Cost overrun on cookies and assembly Estimate for HB was $12.3 k => $33.4k

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Cost overrun on cookies and assembly Estimate
for HB was 12.3 k gt 33.4k Very tight
tolerances underestimated the difficulty new
guy, not enough supervision (none written into
estimate) out of spec cookies delivered to Notre
Dame had to all be measured and some
redone supervision put in place inspection of
finished parts using CMM now required Design
changes on the fly, as well as more expensive
design converting drawings and making changes
costs design time Top Hats modified, new rubber
rings, ZIF lock machining included Go/NoGo
gauges (for DEP and here) Changed thickness of
cookie to just over nominal had to buy larger
stock () and mill off () ¼ material Based
on batches of 100 (fixturing and setup costs
minimized) Schedule changes reduced this to
batches of 20-40 cookies Mountings (alignment)
can never be done in batches of 100 Some MS and
jobs left off estimate Clean, pack and ship all
the itty bitty springs, screws, etc