1. Low Energy Printing MSD Project P10505
David Hatch, ME
May 11, 2009
Design Project Management Project Review

2. Design Project Management Project Review
Project Statement
To develop a low energy printing fuser system, using cold pressure technology, capable of supplying a uniform pressure to sinter, coalesce, and adhere toner to print media
Original Image: Waseda University
May 11, 2009
Design Project Management Project Review

3. Background Information
Project Name and Number
Low Energy Printing Project, P10505
Guide and Consultant
Bill Nowak, Xerox Corporation, Principal Engineer - Motion Quality Systems
Primary Customer
John Knapp, Xerox Corporation, Research Fellow
P10505 is a continuation of P The current project builds on the work completed in P09505.
May 11, 2009
Design Project Management Project Review

4. Design Project Management Project Review
Project Relevance
Fusing is the most energy intensive portion of the printing process.
Xerox has expressed interest in decreasing energy use to open markets where electricity is expensive.
Brazil, Russia, India, and China (“BRIC countries”) are targets for this printing technology.
A fuser that uses cold pressure fusing will reduce maintenance needs due to wear.
May 11, 2009
Design Project Management Project Review

5. Intellectual Property
Xerox is protective of its intellectual property rights. Since MSD is in the public domain, some information may be limited.
The project scope should not be affected by this since our role is well defined.
May 11, 2009
Design Project Management Project Review

6. Staffing Requirements
This primary need in this project is to decrease deflection in the fuser roller system. There is the added difficulty of complicating factors that cannot be directly computed (paper wrinkles, tears, etc).
Three ME students: Strong background in CAD design, statics, dynamics, and finite element analysis.
Two ISE students: Capable in design of experiment and design optimization.
May 11, 2009
Design Project Management Project Review

7. Affinity Diagram Paper is Undamaged Paper is Unchanged
No wrinkles or tears
No paper gloss
Paper is Unchanged
Fuser accepts standard paper orientations
Fuser accepts standard paper weights
Xerox Quality Image
Low toner gloss
Uniformly bonded image
User Safety
User can easily clear paper jams.
Compatible
Fits into Xerox Workstation 245/55
Integrable with current Xerox technology
Profitable
Competitive Lifespan
Easily Manufactured
Low Manufacturing Cost
May 11, 2009
Design Project Management Project Review

8. Objective Tree Highly Marketable Low Energy Fuser Good Image Quality
Paper is Undamaged
No Tears
No Wrinkles
Low Paper Gloss
Uniformly Bonded Image
Low Toner Gloss
Compatible
Fuser Accepts Standard Paper Orientation
Fuser Accepts Standard Paper Weights
Fuser is Integrable in Current Xerox Printers
User Safety
User can Safely Clear a Paper Jam from the Fuser
Profitable
Easily Manufactured
Longer Lifespan
May 11, 2009
Design Project Management Project Review

9. Design Project Management Project Review
Objective Statement
Xerox Corporation wants to develop a cold pressure fuser because a fuser that uses less energy and has increased durability will make printers more marketable.
May 11, 2009
Design Project Management Project Review

10. Function Tree Highly Marketable Low Energy Fuser Good Print Image
Uniform Pressure
Variable Pressure
Low Manufacturing Costs
Manufactured using Common Materials
Easily Manufactured
Durability
Manufactured Using Tough Materials
Designed for Low Wear
Fusing Accomplished by Cold Pressure
May 11, 2009
Design Project Management Project Review

11. Technical Benchmarking
Paper Wrinkle
Correlation Codes
Paper Tear ++
Very Positive
Uniform Pressure +
NO INPUT IN THIS AREA
Positive
Toner Gloss -
Negative
Fuser Size
- -
Very Negative
Paper Gloss
Simplicity of Design --
Energy Use
Manufacturing Cost
Ease of Manufacture
User safety
Lifespan
Preferred
Dwn Up
Customer Perception
Engineering Metrics
Customer Weights
Manufactur-ing Cost
1 Worse 2 3 4
5 Better
Customer Requirements
Paper is not damaged 9
 ABCD
Image is Xerox quality
Fit into current Xerox Workcenter 245/55 Pro 1  s s  s
Use pressure only to fuse toner to paper
ABCD
Accept paper in orientation it currently enters fuser  S S
Compatible with other Xerox models
Fuser cost lower than current fusers  -
Easy to manufacture
User able to safely clear paper jams in fuser
 BC A
Low energy / non-thermal
Technology can be used up and down Xerox product line
Comparable fuser lifespan
Use standard office grade paper (20/24 pound paper) S 
Technical Targets
No wrinkles
No tears
∆pressure
< ±8-10%
Minimal gloss
Fits in 245/55
No metric available
<current
fuser
No metric Available
3 million prints (at least 100,000)
 Better 5
ABCD 
N/A  - 
A: Hot Roll Fuse
 N/A
B: Radiant Heat Fuse
Technical Benchmarking
C: Flash Fuse
D:Solvent Fusing
Worse 1
Raw score 57 84 81 45 15
162 28 27 18 36
Relative Weight 8%
12% 7% 2%
23% 4% 3% 5%
May 11, 2009
Design Project Management Project Review

12. House of Quality Conclusions
The main focus of the project should be on pressure application, followed by paper quality.
Cold pressure fusing is advantageous in regards to manufacturing cost, durability, and energy use. Its main disadvantage is a low quality image.
John Knapp has indicated that a low quality image is expected and considered acceptable for most office use.
May 11, 2009
Design Project Management Project Review

13. Faculty Resource Allocation
Faculty Resources
Source
Description
Available
Project Guide
Xerox Corp.
Bill Nowak worked with P09505 this year and will be guiding P next year.
Yes
Customer
John Knapp, division head of the “Green” Department at Xerox will be the customer for this project.
Technical Assistant
RIT
Gerry Garavuso will be available for technical advice during the project.
May 11, 2009
Design Project Management Project Review

14. Equipment Resource Allocation
Equipment Resources
Description
Available
CNC machining
The Brinkman lab is available on a first come first served basis. However, Xerox prefers to do most machining personally and will be the primary source.
Yes
Manual machining
The Brinkman lab also has capabilities for students to do manual machining.
Outsourced machining
If needed, Rochester has over a hundred machining shops which are potential resources in an emergency.
As needed
Miscellaneous hand tools
Hand tools will be needed during SD II. Tools are available by loan from the MSD center. The Brinkman Labs and project members will also be resources for hand tools.
May 11, 2009
Design Project Management Project Review

15. Materials Resource Allocation
Materials Resources
Source
Description
Available
Miscellaneous components.
McMaster Carr, Reid Supply etc.
Components can be ordered from supply companies as needed.
As needed
Manufacturing materials.
Brinkman Lab, Individual Purchase
Small orders of manufacturing materials can be made through Online Metals, Metals Depot, Instant Metals, etc. if the Brinkman Lab does not have a supply of the needed material. Rochester Steel is also a known supplier of metals in the area.
May 11, 2009
Design Project Management Project Review

16. Design Project Management Project Review
Week One 11/30-12/5
Week Two 12/6-12/12
Week Three 12/13-12/18
Winter Break
Week Four 1/4-1/9
Week Five 1/10-1/16
Week Six 1/17-1/23 S M T
Midweek Th
Friday
LOW ENERGY PRINTING PROJECT SCHEDULE
Project Start
Introduce team
Introduce project
Meet customer - Bill Nowak, John Knapp
Assess customer needs
Create customer statement of need
Product Design
Develop product concepts
Benchmark competitive products
Perform Pugh analysis
Select optimum design
DESIGN REVIEW
Present preliminary product design to sponsor
Solicit feedback
Modify product design as needed
Re-present product design to sponsor
Analysis
Create CAD model
Analyze product with FEA
Document
Develop product documentation
- Project description
- BOM
- FEA analysis
- Product CAD drawings
MID-PROJECT REVIEW
Present Midterm Review to Customer
May 11, 2009
Design Project Management Project Review

17. Risk Assessment Risk Foresight Solution Contingency Solution
Winter break occurs three weeks into SD1. The team will likely lose momentum over the break.
Create a sense of urgency about completing work following winter break.
Use immediate, easily accomplished goals following break to get the team back up to speed quickly.
A necessary tool goes missing.
Keep team equipment in storage when not in use.
Find or purchase a replacement tool.
The team unexpectedly loses a member with a valuable skill set.
Plan redundancy into team member selection and select a large enough team to take up slack.
Re-assign roles so a team member can assume the needed responsibility.
The project scope is unexpectedly changed.
Maintain communication with the customer and stay informed of the project requirements.
Manage customer expectations so requirements can be completed in remaining time.
A necessary component goes missing without time to manufacture or order a new one.
Order duplicates of all parts.
Locate a local supplier or outsource machining to a local machine shop to acquire the part in the required time.
Either the Brinkman Lab or Xerox suddenly cannot machine a needed part.
Try to complete machining as early as possible to allow time to manage difficulties. Consult early with the Brinkman staff about machining to stay in front of issues.
Outsource to a local machine shop or attempt machining personally with the help of faculty elsewhere at RIT.
A supplier is late in shipping a part or cancels the order without time to order a new one.
Use redundancy in ordering parts. Follow up on orders to be aware of delays.
Find a replacement part based on delivery time instead of function requirements. Use local suppliers.
Conclusion: local machine shops and local MRO suppliers need to considered in case of contingency.
May 11, 2009
Design Project Management Project Review

18. Design Project Management Project Review
Summary
The project will be successful when we have created a design that applies a pressure to the print media that does not vary by more than 10%.
Secondary goals are decreasing paper damage from gloss and wrinkles.
May 11, 2009
Design Project Management Project Review

19. Design Project Management Project Review
Questions
May 11, 2009
Design Project Management Project Review

20. Deflection in P09505 Roller Design

21. P09505 Cold Pressure Fuser Prototype

22. Design Project Management Project Review
P09505 Cold Pressure Fuser Design
May 11, 2009
Design Project Management Project Review

23. Design Project Management Project Review
Image: Chicago Postcard Museum
P09505 FEA Deflection in Fuser Design
May 11, 2009
Design Project Management Project Review