1. D ETAILED D ESIGN R EVIEW W EEK 15 María Camila Luna Pablo Santizo Zak Borden Zach Delurey

2. A GENDA Introduction Problem statement Finalized engineering and customer requirements Proposed process design Functional decomposition and flow diagram Components of the system Proposed bill of materials Proposed assembly layout Ergonomics Risk management Team findings

3. E XPECTATIONS Validate final design with customer and peers Future steps (Senior Design II) And schedule for the first 3 weeks Identify areas that need improvement Obtain customer approval for the BOM

4. P ROBLEM STATEMENT Certain applications require smaller color targets Complications: Forming component parts Customization requests Final target assembly Current process: Hand assembled Improper alignment Low yields The objective: Redesign the manufacturing process Lower costs Higher yields Improve customization ability

5. C USTOMER N EEDS CN#ImportanceDescription CN13Color materials are spectrally accurate. CN23 Individual patches are blemish free to provide accurate measurements. CN33Individual patches are aligned. CN42Durable base plate. CN52Logo of the company on the back of the plate. CN63Targets do not have burn marks or surface cracks. CN71Targets are resistant to alcohol and water. CN82Colors are easily and quickly customized. CN91Target sizes are easily customized. CN101Fast production time. CN113Low production cost. CN123Low cost system redesign. CN133High yield rates. CN143Process must be ergonomic.

6. E NGINEERING R EQUIREMENTS Source Function Specification (Metric) Unit of Measure Marginal Value Ideal Value Testing S1 CN4 Base design Durability (drop test) Feet 3ft >3ftDrop test S2 CN9 Base design Target size # of sizes 3 sizes inf.Order one of each desired size S3 CN3 Individual patches Positional accuracy with respect to tile size %5% <5% Use microscope to verify accuracy S4 CN5 Base design Logo is present Pass/Fail Pass Check the logo visibility S5 CN2/CN6/ CN7 Targets Percent damaged surface %50Use microscope to verify damage S6 CN8 Individual patches Number of patches that can be changed #30 Test different paper in the laser cutter S7 CN8 Individual patches Time to change color scheme Min.105 Time study S8 CN10 System Cycle time Min.30 <15 Time study (60 trials) different users S9 CN11 System Production Cost Dollars5525 Add up the individual costs (include labor) S10 CN12 System System Redesign Budget Dollars1500 >1500 Add up the investment costs S11 CN13 System Yield Rate %9095 Inspect final products from the time study (n=60)

7. P ROPOSED P ROCESS - F LOW D IAGRAM 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/ tilted table Place adhesive in pockets Pick individual patch using vacuum pen Place patch in correct pockets using magnification device Inspect for any flaws using digital microscope * Outsourced processes

8. F UNCTION D ECOMPOSITION Produce properly aligned, highly customizable, small scale color targets Obtain color papers Choose specific colors (customer request) Cut paper to desired size Position paper on cutter Protect paper form cutting process Align patches within tolerances Identify pattern according to customer order Vertically and horizontally align patches Check quality Secure colors in place Prevent patches from shifting Protect target from damage Inspect final product

9. B ACK P LATE First iteration of prototypes: Material: Renshape® SL 7820 black resin Quantity: 10 small, 5 large Overall length 0.495” Small target 0.850” Large target Depth of pockets= 0.01” Feasibility of 3D printing Pocket allows for self-aligning Pockets were not deep enough Pockets and patches size did not match

10. B ACK P LATE (C ONT.)

11. PLATEA Pocket width B Rib width C Total thickness D Pocket depth W Wall thickenss 10.0625”0.010”0.0625”0.020”0.025” 2 (gutters)0.0625”0.010”0.0938”0.020”0.025” 30.05540.010”0.0625”0.015”-.030” 0.029” 40.050”0.015”0.0625”0.015”-.030” 0.032” 50.115”0.010”0.0625”0.015”-.030” 0.036” 60.100”0.025”0.0625”0.015”-.030” 0.044” Second Iteration Prototypes:

12. C OLOR PATCHES Laser cutter process outsourced Test the different samples given by customer Small variability 0.056” Small target 0.196” Large target Customer wants to keep working with current employee Possible back-up plan: Boston Laser Cutter

13. V ACUUM P EN Problems identified earlier and potential solution: Picks up more than one tile Tile flips when dropped into the pocket Learning curve Ergonomics expert opinion: Vibration is not a problem Sound is not a problem

14. A DHESIVE Spray Adhesive Scotch: Photo Mount 5 minutes curing time Dry clear Krylon : High strength 30 minutes curing time Does not dry clear Not a feasible solution Liquid Adhesive Gorilla superglue Long curing time Dry clear No test for reflectance available Increases cycle time Tested by the costumer 2 2 1 1 3 3

15. T EST FOR COLOR REFLECTANCE ( SCOTCH PHOTO MOUNTING ) First set of experiments: Individual patch placed immediately after spraying the adhesive Delta E on the yellow patch 2.2 visible difference

16. T EST FOR COLOR REFLECTANCE ( SCOTCH PHOTO MOUNTING ) New application process Wait 1:30 min. after spraying the adhesive Delta E decreased from 2.2 to 0.1 0.1 (no visible change)

17. A DDITIONAL TESTING In order to test the actual curing time a small target was sprayed The tester waited 8 minutes and then start placing the individual patches After all the patches were placed the target was dropped form 3ft in order to test the adhesive quality All of the patches stayed in place

18. S TATIC M AT & T URNING T ILTED P LATE Static Mat: Help to keep the individual patches before they are placed in the target Tilted Plate: Table rotates and tilts to ease the placement of the patches Ergonomic improvement: Helps to improve the position of the user Non-skid surface to hold the plate and reduce the necessity of two hands handling

19. B INS Keep the individual patches separated by color and sizes Increase the organization of the layout Reduces the preparation time 2 different Bins 64 drawers 39 drawers

20. M AGNIFICATION D EVICE Customer ordered a set of professional magnifying lenses Allows for people with corrective lenses Reduces the problem of going into and out of the magnification range Reduces ergonomic problems Comfortable for the user

21. D IGITAL M ICROSCOPE Inspection/quality purposes Measurement software Increase quality control Reduces time Not for alignment purposes: Difficult of use (working in one are while looking at another)

22. B ILL OF M ATERIALS Part NamePart No.SizePrice Color patchesN/A1/8, 1/16”N/A Back plateN/A0.69* 0.81”, 0.44*0.38”$10.00 Vacuum pen & accessories V8100A3*3*6”$499.00 Photo mount spray adhesive B001680QHW4.25 Ounce$13.18 Bins1016410164/ HA01039001 20*16*6 ½” /19.5*15.8*6.2” $30.14/$31.72 Tilting turntableB000674S4Q7 ¾”$61.40 Magnification lenses Provided by Customer $1300 Digital microscopeProvided by Customer $1100 Static matProvided by Customer $850

23. A SSEMBLY L AYOUT

24. E RGONOMICS Main problem: posture and length of the task Sound and vibration are not issues Early to make a decision First pick a design Then consider ergonomic issues Consider inexpensive solutions Turning table instead of whole table Inexpensive microscope/ magnification device

25. R ISK M ANAGEMENT Link to updated risk managementrisk management New Risks Adhesive fails over time Original Sized parts make patches too small to cut Gutters cause structural weakness

26. P LANS FOR SENIOR DESIGN II Review project state Costumer and engineer requirements with costumer Inventory of hardware and parts Review long term adhesive test Select adhesive and method Test prototypes Varying depths and wall sizes Update customer with results Create optimized back plate Trial run process Ergonomic or other issues

27. L ESSONS L EARNED Include several test variables on prototypes Previously plan for the next steps following an experiment Keep organized notes for every meeting Adapt to changes in scope and initial conditions Importance of risk management Continuous process

28. Questions?