EDGE™EDGE™

Final Project PlanP0860X (1-5)

Eula Dozier’s “Tile Measurer”

Paul Gaylo (ME)Ryan Hellems (ME)Cortney Ross (ME)

Jeremy Schiele (ME)Reid Williamson (ME)

EDGE™

EDGE™

THE VISION: May 2008 Products

I. Eula Dozier Tile Layout Tool, ready for production

II. Automated Tile Cutter, prototype

III. Redesign of Tile Marking Tool for Mass Production, ready for testing

IV. Manual VCT Measuring Device, prototype

V. Dual-Function Tool, prototype

Future Development:Refine II. ready for productionDevelop III,IV, & V prototypes

EDGE™

Collaborative Strategy

• Unite for initial SD workshops

• Share component technology

• Develop & share test apparatus

• Unified budget request

But How?

Bi-Weekly Family Meetings

EDGE™

Preliminary Project Plan Feedback

• Can they function with tiles smaller than 12x12?- 12x12 is the most common commercial size

- Future SD projects should address this opportunity

• Can you share team members?- Members can have cross-project responsibilities

• What is your budget?

• III, IV & V - Autonomous or hand-powered?

EDGE™

Duplication of Eula’s Prototype

•Work continues on duplication of Eula’s prototype

EDGE™

P08601Small Production-run Preparation

P08601 Project Vector Re-cap:This project is a redesign of the Eula Dozier prototype. The prototype brought to RIT served as a proof of concept but was not optimized. Over 22 weeks a senior design team will engineer a new prototype, and prepare for a production run.

Guide: John WellinThis project is intended to run under the “Entrepreneurship and BusinessDevelopment” headline for Winter/Spring 2008

The project team will engage in the following activities:• Design modifications of an existing prototype for function and production• Generation of several iterations of a new prototype• Design appropriate fixtures for machining• Develop CNC programming and tooling to manufacture the redesign• Create user documentation• Generate a workable marketing plan for the distribution of this product• Conduct a feasibility study to the production run of 100 units i.e. cost, labor,

etc

EDGE™

Function & ProductionWhy?

• This project is unique amongst previous and up-coming design projects.

• This project has a clear deadline and a clear set of deliverables• The project can turn into a commercial product that will

ultimately be sold and used by professionals to improve upon a manual process

• The project team will have a chance to take a production based mindset and influence the design with respect to that mindset

• The team will engage in production processes that would ordinarily be overlooked in a project.

• Supplementary information such as user documentation, and parts supply chains will need to be established

• A big part of this project is marketability and entrepreneurship

EDGE™

Preliminary Work Breakdown Plan – P08601

Weeks 1-2 Weeks 2-3 Task to be completed

ME1

Project Introduction Begin Brainstorming for redesign Use information brought to the group from new members to organize a progression for future group discussion

Meet with Mr. Dozier Present project history of all known info

Review team values and grading scheme  

ME2

Project Introduction Begin Brainstorming for redesign

Pick a drafting program and draft the nylon block of the prototype.

Meet with Mr. Dozier Review customer interviews project history

Review team values and grading scheme

Begin drafting the prototype with alterations

ME3

Project Introduction Begin Brainstorming for redesign Write a CNC program in a software package compatible to RIT machines. Create a profile of the pen holder of the prototype

Meet with Mr. Dozier review customer interview project history

Review team values and grading scheme

Investigate what will be needed CNC at RIT

ISE

Project Introduction Begin Brainstorming for redesign Locate 3 user manuals of general hand tools and create a two lists. One list of the similarities and another of the differences

Meet with Mr. Dozier Review customer interviews

Review team values and grading scheme Locate potential parts vendors

Bus.Project Introduction

Investigate a previous specialty tool business plan

Locate a business plan from another specialty construction tool and create a list of similarities and differences

Meet with Mr. Dozier Review history of development

Review team values and grading scheme  

EDGE™

P08601This project will succeed because…

• With the benefit motivated team, leadership and guidance, this project will be able to exceed expectations and show what a senior design team can do.

• Interviews, benchmarking, industry experience, needs analysis and advising, all have been components to the scope of this project

• RIT has the facilities to make this project highly successful • The budget of this project is highly flexible. Long lead time and

Hi-tech components are not part of this project. Depending on the feasibly of an actual production run the budget has been clearly defined

• A thorough, detailed PRP has been generated to prove why this project is valuable, and achievable to a senior design team.

EDGE™

Budget P08601  Note Minimum Comfortable

Prototype raw Materials Raw plastics, Metal, etc $300 $500

Fixturing raw materials Raw material to make A CNC fixture $100 $200

general hardware screws, bolts, etc 100 200

Tooling

Tools need for machining of prototypes and fixtureing. End mills, drill bits. To ensure GOOD tools to make GOOD parts 200 200

Test apparatus Applicable for all Tile Layout tool teams 150 150

Benchmarking cost

Not necessary for P08601, useful if funds allow. This would be benchmarking of tools of similar complexity. 0 150

$850 $1,400

EDGE™

Potential Issues and Risks - P08601

• Acceptance in the market place (to be determined by the consumer, business advice)

• Cost of production (this is a number to be determined by the senior design team in the feasibility study part of project)

• Reaching the project goal of a production ready prototype by the end of SD-2 (A concrete goal by which this project will succeed or fail by.)

• Money Supply (No industrial sponsors funding this project. Funding looks to be in the hands of RIT)

EDGE™

P08603 Project Justification

• A design capable of production will provide the most immediate fulfillment of Eula Dozier’s request from RIT

• Focus of high production volumes throughout design process make will for a smooth transition to a sellable device

• Current prototype has minimal functionality and is difficult to use

• Theory for a working tool exists, but needs to be refined

EDGE™

P08603 Staffing Requirements• M.E.-1

– Project Manager responsible for planning and execution of project and required deliverables for senior design. Other responsibilities include assuring proper design for manufacture and the manufacturing techniques chosen to the end product.

• M.E.-2– Engineer will be responsible for mechanical design work pertaining to functionality of product and assisting in materials

selection. Should be familiar with CAD software and proper design considerations for large scale manufacturing. If group size requires it, they may act as the Engineering Lead for the group.

• M.E.-3 – Will be responsible for functionality of mechanical systems that allow the tile measurer to function properly, will also be

responsible for keeping EDGE website up to date, and any major changes to website. They should have class background or work experience in machine design and be familiar with CAD software.

• M.E.-4 (or I.S.E.)– Position will be responsible for assurance of product for high volume production capacity, this may include molding

simulations, cycle times, required production equipment. Will aide ID students with proper material selection. Recommended background in plastic production or manufacturing environment.

• I.S.E.– Engineer will be in charge of meshing work between industrial designer and mechanical design engineers, production

and execution of customer perception testing protocols/reports, aide in hypothesized production flow, and contribute to ergonomic concerns. Industrial Engineer is also eligible for position as Project Manager.

• I.D. (1-2)– Design of exterior shell of tile marking product focusing on aesthetic appeal and manufacturability, while keeping

functional requirements under consideration. Will provide the mechanical engineers an envelope do design within. Should be knowledgeable about ergonomics and plastic product design and materials selection (desired but not required).

NOTE: For all positions, a knowledge or interest in tiling/home finishing is a plus, but not required.

EDGE™

P08603 Project Scope

• Deliver a functional, polished prototype capable of marking 6”-12” vinyl & ceramic tile

• Include customer/user product impression surveys to decide on final design

• Manufacturing needs are known and final design could be given the green light for production, if facilities existed

EDGE™

P08603 Work Breakdown & Budget

Work Breakdown• Wk. 1

– Familiarize team with EDGE, DFM, and tile tool background, populate roles matrix and other weekly deliverables

• Wk. 2 – Begin benchmarking and look into

proper design consideration for plastics

• Wk. 3 – Begin design work for functional and

aesthetic components, establish client base for customer perception surveys

Budget- $750-$1000• Prototyping of multiple iterations

of design (labor & materials)• Raw materials for functional

testing and final prototype• Mechanical components needed

for accurate marking

NOTE: more complete work breakdown structure available on project’s EDGE home node.

EDGE™

P08603 Points to Focus On

• Team members will need to be able to communicate with other types of designers and meet at a common ground on issues

• Relationship with Mr. Dozier (original inventor) must be maintained throughout project

• DFM is crucial to project success, and should be kept in mind when making project decisions

EDGE™

P08601 vs. P08603Small Production Run vs. Large Scale Production

Design for Manufacturing

Business Plan

Production Ready

Attention to Industrial Design

Jigs and Fixtures

Product Testing

Customer Appeal Testing

Part Supply Chain

Ergonomics

Multi-sized Tile

Tile-On-Point

User Manual

End Product

Production Ready, Run

of 5-100

Optimized Functional Prototype

1-100 units >5,000 units

EDGE™

P08604Manual VCT Measuring Device=

Project Goals • A device that will go along the edge of VCT tiles and measure the

distance the device is from the wall• Log and store that data, give to Tile Cutter (P08602)

+ +

EDGE™

Staffing Requirements – P08604Mechanical Engineers (3)

ME1 (Leader): The project leader will make sure that the rest of the members are doing their work efficiently and effectively.

ME2: The first mechanical engineering student will mainly be working on the design of the product. They will also be working with a solid modeling program (Pro-E, SolidWorks, etc.). After design is done, they will help with the assembly of the prototype during SDII.

ME3: The second mechanical engineering student will be assisting with the design of the product. Their main function will be machining the parts for that design. After design is done, they will help with the assembly of the prototype during SDII.

Electrical Engineers (1)EE: The Electrical Engineer will need to be able to come up with a battery power

supply or a plug for the fall to run the device that will measure the distance it is from the wall, and to run the device that will log, store and send the data to the cutter.

Industrial and Systems Engineers (1)ISE: The Industrial and Systems Engineering student will be needed to integrate

P08602 and P08604 together. They will need to be able to make sure that the tile cutter communicates correctly with the measurer.

Computer Engineers (1)CE: The computer engineering student will be working with the data logging, storing

and retrieval for the design. They will need to be able to write, read and understand some coding program. They will need to able to manipulate that code to retrieve data from the measuring device and send it to the cutting device (P08602).

EDGE™

Preliminary Work Breakdown Structure – P08604Member Week 1 Week 2 Week 3

ME1 (Leader)

Familiarize group with projectGet more ideas from group of what to benchmark

Gather questions and comments and go over themBrainstorm and benchmark

Bring together all ideas and designs and go over themGive next weeks assignments

ME2

Familiarization of projectBring back questions and comments on design Week2Meet with P08602 and P08605

Brainstorm ideas for a first generation design based of comments and questions

Bring back ideas/sketches of a first generation mechanical design for Week 3

Meet with all Tile Family Groups

Research different solid modeling programsBring back pluses and minuses for Week 4

ME3

Familiarization of projectBring back questions and comments on design Week2Meet with P08602 and P08605

Research different mechanical or electrical components, and materialsBring back pluses and minuses for Week 4

EE

Familiarization of projectBring back questions and comments on design Week2Meet with P08602 and P08605

Brainstorm ideas for a first generation design based of comments and questions

Bring back ideas/sketches of a first generation mechanical design for Week 3

Meet with all Tile Family Groups

Research different battery/power supply optionsBring back pluses and minuses for Week 4

ISE

Familiarization of projectBring back questions and comments on design Week2Meet with P08602 and P08605

Help EE and CE research power supplies and coding programsBring back pluses and minuses for Week 4

CE

Familiarization of projectBring back questions and comments on design Week2Meet with P08602 and P08605

Research different coding/data sending programsBring back pluses and minuses for Week 4

EDGE™

Justification – P08604

• Large collaboration with P08602 and P06803• Acceptance• Manual – must have enough pressure against tile• Corner tiles• Tiles on point

Issues and Risks – P08604

• Current tile measuring and cutting process• Method• Time• Accuracy

• Combined with P08602, will cut down on time and labor

EDGE™

Budget – P08604

Laser Distance Measurer $150 $200

Roomba $150 $150

Data Acquisition $300 $400

Materials, Tooling, Labor, General Hardware, Fixtures

$400 $500

Totals $1,000 $1,250

Minimum Comfortable

EDGE™

P08602: Automated Tile Cutter =

(P08604)

• Faculty Guide- Professor Tim Landschoot (confirmed)• Project will deliver a device that:

•Cut one vinyl tile at a time to fit provided wall profile. •Two axis platform will maneuver rotary cutting tool to cut straight edges and curves accurately.• Cut tiles faster then they can be cut by hand tools.

EDGE™

08602- Customer Needs – Quantified

Metric Value Unit

Max Time to cut tile 60 Seconds

Max tile to load/unload single tile 45 Seconds

Max tolerance of cut 0.25 Inches

Max tile displacement while cutting 0.125 Inches

Time to replace cutter bit 60 Seconds

Time to program a repeat tile 20 Seconds

Maximum foot print 9 Square Feet

Total Weight 70 Lbs.

Electricity requirements 120 Volts

Rigidity of Frame 0.125 Inches

EDGE™

08602- Quantified Project Value*Time to Lay Tiles per 10 foot section

Est. time to apply

glue (min)

Avg. time of

measure & Cut (min)  Premier United

Straight cuts and install 15 30 3 17.5

Unique cuts and install 30 40 3 30

Estimated cost of labor 30 ($/hour)

Time to load, and cut. 2 (min/tile)

Avg. savings per 10 tiles $2.88*•Potential savings on hundreds of dollars per job•Biggest complaints are lack of competent help and time/energy spent cutting tiles.•Market/profit opportunities if developed for Ceramics•*All times need to be measured (currently estimated)

EDGE™

P08602- Phase 0: PlanningStaffing Requirements and Responsibilities

Mechanical Engineers : 4• Design and develop positioning system for cutter using linear actuators.• Design and develop system to hold tiles securely in place for cutting, without interfering with the cutter.• Develop system to support bottom of tile without getting cut• Design frame to house system, and allow for easy tile insertion/removal, and cutter replacement• Ensure design gives proper consideration to 2nd generation project (ceramic).

Electrical Engineers : 1• Design and implement power supply from wall to control box, to cutter/router and linear actuators.• Return feedback signals from Actuators back to control box to monitor locations.• Assess the speed and accuracy needed for electronic system, and purchase system that best meets needs• Strong programming skills in a language TBD, based on best interface with hardware.

Industrial and Systems Engineers : 1• Systems integration, and collaboration with P08602• Design systems for manufacture• Gather data to determine process savings, and MSRP

Computer Engineers : 1 (total of 2 between P08602 & P08604 & P08605)• Vertically develop software from measurements to storage to cutting• Software will be developed to meet needs of projects ‘02, ‘04, & ’05• Program must be versatile to meet all needs of all three projects• Controls knowledge needed for CNC coding• Create basic GUI to allow for re-cutting of specific tiles out of sequence

EDGE™

P08602- Budget

Ideal Budget- $2000

Minimally possible- $1000

Min Ideal

Control System- Price dependent on Speed/Accuracy 100 500

Router (Harbor Freight), 1HP, 8.5 amps, 28000 RPM 40 40

Cutting Head (Home Depot, RotoZip XB-TC1) 10 10

Linear Actuators (Speed/Accuracy/Range) 220 470

Supports/Bearings for Actuators 70 90

Materials for Frame 160 250

Tile Holding System 300 500

Miscellaneous expenses 100 140

EDGE™

P80602- WBS- Week 1-3

EDGE™EDGE™

Final Project PlanP08605

Dual-Function Tile Tool

Reid Williamson

EDGE™

Prospectus

• FEATURES:– Measures gap – Cuts VCT tile

• HOW:– Digital sensors – Mechanical controls

• IS NOT: – Fully automated– Designed with unique

components– Wireless– Production ready

NEW:Guide = Prof. WellinInstallation Site Visit

Quantified Installation Time

EDGE™

Phase 0: PlanningStaffing Responsibilities

Mechanical Engineers

3

Structure, cutting tool, cutting tool drive controllers, tile feed system, materials science issues, testing, and additional design concerns

Computer Engineer

1

Data processing architecture, sensor integration, mechanical control system, and additional design concerns

Electrical Engineers

3-4

Sensors, power system, data processing architecture, integration with mechanical components, signal processing, and additional design concerns

EDGE™

Work Breakdown Structure { Week 0 to 3 }

EDGE™

P08605 - Budget

• Distance Sensor $300 $600

• Cutting Tool $200 $300

• Controls System $300 $500

• 2-Axis Control $400 $600

• Structure $300 $400

• TOTAL $1500 $2400

EDGE™

Family Budget

• P08601 $850 $1400

• P08602 $1000 $2000

• P08603 $750 $1000

• P08604 $1000 $1250

• P08605 $1500 $2400

• Test Apparatus $100 $200

• TOTAL $5200 $8250

EDGE™

Test Apparatus

NEED:

• Environment testing for ALL projects

FEATURES:

• 10 ft. section of floor & wall

• Re-configurable wall profiles

BOTTOM LINE:

• $100-$200 material cost

• Storage & floor space needed

EDGE™

Additional PRP Information• Interviews• Needs Statement• Quantified Needs• Team Values / Norms• Grading Scheme• Required Resources

AVAILABLE on EDGE sites