Integrated System Build & Test
Table of Contents
Team Vision for Integrated System Build & Test PhasePhase Objectives:
In this phase the team would like to accomplish these tasks:
- Complete Plan to create tile mold
- Complete Plan to create top tile mold
- Complete Construction of Plastic Mold
- Pour first tiles
- Purchase Materials for Zinc Roof
- Purchase Materials for Test Roof
- Meet with Business Team, learn more about Costs
In this phase, the team has divided these goals into these themes and assignments:
- Matt - will be ordering materials and doing design work for the top tile.
- Derick - will be leading project management tasks, working with Saunders team integration, problem tracking, and guiding team discussions.
- Dan - will be in in charge of the technical steps to create the tile molds.
- Connor - will be in charge of researching risks and planning manufacturing requirements.
UpdatesPulse of the Project
With only 24 days until IMAGINE RIT, the Engineering team has been working on making sure that the scope can be created without a heavy crash of work. As of right now, some updates include:
- Mold Creation Process Problems, Material Choices problems, adding to time needed for molding
- Top Tile Choices, same material, same frame, new attachment methods
- Consciousness of choices based on the status of the business: the team is trying to minimize costs from mix, and methods
- Frame has been expanded, now being used for both tiles
- Test Roof ALL materials acquired - ready for building
Pouring and Curing Below is a chart showing when we will be planning to pour some of the tiles. We will be able to pour 4 Normal, N-tiles for each Batch. We will need for our minimum amount to complete our tests, 12.5 tiles, however we are hoping to have at least 14-16, to accommodate for all of our needs and the Saunders team's needs. The legend for the chart is below as well.
Below is the Subsystem Decomposition showing what features the team has been working on this phase:
Current Business Case SummaryWhat the Saunders Team has been working on:
- Really trying to understand who our customer is while factoring in up scaling and expansion possibilities over the next 5-7 years of the business. This includes details like studying the demographics of Nicaragua, what a reasonable price point would look like, and our product's potential marketing points.
- Analyzing how a real distribution/supply chain network would look once the business is initiated as well as considering expansion possibilities. This includes details like material and transportation quotes, supplier locations, different market locations and sizes relative to El Sauce, and the beginning of our supply chain strategy. We have not identified any specific suppliers that are ideal for the project at this time.
- Finally, how the two above points are impacting our financial model. This includes details such as factoring in the start up loan, number of employees and how operations impacts ability to fuel amount of demand presented, potential growth factor analysis, and expansion costs as the business grows. One option that we recognize is there but have not worked with the idea yet is the possibility of franchising the business.
Mold Prep and DesignCreating the plastic molds is a three step process:
- Maching out foam negative
- Two pieces of foam insulation board were glued together with a spray adhesive and machined. Machining was done on the CNC router in the Construct, using a 5/8" ball mill. CAM programming was done in Inventor HSM with the help of Mike Buffalin.
- Pour plaster into negative
- Two 128 oz buckets of plaster were mixed and poured into the mold. During our first attempt to mix the plaster, we made the mistake of putting the powder in first, then putting in water. This caused the plaster to harden before we could pour. For our next attempt, we sprinkled plaster into the water, which worked much better. We allowed the plaster to cool for 8 days before forming.
- Form plastic over plaster positive
Upcoming TestsMatching Tests to Tiles
Below are the tiles that were specified above in the updates section, under the 'Pour Chart'. We have mapped out which tiles will be used for which tests, based on how long the tiles need to cure for, and what strength they have to be. Notice that our priority is to complete our needed tiles with at least one for the Saunders Display, and then continue (In RED) to produce for a better experience for both our team and Saunders for IMAGINE RIT.
As a reminder for the tests that are upcoming in the next few weeks, here are descriptions:
- Test roof with tiles and with zinc roof will be left out in the sun. A temperature sensor will record temperature changes underneath roof. Results of different roofs will be compared.
- Solar Heat Gain Test Procedure
- Solar Heat Gain Test Template
- Water will be poured over tile for an extended period of time. Reservoir underneath tile will collect any water that comes through, which will be measured.
- Waterproof Test Procedure
- Water Durability Test Procedure
- Water Durability Test Template
Wind Resistance Test
- Pry bar will be used to lift tile off of roof. Hanging scale will be used to determine the force required.
- Wind Resistance Test Procedure
- Wind Resistance Test Template
- Weights will be stacked onto a tile until failure.
Task Breakdown Structure
Below is the task breakdown for the manufacturing process with estimated times for each task.
The data was collected by watching the video of EcoSure tile creation and then scaled up by 150% for necessary tasks (pour concrete onto frame, fill nubs with concrete, etc.). From there we adjusted the numbers to account for errors and/or unforeseen circumstances (machine downtime, sick workers, product defects, learning curve, etc.)
The total estimated time to create 20 tiles in a day is 4 hours, 10 minutes, and 29 seconds. (includes cleaning of molds and moving of inventory to next area)
When considering an 8 hour workday, there are 6 hours of productivity for workers. Other time can be used to grind pumice, shred plastic, order more materials, and other miscellaneous
Inventory Movement Time
Below is a chart for the calculations made to determine the time to move designated tiles forward one step.
Bucket Amount Calculation
Space Requirements Table
Below is the space requirements for tasks in the manufacturing process. As you can see for the curing and finished inventory, the required amount of space is significantly lower than the area projected for the task. This is so that there are 3 foot walkways so that workers can ergonomically pick and place tiles.
The total amount of space needed is 50x60 square foot area.
Updated Facility Layout
Below is the updated facility layout. The tasks outlined in yellow are to signify that the task needs a roof over it. All other tasks are covered by a tarp except for plastic shredding & 7 day cure. Any thoughts or suggestions?
Plans for next phase
- Iron out the details of standard work procedures (labeling tiles for standard work)
- When creating tiles for the test roof record any problems we run into and come up with solutions for the manufacturing process
- Create a MASTER PRODUCTION SCHEDULE that would be able to take in demand patterns and help figure out when and how much material needs to purchased. - This will be based on a PULL System' due to the high costs of material that would be wasted in inventory, over the lower cost of labor.
Risks and Problem TrackingBelow is our Risk Assessment for this phase:
Below is our problem tracking table. This tool is useful in conquering some of the obstacles in an organized manner. Note that not all problems have been solved yet.
Plans for next phaseThe team will focus on these deliverables in the next Phase:
- Complete construction of tile mold
- Complete construction of top tile mold
- Complete pouring of at least 13 tiles
- Complete pouring of at least 3.5 top tiles
- Complete product tests
As a Visual, a Critical Path Diagram has been created. This diagram showcases all the steps needed to be taken, which step precedence preserved by the spacing and flow of tasks. As a note, THE RED IS THE CRITICAL PATH, or the longest and most important to complete series of events. This will be a priority to complete right away.