Motor Coach Overhead Luggage Rack

Key Issues

Company
MCI Motor coach industries, Canada
Product
Overhead Luggage Rack
Objectives
  • Reduce product cost
  • Reduce assembly problems
  • Improve function
Approach
Application of Design For Assembly & Manufacturing Analysis on the current product in a team working environment

Function

In addition to its most obvious function, the rack provides a location for lights, window blinds, video monitors and audio speakers. It contains an air plenum for the ventilation system, grab handles for the passengers, carries seat markers and it has to look good too!

Existing Design

The existing design consisted of cast ribs, sheet material and numerous fasteners. At 43ft long it is installed through the windscreen and then held in position while fasteners are inserted horizontally and vertically to secure it. Subsequent replacement of the centre roof trim was not possible.

New Design

The new design uses 3 full length interlocking extrusions and a minimum of fasteners. During installation the lower edge is hooked onto the body side supporting the main weight of the assembly, it is then rotated upward into position and secured to the roof. The centre roof trim can now be removed without disturbing the rack. A wiring harness previously held by ‘p’ clips and prone to damage by screws and screw drivers, is now safely routed through a channel in one of the extrusions and retained by foam rubber blocks.

Benefits

Part reduction from 4730 to 2210
Improved installation time - 62 hrs down to 17 hrs.
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