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Problem Definition

Table of Contents 1 Team Vision for Problem Definition Phase 2 Project Summary 3 Use Cases 3.1 Normal Product Wear and Tear 3.2 Extend System Life 3.3 Rapid Prototyping 4 Project Goals and Key Deliverables 4.1 Key Deliverables 4.2 Other Project Goals 5 Customer Requirements (Needs) 6 Engineering Requirements (Metrics & Specifications) 7 Constraints 8 House of Quality 9 Design Review Materials 10 Plans for next phase

Team Vision for Problem Definition Phase

The team’s goal for the problem definition phase of this project is to have a basic understanding of what Gleason expects to gain from this project. The team also wants to gain a basic understanding of Additive Manufacturing through their own research and on campus resources.

Project Summary

Additive Manufacturing seems to be the technology of the future for any business that creates mechanical parts in a variety of volumes. Gleason has decided to get a jump start in the process of converting over to additive manufacturing by beginning to look at some parts in an additive manufacturing perspective. The goal of the project is to save money in producing mechanical parts by creating a process that decreases waste, increases efficiency, decreases lead time, and decreases manufacturing costs. Several parts that Gleason initially wants to look at are currently very expensive to produce using traditional manufacturing methods, so there is high potential for success with this project. The scope of the project includes taking parts from part prints, through a redesign of the part for the most promising additive manufacturing method, and creating a working prototype that is proven to decrease the costs in producing the parts without sacrificing part quality.

Problem Definition.pdf (Content has been removed due to customer change)

Use Cases

Normal Product Wear and Tear

• Lifespan of the product ends and a new part has to be produced to replace the previous part in a time-sensitive manner.

Extend System Life

• Use additive manufactured parts that have be redesigned to be more efficient in the system in order to create a longer lifespan.

Rapid Prototyping

• Additive manufacturing also will be useful in providing rapid prototypes for other company projects.

Project Goals and Key Deliverables

Key Deliverables

• An optimized additive manufacturing processes
• The additive manufacturing assembly should have the same functionality as a traditional manufacturing assembly
• A complete technical data package that describes the part accurately and is vendor-neutral
• Cost-effective for 1 to 1,000 parts
• The process is transferrable regardless of part or manufacturer
• The process and the matching documentation is complete and easy to understand

Other Project Goals

• Construct a cost analysis of the current manufacturing process versus the new additive manufacturing process
• Have clear and regular communication with the customer (Gleason)
• Gain an understanding of how the parts created with additive manufacturing will primarily be used.
• Identify any improvements that could be made to the part itself and address them using additive manufacturing

Customer Requirements (Needs)

Our Customer Requirements document is a compilation of our customer's needs from the project that they have expressed to us in a variety of ways. If everything in our Customer Requirements list is completed to customer satisfaction, we know we have completed our project.

Live Customer Requirements Document

Engineering Requirements (Metrics & Specifications)

Based on our customer requirements, we came up with some Engineering Requirements to make sure we are satisfying all of the needs of our customer. A live document of the Engineering Requirements can be found in the link below the image.

Live Engineering Requirements Link

Constraints

• Use the part and technical package - provided by Gleason
• Meet the same specifications as original part, and improve upon specifications wherever possible
• Cost of new process should be less than the cost of the current process
• Material constraints such as material properties and difficulty of use of certain materials
• Vendor-Neutral 3D model

House of Quality

Our House of Quality demonstrates that the completion of our Engineering Requirements will inevitably satisfy our Customer Requirements.

Live House of Quality Link

Design Review Materials

• Content has been removed due to customer change

Plans for next phase

To stay organized as a team and to make sure each team member is giving their best effort, we developed a spreadsheet that reviewed team work up until now and went over for team plans moving forward.

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