Customer Handoff & Final Project Documentation
Goals of MSD I and MSD IIThe goal of MSD I was to define the project scope by fully understanding the systems challenges and constraints, perform research to develop initial concepts, and design potential solutions. The goal of MSD II was to verify and validate the potential solutions through prototyping and testing. The end goal of the MSD I and MSD II journey was to learn about the process of solving challenges within a company, solve the customer's challenge, and provide the required deliverables agreed upon by both the RIT MSD team and the customer.
Team Vision for Final Demo and HandoffDuring this phase the team focused on completing all final deliverables for Micropen Medical. The team also aimed to complete the required tasks for ImagineRIT and the course.
The team performed testing and was able to draw conclusions from the new workstation setup. The team worked with Micropen Medical to install the operator tooling and make minor instal modifications to optimize the system for its intended design. Additionally, the camera and monitor system was installed in the workstation system. The stretch sheets were posted and the WIP preliminary prototype was used to show proof of concept.
The team also finalized the ImagineRIT poster and developed the list of items to incorporate in our display for ImagineRIT. The team developed a deliverables checklist to ensure Micropen and the RIT Senior Design team were in agreement about the items and knowledge being transferred during the conclusion of the project. This checklist was filled out during the project handoff meeting.
Test Results SummaryThis page presents the final state of the project and includes the list of final deliverables provided to Micropen during the closing of the project. Customer Requirements vs performance
Initial feedback was collected from the operators during testing. This feedback can be found here Testing Quotes
Some of the notable comments received are -
- “Using the camera is definitely an improvement to the posture. There is a win here.” - Customer
- “That went really smoothly. I just need to do a couple then I am ok. It’s coming along.” - Operator
- “We knew there would be a little learning curve. We just needed someone to fight through it.” - Customer
- “It still feels funny though, because I am not like hovering over or hugging the machine. I love the machine, I want to hug it all day long” - Operator
- “This is definitely comfortable.” - Operator
- “Change isn’t such a bad thing.” - Operator
Risk and Problem TrackingOf the 46 total risks formed throughout the course of the project, 43 were officially closed in Phase 10. The remaining risks pertain to testing still necessary to be completed to ensure optimal efficiency and safety.
Final Project Documentation
Design ConceptsA series of changes in the workstation design have been identified as improving the operators ergonomics while performing the touch-up procedure.
- First, the microscope was replaced with a monitor and camera system to relieve neck discomfort.
- Second, the operator tooling keeps the tip near the point of use. This ensures the tip is in the field of view quickly and easily to perform the process.
- Third, the combination of the WIP stand and WIP tile ease the placement of completed parts by allowing for adjustability in the angle of the stand and increasing the distance between the holes in the WIP tile. The reduced WIP hole count supports process flow and reduces the duration of time the operators are in a static load position.
The operator tooling prototype design and assembly was created using SolidWorks. The system is mounted to the station for stability of the tooling and the horizontal slides provides flexibility and ease of use to the operators when performing the touch-up procedure.
Model of the updated workstation in SolidWorks including the operator tooling, the camera system, and the Micropen chuck fixture and casing. This design was used to test the placement of the camera assembly in relation to the rest of the workstation.
The WIP Stand incorporates adjustability in the angle of the tray portion. This allows the operators to customize the workstation to their individual needs and preferences.
The WIP Tile has been modified to support ease of placement and reduced error rate. The number of holes in the tile has been reduced by over 50%, this allows for the parts to be placed into the tile more easily while reducing the probability of smudging the parts. The layout of the holes has also been modified into a staggered pattern to support part placement.
Conclusions and RecommendationsEach subsystem supports reducing operator discomfort and improving overall workstation ergonomics. The operator tooling and the monitor and camera system place the operator in a more ergonomically friendly position, orienting the operator toward the work and easing performance of the procedure. The use of the monitor reduces neck strain and allows for system usability by a larger range of operators.
Operator ToolingThe operator tooling fixture reduces the operator’s physical stress while performing the touch-up procedure by incorporating a more suitable hand grip and placing the tooling tip close to the point-of-use on an adjustable slide. The degrees of flexibility supported by the system provide the operator the ability to perform the process in a natural and ergonomically friendly position.
Ergonomic Improvements for Operator ToolingThe operator tooling fixture implemented by the team was the first generation of a product that is expected to evolve. The team fully expects there to be changes made to the current design, introducing newer generations of our design. It is our hope that the first generation of the operator tooling provides a baseline for the future design of the fixture. The team identified additional changes that could be implemented to the current fixture in anticipation for these changes.
Ergonomic Improvements for Operator Tooling shows how the tooling and plate extensions would fit into the over scheme of the operator tooling fixture
Short Term Operator Tooling Recommendations
Viewing ApparatusThe microscope was identified as a root cause of discomfort and has been removed from the system. A new camera and monitor configuration was installed to reduce the severe discomforts expressed by the operators and improve the system layout.
WIP StandThe WIP tile layout proposed, reduces the number of parts required to be placed in the area and is organized in a staggered pattern on the tile. These changes result in a decrease in accidental smudging of the ink and provide ease-of-placement of the parts.
Actuating the OpenerThe updated actuator and switch reduce wrist strain for the operators while ensuring control over the operation. The modified location provides a more natural and comfortable position supporting reduced stress on the wrist.
Operator KeypadThe keypad modifications included removing the cloudy cover, reallocating the keys to better utilize the space available, changing out single keys for double keys, and including color to better identify the keys. The transition from single keys to double keys was based on the use frequency of the keys. The new double keys were identified as being frequently used, therefore, easing the entering of these keys eases this portion of the process for the operators. The keypad was required to be reprogrammed based on the computer keyboard inputs after these physical changes were made on the keypad.
Seating PositionPreviously the operators were provided minimal legroom under the desk due to the need to see through the microscope and perform the touch-up procedure. Due to the changes in the tooling and viewing system the operator is able to more easily orient themselves toward the work and the setup reduce stresses on their back. The team will be providing Micropen Medical with ergonomic chair suggestions in the case where down the road the budget allows for updated chairs to further improve the ergonomics of the workstation.
More frequent work rotations for the operators has been recommended for ergonomic and health benefits. The suggested change will be every 2 or 4 hours of work by moving the operator to a different procedure within the manufacturing floor. By changing the type of work more regularly, different muscles will be used for the different procedures; this supports reducing the duration and frequency of repetitive motions.
A series of stretches and exercises in the form of posters has been provided as resources to encourage operators to move from their static position more often. These exercises promote movement and aim to reduce tension and discomfort in areas of the body.
Functional Demo Materials
Click on the following link to view a video summary of the project https://www.youtube.com/embed/v_iZBSNgPLg
Plans for Wrap-up
- Complete project handoff with Micropen Medical by verifying each deliverable on the deliverables checklist is complete and transferred to Micropen. The team realizes there may be additional follow-up questions after the completion of the project hand-off and potentially after the completion of the course. Knowing this, the team aims to be accessible for further clarification.
- In addition, a concise technical paper detailing all aspect of the project is to be completed.
- Present 1-2 minute final project presentation to class on May 12th 2016.
- Schedule and complete MSD II final gate review during finals week.
The above plans for wrap-up have been completed by the team.