Design for Manufacturability

Passenger Car Door Locking System Redesign

Pontiac Grand Prix 2004

Redesign by:

Francisco Aguado
Zsolt Bancila
Job Eliud Garcia
Noel Nava Gonzalez

Winter 2004

The relation between the customer and its car is most of the times through the closures, and because of this reason the components of the doors have been studied several times during the history of the car. The door on a car should be safe, light and should ensure isolation when closes and becomes part of the whole structure.  The locking system is one of the components that should take care of the customer safety and is always in contact with the customer. This important relation made us to create a door locking mechanism with less effort, at a reduce cost and easier assembly for the plant.  The car we selected was the Pontiac Grand Prix 2004 being this one of the latest car released and because of that, having some of the latest designs. The main idea was to create a better system for our customers: the assembly plant and the final customer who buys the car.  One of the future studies recommended is the modification on the lock knob by deleting the knob from the top and creating a side door knob which has better looking and it’s more robust, this requires detailed study and adding more parts in consideration as the harnesses, brackets, etc.  This redesign was developed by Francisco Aguado, Zsolt Bancila, Job Eliud Garcia, and Noel Nava Gonzalez in Winter 2004, instructors: Prof. Sridhar Kota and Mentor Dr. Donald Malen.


 

Project Specifications (pdf)


 

Pictorial Summary


 

1. Inside Handle Redesign:

modify two hooks, delete the hole and create two snap-fits, also delete the rivet, reducing assembly time and manufacturing complexity

2. Rod Secure Redesign:

replace the current clip with a plastic rod clip to make the installation easier and save money

3. Striker Redesign:

remove the metal spacer and the mylar washer, modify the base of the striker by making it thicker and adding coating on the surface that contacts the metal

 

 

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