P17433: Plastic Bottle Upcycling
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Gate Reviews

Table of Contents

Your team will hold a gate review with your guide at the end of each semester. This page should document any information needed for the review, as well as outcomes.

MSD I: Readiness to move to Build & Test

All documents and files used for this phase can be accessed through the following Directory: Detailed Design Documents.

Team Vision for Detailed Design Phase

The following Table outlines the items that we are working on and their approximate percent completion as a result of this phase. A link to the file can be found here.

 Percent Completion Table

Percent Completion Table

Progress Report

In the next phase we want to finalize our designs and refurbish them based on the feedback received from our review. We will continue to iterate and adjust our designs and our BOM will gain detail and will refine as we progress on our designs. One of our main priorities is to consult subject matter experts on both the blade machining and the plastic recycling. Refining the designs will be very important for our progress especially for power systems as they will be some of the more complex parts. Afifi will be working with us on the designs of the touch points in the power system to ensure functionality as well as aesthetics. .

Drawings, Schematics, Flow Charts, Simulations

Our current CAD model for our shredder can be accessed and observed through the following link: http://a360.co/2fPvntd

The Drawing package can be found at the following file path: Drawing Package. This is a comprehensive set of part drawings which contain all necessary dimensions and specifications required for complete development of our Shredder.

Some of the latest drawings are shown below:

Full Shredder Assembly.

Full Shredder Assembly.

Shredder Blades.

Shredder Blades.

Blade Drawing.

Blade Drawing.

Side Panel.

Side Panel.

Front Panel.

Front Panel.

Blade Spacer.

Blade Spacer.

Sieve.

Sieve.

Sieve Mount.

Sieve Mount.

Even under these extreme conditions, there is very little deformation of the blades and this indicates that, provided we have a proper shear pin fail safe, we should see no issues related to blade damage from normal use.

1500 Newton Load Engineering Analysis.

1500 Newton Load Engineering Analysis.

Our designs are among the strongest portions of our project to this point. We have very high detailed models and we are pleased with our progress here. Our main takeaway from the design was focusing on the interaction of the subsystems involved in the shredder. The design should allow for a fluid modular shredder that allows for easy breakdown and maintenance as well as efficient transport. The consultation regarding the materials was incredibly beneficial.

Bill of Material (BOM)

The current Bill of Materials is seen below and a link to the live document can be found here: Bill of Materials.

Current Bill of Materials.

Current Bill of Materials.

Results of Consultation:

After consulting Professor John Bonzo regarding the machining of our blades, we received the following information:

Test Plans

In order to conduct appropriate testing of our system once we begin prototyping, we have developed a set of test plans to ensure we meet our predetermined engineering metrics. Each test plan has its own document to outline the objective, procedure, ownership, and other significant details necessary to complete the test.

A link to the directory containing all of our testing plans can be found here: Testing Plans.

The tests we plan to run consist of the following:

  1. Chip size and sieve effectiveness analysis
  2. Shredding force and shear pin testing
  3. Shredding Apparatus testing
  4. Stand stability testing
  5. Shredded Bottles per hour
  6. Ergonomic fatigue testing
  7. Mean time between failures
  8. Lock Out, Tag Out

We believe these tests will be thorough enough to vet any concerns the shredder may bring about and should help us validate our business case.

Process Steps and Flow

The following folder includes documents related to the flow of our process: Process Flow Documents.

The thought process we employed when making decisions based on our Engineering requirements can be found here.

A section of that can be seen below along with some systems breakdowns.

Engineering Flow Breakdown.

Engineering Flow Breakdown.

Systems Breakdown.

Systems Breakdown.

Functional Decomposition.

Functional Decomposition.

A list of justification for our designs and our procedures are documented in the following Directory: Process Justification.

Some of the justifications can be seen below.

Component Justification.

Component Justification.

Systems Justification.

Systems Justification.

Justifying each step of our process was essential to ensuring the success of our design. Following the flow process for the design phase was very useful and these images show our though process throughout the phase.

Risk Assessment

The following is an up to date image of our Risk Assessment:
Risk Assessment.

Risk Assessment.

The following link will direct you to the current version: Risk Assessment.

We have also updated our Customer and Engineering Requirements which can be found in the following document: Customer and Engineering Requirements.

From this exercise our main takeaway was that there are more variables than we initially identified and we have more risk to plan for. We feel comfortable, but we are also cautious of potential issues arising. Most of our contingency is adequate, but there are some gaps.

Industrial Design Progress

Afifi is a key component of the success of this project and he has been doing extensive research and work on various products and cultural solutions we can provide to the nations we are helping. His progress book and all of his research, sketches, and plans can be found in the following directory.

Industrial Design Work

Nicaragua Trip Progress

We are currently in the process of planning and coordinating a funded trip to Nicaragua to perform some target market research and gather feedback. All of the current progress is in the directory linked below.

Trip Information

Plans for next phase

The early phase of MSD II will be focused on design finalization, material purchasing and Beginning production of our system. We will also be focused on polishing the details of our trip and our product line. The following is a high level breakdown by month for the next phase. When we meet in the early weeks of next semester we will develop a more specific schedule on a weekly basis. A current copy of our MSD II plan can be found here: Project Plan

MSD II Project Plan

MSD II Project Plan

Value Expectations
January/Intercession
  • Finalize Project Plan
  • Finalize Designs
  • Purchase Known Materials
February
  • Finalize BOM
  • Purchase remaining stock materials
  • Begin Machining of materials received
  • Begin Assembly
March
  • Continue Building
  • Troubleshoot Building
  • Travel to Nicaragua to pitch products and consult locals
April
  • Finalize Assembly
  • Test Shredder
  • Finalize Documents for Imagine RIT
May
  • Present at Imagine RIT
  • Last Minute Modifications

The team developed a Team Vision and Individual visions for next semester. They are outlined here.

The following are links to our individual three week plans :
David Swerzenski Three Week Plan.
Evan Oslakovich Three Week Plan.
Michael Kist Three Week Plan.

Additionally, you can observe our team's meeting notes at the following link: Meeting Notes

MSD II: Project close-out

The final documents of our project can be found in the following directory: Final Documentation

A following is a brief summary of the outcome of this MSD Project:

1. Project Status.

While we believe we made great strides on this project, there is still much to be done before final hand off to our customers. The shredder functions well, however it needs some minor improvements and modifications to make it ready for full use. Following those modifications, tests need to be conducted to ensure that it is ready for its application in Nicaragua. Being a first iteration project working with the ID department, we believe this was a very successful project and are excited to see what it may become in future iterations.

2. Lessons learned.

As a team, this project has taught us many important lessons regarding designing and producing new products. It has been a long endeavor with many highs and lows. It taught us how important proper planning and preparation is, as well as proper contingency planning. We had several mishaps with part fabrication that caused severe delays that we were unprepared for. We grew and developed as a team as time went on and realized how to utilize each others' strengths and weaknesses to push towards a successful project. We had a constant battle with time as we all wrestled busy schedules and full work loads and therefore we all improved with respect to time management and prioritization.

3. Comparing project plan to actual status.

Our project plan was initially well laid out and was almost properly followed with the exception of one major set back. When the water jet failed multiple times, it delayed the project by over 6 weeks. This consumed all troubleshooting and test time that was originally set aside to ensure the device was fully operational. As a result, the final two weeks were very busy rushing trying to prepare the project. This was the second delay of the water jet we saw and had the machine been operating properly, we would likely have had no plan issues at all. In hindsight, the best course of action would have been to prepare alternative methods of fabrication such as outsourcing in case machine failure occurred.

4. Future recommendations.

The following are recommendations we make for future teams to improve our system and prepare it for use.

The following are our individual final plans and assessments of MSD 2:

The following are links to our individual Final Plans :
David Swerzenski Final Plans.
Evan Oslakovich Final Plans.
Michael Kist Final Plans.

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