P07008: ARCWorks - Bottle Assembly Process
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P07008 PRP

Table of Contents

Administrative Information

Project Name
ArcWorks Unitary Wash Bottle Assembly
Project Number
P07008
Project Family
P07000 NSF Assistive Devices
Track
Assistive Devices and Bioengineering
Start Term
2006-2
End Term
2006-3
Faculty Guide
Dr. Matthew Marshall (ISE)
Faculty Consultant
Dr. Elizabeth DeBartolo (ME)
Graduate Teaching Assistant
TBD
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
J_Syrkin@arcmonroe.org

Project Overview

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.

Staffing Requirements

Staffing
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 success. mmmeie@rit.edu
Dr. Debartolo ME Faculty Consultant, Will provide ME discipline technical support on an intermittant basis. eademe@rit.edu
Sagar Sheth ISE Team Lead, Inventory Management sss9125@rit.edu
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.

This material is based upon work supported by the National Science Foundation under Award No.BES-0527358.

NSF

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.

Customer Needs

Hierarchical Customer Needs

Needs
Assembly Unit
  • Need 1 - Unit shall be a Robust Design
    • Need 1.1 - Can accommodate different size bottles
    • Need 1.2 - Should come with manufacturing instructions, process instructions, bill of materials, and cost.
  • Need 2 - Unit shall be a Durable
    • Need 2.1 - Should be able to produce large quantities of assemblies
    • Need 2.2 - Should have a long mean time between failure
    • Need 2.3 - Dependable
  • Need 3 - Unit shall be a Serviceable
    • Need 3.1 - Should be easily repairable
    • Need 3.2 - parts used to build machine should be off the shelf
    • Need 3.3 - parts should be easy to obtain
    • Need 3.4 - Should be able to determine what parts will eventually need replacement
  • Need 4 - Unit shall be a Safe
    • Need 4.1 - Should not require operators to hold any parts while building the assembly
    • Need 4.2 - The unit should have way to stop it on command
  • Need 5 - Unit shall be a Ergonomically Safe
    • Need 5.1 - The unit should not create additional disabilities for the operators
    • Need 5.2 - Should require minimal force
  • Need 6 - Unit shall Maintain Quality
    • Need 6.1 - Should create good assemblies
    • Need 6.2 - Should have the spout flushed with the bottle
    • Need 6.3 - Should minimize the damage to the exterior surface of the bottle and the spout
Process Optimization
  • Need 1 - Lean Engineering
    • Need 1.1 - Develop standard work
    • Need 1.2 - Develop U-cell layout to incorporate better flow
    • Need 1.3 - Eastablish takt time
    • Need 1.4 - Establish value stream maps
  • Need 2 - Material flow
    • Need 2.1 - Should be able to distinguish between raw materials, work in process, and finished products

Relative Importance of the Customer Needs

Assembly Unit
Needs Summary
Need The Product Needs Importance
Need 1.1 Unitary Wash Bottle Assembly Machine Can accommodate different size bottles 9
Need 1.2 Unitary Wash Bottle Assembly Machine Should come with manufacturing instructions, process instructions, bill of materials, and cost. 3
Need 2.1 Unitary Wash Bottle Assembly Machine Should be able to produce large quantities of assemblies 9
Need 2.2 Unitary Wash Bottle Assembly Machine Should have a long mean time between failure 3
Need 2.3 Unitary Wash Bottle Assembly Machine Dependable 3
Need 3.1 Unitary Wash Bottle Assembly Machine Should be easily repairable 9
Need 3.2 Unitary Wash Bottle Assembly Machine parts used to build machine should be off the shelf 9
Need 3.3 Unitary Wash Bottle Assembly Machine parts should be easy to obtain 3
Need 3.4 Unitary Wash Bottle Assembly Machine Should be able to determine what parts will eventually need replacement 3
Need 4.1 Unitary Wash Bottle Assembly Machine Should not require operators to hold any parts while building the assembly 9
Need 4.2 Unitary Wash Bottle Assembly Machine The unit should have way to stop it on command 3
Need 5.1 Unitary Wash Bottle Assembly Machine The unit should not create additional disabilities for the operators 9
Need 5.2 Unitary Wash Bottle Assembly Machine Reduce force required to complete assembly 9
Need 6.1 Unitary Wash Bottle Assembly Machine Should create good assemblies 9
Need 6.2 Unitary Wash Bottle Assembly Machine Should have the spout flushed with the bottle 3
Need 6.3 Unitary Wash Bottle Assembly Machine Should minimize the damage to the exterior surface of the bottle and the spout 1
Process Optimization
Needs Summary
Need The Product Needs Importance
Need 1.1 Process Optimization Develop standard work 9
Need 1.2 Process Optimization Develop U-cell layout to incorporate better flow 3
Need 1.3 Process Optimization Eastablish takt time 9
Need 1.4 Process Optimization Establish value stream maps 3
Need 2.1 Process Optimization Should be able to distinguish between raw materials, work in process, and finished products 9

Customer Deliverables

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).

Regulatory Requirements

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.

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.

Engineering Specifications

List of Metrics

The table below presents the metrics that will be used by the team to design against.

Assembly Unit
List of Metrics
Metric No. Need Nos. Metric Importance Units Marginal Value Ideal Value
1 1.1 Demonstrate assembly of spout to bottle for at least 2 cases per size 9 1 L, 500ml, and 250ml bottles assembled. At least 2 case per size Yes Yes
2 1.2 Should come with meaning full manufacturing instructions, process instructions, bill of materials, and BOM 9 Present stated documents in electronic and hard copy format to client Yes Yes
3 2.1 Demonstrate the 6 cases of different size bottles can be assembled with average cycle time not exceeding 60 seconds 3 Number of bottles per day > 630 > 650
4 2.2, 2.3, 3.4 Avoid using parts (component level) that need frequent overhauling 3 Number of Cycles > 116,000 > 125,000
5 3.1 Easy access to components for repairs 9 Amount of time (in hours) needed to completely disassemble and assemble the bottle < 2 < 1.5
6 3.2, 3.3 Avoid excessive use of custom made parts. If inevitable, then provide prints or deliver spare parts 9 Provided prints and or spare parts if using custom parts Yes Yes
7 3.2 Use materials that are off the shelf 9 % of materials > 50% > 75%
8 3.4 Demonstrate that the system (as a whole) does not need major overhauling for atleast 3 months 3 number of cycles > 54,000 > 60,000
9 4.1, 5.1 no intervention between the operator and the machine while actual assembly 9 Visual Yes Yes
10 5.2 Force required to complete assembly should be less than the minimal force required for the smallest bottles 9 lbs. < 20 < 10
11 4.2 Demonstrate that the machine is stoppable on command or if something goes wrong 9 Emergency Stop Yes Yes
12 6.1, 6.2 Produce good assemblies 9 Zero defects across 6 cases. Flushed surface between spout and bottle. Yes Yes
13 1.2, 2.1 Setup time to switch between bottles 3 Minutes (SMED) < 10 < 5
14 6.3 Exterior scratches after assembly 3 No visual damage to text on bottle Yes Yes
Process Optimization
List of Metrics
Metric No. Need Nos. Metric Importance Units Marginal Value Ideal Value
15 1.1, 1.4 Provide process instructions, maintainence manual, value stream maps, standwork combination sheet 9 Visual Yes Yes
16 1.3 Takt Time 3 Time in seconds < 30 < 25
17 2.1 Outside visitor should be able to tell at what stage in the production line the parts are 9 Visual Yes Yes
18 1.2 The cell layout should show clear flow of material and operator from start of production to end of production 9 Visual Yes Yes

The engineering specifications directly relate to the customer needs as previously outlined. The following matrix outlines this relationship.

Needs - Metrics Matrix
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
Need 1.1 X
Need 1.2 X
Need 2.1 X
Need 2.2 X
Need 2.3 X
Need 3.1 X
Need 3.2 X X
Need 3.3 X
Need 3.4 X X
Need 4.1 X
Need 4.2 X
Need 5.1 X
Need 5.2 X
Need 6.1 X
Need 6.2 X X
Need 6.3 X
Inventory Management
Need 1.1 X X
Need 2.1 X
Need 2.2 X X

Safety Constraints

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:
The following tasks should be completed by the end of SD2:

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.

IE:
  1. Team lead and inventory management
  2. Ergonomics, lean, engineering economy, inventory management
ME:
  1. Mechanical Design, Pro-E CAD, GD&T
  2. Mechanical Design, CAD Analysis, Manufacturing
  3. Pneumatics Controllers, PLC, Materials Selection
  4. 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.

Grading Scheme for SD1 and SD2
Grade SD1 SD2
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:

Person 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.

Required Resources

Faculty
Item Source Description Available
Prof. Marshall ISE Faculty Guide/Coordinator/Mentor Yes
Prof. Debartolo ME Technical Consultant Yes
Mr. Syrkin ArcWorks Customer Yes
Environment
Item Source Description Available
RIT Ergonomics Lab ISE TBD Work Space/Storage Yes
ME Shop ME 09-2360 Parts Fabrication Yes