Mike Ternoey is the copyright owner of the first software application used at Navistar used to write the instructions for an entire vehicle program. His assignment as Build Analyst to Navistar required him to write the instructions for more than10 vehicles, with than 27,000 parts, in a one month period. This position required writing thousands of pages of material in a month.
Early Life
High School (Lawrenceville School) Mike Ternoey attended Lawrenceville with Roger Penske’s sons and has read his biography and watched all of his videos on youtube. During his time at Lawrenceville, he tutored socialites from New York’s culture, some of which were Fortune 500 clientele., namely because Mike was a member of the United States Physics Olympiad Team.
DLOT Deliverable (As seen on indeed.com job posting)
The amount of time it would require to write a single assembly group for a given vehicle is .56 hours. However, the design of the vehicle is very unstable, and it is very labor intensive to build a single vehicle’s instructions.
REFERENCE: Contact Navistar’s Legal Team, Tony Heard, the Director of Engineering at Melrose Park used the software in the Dlot Program.
PROBLEM SCOPE
“You have 1 day to write the instructions for 9 vehicles”
Every vehicle is designed on a critical path, with design changes, that happen late in the project as the project matures. A single part may not be cleared for the prototype production because of a design flaw until a few weeks or days before the prototype build date. A donor vehicle is selected for the blue print of a given project, and design modifications are made to the blue print for the donor vehicle, whereby some parts and features are added to the vehicle and some are removed.
If a part is added to the vehicle build it can change the instruction manual for building the truck drastically, much like shuffling an entire deck of cards. Each instruction manual is nearly a thousand pages long. The number of possible combinations of images in the instructions for a given vehicle with 2,000 parts is more than the number of molecules in the universe. This presented a problem for mechanics building the vehicle in the prototype facility in Melrose Park.
Vehicle Program
Vehicle - Each part in a vehicle can be classified by these four sets:
1.) Assembly Group – There are many assembly groups in a vehicle, such as chassy, electrical , wiring, and cab, steering, breaks, engine.
2.) Installation – an installation is a part of an assembly group.
3.) Item – An assembly of screws or washers.
4.) Part Ex: A screw, or washer.
CAD database design:
Vehicle > Assembly Group > Installation > Item > Part
Sincere there are only 30 labels that can be placed in a CAD image for labeling parts, and there are hundreds of parts in an assembly, parts must be grouped by item. The item is the lowest level of resolution available for the CAD image. Only items can be labeled in CAD images but not their detailed parts.
“There are only 30 parts that can be labeled in a CAD drawing, so the labeling system is useless”
How do you label a part in a vehicle with a common item tag such as “001”. There may be 30 pictures in an installation in a cad database with the item 001. One installation may be ten years old. Another installation in the cad database may be only a year old and also contain the item “001”. So, to assign a part in item 1 to the correct drawing in the data base is difficult.
LICENSE OF SOFTWARE
Which images really match the installation or sub-assembly in the Bill of Materials?
Deselection: Which images should be used in the instructions?
An image should not be used if a large percentage of items in the image are not really in the assembly that is being built for the current project.
Rareness
An "baloon", item, or part in that is highlighted in the Solid Works Inspection process, that comes from one assembly group, in the BOM is rare if it is only in a small number of pictures. For example, if "item 1" is in 20 pictures, but "item 77" is in only 2, item 77 is rare.
Ubiquity
Because assembly groups, and sub assembly groups, are cloned for new projects, items, or parts, labeled "001" appear in almost every image, and it is nearly impossible to identify which image in a cad database should show item "001" from a particular vehicle project.