- Project Name
- ArcWorks Unitary Wash Bottle Assembly
- Project Number
- Project Family
- P07000 NSF Assistive Devices
- Assistive Devices and Bioengineering
- Start Term
- End Term
- Faculty Guide
- Dr. Matthew Marshall (ISE)
- Faculty Consultant
- Dr. Elizabeth DeBartolo (ME)
- Graduate Teaching Assistant
- Primary Customer
- John Syrkin (Manager of Production Operations, ArcWorks)
- Secondary Customers
- Heidi Berrios, Roger Sullivan, Tricia Nenni, Employees at ArcWorks
- Customer contact information
- John Syrkin
- Manager of Production Operations
The mission of this project is to improve the current process of manually attaching the spout to the wash bottle by incorporating automation and also concentrating on the physical and ergonomic issues faced by handicapped employees in addition to improving the efficiency and the quality of the entire process. Another part of the project is to help ArcWorks sort out their inventory management problems.
|Team Member||Discipline||Role / Skills||email address|
|Dr. Matthew Marshall||ISE||Faculty Guide, Will work closely with the team on an on-going basis to facilitate firstname.lastname@example.org|
|Dr. Debartolo||ME||Faculty Consultant, Will provide ME discipline technical support on an intermittant email@example.com|
|Sagar Sheth||ISE||Team Lead, Inventory Managementfirstname.lastname@example.org|
|TBD Student||ISE||Ergonomics, Lean, Engineering Economy, Inventory Management|
|TBD Student||ME||Mechanical Design, Pro-E CAD, GD&T|
|TBD Student||ME||Mechanical Design, CAD Analysis, Manufacturing|
|TBD Student||ME||Pneumatics Controllers, PLC, Materials Selection|
|TBD Student||ME||Materials Selection, Manufacturing, Process Instructions|
Continuation, Platform, or Building Block Project Information
The Assistive Devices and Bioengineering Track is focused on the application of technology to improve the quality of life for individuals with disabilities, and the development of technologies related to the broad field of bioengineering.
A number of other projects are intimately related to this project, as summarized in the list below:
|Related Project||Title||Start Term||End Term|
|P06208||ArcWorks Closure Tube Assembly||2005-2||2005-3|
Principle Sponsor or Sponsoring Organization
This material is based upon work supported by the National Science Foundation under Award No.BES-0527358.
Detailed Project Description
The goal of this project is to conceive, design, produce, and test a spout tip to wash bottle assembly system. The goal of this project is not to eliminate operator involvement completely, but rather help eliminate physical and ergonomic issues that go along with performing the operation. The system should allow all users to perform this operation. The system will be developed to help the disabled workers make their jobs less labor intensive and will prevent them from attaining additional injuries from performing this operation. As a result of automation,an increase in productivity should be seen and also a reduction in rejected wash bottle assemblies.
The second goal of the project is to improve the process flow as it relates to raw bottle inventory versus printed (sub-assembly) inventory versus finished goods inventory (complete assembly - printed bottle with spout and packaged). The current inventory management system, Great Plains system, is not effectively tracking these stages and ArcWorks is looking for recommendations from a process/warehouse layout/product identification standpoint that would help ArcWorks more effectively manage this.
Hierarchical Customer Needs
Relative Importance of the Customer Needs
Design, build, and test working prototype of the assembly machine. See the "Detailed Course Deliverables" section for more specifics.
Customer and Sponsor Involvement
The team will be expected to carry out the vast majority of their interactions with the Team Guide (Dr. Marshall). ArcWorks (The customer) will be available for a series of meetings during the course of the project. Mr. Syrkin will meet with the team during the beginning of SD1 to layout common goals, and objectives. Mr. Syrkin, along with other managers, will participate with team communications electronically by e-mail and also by phone (only if information is needed urgent).
- The design shall comply with all applicable RIT Policies and Procedures. The team's design project report should include references to, and compliance with all applicable RIT Policies and Procedures.
- Wherever practical, the design should follow industry standard codes and standards (e.g. Restriction of Hazardous Substances (RoHS), FCC regulations, IEEE standards, and relevant safety standards as prescribed by IEC, including IEC60601). The team's design project report should include references to, and compliance with industry codes or standards.
Project Budget and Special Procurement Processes
Dr. Debartolo, on behalf of The National Science Foundation, has allocated $1,200 for this project for AY06-07. Additional funding (if needed) will be provided by ArcWorks. The team will be required to keep track of all expenses incurred with their project, and to ensure that the individual project budget is being followed.
- The cost to manufacture subsequent copies of the final design, sub-assembly, or part should decrease with increasing volume.
- The cost to manufacture subsequent copies of the final design, sub-assembly, or part should decrease with decreasing levels of instrumentation, but shall remain capable of being retro-fitted with instrumentation after initial manufacturing.
- The cost to manufacture subsequent copies of the final design, sub-assembly, or part should be borne by the team, faculty member, research project, company, or department desiring to use the item for their research and development work.
- The design team is not expected to account for the nominal labor costs of RIT shop personnel as long as their time commitment does not greatly exceed that of other typical SD projects.
- The design team is not expected to account for the nominal labor costs of TAs, Faculty, or other staff assigned to assist and guide then team, as long as their time commitment does not greatly exceed that of other typical SD projects.
- The design team is not expected to recover the investment costs associated with the device development.
Intellectual Property Considerations
All work to be completed by students in this track is expected to be released to the public domain. Students, Faculty, Staff, and other participants in the project will be expected to release rights to their designs, documents, drawings, etc., to the public domain, so that others may freely build upon the results and findings without constraint.
Students, Faculty, and Staff associated with the project are encouraged to publish findings, data, and results openly.
List of Metrics
The table below presents the metrics that will be used by the team to design against.
Needs Related to the Metrics
The engineering specifications directly relate to the customer needs as previously outlined. The following matrix outlines this relationship.
|Needs and Metrics||Metric 1||Metric 2||Metric 3||Metric 4||Metric 5||Metric 6||Metric 7||Metric 8||Metric 9||Metric 10||Metric 11||Metric 12||Metric 13||Metric 14||Metric 15||Metric 16||Metric 17|
- Human safety takes precedence over all other design objectives.
- The machine should be robust to damage by inexperienced operators.
- All burrs, if any, should be removed to prevent cuts to operators.
Detailed Course Deliverables
Note that this level describes an absolute level of expectation for the design itself, and for the hardware. However, the student team must also meet all requirements related to analysis, documentation, presentations, web sites, and posters, etc. that are implicit to all projects.
See Senior Design I Course Deliverables for detail.
- The following tasks should be completed by the end of SD1:
- Complete design of the selected concept
- Complete Fatigue Analysis
- Complete BOM
- Complete parts ordering
- Come up with solutions for inventory management problems
- The following tasks should be completed by the end of SD2:
- Build and test the machine
- Implement machine in to ArcWorks daily production
- Train operators on how to use machine
- Implement solutions to inventory management and track results
- Provide process instructions
Preliminary Work Breakdown
The following roles are not necessarily to be followed by the team. It is merely to justify the number of students from each discipline. The student team is expected to develop their own work breakdown structure, consistent with the general work outline presented in the workshop series at the beginning of SD1. However, the customer requests a level of detail NO GREATER than weekly tasks to be completed by each student team member for the benefit of the other team members. The customer DOES NOT request any level of detail finer than one-week intervals, but will assist the team members if they wish to develop a finer level of detail to support their own efforts.
- Team lead and inventory management
- Ergonomics, lean, engineering economy, inventory management
- Mechanical Design, Pro-E CAD, GD&T
- Mechanical Design, CAD Analysis, Manufacturing
- Pneumatics Controllers, PLC, Materials Selection
- Materials Selection, Manufacturing, Process Instructions
Grading and Assessment Scheme
Grading of students in this project will be fully consistent with grading policies established for the SD1 and SD2 courses. The following level describes an absolute level of expectation for the design itself, and for the hardware. However, the student team must also meet all requirements related to analysis, documentation, presentations, web sites, and posters, etc. that are implicit to all projects.
|D||Design manual, but ergonomic tool(s) to assemble the was bottle and spout||build and demonstrate a manual, but ergonomic tool(s) to assemble the was bottle and spout|
|C||The team will deliver all elements of C Plus: all prints, BOM, and fatigue analysis||Build and demonstrate an automated single unit assembly tool to assemble spout to wash bottle|
|B||Design automatic tool and include and include BOM, all prints and fatigue analysis||The student team will deliver all elements of level C Plus: Each of the team members will operate the tool to complete one case of wash bottles with simulation of certain disabilities|
|A||Student team will deliver all elements of B Plus: have recommendations for inventory management||Student Team will deliver all elements of C and B Plus: The team will implement inventory management recommendations, collect data and track results|
Three-Week SDI Schedule
This project will closely follow the three week project workshop schedule presented in SD1. See the Course Calender for Details.
In Addition, the team will be responsible for:
- Review project readiness package
- Site visit to introduce team and help team understand the current process. Have a look at what last years team developed.
- Determine the downfalls of the current way to complete the assembly
- Develop design concepts in enough detail to assess their feasibility in terms of cost, technical expertise, and schedule
Week 0->1 Tasks
(8 Dec 06)
Week 1->2 Tasks
(15 Dec 06)
Week 2->3 Tasks
(22 Dec 06)
|ME Student: 1||Meet with customer. Understand the process. Review Project Readiness Package. Read through last year's project and how last year's machine works. Obtain force required to effectively attach spout for current method. Obtain force for approx 10 bottles and find mean, std. dev.||Draw bottles and spout in PRO-E to refresh PRO-E skills.||Develop design concept sketch on how the machine should look like.|
|ME Student: 2||Meet with customer. Understand the process. Review Project Readiness Package. Read through last year's project and how last year's machine works. Obtain force required to effectively attach spout for current method. Obtain force for approx 10 bottles and find mean, std. dev.||Examine the machine (currently not in use at ArcWorks) to determine why the assemblies are not working, so same design techniques can be prevented.||Develop design concept sketch on how the machine should look like.|
|ME Student: 3||Meet with customer. Understand the process. Review Project Readiness Package. Read through last year's project and how last year's machine works. Learn the process of assembling the spout to the bottle. Understand the leak test that is done on all the bottles.||Examine the machine (currently not in use at ArcWorks) to determine why the assemblies are not working, so same design techniques can be prevented.||Look in to different pneumatic presses that have sufficient power to complete assemblies. Find cost on these presses.|
|ME Student: 4||Meet with customer. Understand the process. Review Project Readiness Package. Read through last years project and how last year's machine works. Learn the process of assembling the spout to the bottle. Understand the leak test that is done on all the bottles.||Determine what kind of loads are needed in order to attach the spout to the bottle.||Look in to different on-off devices that incorporate e-stops.|
|IE Student: 1||Meet with team before SD1 class to go over PRP once. Meet with customer again.||Finalize project plan of action for SD1 (i.e. gantt chart). Finalize one page project summary.||Get familiar with Great Plains System.|
|IE Student: 2||Meet with customer. Understand the process. Review Project Readiness Package. Read through last years project and how last year's machine works. Obtain force required to effectively attach spout for current method. Obtain force for approx 10 bottles and find mean, std. dev.||Understand the downfalls of the manual way to assemble in terms of Ergonomics. Help the ME's in finding design flaws for the automatic machine.||Get familiar with Great Plains System.|
|Prof. Marshall||ISE||Faculty Guide/Coordinator/Mentor||Yes|
|Prof. Debartolo||ME||Technical Consultant||Yes|
|RIT Ergonomics Lab||ISE TBD||Work Space/Storage||Yes|
|ME Shop||ME 09-2360||Parts Fabrication||Yes|