p16718 micropen workstation redesignedge.rit.edu/edge/p16718/public/detailed design...option 5 -...
TRANSCRIPT
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Rachele Floeser Project Manager
Alex Langkamp Project Manager
Sabrina Caliri Facilitator/Engineer
Nick Accuosti Engineer
Matt DePalo Engineer
Mike Everett Engineer
P16718 Micropen
Workstation Redesign Detailed Design
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Outline
Review and Updates
Operator Feedback
Test Plan
Design Models
Project Management
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Review and Updates
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Review of Project Deliverables
● Design alternatives by subsystem or component● Develop functional prototype of complete system design● Create user guides for operation● Create appropriate design, test, manufacture, and supply chain documentation● Create an improved workstation that eliminates or at least reduces the
ergonomic risk factors for the operator
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Open Items from System Design ReviewIssue
The viewing apparatus solution of using a screen potentially causes different ergonomic challenges for the operator
Action Taken
Performed initial testing using the DinoXcope at the Micropen workstation. Identified some software and hardware requirements of the viewing apparatus solution
Current Situation
Continuing to identify requirements and additional testing methods for the subsystem
Issue
Tooling solutions used for the touch-up procedure creates more challenges for the operator, outside of the known challenges
Action Taken
Researched precise tooling operations. Sketched ideas and created solidworks documents of potential solutions
Current Situation
Developed multiple solutions that vary in difficulty to implement and also in simplicity of the operation for the operator
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Customer Requirements
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Updates to Engineering Requirements
● House of Quality Updated● Added two new engineering requirements:
Requirement # Rank Function Metric Unit Marginal Value
Ideal Value
S36 9 Testing All measured stresses are within a FOS for the given part geometry FOS 3 >5
S37 9 Testing All tests do not fail within avg. hourly output rate
cycles/hour 50 >60
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Operator Feedback
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Operator Survey - Daily Discomfort - Overview
● Time Increments Recorded○ Morning○ Before Lunch○ Evening
● Collected Data for Each Body Part○ Type of Discomfort○ Level of Discomfort○ Frequency of Discomfort
● Operator Comments Summary○ Attributed some discomfort to arthritis
○ Recorded more detail in type and
location of discomfort
● Expressing Discomfort Frequency○ Variable○ Intermittent ○ Stable
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Operator Daily Discomfort Survey - Feedback
Average Discomfort Intensity Discomfort Frequency
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Operator Daily Discomfort Survey - Feedback (continued)
Left Side is a Big Issue
Amount of Issues Recorded Average Discomfort LevelsHighest Point
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Test Plan
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Test Plan Test Type Test Description
Ergonomics Test Take image of worker performing task for each specific component. Compare to Engineering Requirements. May have to be performed for multiple operators
Workstation Measurements
Measure current and finished workstation. May have to be performed for multiple operators
Operator Survey Gather operator survey from both current and future system
Survey of Throughput
Measurement of throughput from current and future system
Survey of Scrap Measurement of scrap from current and future system
Stress Test Solidworks simulation
Endurance Test Continuous use over a certain amount of time (Pass/Fail)
Functionality Test
Ensure components are working as expected (Pass/Fail)
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Component Phases
● Based on operator survey feedback
● Diagram is used to determine when decisions about subsystem components will be made○ Phase 1 - Focuses on initially
identified ergonomic challenges○ Phase 2 - Requirements are
dependent on Phase 1 decisions○ Phase 3 - Additional opportunities for
improvement and based on Phase 1
and Phase 2
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Design Models
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Final Design Model - No Updates ● Material Handling
○ Place kink in wire■ Creates the need to develop a kink tool
● Actuating the Opener (Open/Closing Chuck)○ Solenoid Air Valve
● Stretching & Exercises○ Provide stretching sheets at workstations○ Decrease WIP to increase flow
● Arm & Elbow Support During the “Touch-Up” Procedure○ Adjustable Elbow & Forearm Support
■ Operator’s preferences are different so adjustability will be key ○ Will depend on the choice for back support
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Final Design Model - Viewing the Part
High Cost Option: O.C. White TKMACZ Prolite Macro-Zoom
● Adjustable focal length, zoom and stand● HD 1080p resolution● Cost: $2785
Medium Cost Option: Hitachi KP-d20
● Compact, easy to mount out of the way● Higher resolution than existing camera● Already used in the company● Cost: $600-$900
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Final Design Model - Viewing the Part
Dino-Lite Microscope
● Cheaper model not strong enough for our purposes● More advanced models have much higher specs● Costs can go up to $1200 based on features wanted● Easily adjusted by operators● Very small and easy to mount and manipulate
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Final Design Model - Viewing the Part
Humanscale Monitor Arm
● Full range of motion● Multiple mounting attachments available● Integrated cable control● $239
OmniMount OC40FMX
● Not quite as flexible● Wall mount only● Integrated cable control● $36
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Final Design Model - Viewing the Part
Monitors
● Selection is entirely dependant on camera and stand chosen● Ergonomics comes from placement more than monitor specs
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Final Design Model - Operator Tooling
● Operator Tooling for the “Touch-Up” Procedure○ Modify the handle of the tooling based on operator feedback○ Develop mechanical system to assist in the use of a screen
■ 2D tooling■ 3D tooling
● “Pantographing” design to allow operator to control tooling at more natural level○ Redesign plastic shielding used to block rotation of chuck set screw ○ Plastic Clip/Clamp in field of view of screen for holding the tooling when not in use
● 5 Main Options - Following slides
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Final Design Model - Tooling for “Touch-Up”● Option 1 - Touch up Tooling Clip (Pen Clamp)
○ Placed in Operator’s field of view while completing touch up procedure. Helps to “find” tooling.
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Final Design Model - Tooling for “Touch-Up”● Option 2 - Slotted Touch Up Tooling
Fixture ○ 2 degrees of freedom
○ Tool Tip modification may be necessary
for functional implementation
○ Can add a single drive system which will
stop the vertical input from being inverted
○ Also has the ability to be easily controlled
by a remote linkage system to allow the
operator to manipulate the tool from a
more ergonomically safe position
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Final Design Model - Tooling for “Touch-Up”● Option 3 - Steady Hand Tooling Arm Fixture Based on Da-Vinci-Surgical-
System ● The surgeon's fingers grasp the master controls below the display with hands and wrists naturally
positioned relative to his or her eyes - The system seamlessly translates the surgeon's hand, wrist and finger movements into precise, real-time movements of surgical instruments
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Final Design Model - Tooling for “Touch-Up”
● Option 4-Steady Hand Tooling Arm Fixture
● Developed by benchmarking surgical guided robotic systems
● Using a fixture to help support and stabilize the tooling dramatically increases the precision and accuracy of the operator.
● The seven degrees of freedom of the open kinematic chain allow the systems to inherent motion resembling the actions performed by the operator.
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Final Design Model - Tooling for “Touch-Up”● Option 5 - Simplified Steady Hand Tooling
Fixture with Constrained Ranges ● A Ball Joint possess zero translational degrees of
freedom. Therefore, rails are used to facilitate the linear translation of the tooling fixture sub assembly. Two rails permit precise positioning of the subassembly along the selected axis without allowing rotation.
● A ball joint possesses three rotational degrees of freedom. This Allows for smooth motion to maintain precision alignment and handling of the touch up tool. The ball joint can be heat treated, have lubricated fittings and coated with Teflon, to enhance endurance and increase component life.
● Range of motion is constrained to the desire dimensions required to perform the touch up. Simple way to limited rotation angles and range of motion
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Final Design Model - Tooling for “Touch-Up”
● Touch Up Tooling Arm Extension
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Final Design Model - Proper Seating Position
RGP 400D Hybrid
● Facilitates the same desirable leg position as a saddle stool, ○ Without the groin
compression and also offers a backrest.
● It was found that medium-to-tall dentists and hygienists best fit this stool.
● Rated 'excellent' on comfort and support by evaluators over 5' 5"
● Cost not available
Global Microsurgeon
● Specifically designed for use with microscopes
● Fully adjustable armrests● Seat fully rotates with your seating
posture● provides firm lumbar and back support
in multiple positions
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Final Design Model - Proper Seating Position
Crown Seating Vail C30H Chair
● Hybridized design between saddle chairs and traditional chairs
● Especially well designed for shorter operators
● extra thick backrest● Budget friendly at $436
Virtu C120 Mesh Operator Stool
● Designed to optimally disperse body weight and pressure regardless of position of body
● “Free-Float” backrest stays with operators as they lean forward
● Highly adjustable to operator preferences● $500-$800
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Final Design Model - Proper Seating Position
Denver C1300 Operator Stool
● Distinct shape conforms to body● Smaller size of the chair lets operators
get closer to their work● Wide range of adjustability
Bodybilt Seat
● Designed specifically for manufacturing operators
● Ten different adjustable areas
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Final Design Model - Proper Seating Position
The BamBach Saddle Seat Cost
● Widely used in hospital work● Aims to eliminate back, neck and shoulder
discomfort● Enforces a balanced stance through wide foot
stance● Maintains natural curvature of the spine● $700
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Final Design Model - Operator Keyboard and Keypad
Modify Operator Keypad or Combine Keyboard and Keypad
● Modify location of keypad● Replace current cover with colored & labeled keys
ControlPad 683 & 683-U
This product has been discontinued.
Replacement Unit CP24-USBHID is the same unit with different casing
ControlPad
CP24 USB HIDSolidtek
KB-595BU
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Final Design Model - Operator Keyboard and Keypad
New Keypad Options
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● WIP Fixture for Printed Parts○ Redesign of WIP Fixture Tile
■ Dimensions of tile■ WIP per tile
○ Modifications to WIP Fixture Stand■ Angle Adjustability■ Height Adjustability
○ Additional lighting
● Location of WIP Fixture ● WIP Testing Plan
○ Non-subjective testing○ Response is time
WIP Fixture Model A Model B Model C
Tile Dimensions 4x4 4x8 4x4
WIP 25 50 25
Pattern Grid Grid Brick
Final Design Model - WIP Fixture
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Project Management
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Risk Management
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Next Steps
● More specific tooling development○ Decide what tools are going to be outsourced and tooling the team can design
● Finalize Test Plan● Finalize Detailed Design● U of R Environmental Safety Specialist
○ Phil Rogerson
● Visit Micropen on Tuesday Dec 1st 2015
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Questions