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Intern PresentationJohn Cooley

Manufacturing EngineerDepartment of Mechanical Engineering, IUPUI

Summer 2006-Spring 2009

v sor: r. an e

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Outline

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z Background Information

z

Rolls-Royce Corporationz Myself

z My position and responsibilities

z Pro ect Exam le

z Achievements

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Background Information Rolls-Royce

z Founded in 1906 by Henry Royce, and

ar es o sz Produced cars first

z Developed aircraft engines for WW1

z Head uarters in Bristol En land

z US headquarters in Chantilly Virginia

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Background on Indianapolis Facility

z Acquired Allison

Indianapolis-1995z Pl nt n l nt

z AE2100, AE1107, T56

and Model 250engines

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My Background Informationz Hired as flex-intern in May 2006

zManufacturing Engineer for power gearscell

z Transmissions and structures

z T56 and AE2100 Turbo ro en ines

z Manager-Nathan Harris

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Roles of a Manufacturing Engineerz Own how the part is processed

zReduce wastez Scrap

z Rework

z MRBz Setup and cycle times

z Su ort Team Leader with da to da

problems

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Day to Day Tasksz Missing gauging or tooling

zMachine Tool Routing Verifications

z Rework tickets

z Meetings with quality, operations,

ins ection, desi n and roduction

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Tools of the Tradez Computer Aided Process Planning

z SAP

z AutoCAD

z Stack Pro ramz Gage Insite

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Some of My Projectsz Intermediate drawing z Journal in source

z Stress relievez ourna

reprocessing

z Glass bead cleant l

z

Green spec print

z Schenk horizontalbalancer

z Flange shot peen

z Pinion ProcessIm rovements

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Project Examplez Room for improvement

z4 similar pinion gears processeddifferently

z Heat treat distortion on locating surfaces

z Runout reworks and MRB

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Project Example- Previous Process

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Project Example- My Modification

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Project Achievementsz Reduce setup and cycle times

zImprove quality

z Reduce scrap, rework, and MRB

z Shorter lead time

z +2

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Summary

z Enhanced problem solving skills

z

Green beltz GD&T fundamentals

z Gear basic

z Importance of teamwork and my rolewithin a team

z Hel ed connect school work with real

world problems

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uest ons

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