Detailed Design Review Week 12 María Camila Luna Pablo Santizo Zak Borden Zach Delurey

Expectations Verify designs with experts Validate modified base design Ask for guidance and next steps Validate modified base design Feedback Ideas for optimization

Introduction Suggestions from Design Review: Future Objectives Micro-manipulator Pressure sensitive adhesive Logo sticker Future Objectives Optimization process Ergonomic refinement Smaller patch size

Flow Diagram * Outsourced processes Cut individual patches* Manufacture back plates* Place patches in bins (according to color) Arrange bins according to customer order Place individual patches and base plate on static mat Place adhesive in pockets Pick individual patch using vacuum pen Place patch in correct pockets using magnification device Inspect for any flaws using magnification device * Outsourced processes

Cutting Individual patches vary in size In talks with Boston Lasers for outsourcing the cutting process Currently sending material for patch samples Patches will be analyzed for quality and accuracy No burn marks Perfect size

Cutting (Cont.) Individual patch sizes> pocket sizes 1/16" pieces Measurements (mm)   1/8" pieces 1.649 1.653 3.177 3.266 1.597 1.645 3.285 3.277 1.611 1.655 1.603 1.614 1.622 3.200 3.239 1.661 3.373 3.192 Average= 1.631 3.253 Pocket size= 1.603 x 1.607 3.219 x 3.219 Individual patch sizes> pocket sizes

Base Plate Design Manufacturing of back plate will be outsourced Due to patch measurement, future prototype will include: Wider pockets Deeper pockets Logo is no longer engrained in base plate Logo Sticker

Vacuum Pen Time study results: Time to complete one row (5 patches)   S1 S2 Trial 1  51.27s  49.00s Trial 2  44.16s  42.15s Trial 3  22.24s  26.14s Trial 4  24.76s  39.72s Trial 5  26.01s 24.60s  Trial 6 19.03s 22.19s Trial 7 23.14s 18.81s Trial 8 17.20s 25.06s Trial 9 21.70s Trial 10 17.59s 24.43s Time study results: Time to complete one row (5 patches) Learning curve From ~50s to ~20s Pace is hard to keep for entire target Eye fatigue

Time to complete one small target Vacuum Pen (Cont.) After team was familiarized with task: Time to complete one small target   S1 S2 S3 S4 Trial 1  2.69m  2.63m  2.79m 2.87m Trial 2  2.97m  3.60m  2.33m 3.08m Trial 3  2.65m 2.83m  2.38m 2.48m  Average 2.77m  3.02m   2.50m 2.81m  Team average <3min

Vacuum pen (Cont.) Other observations: Easy to use, steep learning curve No damage to the surface of the patches Vacuum pen sometimes picks up more than one patch Patches sometimes turn around when dropped Tips #1, 4 & 8 are better for small tiles Tip #2 is better for large tiles Ergonomic issues

Ergonomic issues Posture Vibration of the pen Sound of the pen Length of the task Eye fatigue Magnification device

Adhesive Testing Spectrophotometer Measure the color reflectance before and after the spray adhesive Macbeth Color-Eye 7000 Individual Patches tested Green Blue Yellow Testing after curing time and after 3 days

Reflectance Change cause by Scotch Adhesive- Green Patch

Reflectance Change cause by Scotch Adhesive- Blue Patch

Reflectance Change cause by Scotch Adhesive- Yellow Patch

Color Difference Delta E > 1 = Visible difference Delta E for the Yellow Patch >1 There is a significant color difference created by the adhesive The patch gets lighter and greyer (decrease in L* and b*)

Adhesive KRYLON: High Strength Spray Adhesive 30 minutes curing time Does not dry clear Dense material, very messy on the sides Not a feasible solution for this application SCOTCH: Photo Mount Spray Adhesive 5 minutes curing time Dry clear Seems to affect the reflectance of the yellow patch after curing time The effect decreased after 3 days of curing, but it is still noticeable Further testing to verify the results (different application techniques)

Risk Management New risks: Change to existing risks: Cannot get individual patch samples from laser cutting company Variance in the size of the patches is too large, which prevents patches from self-aligning Not receiving the static mat early enough to test it Change to existing risks: Adhesive damages surfaces, cure time, does not dry clear (does not meet requirements) Process is not ergonomic

Preliminary Testing Plan Order at least one of each desired size Order 60 units for final testing This gives >95% confidence for pass fail trials Conduct time trials for: Assembling targets Switching from one color scheme to another Calculate unit cost for all inputs to find UMC Inputs include plate, cut paper squares, glue and labor (assume a wage for labor and multiply by time) Measure assembled targets for % of damage, and positional accuracy with a microscope Calculate yield

Next Steps Test and select adhesive Explore magnification options Explore and verify compliance with applicable ergonomic standards Measure squares from supplier to determine required pocket sizes Order new tiles to test different pocket sizes and depths Block out layout of Assembly area Identify areas where the process or product can be improved Construct a bill of materials