Table of Contents
Manufacturing system to produce reed valves for accordion restorations by Scott Bellinger.
Team Vision for Problem Definition Phase
Planned to accomplish within this phase:
- Gain a general idea of how to create a manufacturing system for accordion reed valves
- Develop customer requirements
- Develop an interactive project plan
- Identify stakeholders and their roles in this project
- Create a project objective statement
- Develop engineering requirements
- Develop a house of quality
- Go through risk assessments associated with the project
Accomplished within this phase:
- Up to date EDGE site
- Developed and adjusted customer requirements according to Scott’s input
- Developed engineering requirements based on customer requirements
- Constructed House of Quality based on above
- Used HOQ to generate risk management and FMEA
Project SummaryProject 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:
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 StakeholdersOur project's key stakeholders are as follows:
- Scott Bellinger (Primary Customer)
- Bellinger's Button Boxes (Investor/Donor)
- Customers for Reed Valves
- Students at RIT
Use CasesScenario 1:
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)
Engineering Requirements (Metrics & Specifications)
ConstraintsThrough the customer requirements given to us by Scott Bellinger the following constraints were arrived upon:
- The size of the system must fit atop a table within the customer's workshop.
- The system must use standard 120V AC power.
- The budget for the system is $1000. Many components and equipment have been provided.
- The system must produce a valve within 10 seconds.
House of Quality
PurposeThe 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.
Below is our constructed Failure Mode and Effects Analysis (FMEA) for our project: