flyrotary@lancaironline.net Mailing List Archive

Here’s a great story in line with more expensive doesn’t always mean better … you have to appreciate this simplicity.

Jeff

A toothpaste factory had a problem: they sometimes shipped empty boxes, without the tube inside. This was due to the way the production line was set up, and people with experience in designing production lines will tell you how difficult it is to have everything happen with timings so precise that every single unit coming out of it is perfect 100% of the time.

Understanding how important that was, the CEO of the toothpaste factory got the top people in the company together and they decided to start a new project, in which they would hire an external engineering company to solve their empty boxes problem.

Six months (and $8 million) later they had a fantastic solution - on time and on budget. They solved the problem by using high-tech precision scales that would sound a bell and flash lights whenever a toothpaste box would weigh less than it should. The line would stop, and someone had to walk over and yank the defective box out of it, pressing another button when done to re-start the line.

A while later, the CEO decides to have a look at the project. No empty boxes ever shipped out of the factory after the scales were put in place...very few customer complaints, and they were gaining market share. "That's some money well spent!" he says, before looking closely at the other statistics in the report.

It turns out the number of defects picked up by the scales was 0 after three weeks of production use. It should've been picking up at least a dozen a day, so maybe there was something wrong with the report. After some investigation, the engineers come back saying the report was actually correct. The scales really weren't picking up any defects, because all boxes that got to that point in the conveyor belt were good.

Puzzled, the CEO travels down to the factory, and walks up to the part of the line where the precision scales were installed. A few feet before the scale, there was a $20 desk fan, blowing the empty boxes out of the belt and into a bin.

"Oh, that," says one of the workers - "one of the guys put it there 'cause he was tired of walking over every time the bell rang."

From: Jeff Whaley
Sent: Monday, January 23, 2012 11:09 AM
To: 'Rotary motors in aircraft'
Subject: RE: Top 7 reasons for using an auto conversion

I agree with Items 2-6 Pat and don’t think there needs to be any more reasons. Items 2-4 are by far the main reasons why I chose an auto conversion; Item 6 is a nice side benefit for the Rotary but not the reason why I chose the rotary. I chose the rotary because of its relative simplicity, power-to-weight-ratio, the fact that at the time of installation there was an active builders group such as this one and that someone (Tracy crook) had already made flight-proven components readily available.

Item #1: Cost to install at 50% may be true but for most people getting to 25% is nearly impossible.

Jeff

From:	Patrick Panzera <editor@contactmagazine.com>
Subject:	Top 7 reasons for using an auto conversion
Date:	Sun, 22 Jan 2012 14:51:08 -0800
To:	CorvAIRCRAFT@yahoogroups.com, Corvair engines for homebuilt aircraft <corvaircraft@mylist.net>, Rotary motors in aircraft <flyrotary@lancaironline.net>

Here's what I wrote.

I was asked to keep the comments short:

Top Seven Reasons to Consider an Automobile Conversion

1. Cost to install. When compared to the cost of a new aircraft engine, a fully installed and properly functioning automobile engine can run 25% to 50% of its certified counterpart when compared new-to-new.

2. Cost to rebuild. When rebuilding an auto conversion, it can typically be brought to zero-time with all new parts for what a used yellow-tagged aircraft crankshaft costs, that’s if your core is serviceable.

3. Cost to operate. Most auto conversions can be operated on automobile fuel, cutting the per-gallon cost nearly in half. Modern auto conversions have tight tolerances eliminating the need to add oil between changes.

4. Cost to maintain. Aircraft spark plugs range from $26 to $60 each. Automobile plugs are one tenth of that and typically require half as many. The same can be said for virtually every maintenance item.

5. Convenience. Nearly every part you might need to repair or maintain your auto conversion can be purchased from any number of suppliers in your home town, even on Sunday, or are a short drive from what ever airport you might have landed at.

6. Smoothness. Virtually every auto conversion is noticeably smoother than its aviation counterpart, reducing fatigue on components and occupants.

7. Because you can. Why are we building an airplane in the first place? If all you are after is the performance offered by homebuilt aircraft, why not just buy one second hand? Most of us build because we want to build. There’s a great amount of satisfaction that stems from standing back and saying, “I built that.” The same applies for an automobile engine conversion, especially if it’s never been done before.

And remember, there are a lot of experimental aircraft that were designed (and proven) from the beginning to use an auto conversion, so many of the points for a certified engine aren't relevant, and many of the reasons against an auto conversion also apply to those who would consider installing an aircraft powerplant where an auto conversion is specified.

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