P20414: Indoor Dry Toilet Base
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Systems Design

Table of Contents

Team Vision for System-Level Design Phase

At the end of the last phase, our team planned to do heavy research and concept selection in this phase. Since our goal is to enter the testing and manufacturing phase as soon as possible, research was needed in order to see what materials to use, what was possible vs impossible, processes, and then new information that popped up when doing the research.

Our team hit all our goals from the previous phase and actually got a little ahead of schedule. After some struggle in the beginning trying to decide what to focuse on, the team split up the research and each member was responsible for a different part. Potential future ideas came up that would never have been thought of before. The team also got access to the concrete testing lab and scheduled trainings which will be necessary to finish feasability testing and actually start prototyping.

Functional Decomposition

The functional decomposition diagram defines the main function of the project and classifies all the subsystems branching out of the main function. The team generated two different functional decomposition diagrams, product functional decomposition and manufacturing process functional decomposition. All the functions in the subsystems have to be completed in order to successfully produce the expected outcome.

Below is the functional decomposition for the product.

Product Functional Decomposition

Product Functional Decomposition

In addition to the snapshot, a link to the live document can be found here, Product Functional Decomposition.

Below is the functional decomposition for the manufacturing process.

Manufacturing Process Functional Decomposition

Manufacturing Process Functional Decomposition

In addition to the snapshot, a link to the live document can be found here, Manufacturing Process Functional Decomposition.

The functional diagrams clarified for the team the functions that need to be considered to achieve the project's goal. The diagrams also helped the team map out and easily tackle the following steps in this phase.

Benchmarking

The team created 4 benchmark tables as part of our research for best ways to manufacture the product. We split the benchmarking into 2 subsystems, The Base and The Diverter. From there we split those subsystems into 2 more. The actual materials that could be used to create said subsystem and different processes that could be used. These 4 tables were thought to have the greatest impact in the manufacturing of the toilet system. Criteria for each table was also decided upon by consulting with the customer requirements from the House of Quality. These researched ideas will help the team in future concept selection or at least give a starting point when creating prototypes. (Although 4 benchmark tables were created only the process tables are shown down below)
Base Forming Benchmarking

Base Forming Benchmarking

Shown above is the Base Forming Benchmark table. In order to decide how to form the base, a team member did research on different possible ways to manufacture the base. There were different criteria that were considered and also researched in order to help with the selection process later on.

Diverter Forming Benchmarking

Diverter Forming Benchmarking

Shown above is the Diverter forming Benchmark table. Just like the base benchmark table, a team member was in charge of the diverter forming. This table helped make important decisions on where to start with the forming process for the diverter.

All 4 benchmark tables PDF's can be found here:

Base Material Benchmarking

Base Forming Benchmarking

Diverter Materials Benchmarking

Diverter Forming Benchmarking

Concept Development

The concept development heavily branched out of the benchmarking step. The team chose the best concepts generated from the benchmarking table, then the team expanded more on these concepts by exploring the weaknesses and strengths to ensure that the chosen concepts are the most efficient and reliable.

Below is the concept development table the team generated.

Concept Development

Concept Development

In addition to the snapshot, a link to the live document can be found here, Concept Development.

Such step was crucial to show the drawbacks of each concept. As a result, the team was able to brainstorm on how to minimize such drawbacks and make the most out of the concepts selected.

Feasibility: Prototyping, Analysis, Simulation

The team identified a list of feasibility questions along with the approach to answer each question. These questions act as checkpoints to prove that the steps the team is taking are practical.

Below are the questions the team constructed.

Feasibility Analysis

Feasibility Analysis

In addition to the snapshot, a link to the live document can be found here, Feasibility Analysis.

This step proved to the team that early testings are needed to gather valid data.

Morphological Charts

Product Morph Chart

Product Morph Chart


Process Morph Chart

Process Morph Chart


Shown above are two Morph Charts that the team completed. The first is one of the end result product. The team mainly focused on the diverter and slight modifications to the product. SOIL likes the current design of the base so the team decided to focus their efforts on areas where improvement would be more beneficial.

The second Morph chart is one of the process. This is where the team wants to focus most of their efforts on. Different processes were considered from the current applying concrete by hand to the highly advanced concrete 3D printer.

PDF's of both Morph charts can be found here:

Product Morph Chart

Process Morph Chart

Concept Selection

The team generated various Pugh charts to help choose the most practical and efficient concept. Product and manufacturing process Pugh charts were created separately.

Below is the legend for the product Pugh chart.

Product Pugh Legend

Product Pugh Legend

Below is the initial product Pugh chart the team constructed.

Initial Product Pugh Chart

Initial Product Pugh Chart

Below is the final product Pugh chart the team constructed.

Final Product Pugh Chart

Final Product Pugh Chart

In addition to the snapshots, a link to the live document that contains all the iterations can be found here, Product Pugh Chart.

Below is the legend for the process Pugh chart.

Process Pugh Legend

Process Pugh Legend

Below is the initial manufacturing Pugh chart the team constructed.

Initial Manufacturing Pugh Chart

Initial Manufacturing Pugh Chart

Below is the final manufacturing Pugh chart the team constructed.

Final Manufacturing Pugh Chart

Final Manufacturing Pugh Chart

In addition to the snapshots, a link to the live document that contains all the iterations can be found here, Manufacturing Pugh Chart.

The Pugh charts helped the team decide which concepts to consider going forward with the project. The chosen concepts meet all the customer and engineering requirements that were generated in the previous phase.

Systems Architecture

System architecture diagrams ensure that the flow of energy, info, material and structural forces are as intended. The team generated two separate system architecture diagrams to tackle both the product and the manufacturing process.

Below is the product system architecture.

Product System Architecture

Product System Architecture

In addition to the snapshot, a link to the live document can be found here, Product System Architecture.

Below is the process system architecture.

Manufacturing Process System Architecture

Manufacturing Process System Architecture

In addition to the snapshot, a link to the live document can be found here, Manufacturing Process System Architecture.

The diagrams helped the team visualize how and where the flow of energy and sources are implemented in the project.

Risk Assessment

The team added more risks to the Risk Assessment file. There were more risks that could be specific this time because the team went into details. The risks now include things that can go wrong with prototyping, testing, and the actual product.

Updated Risk Assessment files for this phase can be found here:

Risk Management PDF.

Risk Management Excel.

Design Review Materials

Plans for next phase

Next 3 Weeks Plan

Next 3 Weeks Plan

Shown above is the plan for the next 3 weeks according to our original Gantt chart. We were on track with the Systems Design Phase and hope to continue this pace and schedule into the next phase. During our next review, the team hopes to have completed all its feasability analysis testing in the concrete lab. We also hope to have started the mold for the base of our toilet if not have finished. it. This will answer if the method we have selected is the right choice and if we should continue it. Having the mold complete will also let us know if the molds are able to be re-used. The team has already found ways to re-use small concrete molds but in this phase it will have to be scaled up and experts potentially reached out to.

Individual Visions

Colin:

Patrick

Jakob

Zyad

Updated Gantt Chart can be found here:

Gantt Chart


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