Team Vision for Detailed Design Phase
Goals for this Phase
- Begin initial implementation of floor plan
- Tape beginning set of tables for new process
- Modify CAD for glue well design, rolling tray, and neckband dispenser legs.
- Purchase wood for rolling tray.
- Create prototype of neckband dispenser legs and complete initial testing.
- Create prototype of rolling tray and start initial testing.
- Complete feasibility analysis of the glue well slope and run experiment to confirm.
- Select battery holder.
- Purchase motor, battery, and push button.
- Complete initial design for motor and push button container.
- Set up taped tables and ran time trials, comparing them to previous trials ran.
- Created operations guide to new taped system.
- Ran experiment with carts to determine their viability in future floor layouts.
- Modified floor layouts for future testing.
- Completed experimental and theoretical testing for slope of glue well.
- Completed bench marking for battery holder.
- Created wiring diagram for push button.
- Created a preliminary mounting and coupling design for the motor attachment.
- Created prototypes of neckband dispenser legs and the rolling tray.
- Tested neckband dispenser legs on dispenser.
- Ran experiment to determine feasibility of glue remover on rollers.
- Modified CAD designs, Bill of Materials, Test Plans, Risk Assessments.
Documentation for Workbench ExperimentThe first experiment that was conducted on site was taping off one of the work benches with visual queues to signal material handlers when to deliver and pick up boxes of bottles. The flow of work moves from left to right. The first iteration of the tape allowed for 6 incoming boxes on the left and 4 outgoing boxes on the right.
The following documents are training materials provided on the following process changes we tested with two operators and all material handlers. In addition, a feedback form was created, for the days we could not observe the experiment.
Feedback & ObservationsThroughout the experiment, observations and feedback from both operators and material handlers were obtained. The following are some of the findings:
- Hard to reach across the table versus if it was on a side table it was closer
- If operator did not have the little table, preferred not having to bend down to pick them up
- Disabled operator liked the old way better and felt the old way was faster
- Not enough room on the table
- Tape was coming up slightly off the desks after a day
- Liked that they didn’t have to bend down to place boxes on the floor
- Easier to pull versus push the cart
- Use of the cart at the initial opening of the skid was chaotic
- Not emptying cart before returning back to skid to restock
- Case fell off of the cart and broke a bottle
Work LayoutThe following layout was the way the floor was setup for the first taped off table experiments with material handlers using carts.
This layout shows a future state with 10 work benches. The aisle widths are able to fit a 31"x 23" cart with ease for the material handlers to use.
Process Changes for MSD II
- The proposed process changes above will begin August 28th, 2017 (with beginning of our fall semester)
- Batching in 4 vs. 6 cases
- Taped-off table feedback (from 2 experiments)
Mechanical Engineering ImprovementsWe are looking to gain approval of the following items:
- Battery Holder Selection
- Attachment of the motor to the knob design
- Approval of Mechanical Test Plan
- Next semester, could we obtain a neckband dispenser to prototype the legs with?
- Can we remove the suction cups from one neckband dispenser?
- Box of Bottles, empty or not, to test with at RIT?
Feasibility: Prototyping, Analysis, Simulation
Glue Well Angle AnalysisSince our last review, we have decided not to pursue the theoretical calculation. Instead, we have experimentally determined the best angle at which to incline the glue well. Next phase we will experimentally test at ArcWorks to obtain more data.
Benchmarking of Battery HoldersThe following table is a list of possible battery holders. At our last review, we decided to go forward with putting 8 AA batteries in series to make the 12V required by our motor selection. All of the battery holders in the table hold 8 AA batteries and have leads. Additionally, some have covers to protect the batteries from a limited amount of liquids and from falling out.
Our recommendation is the Jameco Reliapro 2260851. This battery holder has leads and a cover. It is approximately 4.3" in length, 2.3" in width, and 0.65" in height. It costs $3.95, not including shipping.
For a link to the full spreadsheet, including website links, click on the following: Benchmarking of Battery Holders
Wiring DiagramThe following figure is the wiring diagram for the modified glue well. It consists of the motor, switch (push button), 12 V Battery (8 AA Batteries in Series), and a Diode.
The diode limits the flow of current to one direction. Basically, it allows the current to flow "forward" when the pushbutton is engaged but once the pushbutton is released it prevents current backlash. Meaning that current can not flow in the reverse direction. This is a safety mechanism to prevent the motor from frying. We have obtained the diode from RIT.
Preliminary Mounting DesignThe following figure is our preliminary design for mounting the motor, push button, and battery holder to the knob. A more detailed drawing will be created next phase. This mount will be 3D printed.
Preliminary Coupling Design
Prototyping of the Rolling TraySince our last design review, we have made a prototype of the rolling tray. The rolling tray was fabricated at the machine shop using the following mechanical drawings. The actual rolling tray can be seen in Figure XXXXX. The actual rolling tray was made out of plastic available at the machine shop at RIT, at no cost to ArcWorks.
In the next phase, we will test the rolling tray at RIT and make modifications. Once we believe the prototype is accurate we will test at ArcWorks to ensure it improves the process.
Prototyping of the Neckband Dispenser LegsWe have made a couple of different prototype of the neckband dispenser legs since our last review. The first prototype had an opening that was not sufficient to fit over the bottom of the neckband dispenser.
The second neckband dispenser leg had a slightly larger opening that we believe is adequate to fit over the neckband dispenser.
The final leg will have a rubber coating on the bottom to ensure that it does not slide on the table. The fit of the leg will also be tighter to ensure that the leg does not slip of the neckband dispenser. We request approval to remove the suction cups off one neckband dispenser to ensure the proper fit.
Cleaning Glue RollersSome glue well rollers show signs of corrosion and can sometimes get stuck during operation. Based on the recommendation of the RIT machine shop, Goof Off was used to clean the glue rollers. One end of a roller was submerged in Goof Off for approximately 3 hours before being removed and wiped clean. The Goof Off removed a layer of dried glue but didn't have much of an effect on the corrosion. This could be a possible solution to prevent glue rollers from getting stuck.
Improve Glue Well Design
Rolling Tray Design
Neckband Dispenser Legs
Bill of Material (BOM)The following figure, is the updated bill of materials since our last review. We have purchased the motor and the wood so far. Before our semester ends the push button will have been ordered as well.
Test PlansThe mechanical engineering and process improvement test plans have been updated since the last review and can be found with the following links:
Risk AssessmentMSD I Risk Assessment: Risk Assessment
Design Review Materials
- The Detailed Design review was presented using the EDGE website on 5/10/2017 at ArcWorks.
- The agenda for this presentation: Agenda
- The notes from the review can be found here.
- The following action items were recorded during this review:
Plans for next phaseMSD II Project Plan: Project Plan
Personal Goals for Next PhaseEmily Hebert's Three Week Plan: Emily's Plan
Troy Bailey's Three Week Plan: Troy's Plan
Cassie Kaczmarek's Three Week Plan: Cassie's Plan
Kyle Chrysler's Three Week Plan: Kyle's Plan
Lachlan Newcomb's Three Week Plan: Lachlan's Plan
Justin Cook's Three Week Plan: Justin's Plan