Integrated System Build & Test
Table of Contents
Team Vision for Integrated System Build & Test PhaseWhat we planned to do this phase
- Assemble par frame
- Run oil through pump and test oil circulation
- Assemble one fixture and test fixture engagement with nozzle
- Complete testing of peripherals
- Solidify vendor choice and get quote for fixtures
What we did this phase
- Chose ME machine shop to complete 4/5 fixtures
- Completed oil circulation test
- Tested CF6-80 nozzle engagement successfully
- Completed testing of peripherals
- Summary plan for this review
How we're going to catch up
- Going to an AAT approved vendor for GP7200 that has already provided us a quote and a 2 week lead time
- Ordering remaining par frame parts from McMaster Carr (will arrive right after break)
What we plan to do next phase
Test Results Summary
Risk and Problem Tracking
Major Problems1. Trouble outsourcing parts. Our choice of vendors is limited now because some vendors will put us over budget and some will put us even more behind schedule.
- Solution: Go to machine shop for 4 of the fixtures and find one vendor for GP7200. Get the following IN WRITING:
- When any changes to the parts are agreed upon
- The commit date from the ME shop or vendor
- Will get commit date for the next fixture by Friday 3/18.
- Contact vendors over break and choose a final vendor by 3/20 for GP7200.
2. Wrong parts come in or parts need unexpected adjustments or accessories. Putting us behind schedule and potentially over budget.
- Solution: Implement new process where
- When finding critical parts online, look at the spec sheet and have a meeting with at least 1 other team member to anticipate any associated risks. Anticipate if additional parts need to be purchased or fabricated.
- Team leader adds part to BOM
- Whoever suggested the part double checks that the part number is right.
- Purchasing lead fills out the PO and double checks the part number and quantity.
- When the parts arrive, immediately check that the part number and quantity match up with the BOM.
- If a part number changes, log the reason why in the bill of materials.
- Problem Tracking
Major Risks1. Not enough time to machine parts.
- Resolving the risk by going to the machine shop and asking for help when team members are not experts at machining. This allows everyone to be helpful and for us top catch up on our schedule.
2. Chamber leaks and we can't use the loctite we ordered.
- Resolving by getting a new type of sealant from Cory at AATech. Will seal the chamber to prevent leaks. There is plenty of sealant on hand. Also using teflon tape around threads.
3. Maintaining pressure in oil and air lines.
- Resolving by using a pressure regulator and a visual check to ensure that the oil flows through the system during each run.
- Cost: 89% of budget used. Expected to use almost all of our budget (waiting on quote for single piece from AAT approved vendor).
- Indentured BOM
- See project plan for next phase above.
Functional Demo Materials
Preliminary Oil Circulation Test 3/16
CF6-80 Nozzle Engagement Test 3/16
- Wrong parts were ordered that were critical to our schedule. There was also confusion about a spec sheet for the stainless steel tank leading us to have to order more parts. Need to implement a process where the part numbers are checked at each step of the purchasing process.
- In the future, have parts come to us already machined, such as holes that need to be drilled. This will save time sand effort.
- If there is a critical part with long lead time, find multiple suppliers in the area that you can go to in person for back up.
- Start process sheets earlier for machined parts.
- At the beginning of the semester, look at everyone's schedule and determine when everyone is free outside of class time. Then when workload is high meetings can easily be set up.
- Assess everyone's machining capabilities at the beginning of the semester and outsource parts accordingly.
- When you don't understand someone's process, ask for help so that you can be helpful if a team member is missing in the future.
Results of 3/10 Peer Review
- Don't leave meetings without a solution to every problem.
- Set up meeting times while the team is together instead of over text. Make everyone aware the dates of your next peer review and project review several weeks in advance.
- When you have a meeting or commitment that conflicts with Senior Design, let everyone know 3 days in advance.
- Have your guide observe your peer reviews and solicit feedback when you need it, as MSD II is different from MSD I and feedback is offered less often.