P16718: Micropen workstation design
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Integrated System Build & Test

Table of Contents

Team Vision for Integrated System Build & Test Phase

During this phase, many products were received from Micropen to begin testing. Testing was started on the Operator Tooling, as well as the WIP fixtures to analyze whether these subsystems met the engineering requirements laid out for them. Through initial testing, subsystem functionality was demonstrated for parts received. Preliminary integration was discussed for some subsystems and for the complete system. Additional development of the data collection tables was completed for subsystems.

Some changes to the subsystems structure were made, the Arm and Elbow Support subsystem was combined with the Operator Tooling subsystem and further development of the Arm and Elbow Support subsystem was ended. Progress in each subsystem was made through acquiring parts and through testing.

Additionally, progress has been made on the course technical paper, this is concurrent with the development of the subsystems and integrated systems. In addition, a preliminary Imagine RIT poster has been created.

Bill of Material (BOM)

Updated BOM shows what components have been purchased and the current location.

Results and Updates by Subsystem

Operator Tooling

The operator tooling system was completed and assembled in order for us to run preliminary functionality testing. Upon first assembly there was an issue with one of the linear bearing support brackets failing. After remaking this component, the operator tooling is now fully functional and has passed our initial functionality testing. We saw large improvements in tool point stability and a large reduction in the amount of wrist and shoulder strain which the operator is under during the touch up procedure. From this initial testing we found a few issues which have led us to further explore a palm rest cushion and a tool handle extension for operators who have larger hands. Further testing will need to be conducted at micropen in order to determine the size and location of the palm rest cushion as well as the necessity and length of the tool handle extension.
 Comparing operator hand size while using the operator tooling prototype

Comparing operator hand size while using the operator tooling prototype

 The Mechanical fixture gives the operator a stable performance while simultaneously providing flexibility and maneuverability, enabling the operator to manipulate tooling with precision.The tooling keeps the wrist in a neutral position, reduces awkward elbow and shoulder posture and requires less effort and rotational movement to use

The Mechanical fixture gives the operator a stable performance while simultaneously providing flexibility and maneuverability, enabling the operator to manipulate tooling with precision.The tooling keeps the wrist in a neutral position, reduces awkward elbow and shoulder posture and requires less effort and rotational movement to use

Further description of initial prototype assembly and pictures from assembly can be seen in the document Operator Tooling Prototype Development

Actuating the Opener

With guidance from an expert at Micropen, we have arrived at a final decision for an air solenoid to be used with the system. The Humphrey 15337-24VDC air solenoid meets all of the requirements to operate properly with the air system that is currently in place in the production cell at micropen. We have also chosen a 3 position toggle switch that will compliment the humphrey solenoid to complete the airflow control system.

Click on the following link for the complete summary of the Airflow Control System

Camera and Monitor System

After discussion with Micropen and a representative at Spectra Services, we decided that the best solution for the workstation was to add a KP-D20 AU camera to view the part, connected to a monitor in the back of the station that the operator can look at and work off of without straining their back or neck. That camera can come from elsewhere within the factory, and Micropen will purchase a higher quality camera to upgrade the station they pull the KP-D20 from. With the purchase of a new monitor and the proper mounting equipment, the station will see a large improvement to the operator comfort during work.
 Model of the updated workstation in solidworks to test out exact placement of the camera assembly in relation to the rest of the workstation.

Model of the updated workstation in solidworks to test out exact placement of the camera assembly in relation to the rest of the workstation.

Click on the following link for the complete summary of the Viewing Subsystem

Operator Keypad

Two designs for the keypad are being proposed through the operator survey. The survey will allow the operators to give input as to what the believe the optimal configuration of the keypad will be. The best layout will allow us to optimize efficiency and easy of use for the operators while minimizing ergonomic risk as much as possible. While the covers for the keyboard were a concern previously we have also determined that they will not be necessary. The keypad covers were a leftover component from when the production process utilized the use of acetone much more liberally. Since that is not longer a significant concern we will be using keys that have a built in clear plastic cover on each individual key instead.

Click on the following link for the complete summary of the Keypad Redesign

Proper Seating Position

The solution agreed upon for the Operator Seating Position subsystem was determined to be a recommendation by the RIT MSD team for an ergonomic chair that could be purchased in the future.

Fulkerson Services Visit

The team visited Fulkerson Services to look at their ergonomic chair inventory to see if any of their supply works for creating proper seating position for the workstation. Fulkerson Services is a company that buys out old company’s inventory and sells it for a reduced price. After surveying their vast chair selection, there was no chair that improved the current seating in the workstation. Pictures were taken and the notes from the trip is documented here Fulkerson Services Interview Notes

Stretches and Exercise

Reviewed sheets with SME and gained approval of the Stretches and Exercise sheets. They will be laminated and posted in the work area for the operators to reference throughout the day.

WIP Fixture Tile and Stand

A height and angle adjustable WIP fixture holding stand was created in order to conduct testing of the various WIP fixture layouts which the team has proposed. The adjustability of the stand allows us to also examine the possibility of adjusting how the WIP fixture itself is oriented in space while the operator is placing the completed parts into it. We have determined a set of tests that will be conducted in order to determine the optimal part loading angle for the WIP fixture.

Initial testing of various WIP fixture configurations have also been performed. Initial observations from the team show the ease of placement of the parts is improved with the proposed layout configurations and sizes. Testing will continue in order to determine what the optimal WIP fixture size and layout will be in order to maintain throughput, not increase scrap, and most of all reduce the ergonomic risk on the operator.

 The times displayed above are the average seconds per hole. The errors are a count of the number of defect parts that would be produced by the tester using this method and tile set up. The grey combinations are not supported by improving the ergonomics of the workstation and easing the difficulties associated with placing the parts in the WIP fixture.

The times displayed above are the average seconds per hole. The errors are a count of the number of defect parts that would be produced by the tester using this method and tile set up. The grey combinations are not supported by improving the ergonomics of the workstation and easing the difficulties associated with placing the parts in the WIP fixture.

Click on the following link for a summary of the initial testing for the WIP Fixture Tile

Kink in the Wire

An initial prototype of the Wire Kinking tool has been completed, but during testing it was found that the hinge needs to be more robust in order to support the kinking of a large number of wires with a single action. The kinking tool is currently being redesigned in order to have a hinge that will be able to withstand the force of bending 50+ part holding wires at once.
Machine shown above is comprised of a base, hinge, and lever which control the movement of the crimping forms for the wires.

Machine shown above is comprised of a base, hinge, and lever which control the movement of the crimping forms for the wires.

Additional Recommendations

Work Schedule Modifications

There are process changes that can improve the physical well being of the operators who are performing repetitive movements on a regular basis. Our team advises a change in the work shift schedule that rotates operators throughout the factory at a much more rapid interval. Click here for more detail about our recommendation.

Click on the following link for the complete summary of the Suggestion For Work Schedule Modification

Risk

 Updated Risk Management

Updated Risk Management

Click on the following link for the latest version of the Risk Management

Plans for next phase

As we enter the next phase of our project, we approach the completion of the design course. We will be finishing the testing of all our engineering requirements and documenting the results in a meaningful manner. The technical paper will need to be mostly complete by the end of the phase, so it can be finished in the final weeks of the semester. Imagine RIT will be one of the later weeks of this phase, and our team needs to be ready. We will have a poster prepared detailing our project progress, as well as a plan on what we will present during the event.

Additionally, as our testing draws to a close, we can begin integrating our subsystems into the workstation at Micropen so that they can begin their vetting process that is required by companies that make medical devices. It also gives their operators a chance to work with the new improved station and give us feedback on what was improved and what needs to be worked on in future iterations of the workstation.

Click on the following link for the rough draft of the ImagineRIT Poster

Products will begin to be integrated into the testing workstation at Micropen for analysis


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