Elimination of Gear Lever Boot cover Mounting Colts not fitted in UV Models

This document provides information about the project of Elimination of Gear Lever Boot cover Mounting Colts not fitted in UV Models. It discusses the objectives, responsibilities, and accomplishments of the project. It also highlights the engineering knowledge and skills applied in the project.

CE 3.1 Project Information
Name of the project: Elimination of Gear Lever Boot cover Mounting Colts not
fitted in UV Models
Location of the project: Please fill
Project Duration: Please fill
Organization: Please fill
Role and Designation during the time: Mechanical Engineer
CE 3.2 Project Background
CE 3.2.1 Characteristics of the project
The gear level can be referred to as metal lever that is being attached to the respective
shift assembly within a manual transmission equipped automobile and is even utilized for
changing the gears. Within the automatic transmission equipped vehicle, a similar device is
termed as a gear selector. This type of gear level can even be utilized for changing the gear
while depressing the subsequent clutch pedal with left foot for disengaging engine from
wheels and drive train. While working with car manufacturing company, I got a distinctive
opportunity to become a part of this particular project. Since, this was my second project in
professional career, I was experienced and was able to execute the project without much
complexities. After analyzing the project details, I understood that it was needed to eliminate
the gear level bot cover for the mounting bolts that were not fitted within UV models. I took
up case location of Zahirabad, India, where I was working with my team. Thus, in this project
work, I had eliminated gear level boot cover mounting colts that are not fitted in the UV
models only after consideration of these above provided specifications in the project.

CE 3.2.2 Objectives developed for the project
The project of Elimination of Gear Lever Boot cover Mounting Colts not fitted in UV
Models was eventually carried out after considering a subsequent purpose to eradicate the
issues and complexities by involving proper software deployment. After starting this
particular project, I have to develop some of the major objectives such as:
 To efficiently eliminate the gear lever boot cover mounting colts after not fitting
within UV models.
 To resolve the issues of gear lever boot cover after considering the mounting colts.
 To complete a risk assessment and then analyze the level of risk, it eventually falls
under.
 To directly actuate the mounting colts that are not fitted in the UV models.
 To properly maintain the low production as well as maintenance expenses to design
the project work.
 To identify the problem after analyzing the defect rate of gear lever boot.
 To setup this entire experiment for the purpose of making my project effective.
 To contrast as well as investigate the several experimental outcomes with each
previous examination and then gain better solutions.
CE 3.2.3 My area of work
To work out over this project of Elimination of Gear Lever Boot cover Mounting
Colts not fitted in UV Models; I was eventually engaged as the major mechanical engineer by
the project supervisor. Since I have formerly completed several similar types of project
works, hence I was confident that I would be able to complete this task completely by myself.
The entire setup and low maintenance costs were properly considered in this scenario and
hence I did not face any distinctive problem during the completion of this task. With my
fundamental skills of complex problem-solving and the most significant concepts mechanical

Head of the
Department
Project Supervisor
Mechanical Engineer (Me)
engineering, I comprised of the core capability to fulfil my responsibilities and then to make
this project efficient and successful.
CE 3.2.4 Project Group
Figure 1: People involved in the project
CE 3.2.5 My responsibilities throughout the project
During this project of elimination of gear lever boot, I was hired as the major
mechanical engineer by my supervisor and I had some of the major responsibilities. The most
significant responsibility was to check the defect rate of gear lever cover mounting bolts.

Figure 2: Defect Rate of Gear Lever Boot Cover Mounting Colts not fitted
My other responsibilities included comparing the results for different parameters. I
checked the average rework of last 6 months was 32% and the inference of this issue
occurred was 3369 from January 2016 to December 2016. For understanding the problem, I
had to analyse accurate and erroneous gear lever boot cover mounting of bolts.
Figure 3: Accurate and Erroneous Gear Lever Boot Cover

I started the project with assembly of input panels for producing a vehicle cabin and
ended with fitment of knob gear lever to the rod gear lever. Finally, I calculated sigma
performances before and after and analysed them for result verification.
CE 3.3 Distinctive Activity
CE 3.3.1 Comprehending the Theory of Project
For the various theoretical studies or conceptions within this project, I had to consider
the major theories of gear lever boot cover and mounting colts. I undertook four steps of
removing bolts tightening the gear lever boot cover and taking boot off from floor centre
tunnel, taking boot off the gear lever cover and moving it up towards knob, removing 3 bolts
tightening gear lever cover and finally pulling gear lever out of the gear shift lever case.
Figure 4: Gear Lever Boot
I identified the interacting elements while conducting the project.

I inspected the components of this project after checking lower end of gear shift lever
to make the process smoother.
Table 1: Tightening Torque and Greasing Point
CE 3.3.2 Engineering knowledge and skills applied in the project
I had utilized my significant skill of mechanical engineering to successfully complete
this project. For the purpose of calculating the various gear lever boot cover efficiencies, I
had to consider my core knowledge of mechanical efficiency and overall efficiency.
The calculation is given below:
Mechanical Efficiency:

Overall Efficiency:
I even had utilized my major skill for the design calculations as well as mechanical
specification. I have also applied fluid mechanics and machinery and strength of materials to
complete the work.
CE 3.3.3 Accomplishment and Task Performed
To complete the project, I had obtained the significant project objectives. For the first
step, I implemented quick win. The first and the foremost step in this plan was to tap every
welding nuts that were to be initiated. The next step was to replace the socket with new one
and establish the frequency of changing socket. The results obtained from this quick win
implementation are as follows:
Figure 5: Results of Quick Win Implementation

I even used 2P analysis test for drawing statistical and practical conclusions. The
statistical conclusion was to reject the null hypothesis as P value being observed was greater
than 0.05, however, practical conclusion was that he defect rate was reduced after
undertaking corrective measures by quick win. The major causes of this project were:
Figure 6: Ishikawa Diagram of Probable Causes
I calculated sigma performances of both current and target and got the following
results.

For data collection, I utilized Component Search method and obtained the D/d ratio as
0. As per Component Search rule, if D/d ratio < 3, Assembly process is creating the problem
and if D/d ratio >3, the components in assembly is the reason for the problem. Since, I got 0,
it proved that assembly process was creating problem. For funnelling to the next level causes,
I got the root cause:

Finally, I was able to gauge that was required to be provided for arresting the degrees
of freedom at subsequent dimensions before full tightening of transmission cover.
CE 3.3.4 Identified issues and their solutions
3.3.4.1 Issues
The most significant issue, which I have faced in this project was while completing
the experimental analysis of elimination of gear lever boot cover mounting colts was that the
project got delayed by some time than I estimated. The main for this type of delay was that
the graph was properly plotted. When I checked the graph, I understood that the graph was
not perfect and proper and it was completely erroneous in respect to other parameters. The
next issue that I have faced in this project was while drawing practical conclusion with
component search method. I was unable to complete it within 1 trial.
3.3.4.2 Solutions
To solve the significant issue, I gave the idea that to plot the graph with new and
updated parameters. Finally, I was able to solve this issue effectively and got the project
saved. For the next issue, I tried once again and in the second trial was able to get proper
conclusion without any issue.
CE 3.3.5 Plan to produce creative and innovative work
My most significant or important plan in the work was to provide the most innovative
works by effectively working completely. I also subdivided the complete works properly and
individual task was eventually and perfectly executed.

CE 3.4 Project Review
CE 3.4.1 Project Overview
I have to successfully order the several materials required. The material testing was
being done properly to energize circuit. Finally, I had successfully utilized my mechanical
engineering skills to complete this project work.
CE 3.4.2 My Contribution to work
I had to propose a proper solution to elimination of gear lever cover boot, as I was
selected as the chief mechanical engineer. Furthermore, I also evaluated several project
parameters and then completed the work after eradicating the issues faced here.