P19667: Accordion Valve Manufacture

Problem Definition

Table of Contents

Objective Statement:

Manufacturing system to produce reed valves for accordion restorations by Scott Bellinger.

Team Vision for Problem Definition Phase

Planned to accomplish within this phase:

Accomplished within this phase:

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Project Summary

Project Summary

Bellingers Button Boxes wants to develop a table top manufacturing system for producing accordion reed valves. These valves are comprised of 2 or 3 different length layers of flexible plastic film adhered at one end. The valve functions to block airflow in one direction while allowing air flow in the opposite direction. Below is a matrix of all possible combinations, with a tolerance of 0.05mm:

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On average 7,000 reeds per year are produced, and this figure is expected to grow to 20,000 per year within the next 4 years. Currently these parts are only manufactured in Italy which includes the associated cost of international shipping. The purpose of this project is to create the first US manufacturing system for this assembly. There is potential for future business from restoration establishments in the USA and elsewhere to further increase yearly production and reduce the time for return of investment.

With a project budget of $1000, input to the system would be sheets or rolls of thin plastic film and potentially adhesives or solvents. Output would be finished valves assemblies configured for the possible combinations of width, lengths and number of layers specified above. Additionally, output valves may or may or may not have a hole at the adhesive end. The manufacturing system itself should be able to run in a single cycle mode as well as a fully automatic mode with a programmable counter to end the automatic run.

Key Stakeholders

Our project's key stakeholders are as follows:

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Use Cases

Scenario 1:

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Scenario 2:

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Project Goals and Key Deliverables

The customer can expect a system that can produce accordion reed valves automatically and without supervision. The system will have single valve and multiple valve production modes. Valves will be produced to multiple lengths and widths, as well as with either 2 or 3 layers of material per provided specifications.

Customer Requirements (Needs)

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Engineering Requirements (Metrics & Specifications)

Engineering Requirements

Engineering Requirements

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Through the customer requirements given to us by Scott Bellinger the following constraints were arrived upon:

House of Quality


The purpose of the House of Quality is to compare the customer and engineering requirements in order to verify that all customer needs are being met while at the same time checking that all engineering time is only going to needs of the customer.

Along with this the "attic" of the house is used to compare the engineering requirements, noting each relation with one another, both positive and negative.

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Risk Management

Below is our constructed Failure Mode and Effects Analysis (FMEA) for our project:

 Failure Mode and Effects Analysis for P19667

Failure Mode and Effects Analysis for P19667

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