Door Check Jig Re-Design

Overview

Toyota’s current door check jig design poses ergonomic challenges in car manufacturing, impacting efficiency and worker safety. The project aimed to redesign this critical component to be universal, cost-effective, and ergonomically friendly while ensuring compatibility with all doors and maintaining mechanical integrity.

Objectives

• Redesign and prototype an ergonomically friendly, universal door check jig.
• Ensure compatibility with all car doors, optimize installation time, and maintain or improve mechanical integrity.

Approach

• Conducted customer needs analysis focusing on ergonomics, safety, economics, durability, and universal fit.
• Generated concepts for car body attachment, rotation motion, and car door attachment.
• Utilized a weighted decision matrix for concept selection.
• Conducted finite element analysis and cost analysis to validate design choices.
• Developed Cad models and fabricated prototypes for testing.
• Refined design iteratively based on test results and feedback.

Outcomes

• The final design achieved ergonomic friendliness, universality, and mechanical integrity.
• Reduced installation time and improved worker safety.
• Projected cost savings for the sponsor due to optimized design and materials.
• Prototypes validated design choices, ensuring suitability for automotive manufacturing processes.
• Created a mechanism that will not require any adjustments for the workers to install on the line.