Description of Parts:-

1. Base (Cast Iron):- Base is the stationary part of the linear mechanism. It is mounted to the
main body. All the parts are assembled on it directly or indirectly. The assembling process
starts from it.

2. Carriage (Aluminium):- Carriage is the end effector of complete mechanism go linear

mechanism. It slides on the Base. The tolerance between Base and Carriage is managed in
such a manner that it only slides over it without any wobble.

3. Lead Screw Nut (Steel):- Lead screw is Lead screw is among functional parts of the
assembly it is rotated by handle base. While on other hand lead screw is forced by its helical
periphery.

4. Lead Screw Nut (Brass):- Lead screw nut is mounted on Carriage. It is pushed and pulled
by lead screw by its helix. Its function is to convert rotary motion of lead screw into linear
motion.

5. End Support (Brass):- The end support bears the reaction force from movement of load
on Carriage. This transfers the load from carriage to lead screw to Base through it. It is
among the function parts.

6. Handle (Aluminium):- It is to allow the ease of rotation of the handle base. It is among
non-functional part

7. Handle Base (Aluminium):- Handle Base is mounted to lead screw. It is rotated to rotate
the lead screw.

8. End Plate (Aluminium):- End plate is to stop the over travel of carriage. It is there just for
safety.
Assembly before LUCAS optimization:-

Manual Handling and Fitting Analysis of Original Assembly:-

Lucas Optimization:-
In manual linear sliding assembly there is two parts that can be optimized as per LUCAS
parameters. Those two parts are End supports or End plate. The optimization of both parts is
described as below.
Optimization of Front End Plate:- The front end plate is bolted to Base by two bolts. In
assembling of it the assembling person have to hold the plate at location. This increases the
part placing and fastenning index number. With this optimization the index is decreased by
1.In this optimization we have created the guiding tubes in the back of it, so that the person
assembling it does not have to hold it in place as the end place will stay temporarily
assembeled to the base all the time.

Optimization of Rear End Plate:- The main function of the end plate is to prevent the over
movement of carriage.The rear end plate in original assembly is bolted by two bolts. With
this optimization we had optimized it by 10.1 and removed the any necessity for bolts and
plates and still providing all travel required for carriage and removing the necessity for end
plate.The end plate is merged with the base cast iron as one part. The person assembling does
not have to hold the end plate and we as whole reduced the one part by making the end plate
and base cast as one part.
Assembly after LUCAS optimization:-

Manual Handling and Fitting Analysis of Optimized Assembly:-