maría camila luna pablo santizo matheu zachary borden zachary delurey eniordesigneniordesign
TRANSCRIPT
MANUFACTURING
OPTIMIZATION OF SMALL
SCALE COLOR IMAGING TARGETS
María Camila Luna
Pablo Santizo Matheu
Zachary Borden
Zachary Delurey
SENIOR
DESIGN
AGENDAProject Background
Alternatives Considered
Risk Management
Updated Schedule
Benchmarking
Functional Decomposition
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: Design a manufacturing process lower costs higher yields improve customization ability
Problem Statement
Stakeholders
ISA Customers
SD Team
Don Williams
Operator
Susan Farnand
Customer Need
Importance
Description
CN1 3 Color materials are spectrally accurate.
CN2 2Individual patches are blemish free to provide accurate measurements.
CN3 3 Individual patches are aligned.
CN4 2 Durable base plate.
CN5 2 Logo of the company on the back of the plate.
CN6 3 Targets do not have burn marks or surface cracks.
CN7 1 Targets are resistant to alcohol and water.
CN8 3 Colors are easily and quickly customized.
CN9 1 Target sizes are easily customized.
CN10 2 Fast production time.
CN11 3 Low production cost.
CN12 3 Low cost system redesign.
CN13 3 High yield rates.
Customer Needs
Engineering Requirements
S#
SourceFunctio
nSpecification
(Metric)
Unit of Measur
e
Marginal
Value
Ideal Value
Comments/Status
S1 CN4Base design
Durability (drop test) Feet 3ft >3ftDrop from 3ft without making the surface crack or target break
S2 CN9Base design
Target size # of Sizes 3 sizes inf.Only 3 sizes available currently
S3 CN3Individual patches
Positional accuracy with respect to tile size
% 5% <5%
S4 CN5Base design
Logo is present Pass/Fail Pass Pass
S5CN2/CN6/CN7
TargetsPercent damaged surface
% 5 0Separate test for alcohol/water
S6 CN8Individual patches
Number of patches that can be changed
# 30 30
S7 CN8Individual patches
Time to change color scheme
Min. 5 5
S8 CN10 System Cycle time Min. 30 <15
S9 CN11 System Production Cost Dollars 55 25
S10
CN12 SystemSystem Redesign Budget
Dollars 1,500 >1,500
S11
CN13 System Yield Rate % 90 95 Currently at 75%
Matrix
Eng. Requirements
S1 S2 S3 S4 S5 S6 S7 S8 S9 S10 S11
Customer NeedsPriority
Base Desi
gn Durability
Available Base Desi
gn Sizes
Individual Patc
h Alignmen
t
Base Desi
gn logo
is present
Target
percent
damaged surfa
ce
Individual patches that can be
changed
Time that
takes to
change
color
Syste
m Cycle time
System Production Cos
t
System
redesign
budget
System yiel
d rate
CN1Color materials are supplied from Munsell Div. of X-Rite, Inc. 3
CN2Individual patches are blemish free to provide accurate measurements. 2 x
CN3 Individual patches are aligned. 3 x CN4 Durable base plate 2 x CN5 Logo on back of plate 2 x x
CN6Targets do not have laser burns or surface cracks 3 x
CN7 Targets are resistant to alchohol and water 1 x CN8 Colors are easily and quickly customized 3 x x CN9 Target sizes are easily customized 1 x CN10 Fast production time 2 x CN11 Low production cost 3 x CN12 Low cost system redesign 3 x CN13 High yield rates 3 x
Functional Decomposition
Produce properly aligned, highly customizable, small scale color targets
Obtain color
papersChoose specific colors(customer
request)
Cut paper to desired
sizePosition paper
on cutter
Protect paper form cutting process
Align patches within
tolerancesIdentify pattern according to
customer order
Vertically and horizontally align
patches
Check quality
Secure colors in
placePrevent patches
from shifting
Protect target from damage
Inspect final product
Benchmarking
Circle pocketsPrecision punch instead of laser cutterCNC quotes for revised metal plate
Grid frameTalked with Dr. Cormier about 3D printing
feasibility Machine Slots
CNC quotes for revised metal plate Pick and Place
Talked to Scott Elithorpe at Abacus Automation about viability
Alternatives Considered
Pick & Place
Machine Pocket
Machine slot
90 x 90 guide
Circle Tiles
Grid Frame
Circle Pockets
Window Alignment Guide
Current Process
Low Cost - 0 0 - 0 0 0 + 0
Tech Availability + + + + + + + + 0
Ease of Use + + + + + + + + 0
Complexity - - - - - - - - 0
Accuracy + + + + + + + + 0
Size Flexibility + - - + + - - - 0
Protect Color - 0 0 - 0 + 0 0 0
Durable End 0 + + 0 0 - + 0 0
Low Cycle Time 0 + + 0 + + + + 0
Low Unit Cost + - - 0 + + + 0 0
Aesthetics + - - 0 - - - 0 0
+ Total 6 5 5 4 6 6 6 5 0
- Total 3 4 4 3 2 4 3 2 0
Option 1-Circle Pockets
Pros Cons
Cirle PocketsPlace adhesive paper and the patch in every pocket
Quality control check
Option 2-Grid Frame
Pros Cons
Grid Frames
Grid Frames
Option 3-Machine Slots
Pros Cons
Machine Slots
Uses current process Casing has slots to provide for
alignment
Option 4- Window Alignment Guide
Pros Cons
Window Alignment Guide
Risk Management
No. Risk Mitigation Plan
1Misunderstandings with the customer and within team members
Keep team members and customer informed of all decisions taken and any changes in scope
2Unable to meet deadlines/milestones
Before each deadline meet before with sufficient time to solve any issues
3Expensive alternatives to current process
Innovate with lower cost technologies
4Alignment or cutting system damage color surfaces
Test systems before committing resources to it. Change system if it is damaging surfaces
5 Process is not ergonomicPerform studies of the process and find alternatives to help the ergonomics for example new layout for tools
6Adhesive does not allow for re-allignment
Perform a pass/fail test of alignment before putting the adhesive. Change the adhesive to allow for movement after applied (slow cure)
7Proposed product redesign (circles) are not well accepted in the market
Transfer risk to customer
8Not able to review the current manufacture process
Design a completely new process
Updated Schedule
Issues and Corrective Actions
Questions?