P18031: Accessible Motorcycle Sidecar
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Integrated System Build & Test

Table of Contents

Team Vision for Integrated System Build & Test Phase

Objective

For this review, our goal is to update the customer and guide on status of the project as well as identify any changes we have made to the design, engineering requirements, and explain our plan forward to allow for timely and acceptable final product delivery.

Agenda

The agenda for this review will be:

Team Vision

For this phase, the team's initial priority was to complete manufacturing of the sub-systems, as well as continue working on final documentation and begin validation. As we began validation, issues arose and a redesign was needed. The teams goal toward the end of the phase was to complete the redesign of the sidecar, discuss and approve these changes with the customer, and complete detailed plans for the next phase.

Changes since last phase

With the approval from the customer and the guide, the following will be changed:

Planned Deliverables

Most deliverable are incomplete primarily due to large design changes
Type Validation Resource Status Comments
Fabrication Full Assemlby Jeremy Incomplete Phase 4
Fabrication Paint Erol Incomplete Design Change
Fabrication Assembly of Seat system Matt Incomplete Pre-assemble incomplete
Fabrication Lever Hiroki T Incomplete Design Change
Validation (Phase 3) Bolt pattern check Dobhran Incomplete Validation
Validation (Phase 3) Fit check Dobhran Complete Validation
Validation (Phase 3) Center of gravity Jeremy Incomplete Validation
Validation (Phase 3) Adequate storage Dobhran Incomplete Validation
Validation Full rider experience Erol Incomplete Validation
Validation Bike Design Hiroki T Incomplete Validation
Validation Aerondynamic function Matt Incomplete Validation
Validation Water resistance Matt Incomplete Validation
Validation Maintain stock lighting on tub Matt Incomplete Validation
Validation Ingress Egress Support Erol/Dobhran Incomplete Validation
Validation Ergonomic Test Erol Incomplete Validation
Validation Ingress/Egress Time Erol Incomplete Validation
Validation Support / safety system for passenger Hiroki/Erol Incomplete Validation
Validation Fullfills Dot requirement Hiroki Incomplete Validation
Validation Production cost less than 4000 Erol/Dobhran Incomplete Validation
Validation Producable by mechanic/machineist in 20 hours Dobhran/Jeremy Incomplete Validation
Report Bill of material (75%) Dobhran Complete Documents
Report Paper Report (75%) Dobhran Complete Documents
Report Drawings (75%) Dobhran Complete Documents
Report Manufacturing Process sheet (75%) Dobhran Incomplete Documents
Process Problem Tracking Hiroki Complete Problems found
Process Risk Management and Chart updated Hiroki Complete 7 risk added
Process Budget Sheet updated Erol Complete Expense within budget
Process Project plan updated Hiroki Complete MSDII phase 4 plan created

Risk and Problem Tracking

Problem Tracking Sheet

Problem Tracking Sheet

Risk Assessment

Risk Assessment

Risk Chart

Risk Chart

Design

Problems

Problem statement

5-Whys

5 WHYS

5 WHYS

Lessons learned

Lessons learned Action taken
We should have made model of the wheel frame and the bike itself to catch any interference We made the model of the Wheel frame and area for handles
We should of created a mock-up to figure out whether the dimension will fit the design. We created a mockup as soon as the new design was agreed by the team

Action Taken

Action Taken

Action Taken

Design Changes

CAD drawings

CAD drawings

Body Frame

Body Frame

Body Sheet

Body Sheet

V Riser

V Riser

Shock Square

Shock Square

Shock Stripe

Shock Stripe

Mockup

Mockup

Mockup

Mockup

Mockup

Validations

Validation Accountability Status Comments
Bolt pattern check Dobhran Incomplete Found fitment Issue during fit check, which resulted in design changes. Next fit check 4/5.
Fit check Dobhran Complete Initiated Fit check and found fitment Issue, which resulted in design changes. Next fit check is scheduled 4/5.
Center of gravity Jeremy Incomplete Delay due to design change, New date 4/14-4/16.
Adequate storage Dobhran Incomplete Delay due to design change, New date 4/14-4/16
Full rider experience Erol Incomplete Delay due to design change, New date 4/14-4/16. Requires Mark cooperation.
Bike Design Hiroki T Incomplete Delay due to design change, bike Design altered due to design change.
Aerondynamic function Matt Incomplete Delay due to design change, New date 4/14-4/16.Major changes due to the increase in size of the Tub.
Water resistance Matt Incomplete Delay due to design change, New date 4/14-4/16
Maintain stock lighting on tub Matt Incomplete Delay due to design change, New date 4/14-4/16. Only few validation required
Ingress Egress Support Erol/Dobhran Incomplete Delay due to design change, New date 4/14-4/16. Will be completed with help of Mark.
Ergonomic Test Erol Incomplete Delay due to design change, New date 4/14-4/16. Will be completed with help of Mark.
Ingress/Egress Time Erol Incomplete Delay due to design change, New date 4/14-4/16. Will be completed with help of Mark.
Support / safety system for passenger Hiroki/Erol Incomplete Delay due to design change, New date 4/14-4/16. Will be completed with help of Mark.
Fullfills Dot requirement Hiroki Incomplete Delay due to design change, New date 4/14-4/16.
ergonomic Test Erol Incomplete Delay due to design change, New date 4/14-4/16. Will be completed with help of Mark.
Production cost less than 4000 Erol/Dobhran Incomplete Delay due to design change, New date 4/14-4/16. May need to alter the Production hour.
Producable by mechanic/machineist in 20 hours Dobhran/Jeremy Incomplete Delay due to design change, New date 4/14-4/16. Most likely need to change the manufacturing hours based on current data.
Engine Temperature check Dobhran/Jeremy NEW Additional Validation, scheduled on 4/14 - 4/16. Free Thermocouple has been found for borrow.
fit check

fit check

Documents

Tech paper

Test plan

Test plan summary

Test plan summary

Test Plans

Budget

The Budget has not changed much since last review. Due to some of the frame changes we ordered more tubing from Klien Direct.
Spent to Date $2096
Budget $2500
Reserve $403

Phase 3 plan

MSD II phase 3 plan

MSD II phase 3 plan

MSD II phase 3 individual plan

MSD II phase 3 individual plan

Schedule

Member Individual Contributions Contribution Percentage
Erol Arican Budget, Part Orders (Jig, Seat, extra material), EDGE, Seat system assembly 19%
Dobhran Black Tech Paper, Update Drawings, Process Sheet, creating modified CAD drawings 19%
Jeremy Davin Jig, Cutting, bending, Tack welding 20%
Matthew Doroz Test plan(Finalization), Seat system assembly, mock up creation 19%
Hiroki Tanaka Problem sheet, MSDII plan, Risk Plans, coping and fishtail 21%

Plans for the Finish

Overall Plan for MSD II

Overall Plan for MSD II

Plan for MSD II P4

Plan for MSD II P4

Individual Plan for MSDII P4

Individual Plan for MSDII P4

Deliverables for MSDII P4

Deliverables for MSDII P4

Schedule

Individual Lessons Learned

Team Member Lessons Learned Action Taken
Hiroki Skipped Mock up of the door and the full dimension. Created mock up for the redesign, found a potential problem.
Dohbran A complete picture of package dimensions is vital for a working design Further constrained package space and altered design to fit
Erol Mockups and package dimmensioning is key Created redesign mockup and CAD models for the engine shock tower.
Matt Building a mock up for sub-systems is important before manufacturing. Constance contact with Guide is important for success in senior design. After issues were found, we created a mockup to see if our proposed solutions would resolve the issue. Plan to keep more contact with guide during phase 4.
Jeremy Creating Detailed mockup for the dimension Verify Trivial asepct of the design

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