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

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

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

4. 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

5. 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

6. 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

7. 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

8. 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

9. 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

10. 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

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

12. 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

13. Reflectance Change cause by Scotch Adhesive- Green Patch

14. Reflectance Change cause by Scotch Adhesive- Blue Patch

15. Reflectance Change cause by Scotch Adhesive- Yellow Patch

16. 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*)

17. 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)

18. 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

19. 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

20. 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