Integrated System Build & Test
Team Vision for Subsystem Level Build & Test Phase
What we planned to do during this phase
- Finish design of bottom of Motor Box
- Finish design of motor coupling
- Begin design of motor box top
- Complete the wiring of the system
- Finish prototyping rolling tray
- Complete the design of the neckband dispenser legs
- Choose material to place on bottom of neckband dispenser legs
- Begin testing of mechanical improvements
- Continue testing of industrial engineering improvements and monitor production levels
What we accomplished during this phase
- Determine the level of glue to place in glue well's
- Finalized the motor box bottom design
- Initial prototyping of motor box top design
- Tested different materials for underneath the bottom of the neckband legs
- Finialized the neckband dispenser leg design
- Tested push-button response time
- Designed the second prototype for rolling tray and ordered material
- Tested the 3D printed coupling and determined that a 3D printed part would not work after speaking with the machine shop.
- Redesigned coupling so that the machine shop can manufacture the coupling out of aluminum.
Industrial Engineering Improvements
After measuring the glue-level in 10 of the glue wells during a break at ArcWorks this is what we found:
Increase in production per operator in bottle-wrapping station since January 2017 (almost 11 months ago):
Standard Work Survey Results
During the last review, everyone filled out a Standard Work Survey so we could gauge how far to go when developing standard work documents for the bottle-wrapping station. Here are the results from that survey:
Since most of the averages were around 2 we've decided to create standard work documents for restocking, cart use, setup, cleanup, and changeover (not the actual bottle-wrapping but we will create one for the rolling tray's operation).
Standard Work Documents
Opportunities for Increased Productivity
Here are additional tasks we can pursue to increase productivity within the bottle wrapping station:
- Material handlers pre-stamping labels
- Quality/ production metrics on white-board posted in bottle-wrapping area
- Continuous changeovers (even when flavor changes)
- Utilize additional cart
- One cart to distribute cases, another to collect
- Never carry cases rule
- Signals (flags for example) for when operator is running low on cases and needs material handler to deliver additional cases
Mechanical Engineering Improvements
Motor Box BottomThe motor box has been modified since the last review:
- The box for the push button was added.
- The length and width of the motor box were increased.
- A piece was attached towards the end of the motor to hold it in place better.
- The motor holders and hole were raised.
Motor Box TopThe motor box top has changed since last time:
- The outer dimensions of the motor box top have been enlarged to fit the new dimensions of the motor box bottom.
- A support to hold down the motor has been added
- The height of the top has been lengthened
- The slot for the motor shaft has been modified for a better fit.
Motor Coupling / Motor WobbleThe final CAD model of the motor coupling has been completed. The following figures show the finalized design.
After the CAD model was completed, we 3D printed the coupling. Then we permanently attached the rolling pin to the coupling using J-B Weld. We attempted to remove the coupling using force to no avail. Only by grinding or heating the J-B weld can it be removed.
Then we started testing the motor and rolling pin. A noticeable wobble was detected in the rolling pin when the motor was engaged. We brought the setup down to the machine shop. The shop analyzed the system and determined that the error was with the 3D printed coupling.
To address this error we have decided to make the coupling out of Aluminum. The aluminum coupling will have a set screw to make sure that it is removable from both the motor and knob. The material has been sourced from the RIT machine shop at no cost to ArcWorks. The following figures detail the new design.
Gate HookWe went to purchase the gate hook at Lowe's a few weeks ago and were surprised by the bulk. It is 6" in length, which is what we wanted but it is too bulky. The diameter is too large as are the attachment brackets. This is no longer a viable option. Other attachment ideas are currently being explored.
Modified Neckband Dispenser LegsThe last prototype was finished:
- The thickness of the side walls were increased
- The top of the leg was decreased to fit underneath the metal bar.
These were tested at Arcworks on one of the Neckband Dispensers. When fitted with a nearly full roll, there was more than enough room underneath for the device to function properly.
Rubber for Under LegsDifferent materials were tested to put on the bottom of the neckband dispenser legs.
The first was rubber bumpers made for kitchen cupboards:
These cost $3.98 and did not work well. The base with the adhesive is larger than the portion that touches the table. This makes the neckband dispenser leg unstable. These rubber bumpers are intended to soften the slam of a cupboard.
The second was a Non-slip Mat for Car Dashboards:
This cost $5.99 and is a non-slip mat made for the dashboard of a car to keep your cell phone from sliding. The mat is 11" x 6" and weighs 2.1 ounces. This material does not an adhesive side so it will need to be glued to the bottom of the neckband leg.
This material seems to work the best out of the three. This mat could be cut so that 65 legs could be done with one sheet. This is equivalent to 16.25 sets of 4 legs. The cost would be approximately $0.09 per leg or $0.37 per set.
The third was a non-slip grip pad:
This cost $3.97 for 2 sheets that are 4" x 5". These pads are intended to keep household objects in place, such as lamps and stereo systems. One side has the non-slip grip and the other has adhesive. The adhesive is most likely not sticky enough to keep the material bonded to the leg forever. Further testing would need to be done to determine if an additional glue would need to be used. From one sheet, 20 legs could be done. Two sheets come in one pack so 40 total legs could be done or 10 sets. Each leg would cost $0.10 to cover or $0.40 per set of 4.
The major change to the original rolling tray made during this phase was changing the distance between the edge of the tray and the curved rolling edge that guides the bottles during label application. Initially the labels were not aligned properly so that the print at the bottom was not visible. After testing the tray at Arcworks we concluded that this change fixed this alignment issue.
A second piece of HDPE was ordered from McMaster-Carr and will be used to create a second tray. The primary differences between this second tray and the original are slight dimension changes made to the curved rolling edge that guides the bottles and a dimension change to the overall length of the indented area that is intended to help prevent the label from shifting during the application process. Finally, the second tray will also be thicker to help make it more resistant to warping in the future.
Costs of 3D Printing
Bill of Materials
This BOM has been updated to omit the gate hook. Additionally, the HDPE material for the second rolling tray prototype has been added. Also, the costs of the motor and push button have been updated to include shipping. The new total is $176.06.
This total include the $40+ for 1 day shipping of the HDPE sheet. Since this item did not arrive the next day, we will be contacting UPS for a refund.
Test PlansME Test Plan
Risk and Problem Tracking
- Updated Risk Management Plan
- Updated Problem Tracking
Functional Demo MaterialsThe agenda for this presentation can be found at the following link: Agenda
Plans for next phase
Entering Verification & Validation Phase:
Emily Hebert's Integrated System Build & Test Phase Plan: Emily's Plan
Troy Bailey's Integrated System Build & Test Phase Plan: Troy's Plan
Justin Cook's Integrated System Build & Test Phase Plan: Justin's Plan
Cassie Kaczmarek's Integrated System Build & Test Phase Plan: Cassie's Plan
Lachlan Newcomb's Integrated System Build & Test Phase Plan: Lachlan's Plan
AMA IE Side Project
- Visited AMA in Churchville with Mike and Tricia
- Got to see AMA's facility, layout, and meet their operational staff and owner
- Continuing to develop cost estimate for bringing printing in-house
- Meeting with printing professor from RIT (who we've met with previously)
- Question: Monthly demand (# of bottles) for printing? Need estimate for cost analysis