Preliminary Detailed Design
Team Vision for Preliminary Detailed Design Phase
Prototyping, Engineering Analysis, Simulation
Time Study Data
Avg Trial Time
Time to Insert 5 WindowSkins
Feasibility: Prototyping, Analysis, Simulation
Jamestown Shipper Options
Jamestown shipper options without required tooling are Regular Slotted Container (RSC) or Full Overlap (FOL).
Regular Slotted Container (RSC) is recommended by Jamestown, requires less material, and is cheaper. RSC will be used for all the propsed shipper sizes.
Full Overlap (FOL) is stronger from overlapping material and more expensive but the extra strength is not needed for the packaging. Because the extra strength is not needed, RSC boxes will be used as the shipper.
Packaging Solution Concepts:
Fold Over Concept
The fold over concept shown above helps protect the corner and edges. This concept also helps simplify the unpackaging process improving customer experience.
Bump Out Design
The bump out concept helps prevent sagging.
Drawings, Schematics, Flow Charts, Simulations
The proposed shipper sizes were selected from considering standard pallet sizes and looking at current WexEnergy order sizes. Four standard shipper sizes will accommodate all possible size WindowSkins. The sizes were optimized to best fit various WindowSkin sizes while easily packaging different proposed shipper sizes to fit on pallets. The shippers will be RSC boxes as explained above. Shipper size 1&2 can fit on a standard 48”x40” pallet and size 3&4 can fit on a custom 60”x40” pallet. The shippers will be made out of 32 ECT corrugated cardboard and the extra strength from the 44 ECT is not needed for the shipper.
The four standard size shippers can accommodate all possible size WindowSkins. The size range of WindowSkins is listed in the chart above.
Four different dividers will be made, one for each proposed shipper size. The chart above shows the required height and length of each divider for each standard shipper size. All dividers will be corrugated so that they are strong enough to protect the WindowSkins.
Bill of Material (BOM)
Bill of Materials
Design and FlowchartsSub-assembly Interface Diagram
Risk AssessmentDuring this phase, two new risks were added to the risk table and accompanying graph:
- New proposed insert design is too costly to make. While our new design for the insert solves a lot of the problems and flaws that we found in the current design, cost is always an issue. if the design is too expensive to manufacture then we will have to start over in coming up with a new design for it.
- Customer has issues unpacking the WindowSkins upon delivery. The customer is an integral part to WexEnergy's success. If they have a hard time removing the WindowSkins from the box and are unsure of what to do, then they may be less inclined to purchase them again in the future. This tarnishes WexEnergy's reputation, and goes against their policy of having a high level of quality/service with their product.
When comparing all of the risks we found two that were tied with the highest score, and are therefore the ones will shall try to mitigate the most:
- Cost of current solution is greater than WexEnergy's cost
- New process takes longer than WexEnergy's current state
For any supplementary information on the risks please see the associated live document with all risk data.