Integrated System Build & Test with Customer Demo
Team Vision for System Level Demo with Customer
The team wrapped up their prototypes and continued testing and implementing improvements for the customer hand off.
Industrial Engineering Improvements
Daily Production BoardIn the past few weeks, we've created and implemented a daily production board in the bottle wrapping area. Here's a picture of our first board (only made using white board markers):
After testing the board for a few weeks, we added tape to make the board somewhat permanent. Here's a picture of the final board:
Standard Work Documents
Mechanical Engineering Improvements
Motor Box Bottom
The following changes have been made to the motor box bottom since the last review:
- Reduced the height of the motor shaft exit.
- Reduced the height of the motor holders within.
Motor Box Top
The following changes have been made to the motor box top since the last review:
- Increased the width and depth of the motor box top to fit over the bottom piece.
- Shortened the maximum height of the top.
- Removed the internal motor holding.
- Moved the location of the push button hole.
Motor CouplingAs discussed in our last review we no longer are 3D printing our coupling. Instead, we had the RIT machine shop make it out of brass. One end is permanently affixed to the rolling pin and the other end utilizes a set screw to attach to the motor shaft. The set screw makes the motor and subsequently the motor box detachable from the rolling pin. This is crucial for cleaning the rolling pin at the end of each day.
The final coupling can be seen in the following image:
Additionally, we explored modifying the other end of the rolling pin. This modification was tested and determined to be detrimental. The longer end does not fit in all of the glue wells for starters. Also, it puts too much pressure on the bottom roller and a result too much glue is on the roller.
Modified Neckband Dispenser LegsFrom testing, we noticed that the upper portion of the legs, on occasion, broke off.
This is a design flaw that we rectified by adding a chamfer to the inside of neckband leg. This modification can be seen in the following figure:
Rubber for Bottom of Neckband LegsDifferent adhesives were used to attach the rubber to the bottom of the legs. In the end, just plain super glue worked the best. The following are the various types of adhesives tested:
Rolling TraySince the last phase, HDPE material was purchased to make a second rolling tray. The second tray was made using the CAD model presented during the last review for the Integrated System Build and Test phase. After testing it was determined that this second tray was superior to the first prototype in that the problem of labels moving during use was fixed.
Test Results Summary
Uniform Layer of Glue on LabelRIT
REQUIREMENT: Perform 20 trials, with 20 labels of applying glue to the label with the modified glue well. Test on 2-3 different people.
RESULT: 20/20 trials performed perfectly. PASS
REQUIREMENT: Perform 12 trials, with 12 labels of applying glue to the label with the modified glue well. Test on 4 different people.
RESULT: Four operators tested the glue well; three were non-disabled and one was disabled. Each operator tested a case and out of all of them, only 1 fail occurred. So 47/48 labels passed. PASS
- The one that failed can be explained because the operator failed to push the button as she pulled the label across the glue well.
- Also of note, with Indau test the labels were too wet. This is due to the modification to the other end of the roller.
Glue Well Touch Button Response TimeRIT
REQUIREMENT: Push button responds in 0.1 - 3 seconds. Test with 3 different people, testing 15 different times.
RESULT: Push button on average responds within 0.49 seconds. This is within the 0.1 - 3 seconds range. PASS
REQUIREMENT: Measure response time of glue well touch button after implementation. Perform 15 trials on 3-4 operators.
RESULT Non-Disabled: Push button on average responds within 0.75 seconds. This is within the 0.1 - 3 seconds range. PASS
RESULT Disabled: Push button on average responds within 0.57 seconds. This is within the 0.1 - 3 seconds range. PASS
Movement of Neckband DispenserRIT
REQUIREMENT: Perform 10 trials of removing neckband labels from the dispenser to test for any movement. Test with two different people.
RESULT: Both tests yield a pass/ fail rate of 10/10. PASS
REQUIREMENT: Perform 24 trials with three different operators ensuring that the dispenser does not move from its original position.
RESULT: Two out of three tests yielded a pass/fail rate of 24/24. Only one operator has anything less than perfect and that encompassed only 1 fail. PASS
Regarding Melissa's comment, this is what she does:
Time to Use Glue WellWhen we first started this project we predicted that the time to use the automated glue well would be:
REQUIREMENT: Collect time study data on at least 5 operators, two boxes of bottles each, to determine the time to use the modified glue well. This is from when they push the button till they remove the label from the rolling pin.
RESULTS: Four out of the five tests resulted in an average time that fell within the desired range of 3 – 7 seconds. The fifth test resulted in an average time exceeding 12 seconds.
Risk and Problem TrackingRisk Management
Bill of Materials
Cost of 3D Printing
Functional Demo MaterialsThe agenda for this presentation can be found: Agenda.
Suggestions for Continued Design
Industrial Engineering Suggestions
- Continue to set in place more ergonomic equipment to ease the stresses of the work such as ergonomic chairs and pallet jacks.
- Incorporate more 5S and lean principles through the use of the production board, introducing more visualization in quality tracking, and following standard processes.
- Ensure employee engagement to get buy-in for improvements and changes made.
Mechanical Engineering Suggestions
- Developing a pulley system for the top and bottom roller of the glue well so that they move together. This will reduce the unevenness of glue along the roller.
- Origninally, the motor box was going to be powered by batteries so to conserve their power we chose to use a latching push button. This means that to turn the motor the push button must be held down. Since we are now utilizing an outlet the power supply is not a concern. We would recommend exploring a continuous push button so that it does not need to be held down. The push button would be pressed down once to supply power and then pressed again to shut the power off.
- An automatic glue dispenser so that the glue wells maintain a constant level of glue.
- Continued development of the rolling tray.
Final Project Documentation
- Here is our team's final technical paper Final Technical Paper
- Here is our team's final poster Final Poster
- All documents to replicate this project have been downloaded to a flash drive. This flash drive was handed over to ArcWorks at the final review on 12/7/2017.
Plans for Wrap-up
- Plan on testing the modified prototype of the rolling tray. If modifications work we will modify the new rolling tray and hand off to ArcWorks.
- Finish printing the remaining sets of neckband legs and hand over to ArcWorks.