- User Since
- Mar 5 2018, 7:19 AM (68 w, 2 d)
I'm thinking then that Weiser either didn't really look at these specs or that they didn't communicate them to their powder coat subcontractor. If that's the case then @jperry can try to have them fix this without cost to AO. The only additional cost they may want to(reasonably) charge us for is the additional 8mm diameter masking. I can make an NCMR for these and just follow the regular process for sending stuff back for rework based on this information.
Mon, Jun 24
NCMR's for this part should be uploaded to this ticket so that there are reference pictures for what has been failed and sent back to the supplier.
Has the data that Kent created been communicated to E3D?
Wed, Jun 19
Issues corrected on the last inspection from PO# 29472:
Mon, Jun 10
Thu, Jun 6
The current plan with MER is to release 20 units to have built out and tested for issues.
Notice to accumulate a full set of parts in QC? I don't usually let those parts accumulate, so to get a full set together for a review we'd need to pull them temporarily from backstock, or grab a completed alpha/beta build.
Tue, Jun 4
Fri, May 31
Which hole was drilled at an angle? The large one for the motor or the hole between the two smooth rod holes?
Thu, May 30
Wed, May 29
The white paint dots are on the PP-FP0135's.
A recent shipment of the PP-FP0135's had a white paint mark consistently in the same spot( a non-visible area once assembled). It looks like the supplier is adding this mark to differentiate the PP-FP0135 from the PP-FP0162.
Oliver and I have talked to PMM about this. They have suggested that the holes should be centered on the flange rather than offset towards the curved side, because their machines have trouble putting the inserts in so close to a curved edge. I told them to submit a redesign to Josh Perry to be approved by R&D to improve the manufacturability of this part.
Apr 24 2019
Here is an image showing the correct position in regards to our manufacturing process.
In terms of a drawing change, I believe the PC-CN0119 Housing/EL-MS0355 Housing needs to be moved above the EL-MS 0490 Housing/EL-MS0509 Housing.
@west Can you confirm this?
I'll make sure @kim gets feedback for Igus.
Apr 18 2019
Just as a side note, I know that in terms of prioritization, revamping every part's specification sheet in this manner isn't going to be possible to do all at once due to labor resource constraints. That being said, I would suggest that we focus these specification callouts and clarifications on parts that have consistently been a source of AO production bottlenecks across multiple suppliers. This more limited list of parts would include the bed mount plates(Taz/Mini), Mini bottom plate, electronics case(Mini), and electronics chassis/cover(Taz). This would help resolve the most serious production issues that suppliers have communicated to us.
Surface Condition Callouts, ABCD:
My explanation to Epocs Mfg Inc today regarding the surface condition workmanship standards explained that in general, a back facing area is a C face, a downward surface facing(non visible) or interior facing(non visible) surface is a D face, front and top facing areas are A face, and side facing areas are B. On drawings we submit to them, we need to make sure we utilize all of these in this manner so that our workmanship document supports our specification sheets.
Apr 8 2019
Dimension Specification: Pass
Cosmetics: Pass, Very good quality. some units had shipping damage, example show on Picture 1. Picture 2 is provided to show the general appearance of the unit.
Cosmetic Notes: The black silkscreen is appears to be thin, causing it to have a more textured appearance than our current products.
Apr 5 2019
Dimension Specification: Pass
Cosmetics: Pass, but needs improving
Cosmetic notes: Silkscreen is appears to be thin, causing it to have a more textured appearance than our cu Some defects apparent on two parts. One unit had powder coat discontinuity(visible on the right edge in the picture)(Picture 1)
Another unit had discontinuity in the texture of the black silkscreened area, I would suggest increasing the thickness of the silkscreen as a potential solution, as that will reduce the visibility of the powder coat surfaces's variation in texture(Picture 3)
Picture 2 is just intended to show the overall appearance of the unit.
Dimension Specification: Pass
Cosmetics: Pass, no defects apparent, powder coat appears to match our other suppliers.
@kim : We are good to proceed with the supplier on this part.
Mar 18 2019
Mar 15 2019
PP-FP0135, Mirrored Aero Idler Lever
PP-FP0162, Standard Aero Idler Lever
Our supplier for this part, E3D, appears to have accidentally mixed some PP-FP0162's into bags of PP-FP0135's. Inspecting one bag of 500 PP-FP0135's, we found one PP-FP0162 mixed in.
It has been reported by MER that another bag also had this issue.
Due to this issue, and also the parts being nearly identical and easily mixed up on the assembly line, assemblers will need to know how to differentiate between the two.
Refer to the photos to see the difference between the pin that holds the bearing in place. The end of the pin is being referred to as a "Nub" in the photos.
Feb 25 2019
Jan 29 2019
First Article report. Dimension issues are noted in the Notes section on the first page.
Jan 25 2019
Something I hadn't yet mentioned, there are artifacts from RevF on page two, the dimensions I've numbered as 4 and 5 on this spec are leftover from the previous flange folding method, and no longer post-PMM manufacturability revision. To avoid confusion, it should be removed.
Jan 24 2019
Once I have the FA report done, we should have a complete list of features on the specification sheet requiring revision. Should be done by Tuesday at the latest. The issues relate to changes made by the supplier and masking callouts primarily, but there may be more, as I have only finalized 3 pages (out of 7 pages).
Nov 29 2018
Nov 16 2018
I pretty much just need to run through the BOM with someone who can explain and pull up a spec for any part I am not familiar with.
Nov 13 2018
I do think the extra time and effort constitutes post-processing on our part(for Production). At some stage, each hole has to be dealt with either by the supplier(inserting reuseable silicon plugs like Rapid or PMM), or on our part(extra time and effort with clogged threads).
I suggest starting the fasteners by hand and doing the first few turns by hand. Using the driver alone is more likely to result in putting the fastener in at an angle, which causes cross-threading. Also, viewing from multiple angles as the first few threads are cleared allows you to make sure it is going in completely straight. This process takes much longer, but I'm not finding it to be very technically challenging. Eventually wrist fatigue will likely happen to whoever is doing this though, because it does take a bit more hand strength to put the fasteners in. In my hand fastening tests, I haven't had any get stuck.
Nov 7 2018
Some feedback on the chamfer dimension:
I've been rejecting chamfers over 6.64mm, so I think 6.4mm chamfer size limit in the drawing would work well. Specifying it well under 6.64(the highest diameter we know works with the Reprap nozzles) will make inspection much quicker and keep fallout to a minimum. Due to the size variance in Reprap nozzles, 6.4mm as a chamfer diameter limit will hopefully eliminate all nozzle leaks going forward.
Oct 25 2018
I also just received some new Quattro C&C'd parts that will need FA Reports:
PP-MP0228, Top Rod Mount
PP-MP0229, Back Plate
PP-MP230, Actuator Connector
PP-MP0231, Bottom Plate
PP-MP232, Motor Mount_Ambidextrous
There was a sheet metal part that I wasn't aware of that needs to be added to the done list:
PP-FP0156(Precision Metal Mfg.), Z Upper Top Plate.
Oct 22 2018
I haven't yet received first article units for the Bed Plates and Chassis. The first articles for the other sheet metal parts are done.
Aug 24 2018
Concerning red tag E3D hotends from production, we have had a over a dozen red tagged Universal Aeros (AS-HE0025/26) red tagged for stuck filament. There appears to be an dimensional issue with some of the hot ends where the Heatsink entrance to the Heatbreak has a smaller diameter than the heatbreak. This results in the filament becoming stuck when Pre-Sub is trying to pull it out. Letting the hot end heat up over time(with no fan) allows the obstruction to be pushed through. If left to get hot long enough(10 minutes or more at 230), the filament can be pulled out sometimes.
Jun 12 2018
To date, QC hasn't had any involvement with materials relating to the shipping process or the printer kits. As far as I know, inventory manages damaged or non-conforming shipping material. I know that some MER personnel also do some NCMR's for some Preferred Packaging materials, but I do not know what the trigger is for their involvement. The post-calibration shipping people do QA on the boxes and kits. They red tag any non-conforming materials for Inventory. Once the supplier gets pictures of the issue, they should be able to get back to us with answers regarding how long it will take to resolve the discrepancy in color. If any retailer displays these boxes(as opposed to keeping them in backstock with only a floor model up front), I would advise them in organizing boxes in a way so as to prevent customers easily seeing different boxes side by side.
May 3 2018
Our current corrective action in regard to the Weiser PP-FP0055 is to have units be straightened out before going on the line. Due to the differences in dimensional averages from Rapid and Weiser, it is difficult to ask for corrective action from the suppliers, but I will try to apply some pressure on them by providing them additional feedback on the perimeter values of their lefts, rights, bottoms, and tops, when the opportunity arises. I would like to see more of their units fall closer to the stated dimension, and less towards the extremes of the tolerance. The lead time on any positive outcome from this feedback could be months, or it could be indefinite(they may not take any action). Currently I haven't found any outside of spec for flatness on the Left side, but it may help alleviate production issues to have them straightened. I have trained Chris, Shane, and Luke on how to do this prior to stocking them out. This is not a fix-all unfortunately.