Planning & Execution
Table of Contents
Intellectual Property Considerations
- AAT Quality dictates what materials and documentation Jim and Dave are allowed to share with the MSD group.
- All nozzle drawings, models, and AAT parts belong to Parker Aerospace/GE Aviation.
|Nicole Anklam||Systems Integration (EE)||email@example.com|
|Maria King||Project Manager (ISE)||firstname.lastname@example.org|
|Jessica Reed||Purchasing (ME)||email@example.com|
|Philip Couturier||Controls Systems (EE)||firstname.lastname@example.org|
|Samantha Orlando||Systems Design (ME)||email@example.com|
|Bryce Mowers||Manufacturing (ME)||firstname.lastname@example.org|
Team Values and NormsTo view a PDF of the team's Values and Norms, click here.
Project Plans & Schedules
To view the most up to date Gantt Chart in MS Project, click here.
AA Tech Customer Interview Questions
- Will we be provided with sample nozzles/nozzle constraints?
- Is there a maximum weight to the device that we
should be aware of?
- i.e. does it need to fit on an elevator or platform
- “Height to be set for ergonomic ease of use” – what type of area would it be placed in?
- Will AATech provide the barcodes to be used if the scanning method is to be used?
- How much control is the operator expected to have
over the device?
- Is it limited to inputting a part number or scanning a bar code?
- Is the oil to be recycled in a certain manner so that it is immediately reused, or does it need to be filtered and stored elsewhere?
- Are there any air specifications that we need to be aware of for the spraying?
- Is the former project being used currently?
- What are the current cycle times?
- Can we visit the facility to see it in use?
- More photos of the project available?
- Any issues that occurred since it began being used?
- Is there a specific Allen Bradley module that needs to be used?
- Is the MIL-PRF-6081 oil the only oil to be used in the device?
- Will the bags for the nozzle be provided or are there specifications for the type to be used?
- What exactly is meant by “Quick and Easy Change Over?”
AA Tech Customer Interview Aug. 27th.
From Previous MSD Team
- Previous MSD team spent most time dealing with the
- leaks and troubleshooting
- Receiving PLC controller as an update, initially used a breadboard
- Team was all MEs and had little experience with controls
Current Oil System
- Current Oil System used for high volume line
- Accommodates single inlet nozzles
- Current oil system is moved via forklift – need more compact system
- Only one type of oil used
- Different bags used
- Current changeover can take ~ 15-20 minutes
- Longest time spent aligning the nozzle
- Fitting a nozzle to the system is very individualized
- Fitting is screwed into nozzle to attach to fixturing
- Nozzle is screwed off after cycle is completed
- Nozzle is bagged individually
- Leads to several ergonomic issues
- GE Aviation has representative at location at all
- Reviews production parts daily
- Reviews parts between 1-3pm
- Acceptable parts are oiled and bagged, then sent to shipping before 5pm every day
- Process can sometimes feel rushed
- Nozzles are shipped to various locations and put in storage for different lengths of time that are unknown
- Operators have little to no training on using oil system
- Typical users are new hires
- Operator oils ~10 nozzles and stores them in draining
area to be bagged
- Operator typically waits and drains excess oil from nozzles before bagging
- Once draining area is full, operator bags nozzles in batches and sends them off to next area
Project Details and Considerations
- This project should focus more on controls
- Accommodate a wide range of different single inlet nozzles and sizes (~10)
- Accommodate only one type of oil
- Oil system should be able to be rolled to the end of the production line, then off to shipping
- Operator should be able to load part in chamber,
close safety doors, and scan paperwork
- System should be automated to complete the rest of the oiling process
- Oil can be directly recycled after initial use, back into oil system
- Outsource chamber design in order to focus more on controls
- Should be as automated and “fool proof” as possible
- Potential idea of using dowel pins to locate and align nozzles
- Ergonomic issues must be addressed
- One level facility; no platforms or elevators
- Large variation in operator height – 5’0 to 6’4”
- Should either accommodate average height or adjustable height
- 50dB is ideal case
- Potentially flexible
- Must comply with OSHA standards
- Current operators have issues with carpel tunnel, bending / twisting wrists, and being sprayed with oil
Action Items for MSD Team
- Follow up with AA Tech about interview
- Make sure all notes accurately describe what was discussed
- Complete updated list of Customer Requirements based on Interview
- Complete updated Use Scenario based on AA Tech discussion
- Set up a time to visit the facility
Action Items for AA Tech
- Provide pressure specifications for all nozzles
- Provide samples of hardware
- Smallest nozzle that will be used in production
- Largest nozzle that will be used in production
- Provide the bar codes that will be used
- Allen Bradley specific module to be provided
- Provide current cycle times
- Pictures of current oil system and previous MSD team’s system
- Provide schedule in order to find best meeting time
AA Tech Team Visit Scheduled for Sept. 1stCurrent Oil System Observations
- Oil reserve on bottom
- Operator manually sets conditions and turns pump on
- Fitting is screwed onto system fixture and nozzle is
either directly connected or connected by hose
- Operator bends over to screw on fitting
- Sponge-like material on sides and bottom to act as filter
- Oil is not changed or replaced, just continually added to the system
- Dials used to indicate pressures and times
- Operators currently use oil and bag station between 10-12
- Operators oil and bag nozzles in batches, doing one program at a time
- No set oil time duration, just enough time to ensure oil comes out every opening
- Generally all parts can run at the same pressure (300-350 psi) however may be different for GENX
- GENX is a stretch goal if we can accommodate that nozzle as well
- Oil ~144 CFM nozzles a day
Previous MSD Project Observations
- Bucket used as oil reservoir
- pump and motor on bottom
- angled acrylic inside chamber to drain and recycle oil
- pressure sensors and timers used
- separate draining area
- pneumatic platform to lock onto nozzle
- fixture to hold nozzle, sliding fit onto nozzle diameter where o-ring would be applied
- not all nozzles have location for o-ring
Current System Component Specifications
- Dayton Industrial Motor/ Pump
- S.N.: 1429605226
- Parker Fluid Control Valve
- Valve Number: 71215
- S.N.: 2EN000N0C111C2
- Allen Bradley Micrologix1000 Controller
- Model: 1761-L32AAA
- Series E FRN1.0
- CTC HMI
- Model: P11-314DR; BLR-6050
- SN: 1P07002328-200
Future System Considerations
- Interchangeable plates to hold different size nozzles
- Work with a subcontractor to get the enclosure built, as long as we design it
- Potentially use touch screen, PLC, and bar code
scanner that they already have at the plant
- May have to get software
Action Items for AATech
- Bring sample nozzles, PLC, touch screen, and bar code scanner to design review on 9/10.
- Provide drawings, bar code data (given to us on flash drive at the visit)
- Provide data on oil usage.
- Incorporate Genx into the list of part numbers - not in original list, but still a stretch goal.
Risk Assessment and Growth Curves
- This is the original risk document created by the team. Updated risk assessments can be found at the end of each phase's respective page.
Meeting Minutes, Notes, & ActionsNotes from Practice Problem Definition Review
- Add Key Processes utilized from MSD
- i.e. How to determine risks, etc.
- Consolidate the first few slides
- What are we looking for from the customer? What type of feedback?
- Add mitigation for major project risks - choose the ones that are important and more likely to happen
- Update the Use Scenario with door locking and the program loading correct setpoints
- State what the scale is for 1-9 on Customer Requirements, and specify the differences between the pressure setpoints (currently three)
- No need to go over each one, just the important ones
- Anything that needs to be tested should be an
- Anything else should be a constraint that is stated
- Line up CRs with ERs
- include spray duration as engineering Rq
- AKA Just revamp all the ER’s
- Nozzle types should be the ones specified, and have been in production for a while
- Look at ergonomics and height from a previous team
- Leakage and the “rats nest” of wires is
why the previous one is not being used
- Professional look.
- Make the maintenance team happy..
- Change the marginal/ideal for the pressures on ER
- Add test cycle time
- Measurement precisions - how precise will we be able to test and what are the equipment tolerances
- Use Gantt charts and major milestones to accomplish
- Remove the last two bullets on the Next Steps chart
- Determine how we are communicating with Dave and timing between emails/etc.
- Make the ‘Next Steps’ very specific
- Ask about serial connections needed for HMI, PLC,
- Software licenses? Is there a spare computer to use for programming?
- How was the scanner programmed previously
- Ask about serial connections needed for HMI, PLC, Scanner.
- House of Quality and Peer Reviews - need to do this all still
Peer ReviewsPeer reviews will be based on the Team values and Norms listed above.
Presentations for Problem Definition, Systems Design, and Subsystems Design reviews can be found at the end of each phase's respective page. Beginning with the Preliminary Detailed Design Phase, EDGE is used to present.