UNIVERSIDAD TECNOLÓGICA EL RETOÑO

ACADEMIC DIVISION: TECHNOLOGICAL CAREERS

“IMPLEMENTATION OF AN AUTOMATIC TRANSMISSION

BOX”

INTERNSHIP REPORT

TO OBTAIN THE TITLE OF

MECHATRONICS ENGINEER

PRESENTS:
CINTHIA VERÓNICA DELGADO CALZADA
JORGE ADRIÁN MARTÍNEZ ZAMARRIPA
GAEL JAIR SOTO MUÑOZ
LEONARDO MANUEL COBOS BECERRA
JORGE ABRAHAM PADILLA CONTRERAS
JOSUÉ PÉREZ RAMOS

BUSINESS ADVISOR ACADEMIC ADVISOR

ING. MÓNICA CECILIA ING. ERICK FABIÁN

PADILLA ACOSTA VÁZQUEZ LÓPEZ

EL RETOÑO, AGS., AUGUST 2023

INDEX
EXECUTIVE SUMMARY 1
CHAPTER I. BACKGROUND OF THE COMPANY AND DIAGNOSIS 3
1.1. Background of the company 3
1.1.1. Company description 3
1.1.1.1. Company name 3
1.1.1.2. Company logo 3
1.1.1.3. Company location 3
1.1.1.4. Turn of the company 4
1.1.1.5. Company size 4
1.1.1.6.Principal products or services 4
1.1.1.7. Principal customers 5
1.1.2. Company History 5
1.1.3. Company philosophy 5
1.1.4. Company presence 6
1.2. Company impact 6
1.2.1. Impact of the environment on the company. 6
1.2.2. Impact of the company on the environment. 6
1.3. Diagnosis. 6
1.3.1. Description of the situation. 6
1.3.2. Diagnostic results 8
1.4. Project objectives 8
1.4.1. General Objective 8
1.4.2. Specific objectives 9
1.5. Description of the problem 9
1.6. Justification of the problem 9
CHAPTER II. THEORETICAL FRAMEWORK 10
2.1 State of art 10
2.2 Theoretical framework 11
2.3 Benchmarking 17
CHAPTER III. DEVELOPMENT: METHODOLOGY, TECHNICS AND PROCEDURES 19
3.1 Project planning 19
3.3.1. Flowchart 19
3.1.2. Gantt Chart 20
3.1.3. Methodology to be used 21
3.2. Implementation 25
3.2.1. Description of the project 25
3.2.2. Description of the process 26
3.2.2.1. Main Control Program 27
3.2.2.2. Automatic Mode Subroutine 28
 3.2.2.3. Manual Mode Subroutine 28
3.2.2.4. ABS Brake System Subroutine 29
3.2.2.5. Visualization 29
3.2.2.6. Global Variables List 30
3.2.3. Graphic Tools 30
3.2.3.1. Grafcets 30
3.2.3.2. Visualization for the final user / Inputs and Outputs 33
3.2.3.3. Automate 34
3.3. Control 34
3.3.1. Performance indicators 34
CHAPTER IV. ANALYSIS OF RESULTS 36
4.1. Results Obtained 36
4.2. Analysis of results 36
CHAPTER V. CONCLUSIONS AND RECOMMENDATIONS 42
5.1. Achieved goals 42
5.1.1. General objective 42
5.1.2. Specific objectives 42
5.2. Conclusions 43
5.2.1. Contributions 43
5.2.2. limitations 44
5.3. Recommendations 44
BIBLIOGRAPHY 46
ANNEXES 47
INDEX OF ILLUSTRATIONS

Figura 1. Company logo 3

Figure 2. Google Maps location 4
Figure 3. Flowchart 19
Figure 4. Gantt Chart 21
Figure 5. Representative image of a acrylic gearbox 25
Figure 6. First level grafcet 31
Figure 7. Second level grafcet 31
Figure 8. Third level grafcet 32
Figure 9. GRAFCET GEMMA in Codesys. 32
Figure 10. Board for the operator 33
Figure 11. Table of Inputs and outputs in Codesys 34
Figura 12. Performance indicators 35
Figura 13. Performance results 36
Figure 14. Design of gearbox in solid works 40
Figure 15. Physical result of gearbox 41
Annexe 1. Manufacturing software 47
Annexe 2. Manufacturing process 47
ABSTRACT
This document provides an overview of a project focused on developing a
hybrid gearbox automation system, featuring both automated and manual mode
capabilities. The primary objective of this project is to create an innovative gearbox
that seamlessly integrates different subjects related with mechatronics such as
production processes, programming in Codesys for PLC, CAD, CAM, while allowing
users the flexibility to manually control gear shifts and change velocities. The entire
design process, from conception to manufacturing, is meticulously executed using
CAD (Computer-Aided Design) and CAM (Computer-Aided Manufacturing)
techniques, resulting in a functional prototype constructed from acrylic material. The
aim of this project is to revolutionize conventional gearbox systems, bringing
significant advancements in efficiency, performance, and sustainability. Gearbox
promises to deliver a transformative impact on various industrial sectors. The hybrid
gearbox automation system harnesses data processing to achieve optimum gear
selection and smooth gear transitions in automated mode. This automated
functionality ensures optimal power transmission, reduced energy consumption, and
improved overall efficiency, making it ideal for a wide range of industrial applications.
The standout feature of this project lies in the gearbox's manual mode capability,
granting users the freedom to switch from automated to manual control. In manual
mode, users can intuitively change velocities and gears to suit specific requirements,
offering a hands-on driving experience that empowers operators to tailor gearbox
performance to their preferences and real time conditions. The hybrid gearbox project
stands as a pioneering initiative to revolutionize industrial processes.
EXECUTIVE SUMMARY
The internships took place at the Sensata Aguascalientes plant, located in the
city of Aguascalientes, Mexico. This plant is renowned for manufacturing sensors and
control solutions for a wide range of industries, including automotive, aerospace,
industrial, and more. They have a global presence and offer products and services
worldwide. During the internship period at the plant, I had the opportunity to work
alongside a highly skilled and experienced team, immersed in a dynamic and
continuous improvement-oriented environment. The plant provided a conducive
atmosphere for internship projects, offering a solid platform to implement
improvements and contribute to the company's success.

The best thing about an automatic transmission is that it shifts gears smoothly
without needing any manual help. On the other hand, a manual transmission needs
some learning but can give a smooth ride and better fuel efficiency. As autofichas
mentions us “It describes the advantages and characteristics of various transmission
types like automatic, manual, and CVT. The main advantage of an automatic
transmission is seamless gear shifting without manual intervention. In contrast, a
manual transmission needs time to learn but offers benefits like a smooth ride and
improved fuel efficiency. Which is like a manual transmission but uses paddle shifters
to eliminate gear shift worries. Overall, it provides insights into different transmission
options, including the automatic transmission box.” The main advantage of an
automatic transmission is its seamless gear shifting without requiring manual
intervention. On the other hand, a manual transmission may take some time to learn
but offers benefits such as a smooth ride and improved fuel efficiency. The text also
highlights the CVT, which functions similarly to a manual transmission but eliminates
gear shift concerns by using paddle shifters. Overall, the text offers valuable insights
into various transmission options, including the automatic transmission box.

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 The process of making an acrylic-based automatic gearbox involves designing,
planning, material sourcing, and manufacturing. It starts with determining design
requirements and creating a detailed design using CAD software, including necessary
components like gears, shafts, bearings, and housings. The manufacturing process is
planned, considering tools, equipment, timeline, and resource allocation. Acrylic
sheets and metal components are sourced, ensuring quality. Acrylic sheets are cut
and shaped with laser cutters or CNC routers, and metal components are machined.
Parts are then assembled with proper lubrication and alignment. The gearbox is
programmed using a microcontroller or PLC to automate gear changes based on
vehicle parameters through reading input signals from sensors and sending output
signals to actuate the components accordingly.

The project was successfully completed with accurate implementation of all

activities. An initial review was conducted, which, despite a slight delay due to
information shortage, was promptly resolved. Designs were created using
SolidWorks, completing this phase with precision and without issues. The parts were
seamlessly fabricated using a laser cutter, meeting required specifications precisely.
Assembly of the fabricated parts was flawless, and the entire process progressed
without any problems. The project's success is attributed to careful planning, precise
execution, skillful resource management, attention to detail, and prompt resolution of
challenges, resulting in a final product that met all criteria and requirements.

The project's main objective was to create an automatic transmission box to

enhance process efficiency and productivity, successfully achieved by executing each
step as planned. However, limited experience with such projects impacted the
generation of gear relationships, leading to design challenges. To improve future
projects, seeking detailed explanations from the instructor regarding gear
relationships is recommended. Despite the challenges faced, the project provided
valuable learning experiences, emphasizing clear communication and understanding
of key concepts for successful execution. These lessons will help us refine our skills
and confidently tackle more complex projects in the future.

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CHAPTER I. BACKGROUND OF THE COMPANY AND
DIAGNOSIS

1.1. Background of the company

1.1.1. Company description
1.1.1.1. Company name

SENSATA TECHNOLOGIES DE MEXICO S DE R.L. DE C.V.

1.1.1.2. Company logo

Figura 1. Company logo

1.1.1.3. Company location

Sensata Technologies de México S de RL de CV. Av. Aguascalientes Sur #
401, Ex Ejido Salto de Ojocaliente. CP. 20290 Aguascalientes, Ags. México.

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 Figure 2. Google Maps location

1.1.1.4. Turn of the company

Manufacture of sensors and controls for automotive use.

1.1.1.5. Company size

It is a large company with 4,600 employees in the state.

1.1.1.6.Principal products or services

Pressure Sensors, Contactors & Fuses, Inverters & Chargers, Temperature,

Relays, Position Sensors & Encoders, Switches, Blind Spot Monitoring Systems,
Force Sensors, Circuit Breakers, Battery Management Systems, Liquid Level & Flow,
Motor Protectors, Speed, Motors & Actuators, Operator Controls, Insulation
Monitoring Devices, Current & Voltage Sensing, Tire Management Solutions / TPMS,
Electric Vehicle Communication Controllers.

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1.1.1.7. Principal customers

“General Motors, Caterpillar, Emerson, Nissan, Ford, Continental Automotive,

LandRover, Airbus, industria automotriz y enseres domésticos”.

1.1.2. Company History

"This company was created when many of the devices that work with the
devices it manufactures did not yet exist. Sensata, born in 1916 as a supplier to the
jewelry industry, is now one of the world's leading manufacturers of sensors and
electrical protection. It entered the electric motor protection business in 1931. Later, in
1959, it was bought by Texas Instruments and expanded its markets in quantity and
variety of the devices it designed and built.
Attracted by the geographic location and the supply of highly qualified
professionals, the company arrived in Aguascalientes in 1984. Converted into
Sensata in 2006, it is currently one of the most relevant sources of employment in the
state. Its plant in the capital city, where it manufactures 35 percent of the world's
production, is the corporation's most important.
To manufacture many of the components it exports worldwide, it implements
some highly automated processes; but it also lives up to its name -those things
endowed with meaning- and employs high-precision manual labor (similar to filigree,
some say).
In recent years, the transnational has grown at an accelerated pace and
acquired other companies and products. In this expansion, the Aguascalientes plant
has been proposed to be the most efficient in order to attract more production and
sources of employment for the state".

1.1.3. Company philosophy

"Its mission is: To be the world's leading supplier of sensors and controls.

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 Its vision is: To be the world leader and innovator in mission-critical sensors
and power protection; meeting the world's growing needs for safety, energy efficiency
and a clean environment; being an excellent partner, employer and neighbor.
Its values are: Integrity, Innovation and Commitment."

1.1.4. Company presence

Sensata Technologies is one of the most important companies worldwide in the

sensor market, standing out in the automotive market by providing several of the
sensors that are necessary for the development of automobiles. It is a company that
competes with globally recognized companies such as Microchip, Samsung
Electronics and Qualcomm.

1.2. Company impact

1.2.1. Impact of the environment on the company.

Since the facilities are located in a state that is in the heart of Mexico, it is easy
for the company to obtain the necessary resources to create its products, in addition
to the fact that it is an easily accessible area for workers and has several routes for
the delivery and reception of parts.

1.2.2. Impact of the company on the environment.

The company's presence in the state has been a source of several new jobs
and opportunities for Aguascalientes. The facilities are located in an area where local
flora and fauna are found, so there may be impacts in that regard.

1.3. Diagnosis.
1.3.1. Description of the situation.

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 The company has come to a profound realization regarding the imperative
need for improving its production process. Among the key areas that demand
immediate attention is the implementation of an automatic transmission box. The
current convergence and stacking procedures employed for the company's four
primary products have proven to be excessively time-consuming, resulting in a
multitude of inefficiencies that have hindered the organization's performance.

In order to confront this pressing challenge head-on, the company has devised
a comprehensive plan to introduce an innovative automated system, specifically
tailored for the automatic transmission box. The core objective of this cutting-edge
technology is to revolutionize the convergence and stacking procedures, thereby
bringing about a substantial reduction in the time required to complete these critical
tasks.

The forthcoming automated transmission box system holds the potential to

revolutionize the company's production process by streamlining operations and
bolstering overall efficiency significantly. The intricate workflow that encompasses
product categorization, convergence, and stacking will be completely automated,
thereby eradicating the need for manual intervention and significantly diminishing the
likelihood of human errors.

Foremost among the anticipated benefits of implementing this automated

solution is the optimization of the production process, which is set to yield
unparalleled levels of productivity and proficiency. By harnessing the power of
advanced technology and cutting-edge automation, the company aspires to attain a
highly streamlined and frictionless production workflow, bolstering its competitive
edge in the market.

The implications of integrating the automatic transmission box into the

production process extend beyond mere operational enhancements. This
transformation has the potential to propel the company's production capabilities to

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new heights, granting it the ability to accelerate production rates while concurrently
mitigating expenses. As a result, the company is poised to achieve an unprecedented
level of cost-efficiency, directly translating into improved profit margins and long-term
financial sustainability.

1.3.2. Diagnostic results

Based on the provided information, the diagnosis suggests that the company's
production process can be improved through the implementation of an automatic
transmission box. The current convergence and stacking procedures for the
company's primary products are identified as time-consuming, resulting in
inefficiencies.
By introducing an automated system for the automatic transmission box, the
company aims to address this challenge effectively. This technology is expected to
streamline the convergence and stacking procedures, significantly reducing the time
required for these tasks.
The implementation of the automatic transmission box will optimize the
production process and enhance overall efficiency. It will automate the categorization,
convergence, and stacking of products, eliminating the need for manual intervention
and minimizing the potential for errors.
This automation holds the potential to accelerate production, increase
productivity, and ultimately lower costs for the company. By leveraging advanced
technology and automation, the company aims to achieve a more streamlined and
efficient production workflow.
1.4. Project objectives

1.4.1. General Objective

Design and build an automatic transmission box that enhances the efficiency
and productivity of the production process

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1.4.2. Specific objectives
Analyze areas of opportunity in a production line to implement improvements
with a gearbox
Make the pertinent improvements by placing the gearbox in the line
Monitor line operation with improvements
Do preventive maintenance
1.5. Description of the problem
The problem faced is inefficiency in the production process of a company
where four main products converge at the end to be categorized and stacked for
storage. This process lacks efficiency and requires improvement. In order to address
this, the company aims to implement a gearbox in the line to improve the process.
The implication of the current inefficiency is a decrease in productivity, an increase in
time consumption and the potential for errors or damage during the stacking process.
By implementing these improvements, the company can streamline the production
process, optimize resource utilization and improve overall productivity and accuracy.
1.6. Justification of the problem
The current inefficiency in the company's production process, specifically in the
transport of the main products to the processes points, has significant implications on
productivity, consumption time and the potential for errors or damage. Implementing a
gearbox can increase production efficiency, improve accuracy and quality of products:
Automatic transmissions can be used in precision equipment, such as cutting
machines or assembly equipment, to achieve precise speed and torque changes. .
This can contribute to improving the quality of the final products by avoiding errors
caused by sudden changes in speed. Reduce equipment wear and maintenance:
Automatic transmissions can help reduce equipment wear and lower maintenance
costs. By providing smooth gear changes and avoiding excessive slippage and
vibration, automatic transmissions can help extend component life and reduce the
need for frequent repairs.

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CHAPTER II. THEORETICAL FRAMEWORK
2.1 State of art
"Automatic transmissions surpass manual transmissions in various aspects.
They provide a more comfortable and relaxed driving experience by eliminating the
need for manual gear shifting. Additionally, they optimize fuel efficiency by
automatically selecting the most appropriate gear for each situation, and offer smooth
and precise gear changes that enhance the driving experience. Moreover, due to
requiring less driver intervention, automatic transmissions can exhibit greater
durability and lower long-term wear. Overall, automatic transmissions have become
the preferred choice for those who value ease of use and optimal performance in their
vehicles."
Automatic transmissions, also known as auto transmissions, have
revolutionized the way we drive. With the advancement of technology, these
transmissions have become increasingly popular in modern vehicles.
One of the key advantages of automatic transmissions is the convenience they
offer. Unlike manual transmissions, which require the driver to manually engage the
clutch and shift gears, automatic transmissions handle all gear changes automatically.
This feature makes driving in heavy traffic or on long journeys much more comfortable
and less physically demanding. It allows the driver to focus more on the road and the
surrounding environment, promoting safer driving practices.
In terms of fuel efficiency, automatic transmissions have made significant
strides. Many modern automatic transmissions are designed to optimize gear
selection based on driving conditions and engine demand, resulting in improved fuel
economy. By constantly monitoring various parameters, such as vehicle speed,
engine load, and throttle input, automatic transmissions can effortlessly select the
most appropriate gear ratio, maximizing efficiency and minimizing wasted energy.
Another advantage of automatic transmissions is the smoothness of gear
shifts. With advanced hydraulic or electronic control systems, gear changes occur
seamlessly and almost imperceptibly. This not only enhances the overall driving

10
experience but also contributes to passenger comfort and reduces wear and tear on
the drivetrain.
Furthermore, automatic transmissions often require less maintenance
compared to manual transmissions. This is because the internal components, such as
the clutch and synchros found in manual transmissions, are absent in automatic ones.
As a result, there is less risk of these components wearing out or needing adjustment
or replacement, leading to potential cost savings for the vehicle owner.
It is worth noting that the continuous development of automatic transmissions
has also brought forth innovations such as dual-clutch transmissions and
continuously variable transmissions (CVT). These variants offer additional benefits,
such as faster gear shifts and seamless power delivery, respectively.
In summary, automatic transmissions provide a host of advantages over
manual transmissions. From the convenience and ease of driving to improved fuel
efficiency and reduced maintenance requirements, it's no wonder they have become
the preferred choice for many drivers. As technology continues to advance, we can
expect even more enhancements in automatic transmission design, further solidifying
their superiority in the automotive industry.
According to Castillo "SCARA and articulating arm robots might be the most
recognizable form of robot on the market today, but look to gantry robots for getting
the big jobs done in the least amount of space.

2.2 Theoretical framework

“The relationship between the given text and the project of an automatic
transmission box is that it describes the advantages and characteristics of different
types of transmissions, namely automatic, manual, and CVT. The text highlights the
key positive aspect of an automatic transmission, which is the seamless gear shifting
without the need for manual intervention. It contrasts this with a manual transmission,
which requires some time to learn but can offer benefits such as a smooth ride and
improved fuel efficiency. Additionally, the text mentions the CVT, which provides a
driving experience similar to a manual transmission but eliminates the need to worry
about gear shifts by utilizing paddle shifters. Overall, the text provides insights into the

11
features and considerations associated with different transmission options, including
the automatic transmission box”.
“The key positive of the automatic transmission is that it doesn’t take any steps
to kick it into the next gear. You simply press the gas pedal and go. The manual
transmission takes some time to learn but can have benefits of a smooth ride and can
have benefits of being more fuel efficient. The CVT is for those who want the kind of
driving experience a manual transmission can give but not have to worry about the
gear shifts and just use the paddle shifters.”(HONDA, 2022)
The main advantage of an automatic transmission is that it doesn't require any
manual shifting to change gears. You just need to press the accelerator and the car
will smoothly transition to the next gear. On the other hand, a manual transmission
requires some practice to learn, but it can provide a smoother ride and improved fuel
efficiency. The CVT (continuously variable transmission) is designed for individuals
who desire the driving experience offered by a manual transmission, but without the
hassle of gear changes. With CVT, you can use paddle shifters to control the
transmission and enjoy a similar feel to a manual transmission.

In the words of Redacción autofichas (2023) "An automatic gearbox or

automatic transmission is a type of transmission that shifts gears automatically,
without the need for the driver to do so manually. Instead of having to depress the
clutch pedal and manipulate the gearshift, the driver only has to select the desired
driving position.
The operation of the automatic gearbox is based on a series of mechanical,
electronic and hydraulic components that work together to change gears
automatically. The heart of the automatic gearbox is a set of planetary gears that
combine to provide different gear ratios".
“There are many different types of gears that can be used in different places.
Therefore, the application of gears is diverse, and we cannot give a concrete list. We
can see that the mechanical industry has rapid development. There is no doubt that
the market demand for gears that are used in industrial applications is increasing.

12
 Obviously, the application of gears is quite wide. For example, they can be
used in fertilizer industry, railway industry, printing industry and earthmoving industry,
etc. Except for these industries, there are also many other industries where gears can
play quite an important role. Next, let's look at some of the applications of gears”
(From Transmisión Automática, 2020)

Gearboxes are commonly used in conveyors for several reasons:

Speed control: A conveyor system may need to transport materials at different
speeds depending on the application. Gearboxes allow for speed control by changing
the rotational speed of the conveyor belt or other components. By using different gear
ratios, the gearbox can increase or decrease the speed of the output shaft, thus
adjusting the conveyor's overall speed.

Torque multiplication: In many cases, conveyors need to move heavy loads or

overcome resistance. Gearboxes provide torque multiplication, which means they can
increase the force or torque applied to the conveyor system. By using a gearbox, the
motor can operate at a higher speed with lower torque while delivering the necessary
power to move the load.

Directional changes: Conveyors often require changes in direction to navigate

through a facility or production line. Gearboxes can be used to redirect the rotation
from the motor to change the conveyor's direction. By using appropriate gears and
shaft arrangements, the gearbox can transmit power at different angles and redirect
the movement as needed.

Motor compatibility: Gearboxes provide a way to match the rotational speed

and torque requirements of the conveyor system with the capabilities of the motor. In
many cases, motors operate at high speeds, while conveyors require lower speeds
with higher torque. By using a gearbox, the motor can operate at its optimal speed
while the gearbox adjusts the output to suit the conveyor's needs.

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 Overload protection: Gearboxes can act as a protective mechanism for the
conveyor system. They are designed to withstand and distribute the load, helping to
prevent damage to the motor or other components. In case of sudden changes in
load or torque, the gearbox can absorb and distribute the force, preventing
catastrophic failures.
As amarillo gear service says in his website (2017) “A conveyor gearbox is the
heart of any conveyance system. Conveyor belt systems are the most used method
of moving a substantial amount of goods. The gearbox is the center of the conveyor
system that pulls the various belts, chains, and rollers to move the products.
Therefore, if the gearbox fails, the entire system fails. The following details three
kinds of conveyor systems and the types of gearboxes that are used to power them.”

A conveyor gearbox as a system is one of the most useful tools in line

production. Overall, gearboxes are an integral part of conveyor systems as they
enable speed control, torque multiplication, directional changes, motor compatibility,
and provide protection against overloads. They allow conveyors to efficiently transport
materials in a controlled and adaptable manner, making them essential for various
industries and applications.

Once the requirements and objectives are clear, the next step is to analyze the
functional requirements and constraints for the transmission box. This includes
considerations such as load capacity, dimensions, material compatibility, and
assembly requirements. By evaluating these factors, conceptual designs can be
generated to explore different possibilities for meeting the objectives and
requirements. SolidWorks, a powerful 3D CAD software, can be used to create a
detailed digital representation of the transmission box, allowing for visualization and
evaluation of the design concepts.

To ensure the integrity, strength, and durability of the transmission box design,
structural analysis and simulations are performed using SolidWorks. This step helps
validate the design and identify any potential issues or areas for improvement. By

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iteratively refining the design based on simulation results and design constraints, a
robust and optimized design can be achieved. Virtual testing and validation under
various operating conditions further verify the performance and reliability of the
transmission box design.

With the design validated and optimized, detailed engineering drawings and
specifications are created using SolidWorks. These drawings incorporate necessary
manufacturing considerations such as tolerances, assembly instructions, and material
selection. Additionally, a comprehensive bill of materials (BOM) is generated, listing
all the required components for the transmission box. This documentation provides
precise instructions for manufacturing and assembly.

The next step involves translating the 3D CAD model into 2D cutting files
compatible with the laser cutter. SolidWorks can be used to generate accurate flat
patterns of each component that needs to be laser cut. These flat patterns are then
exported in a format compatible with the laser cutter's software. Following the laser
cutter's operating instructions, the required components are precisely cut from the
chosen materials, ensuring accuracy and consistency in manufacturing.

Identifying the automation requirements and functionality needed for the

automatic transmission box system is essential. CODESYS, a widely used software
development platform for industrial control systems, can be leveraged to develop the
automation logic. This involves programming the automation code and integrating it
with the hardware components such as sensors, actuators, and controllers that
enable the automation system to work seamlessly with the transmission box.
Thorough testing and verification ensure that the automation system meets the
desired objectives and operates harmoniously with the transmission box.

In order to automate the gearbox we used codesys to simulate the process and
the leader programming “Ladder is one of several programming languages for
programmable logic controllers (PLCs) standardized with IEC 61131-3. In Ladder, the

15
energy moves from left to right instead of up and down as in the electrical schematics.
In a typical circuit, contacts appear on the left side and a coil on the right side. The
control logic that represents this circuit can be seen as a logical inference that has as
antecedent the logic of the contacts and as conclusive the coil.” (from bookdown, sf).
“There are many different types of gears that can be used in different places.
Therefore, the application of gears is diverse, and we cannot give a concrete list. We
can see that the mechanical industry has rapid development. There is no doubt that
the market demand for gears that are used in industrial applications is increasing.
Obviously, the application of gears is quite wide. For example, they can be used in
fertilizer industry, railway industry, printing industry and earthmoving industry, etc.
Except for these industries, there are also many other industries where gears can
play quite an important role. Next, let's look at some of the applications of gears”
(From Transmisión Automática, 2020)

“Simulation software programming involves writing code to build and customize

simulation models using simulation software platforms. The programming languages
used for simulation software programming can vary based on the software being
used. For example, Arena Simulation Software utilizes a proprietary language called
SIMAN which is similar to Pascal syntax, while others such as AnyLogic offer the
ability to write code in Java, or Python. Additionally, some simulation software such as
LINDO allow input in a variety of different formats such as text files, spreadsheets, or
even through algebraic expressions. Regardless of the software, programming is
necessary to create models, customize parameters, and perform analysis on
simulated data.” (uh.edu, 2022)

"The ladder diagram is a very popular graphical programming language for

programmable logic controllers because it is based on classic electrical control
diagrams. Thus, with the knowledge that any electrical engineer or technician
possesses, it is very easy to adapt to programming in this type of language. In STEP7
it is called "KOP". Ladder is one of several programming languages for programmable

16
logic controllers (PLCs) standardized with IEC 61131-3. In Ladder, power is moved
from left to right instead of top to bottom as in electrical schematics.

A typical circuit shows contacts on the left-hand side and a coil on the
right-hand side. The control logic represented by such a circuit can be seen as a
logical inference with the contact logic as the antecedent and the coil as the
conclusive. To program a Ladder controller, in addition to being familiar with the rules
of switching circuits, it is necessary to know each of the elements of this language".
(Herrero, s. f.)

The automated transmission box system is installed within the company's

production facility. The automation system is calibrated and configured to align with
the specific production requirements and workflows. Thorough testing and validation
are conducted to ensure the system operates reliably and optimally. Furthermore,
relevant personnel are trained on how to operate and maintain the automated system
effectively, ensuring smooth integration into the production process.

Implementing a monitoring system is crucial to track and analyze key

performance indicators (KPIs) related to the automatic transmission box system.
Regular assessment of the system's performance helps identify areas for further
improvement. Based on feedback and data analysis, continuous refinement and
optimization of both the automation system and transmission box design can be
undertaken to enhance efficiency, productivity, and overall performance.

2.3 Benchmarking

Sensata Technologies stands out as a global industrial technology leader

renowned for its exceptional expertise in the design, manufacturing, and distribution
of high-quality sensors and sensor-based solutions, catering to diverse industries
such as automotive, aerospace, and industrial sectors. Their innovative products play

17
a crucial role in enhancing efficiency, safety, and performance across a wide range of
applications.

Honeywell International Inc., a multinational technology giant headquartered in

New Jersey, USA, commands a strong presence across various sectors, including
aerospace, automation, process control, security, and energy. Their remarkable
diversification sets them apart from Sensata Technologies, as Honeywell offers an
extensive portfolio of products and services tailored to meet the needs of global
industries. With its robust revenue, Honeywell has established itself as a prominent
player in the technological landscape.

Infineon Technologies AG, a prominent German company specializing in

systems and semiconductors, is acclaimed for its cutting-edge solutions primarily
focused on the automotive, energy, communications, security, and industrial
automation sectors. While Infineon's core expertise centers around semiconductor
solutions, it continues to push the boundaries of technological innovation to meet the
evolving demands of its target industries. Notably, Infineon's strategic focus on the
European market contrasts Sensata Technologies' broader global reach, reflecting
their distinct market penetration strategies.

In conclusion, each of these renowned companies brings its unique strengths

and capabilities to the industrial technology landscape, serving a wide range of
industries with innovative solutions. Sensata Technologies, Honeywell International
Inc., and Infineon Technologies AG each play pivotal roles in advancing technological
progress and shaping the future of industrial applications on both regional and global
scales.

18
CHAPTER III. DEVELOPMENT: METHODOLOGY, TECHNICS
AND PROCEDURES
3.1 Project planning
3.3.1. Flowchart

Figure 3. Flowchart

19
3.1.2. Gantt Chart

Figure 4. Gantt Chart

3.1.3. Methodology to be used

To initiate the project successfully, the first crucial step is to conduct a

comprehensive inventory of the company's production process. This entails
meticulously gathering detailed information about the current practices, which
involves studying the convergence and stacking procedures employed. Through this
meticulous assessment of the existing inventory, the project team can gain a profound
and nuanced understanding of the processes at play. By identifying areas that
necessitate improvement, they can effectively lay the groundwork for implementing
targeted enhancements and optimizations. This proactive approach ensures that the
project starts off on the right foot, paving the way for meaningful and impactful
improvements in the company's production process.

After successfully conducting the comprehensive inventory, the project enters

the next critical stage, which involves measuring the current performance of the
production process. This stage is pivotal in understanding how well the convergence
and stacking tasks are performing in terms of efficiency and effectiveness. To achieve
this, the project team diligently collects relevant data and metrics that shed light on
20
various aspects of the process. By quantifying the performance through these
objective measures, the team establishes a valuable baseline that serves as a
reference point for future improvements. This quantitative analysis also helps in
identifying and precisely defining the challenges and inefficiencies that the production
process currently faces. Armed with this empirical data, the project team gains the
insights needed to design targeted solutions and make informed decisions to optimize
the production process. This evidence-based approach ensures that improvements
are rooted in concrete data, leading to more effective and sustainable enhancements
to the company's operations..
With the data collected, the project team proceeds to analyze the processes
involved in the convergence and stacking tasks. This analysis aims to identify the root
causes of the challenges and inefficiencies. By thoroughly examining each step and
the associated factors, such as manual intervention, bottlenecks, or communication
issues, the team can pinpoint the specific areas that contribute to the problems.

During the crucial analysis phase, the project team dedicates considerable
effort to uncovering and scrutinizing any potential defects within the convergence and
stacking processes. With meticulous attention to detail, the team methodically
examines every aspect of the tasks, searching for any errors, inconsistencies, or
quality issues that might surface during the production process. By delving deep into
these potential defects, the team gains invaluable insights into the precise areas that
demand immediate attention and improvement.

Through this thorough examination, the team not only identifies existing
defects but also uncovers the root causes behind them. This root-cause analysis is a
key element in developing effective strategies to address and eliminate the defects,
ensuring a sustainable and lasting solution. Armed with this newfound understanding,
the project team is equipped to implement targeted corrective actions and preventive
measures that will fortify the convergence and stacking processes against future
defects.

21
 The analysis phase serves as a vital detective work, where the team
meticulously collects and analyzes data to piece together the puzzle of potential
defects. This exercise in uncovering and understanding the shortcomings ensures
that the subsequent stages of the project are built on a solid foundation of knowledge.
As the project progresses, the team's efforts during the analysis phase prove to be
instrumental in achieving enhanced efficiency, product quality, and overall process
optimization. By fostering a culture of continuous improvement, the project team
paves the way for a successful and thriving production environment that is resilient to
defects and primed for excellence.

Following the analysis, a comprehensive assessment of the current

performance is conducted. This assessment considers the measured data, analysis
results, and defect identification. By evaluating the performance against predefined
benchmarks or industry standards, the team can determine the extent of the
deviations and areas that require remediation.

To control the current processes effectively, the project team implements

measures to address the identified challenges and improve the convergence and
stacking tasks. This may involve implementing standardized procedures, introducing
quality control mechanisms, or streamlining communication channels. The objective is
to ensure that the processes are managed efficiently and consistently.

Based on the assessment of current performance and the analysis of

processes, the project team defines improvement opportunities. These opportunities
outline the specific areas and actions required to address the challenges and
enhance the convergence and stacking tasks. By focusing on these opportunities, the
team can effectively target the root causes and make meaningful improvements.

Having defined the improvement opportunities, the team creates a

comprehensive plan to solve the identified problems. The plan includes specific

22
actions, timelines, responsibilities, and resources required for each improvement
opportunity. This ensures a structured and systematic approach to address the
challenges and improve the convergence and stacking processes.

Once the meticulously crafted plan is in place, the project team enters the
dynamic implementation phase, where they put their well-defined actions into motion.
With a clear roadmap in hand, the team works diligently to bring about the necessary
changes to the existing processes. This entails introducing targeted improvements,
streamlining workflows, and optimizing operations to maximize efficiency and
productivity. Embracing technological advancements, the team incorporates
automation solutions to streamline repetitive tasks and enhance overall performance.

During the implementation phase, every step is taken systematically, ensuring

that the plan is executed with precision and effectiveness. The team collaborates
closely, communicating seamlessly to ensure a synchronized effort. They remain
attentive to any challenges that may arise and respond proactively, making necessary
adjustments to stay on track.

Throughout this crucial stage, the team's dedication and coordinated efforts
drive the successful execution of the plan. By adhering to the planned strategies and
leveraging the latest technologies, the project team sets the foundation for a
seamless and transformative process. The implementation phase serves as the
bridge that connects the vision to reality, turning carefully crafted ideas into tangible
outcomes. It is a period of dynamic progress, where the project team's expertise,
adaptability, and commitment are instrumental in bringing the plan to life and
unlocking the full potential of the optimized processes.

Throughout the implementation phase, the project team continuously monitors

and improves the processes. By closely supervising each change made, the team
ensures that the improvements are implemented correctly and achieve the desired

23
outcomes. This includes assessing the impact of the changes, identifying any
potential issues, and making necessary adjustments to optimize the processes.

3.2. Implementation
3.2.1. Description of the project
The acrylic prototype of this automated gearbox represents a remarkable
combination of aesthetics and functionality. Its transparent body showcases the
intricate inner workings, allowing observers to appreciate the precision engineering at
play.

Figure 5. Representative image of a acrylic gearbox

At the heart of the acrylic prototype lies an advanced automation system

controlled by CODESYS, a powerful software platform for industrial automation and
control. This integration enables seamless communication and coordination between
various components, enhancing the overall performance and reliability of the gearbox.

The gearbox's automatic mode is designed to offer a user-friendly experience.

A display unit, linked to the CODESYS system, provides drivers with essential
information, including the selected gear, driving mode, and system status. Drivers can
effortlessly switch between manual and automatic modes through intuitive controls on
the dashboard.

24
 In manual mode, the driver can enjoy the tactile experience of gear shifting
using a sleek and ergonomically designed gear lever. The CODESYS system
monitors the driver's input and assists in executing precise gear changes, avoiding
any potential clutch-related issues.

3.2.2. Description of the process

First, let's go through the process of designing, planning, material sourcing,
and manufacturing a homemade acrylic-based automatic gearbox. The first step is to
determine the design requirements and specifications for the gearbox. This involves
considering factors such as the intended use, torque and power requirements, gear
ratios, and available space. With these parameters defined, a detailed design can be
created using computer-aided design (CAD) software. The design should include all
the necessary components, such as gears, shafts, bearings, and housings.

After finalizing the design, the next step is to plan the manufacturing process.
This involves determining the sequence of operations required to fabricate the
gearbox. The plan should include steps such as cutting and shaping the acrylic
sheets, machining the metal components, and assembling the gearbox. It is crucial to
consider the tools and equipment needed for each operation and ensure that they are
available or can be obtained. Additionally, it's important to establish a timeline for the
project and allocate resources accordingly.

Once the design and planning stages are complete, the material sourcing
phase begins. For the acrylic base, suitable sheets of acrylic can be obtained from
local suppliers or online retailers. It is important to select acrylic with the appropriate
thickness and strength for the gearbox application. Metal components, such as gears
and shafts, can be sourced from specialized suppliers or salvaged from other
mechanical systems. Ensuring the quality and compatibility of the materials is
essential for a successful gearbox.

25
 Finally, we come to the manufacturing process and programming of the
gearbox. The acrylic sheets can be cut and shaped using tools like a laser cutter or a
CNC router, based on the CAD design. The metal components can be machined
using lathes, milling machines, or other appropriate equipment. Once all the parts are
ready, they can be assembled according to the design specifications. Lubrication and
proper alignment of the gears and shafts should be ensured. As for programming, a
microcontroller or a programmable logic controller (PLC) can be used to control the
shifting mechanism and automate gear changes based on various parameters such
as vehicle speed, throttle position, and engine RPM. The programming code would
involve reading input signals from sensors, processing the data, and sending output
signals to actuate the gearbox components accordingly.

After the manufacturing of the gearbox was done, the automotion of the project
was carried out. For this purpose Codesys software was used. The development of
the automatic gearbox system using CODESYS followed a systematic methodology,
primarily focusing on ladder programming to implement the main control program and
various subroutines. These subroutines were responsible for managing specific
functionalities, including automatic mode, manual mode, ABS brake system,
visualization, and a global variables list. For the project implementation we develop
the following contents.

3.2.2.1. Main Control Program

- Initialize the PLC and set up global variables, sensors, and actuators for the
automatic gearbox system.
- Create a user interface for mode selection, allowing the user to choose
between automatic and manual modes.
- Implement logic to call the appropriate subroutine based on the selected mode
(automatic or manual).
- Integrate the ABS brake system into the main control program to ensure safe
braking during gear shifts or emergencies.
- Implement safety mechanisms to prevent hazardous conditions, such as gear
shifts while the vehicle is in motion or handling emergency stops and fault
conditions.
26
 - Coordinate the gear shift control logic, ensuring smooth gear transitions in both
automatic and manual modes.

The development process began with the creation of the main control program,
serving as the core of the automatic gearbox system. The ladder logic within this
program coordinated the different subroutines and managed the overall functioning of
the gearbox. An initialization routine was implemented to handle the initialization of
global variables, sensors, and actuators, ensuring that the system started in a safe
state with default parameter values.

To provide user flexibility, the main control program offered a mode selection
interface, allowing the user to choose between automatic and manual modes. Based
on the user's input, the appropriate subroutine was called to handle the selected
mode. Additionally, the main control program integrated the ABS brake system
functionality to ensure safe and efficient braking during gear shifts or emergency
situations. It monitored the brake status and interacted with the ABS brake subroutine
as needed.

Safety mechanisms were integrated into the ladder logic of the main control program
to prevent hazardous conditions. These mechanisms included preventing gear shifts
while the vehicle was in motion, handling emergency stops, and reacting to fault
conditions to ensure the safety of both the vehicle and its occupants.

3.2.2.2. Automatic Mode Subroutine

- Continuously monitor inputs to determine the optimal gear ratio for

performance and fuel efficiency.
- Utilize ladder logic to control gear shifting solenoids and manage smooth gear
transitions based on predefined shift points.
- Implement logic to prevent conflicting gear changes and ensure the selected
gear is engaged safely.
-
The automatic mode subroutine continuously monitored inputs. The ladder logic
controlled gear shifting solenoids and ensured smooth gear transitions based on
predefined shift points, preventing conflicting gear changes and ensuring safe gear
engagement.
-
3.2.2.3. Manual Mode Subroutine

27
 - Allow the user to take manual control of the gear shifting process.
- Receive input from the user for gear selection commands and execute the
corresponding gear shifts.
- Implement logic to prevent unsafe gear changes and handle user inputs
appropriately.

On the other hand, the manual mode subroutine allowed users to manually control
the gear shifting process. It received input from the user for gear selection commands
and executed the corresponding gear shifts accordingly, ensuring the selected gear
was engaged safely and avoiding unsafe gear changes.

3.2.2.4. ABS Brake System Subroutine

- Monitor the status of ABS sensors to detect braking conditions.

- Implement logic to prevent wheel lock-up and skidding during gear shifts or
emergency stops.
- Control the ABS valves and pumps through ladder logic to achieve safe and
controlled braking.

The ABS brake system subroutine monitored the status of ABS sensors to detect
braking conditions. It implemented logic to prevent wheel lock-up and skidding during
gear shifts or emergency stops, and through ladder logic, it controlled the ABS valves
and pumps to achieve safe and controlled braking.

3.2.2.5. Visualization

- Design a graphical user interface (GUI) for the visual simulation of the
automatic gearbox using CODESYS's graphical capabilities.
- Implement ladder logic to update the GUI in real-time, providing a dynamic and
interactive simulation experience for the user.

Additionally, the visualization subroutine was responsible for creating the graphical
user interface (GUI) for the visual simulation of the automatic gearbox. It utilized
CODESYS's graphical capabilities to design an interactive interface that represented
the gear shift lever, real-time gear ratios, vehicle speed, and other relevant
information. The ladder logic within this subroutine updated the GUI in real-time,
providing users with a dynamic and engaging simulation experience.

28
3.2.2.6. Global Variables List

- Define critical parameters and data as global variables to facilitate efficient

communication and data sharing among different subroutines and the main
control program.

Furthermore, a global variables list was defined, containing critical parameters and
data shared among different subroutines and the main control program. This
facilitated efficient communication and data sharing across different parts of the
automatic gearbox system, ensuring smooth coordination and reliable operation.

3.2.3. Graphic Tools

3.2.3.1. Grafcets
In the development of the system in CODESYS, GRAFCETs (Graphic Function Chart
Editor) played a central role in the design and implementation process. GRAFCETs
provided a powerful graphical representation of the control logic, enabling a clear and
intuitive visualization of the system's behavior. With its drag-and-drop functionality, the
development team could easily model the sequential steps and transitions of the
gearbox's automation process.

Using GRAFCETs in CODESYS, the team created a comprehensive flowchart of the

gearbox's operation, mapping out the different modes (manual and automatic) and
the corresponding actions and decision points. This approach significantly simplified
the design process, reducing the complexity of writing traditional code and minimizing
the potential for errors.

29
 Figure 6. First level grafcet Figure 7. Second level grafcet

The flexibility of GRAFCETs allowed for the seamless integration of various

components, such as sensors, actuators, and control logic blocks. By representing
the control flow visually, the team could better understand the system's behavior,
making it easier to optimize performance and make adjustments as needed.

30
 Figure 8. Third level grafcet

Figure 9. GRAFCET GEMMA in Codesys.

31
3.2.3.2. Visualization for the final user / Inputs and Outputs
Having a good visualization and clear identification of inputs and outputs are of
utmost importance for the final user's experience and system functionality. A
well-designed visualization provides an intuitive and user-friendly interface, enabling
users to understand the system's operation at a glance. It fosters ease of use,
reduces the learning curve, and minimizes the chances of user errors. By presenting
information in a visually appealing manner, users can quickly interpret data, make
informed decisions, and effectively interact with the system.

Figure 10. Board for the operator

Element type Input Output Comments

Indicator – M0 Indicates when Gearbox is ON
Indicator – PRIMERA Indicates when Gearbox is in 1st position
Indicator – SEGUNDA Indicates when Gearbox is in 2nd position
Indicator – TERCERA Indicates when Gearbox is in 3rd position
Indicator – CUARTA Indicates when Gearbox is in 4th position
Indicator – NEUTRAL Indicates when Gearbox is in Neutral position
32
 Indicator – REVERSA Indicates when Gearbox is in Reverse position
Button MAN – Manual Mode
Button AUTOMA – Automatic Mode
Button ON – Gearbox process in ON
Button OFF – Gearbox process in OFF
Button STOP – Break
Button RESET – Reset
Button ARRIBA – Up for Manual
Button ABAJO – Down for Manual
Button I2 – Up for Automatic
Button I3 – Down for Automatic
Button I4 – Neutral
Button I1 – Reverse

Figure 11. Table of Inputs and outputs in Codesys

3.2.3.3. Automate
An automata is essential for this project to ensure efficient and precise gear shifts,
seamless mode transitions between manual and automatic modes, real-time
adaptation to driving conditions for optimal performance and fuel efficiency,
integration of safety features, consistent and reliable operation and seamless
integration with the visualization system for a cohesive user experience. Its
implementation enhances the functionality, safety, and convenience for the end-users,
making it a crucial component of the gearbox system.

3.3. Control
3.3.1. Performance indicators

33
Figura 12. Performance indicators

34
CHAPTER IV. ANALYSIS OF RESULTS
4.1. Results Obtained

Figura 13. Performance results

4.2. Analysis of results

Do Inventory: In this initial step, the team conducted a thorough inventory of all
elements involved in the production process. From machinery and equipment to raw
materials and manpower, every component was cataloged to establish a
comprehensive understanding of the production line's setup and resources. The
process began with a systematic approach, involving thorough documentation and

35
physical inspection of the production line. Every equipment, raw material, and
resource involved in the manufacturing process was meticulously cataloged, ensuring
a comprehensive understanding of the workflow. Specialized software and data
collection tools were utilized to maintain accuracy and efficiency during the inventory
process. The team collaborated closely, cross-referencing information, and
addressing any discrepancies promptly. The resulting detailed inventory provided a
solid foundation for subsequent analyses and improvement initiatives, enabling the
team to make data-driven decisions and optimize the production line effectively.

Measure Current Performance: The team collected precise and detailed data
on the production line's current performance. Quantitative metrics such as production
rates, cycle times, and defect rates were diligently measured and analyzed, providing
a factual baseline for future evaluations. This activity was executed with precision and
attention to detail by the Sensata team. Key performance indicators (KPIs) were
identified, including production output, cycle times, defect rates, and other relevant
metrics. Data collection methods were carefully chosen to ensure accuracy, with
automated systems and manual observations where necessary. Regular monitoring
intervals were established to capture fluctuations in performance. Collected data was
meticulously analyzed, providing valuable insights into the current efficiency and
effectiveness of the production line. The team employed statistical tools and
visualizations to interpret the data, allowing them to identify trends and patterns. This
quantitative analysis formed the basis for subsequent improvement strategies,
enabling data-driven decision-making and targeted interventions.

Analyze Process: Armed with the gathered data, the team embarked on an
in-depth analysis of the entire production process. Each stage was scrutinized,
examining workflow efficiency, bottlenecks, and potential areas for optimization. This
step activity was systematically conducted by the Sensata team. They scrutinized
each stage of the production process, examining workflow efficiency, identifying
bottlenecks, and evaluating interdependencies. Detailed data from various sources
were meticulously analyzed, allowing them to gain valuable insights into the

36
intricacies of the process. Brainstorming sessions and collaborative discussions
facilitated a comprehensive understanding of the process's strengths and
weaknesses. The team used this analysis to identify potential areas for improvement,
setting the stage for targeted interventions and optimizing the production line's overall
performance.

Find the Causes: Through meticulous analysis and root cause identification,
the team uncovered the underlying factors contributing to inefficiencies and defects in
the production process. By understanding the causes, targeted improvements could
be developed. The team conducted a thorough investigation to identify the root
causes of inefficiencies and defects in the production process. Data was analyzed to
perform root cause analysis, and utilized process mapping techniques to trace issues
back to their sources. Cross-functional teams collaborated, sharing insights and
perspectives to ensure a comprehensive understanding. The team sought to uncover
underlying factors contributing to suboptimal performance, which served as a crucial
step in formulating effective solutions.

Discover the Defects: Defects were meticulously identified and categorized to

gain a clear picture of the production line's quality issues. This step enabled the team
to prioritize and focus their efforts on areas requiring urgent attention. It was
employed a rigorous approach to discover defects within the production process.
Through meticulous inspections and quality control measures, they identified and
categorized various defects. Advanced testing methods and statistical analysis were
utilized to understand defect frequency and distribution. This enabled them to
prioritize defect resolution and allocate resources efficiently for improvement efforts.

Assess Current Performance: With insights from the analysis, the team
reevaluated the production line's performance to ensure the accuracy of identified
improvement opportunities and gauge the impact of potential changes. The team
conducted a comprehensive assessment of the production line's current performance.
By comparing key performance indicators (KPIs) to established benchmarks, they

37
evaluated the effectiveness of existing processes. This analysis provided valuable
insights into areas that required enhancement and served as a basis for setting
performance improvement targets.

Control Current Processes: Before implementing improvements, the team

established control mechanisms to ensure stability during the improvement phase.
Proper controls were put in place to monitor performance and maintain consistency.
Rigorous controls were implemented to maintain stability during process improvement
initiatives. The team established standard operating procedures (SOPs) and
implemented measures to monitor critical process parameters. Regular audits and
inspections were performed to ensure compliance with established protocols and to
swiftly address any deviations.

Define Improvement Opportunities: Drawing from the analysis and defect

discovery, the team defined specific opportunities for improvement. These focused on
addressing root causes and optimizing critical aspects of the production process.
Armed with insights from previous analyses, the team identified specific opportunities
for improvement. They focused on critical areas with the potential to yield significant
performance gains. Through collaboration and data-driven decision-making, they
outlined clear objectives and performance targets for each opportunity.

Create a Plan to Solve the Problems: A comprehensive improvement plan was

developed, outlining actionable steps, timelines, and responsibilities. The plan was
carefully aligned with the company's strategic goals and designed to tackle the
identified issues effectively. It was meticulously crafted a comprehensive improvement
plan to address identified issues. The plan included specific actions, timelines, and
responsibilities. They integrated input from cross-functional teams to ensure a
well-rounded and effective approach to solving problems.

38
 Figure 14. Design of gearbox in solid works

Implement Plan: The improvement plan was executed with precision.

Communication was paramount, ensuring that all relevant stakeholders were aware
of the changes and their roles in the implementation. With precise planning and
coordination, the improvement plan was put into action. The team adhered to the
established timelines and communicated effectively throughout the implementation
process. They closely monitored progress and made real-time adjustments to ensure
the plan's success.

39
 Figure 15. Physical result of gearbox

Improve Processes: Throughout the implementation, continuous improvements

were pursued. The team remained adaptable, incorporating feedback and making
necessary adjustments to achieve the desired outcomes.

Control Subsequent Processes: Post-implementation of improvements, strict

monitoring and oversight measures were established to ensure the sustainability of
gains achieved. Key performance indicators (KPIs) were closely tracked, and regular
reviews were conducted to assess process performance. Any deviations from
expected results were promptly addressed through well-defined corrective action
protocols. Feedback loops were maintained to gather insights from team members
and stakeholders, enabling continuous improvement efforts and reinforcing a culture
of vigilance and excellence in process control.

Supervise Each Change Made: this activity was conducted with meticulous
attention and care by the team. Following the implementation of improvements, the
team closely monitored the effects of each change. Regular reviews and inspections
were performed to assess the impact on production processes and overall
performance. Feedback from team members and stakeholders was actively sought to
evaluate the effectiveness of the changes and to identify potential areas for further
refinement. This continuous supervision ensured that adjustments were made
promptly, fostering a culture of continuous improvement and driving sustained
success in the production line.

40
CHAPTER V. CONCLUSIONS AND RECOMMENDATIONS
5.1. Achieved goals
5.1.1. General objective
The general objective of designing and building an automatic transmission box
to enhance the efficiency and productivity of the production process for Sensata was
successfully achieved. Through meticulous planning, innovative engineering, and
collaborative efforts, the team developed an innovative transmission box that
revolutionized their manufacturing operations. The new automated system
streamlined the production line, reducing manual labor and significantly increasing
throughput. It optimized the overall production process, leading to quicker turnaround
times, reduced errors, and improved product quality. The automatic transmission
box's implementation also resulted in cost savings, as it required less maintenance
and minimized downtime. Moreover, the enhanced efficiency allowed Sensata to meet
increasing market demands, expanding their customer base and revenue. The
success of this project solidified Sensata's position as an industry leader, setting new
standards for productivity, and reinforcing their commitment to innovation and
excellence.

5.1.2. Specific objectives

The objective of analyzing areas of opportunity in the production line was
successfully achieved through an in-depth study and collaboration with the production
team. By employing data-driven methodologies, the team identified specific pain
points and bottlenecks, providing clear insights into where gearbox integration could
yield the most significant improvements.

The successful implementation of the gearbox in the production line was

achieved through meticulous planning and seamless collaboration between engineers
and technicians. Detailed blueprints were developed, ensuring smooth integration
without disrupting ongoing operations. Rigorous testing and quality assurance

41
measures were undertaken to guarantee the gearbox's proper functioning within the
line.

The monitoring of the production line with the gearbox improvements was
accomplished through the implementation of advanced sensor systems and real-time
analytics. Constantly monitoring key performance indicators allowed for prompt
adjustments and fine-tuning, ensuring optimal operation and maximum efficiency.

Preventive maintenance was carried out meticulously to ensure the gearbox's

continuous functionality. Proactive maintenance schedules were established, and the
production team received specialized training to detect early signs of potential issues.
By staying ahead of potential problems, downtime was minimized, contributing to the
successful achievement of the objective.

5.2. Conclusions
5.2.1. Contributions

Creating a manual gearbox as a university project is an enriching experience

that benefits students' learning in various ways. It provides them with the opportunity
to apply theoretical knowledge in practical situations and tackle real challenges in the
design and construction of the gearbox, developing skills to solve problems effectively
and creatively. Through manufacturing the components and working as a team, they
improve their technical abilities and learn to collaborate and communicate efficiently.
Additionally, they gain a profound understanding of manufacturing processes and the
importance of complying with regulations and standards to ensure the quality and
safety of the final product. The project also fosters their creativity and innovation,
allowing them to explore different approaches and solutions to enhance the gearbox's
efficiency and performance. In summary, this hands-on learning experience prepares
students to face real-world challenges in their future careers as competent engineers
capable of providing innovative solutions to complex technical problems.

42
5.2.2. limitations
There were some circumstances that made the project difficult and were
limitations at some stage of the development of the integrating project, in the first
instance there was resistance to change, this resistance to change on the part of the
staff or the lack of support at all levels of the organization made it difficult the
implementation of an innovative project proposed by the work team. This was a
challenge during the development of the project that could be resolved by having
many meetings with staff from all areas.
The project was carried out over a period of four months, which placed
restrictions in terms of how much could be accomplished in that time. Some more
complex improvements or initiatives require a longer implementation period, which is
why they could not be developed in this term and a base project was implemented
that complied with each designated area.
The available resources, such as equipment and budget, were limited, so the
ability to carry out all the necessary actions to fully address the deficiencies and
achieve the desired objectives was not an easy task, options to purchase new
materials were eliminated and innovation was in the implementation of materials,
looking for reuse options.

5.3. Recommendations
In order to keep the improvements on track, the company is recommended to
take some points into account, such as documenting the procedures: It is essential to
maintain a manual and detailed documentation that describes the new processes,
improvements, and practices implemented during the project, serving as a guide for
the operational staff. Establish a continuous training program It is recommended to
establish a regular training program to ensure that all team members are aware of the
improvements implemented and can maintain quality and efficiency in the long term
and finally it is recommended to carry out regular audits to evaluate compliance with
the processes and the improvements implemented. These audits can identify

43
potential gaps and further improvement opportunities, ensuring improvements are
sustained over time.

44
BIBLIOGRAPHY

GONZÁLEZ, J. (2015). Sensata, excelencia operativa con sentido.

Recuperado el 19 de mayo de 2023 de liderempresarial. Website:
https://www.liderempresarial.com/sensata-excelencia-operativa-con-sentido/

HERNÁNDEZ, N. (2017). Sensata Technologies edifica su centro de

operaciones. Recuperado el 19 de mayo de 2023 de somosindustria. Website:
https://www.somosindustria.com/articulo/sensata-technologies-edifica-su-centro-de-o
peraciones/

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ANNEXES

Annexe 1. Manufacturing software

Annexe 2. Manufacturing process

46