 2019, 9:31 AM

@sherylb to summarize:

Three out of the 6 reports are completed.

The case, bottom plate, and left side are in progress by @AOJAS and @stanback who are currently on the recording measurements step of the FAI.

In the mean time, I will contact EPOCs with details about the silk screen issues and make sure they have the updated drawing.

Kent thank you for calling and talking through this. @AOJAS @stanback will be working on the remaining three items. I have told them you will come up today to help process these.

The drawing in "electronics-case-mini-white_PP-FP0167_revIR.odg" appears to only have one page, maybe the rest of the pages didn't get saved or exported to the final document?

kent added a comment.Sep 5 2019, 10:47 AM

I think I made one for the case that's revB.

Yeah I did.

Use this one: https://code.alephobjects.com/F3910964

kent added a comment.Sep 5 2019, 10:48 AM

also in libreoffice draw, you have to hit "PgDn" (pagedown) to see the other pages. Or there is a page navigator you can pull up.

Do I need to use to RevIR FA Report template or is there a RevB version?

PP-FP0170 Kangaroo Paw, MINI, Left Side.
FAI Complete and added to proper folders
I had a few problems with the powder coat being to thick. measuring at 8 mils/ 21mm. should be .05-.12 mm's!
this was causing all other dimensions to run high.

Thank you all for jumping on this, I do appreciate it. Will I spoke to Kent and he stated that he believes we are ok on the specs on these going forward. He will be stopping by Epocs with some metals to show them what you have all measured.

AOJAS added a comment.EditedSep 6 2019, 7:39 AM

@kent Measurement for the PP-MP0258 Bottom Plate (since you don't have a granite surface at home)
Some of these were nonconforming. Below tolerance edges were all on the outside end of the shelf, not at the base of the shelf(adjacent to the bent).
Measurements were taken on all 4 corners of the shelf, a range is being provided for each shelf on 3 different units.
It appears that they need to work on making the two shelves more parallel, and pay closer attention to the height of the Motor Shelf(the one with the large circular cutout), as 2 of the 3 units I grabbed randomly failed the specification tolerance for shelf height.

Unit 1
Idler Shelf: 50.82 to 51.32
Motor Shelf 50.38 to 51.15 (Fail)

Unit 2
Idler Shelf: 51.45 to 51.67
Motor Shelf: 51.24 to 51.32

Unit 3
Idler Shelf: 50.87 to 51.38
Motor Shelf: 50.67 to 51.19 (Fail)

Checked two additional PP-MP0258 Bottom Plate

Unit 4
Idler Shelf: 51.53 to 51.96 (Fail)
Motor Shelf: 51.24 to 51.42

Unit 5
Idler Shelf: 51.06 to 51.45
Motor Shelf: 50.51 to 51.24 (Fail)

I checked the 250mm perimeter spec on all 5 units to investigate if there was an interaction between that and the out of spec shelves(this has been common with Weiser Bottom Plates). I didn't measure any perimeter values higher than 250.25mm or lower than 250.00mm.

Multiple suppliers have brought up that the design of this part creates manufacturability issues. If we want this part to be a production deliverable and not be a cause of production issues(as it has been on Mini 2), we may need to revisit this subject and act on design feedback from Epocs.

Thank you Justin. @kent any information you can add on this?

kent added a comment.Sep 6 2019, 9:25 AM

Yes I'm finishing up the FAI for the bottom plate now.

kent added a comment.Sep 6 2019, 10:34 AM

The result on the bottom plate is a fail, since the inserts that the bottom of the electronics case are missing.

kent moved this task from Restricted Project Column to Restricted Project Column on the Restricted Project board.Sep 6 2019, 10:34 AM
AOJAS added a comment.EditedSep 6 2019, 10:34 AM

PP-FP0167 Electronics Case First Article
Also attached: Picture of silkscreen pitting

kent added a comment.Sep 6 2019, 11:16 AM

Here are the joined reports for the remaining three parts.

kent updated the task description. (Show Details)Sep 6 2019, 11:21 AM
kent moved this task from Restricted Project Column to Restricted Project Column on the Restricted Project board.
kent claimed this task.Sep 6 2019, 11:44 AM
kent added a comment.Sep 6 2019, 2:17 PM

I created a QCI for this: QCI/2019/01021

kent closed this task as Resolved.Sep 9 2019, 8:17 AM

The FA is complete and we have communicated the issues back to the vendor.