system design review p15420: rochester roots lip balm/hand salve production line ohimai aisiku...

System Design Review

P15420: Rochester Roots Lip Balm/Hand Salve Production Line

Ohimai AisikuStephanie BloechlKenneth Costello

Jessica DillJeff Lariviere

P15420 - System Design Review 2

Agenda

Background Current Process Problem Statement Customer and Engineering

Requirements Benchmarking

System Analysis House of Quality Functional Decomposition Feasibility Analysis

Concept Development Morphological Chart Concepts Considered Pugh Chart Concept Selected Engineering Analysis Risk Assessment Test Plan Project Plan

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Background

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Current Process

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Problem Statement

Current State Small batches made with minimal student involvement

Desired State Students active in as many steps of the process as possible Faster process able to keep up with demand

Constraints Safe process for students to use Easy to clean

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Problem Statement

Deliverables Straining system Heating and pouring system Capping and labeling process Instruction and Maintenance Manual

Stakeholders Rochester Roots Jan McDonald Montessori School and students RIT and our MSD team

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Action Items from last review

Update Engineering requirements with specifics - quantify Clean up requirements to look more professional Customer requirements importance scale Add Benchmarking

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Customer RequirementsCustomer Rqmt. # Category Importanc

e Description

CR1 Teaching 1 Follow Healthy Urban Food System ModelCR2 Teaching 1 Maximizes STEM inputCR3 Teaching 2 Involves student in each step of process

CR4Physical

Constraints 3 Fit in allotted classroom space

CR5Physical

Constraints 1 Maximizes use of recycled material

CR6Physical

Constraints 2 PortableCR7 Ease of Use 3 Easy to cleanCR8 Ease of Use 2 Easy to set up and tear downCR9 Diversity 1 For ages 8 and upCR10 Diversity 1 Can be used at multiple schools and locationsCR11 Cost 3 Within budgetCR12 Cost 1 MultipurposeCR13 Cost 3 Financially self-sustainingCR14 Safety 3 School safeCR15 Safety 3 Sanitary

1: preference only2: nice to have3: must have


Customer RequirementsCustomer Rqmt. # Category Importanc

e Description

CR16 Safety 3 Too large to choke on (based on safety standards)CR17 Engage Students 1 FunCR18 Engage Students 1 Team OrientedCR19 Durable 2 Resistant to vandalismCR20 Durable 2 Long product lifeCR21 Durable 2 Easy to repairCR22 Durable 2 Low maintenanceCR23 Product Creation 3 Makes usable productCR24 Product Creation 2 Adjusts to different ingredientsCR25 Product Creation 2 Adjusts to different containersCR26 Process Related 2 Process is quickCR27 Process Related 3 Can heat beeswax to liquidCR28 Process Related 3 Can strain product to mostly particulate-freeCR29 Process Related 2 Dispensing of hot liquid is automated

1: preference only2: nice to have3: must have

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Engineering Requirementsrqmt. # Source Engr. Requirement (metric) Unit of

Measure Marginal Value Ideal Value Comments/Status Test (how are you going to verify satisfaction)

S1 PRP Footprint Size sq ft 12'x13' Measuring TapeS2 PRP Weight lb 50 30 ScaleS3 CUSTOMER Elapsed Process Time hr 6 4 TimerS4 CUSTOMER Yield Size Capability oz 130 200 Measure OutputS5 PRP Adjustable Height Range ft 2-3.5 Measuring TapeS6 PRP Prototype Cost $ 800 S7 PRP Manufacturing Cost $ S8 CUSTOMER Heating Element Temperature Range °F 140-160 ThermometerS9 CUSTOMER Number of Students Involved students 20 Observation

S10 PRP Time to clean min 30 15

S11 CUSTOMERPercentage of single use material that is compostable % 50% 95%+

S12 CUSTOMER Degree of automation of pouring process degreePartially

automatedHighly

automated S13 PRP Storage Size sq ft 6'x6' fits in back of truck Measuring TapeS14 PRP Breaktown/set up time min <60 <30 TimerS15 CUSTOMER % acceptable products based on oz % 90% 95% Scale/Measure OutputS16 PRP Maximum particle size after straining in 0.01" 0.005" Smallest strainer mesh

S17 PRPMinimize student contact with heating source/hot liquids binary N/A

S18 CUSTOMER Degree of automation of capping process degreePartially

automatedHighly

automated S19 PRP No parts smaller than lip balm cap in 0.61" x 0.67" 0.61" x 0.67"

BenchmarkingBenchmark parameters Current Product

Martha Stewart Homemade lip balm Commerical Chapstick Burt's Bees

Ingredients

2 cups infused almond oil4 oz beeswax4 tsp honey10-15 drops vanilla fragrance oil

3 teaspoons grated beeswax5 teaspoons oil (carrier, sunflower, castor, or jojoba)6 or 7 drops essential oil1 teaspoon honey

camphorbeeswaxmentholpetrolatumphenolvitamin Ealoeoxybenzone

sunflower seed oilcoconut oilbeeswaxflavorcastor seed oillist continues

Shelf life 6 months 6 monthsdoes not expiresuggested use within 1 year

should be good for 3 yearssuggest use within 1 year

Batch Size 20.67 oz 1.33 oz continual 666K oz

Heating apparatus crockpot double boiler giant pot giant pot

Ease of Cleaning

very difficult, scrap out remaining beeswax then run through industrial dishwasher

use very hot water to clean off beeswax mixtures

continuous process, cleaning not explained

continuous process, cleaning not explained

Power Sources required plug for crockpot stove commercial plant commercial plant


System Analysis

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S1 S2 S3 S4 S5 S6 S7 S8 S9 S10 S11 S12 S13 S14 S15 S16 S17 S18 S19

House of Quality footp

rint size

weight

elapsed

process

time

yield size

capability

adjustable heig

ht rang

e

prototype cost

manufacturing cost

heating

element

temperatu

re rang

e

number

of students involved

time to

clean

% of singl

e use mate

rial that

is compostable

pouring

system is auto

mated

Storage

Size

breakdown/set

up time

% acceptabl

e products

visual - is prod

uct clear after straining

minimize student contact

with heating

source/hot liquids

capping is auto

mated

avoid

choke

hazards

CR1 Follow Healthy Urban Food System Model x CR2 Maximizes STEM input x CR3 Involves student in each step of process x CR4 Fit in allotted classroom space x CR5 Maximizes use of recycled material x CR6 Portable x x x CR7 Easy to clean x CR8 Easy to set up and tear down x CR9 For ages 8 and up x x

CR10 Can be used at multiple schools and locations x x CR11 Within budget x x CR12 Multipurpose x CR13 Financially self-sustaining x x CR14 School safe x CR15 Sanitary x x CR16 Too large to choke on (based on safety standards) xCR17 Fun x x CR18 Team Oriented x CR19 Resistant to vandalism x CR20 Long product life x CR21 Easy to repair x CR22 Low maintenance x x CR23 Makes usable product x x CR24 Adjusts to different ingredients x CR25 Adjusts to different containers x CR26 Process is quick x CR27 Can heat beeswax to liquid x CR28 Can strain product to mostly particulate-free x x CR29 Dispensing of hot liquid is automated x


Functional DecompositionMake Lip Balm/Hand Salve

Gather Ingredient

s

Infuse Oil

Pic k Pla nts

Dry M ater i

als

Buy Ingredient

s

Strain Oil

Combine Ingredient

s

Measure Ingredient

s

Heat Ingredien

ts

Sti r Ingredients

Reg ulate Temp er atu r e

Add Fragranc

e

Pour into containers

Secure Container

s

Fill Container

s

Mea sure amo unt

Di spense

Li quid

Cool Liquids

Cap Containers

Label Containers

Clean Product

Line

Clean Heating Element

Clean Pouring Element

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Feasibility Analysis: How much can we improve the time to melt beeswax?

Property Value UnitsMelting Point 65 °CHeat of Fusion 145 J/gSpecific Heat 3.4 J/g*KDensity 964 kg/m^3

Properties of Beeswax

Property Value UnitsSpecific Heat 2.5345 J/g*KDensity 921.43 kg/m^3

Properties of Almond Oil

Need heat flux of crock pot, know the followingBeeswax 3.985 fl. oz.Time to melt, T 3000 secondsHeating area of crock pot, A 329.87 in^2 Assume 12" x 8" x 8" high oval

0.21 m^2Energy Required to heat mixture 237407 J mCΔTEnergy Required to melt beeswax 16385 J m*HfTotal Energy Input, E 253792 JHeat Flux of Crock Pot 397.51 W/m^2 Q=E/(T*A)

Recipe includes 2 cups (16 fl. oz) and 4 oz. (weight) beeswaxBeeswax pellets 4 oz. weight = 3.985 fl. oz.Almond oil 2 cups = 16 fl. oz.

Total 19.985 fl. oz.


Feasibility Analysis: Extrapolating to a full batch…

Batch Size: 200 fl. oz.Beeswax pellets 39.9 fl. oz. = 1134.831 gAlmond oil 160.1 fl. oz. = 4363.258 gSpecific Heat of Mixture 2.70708 J/g*K

Melting beeswax occurs in two stages:Energy Required to heat mixture from room temperature to melting 490020 JEnergy Required to melt beeswax 164551 J mCΔTTotal Energy Input, E 654571 J m*Hf

% improvement Flux, W/m^2Time to heat and

melt, min10% 437.26 117.23420% 477.02 107.46530% 516.77 99.19840% 556.52 92.11350% 596.27 85.97260% 636.02 80.59970% 675.77 75.85880% 715.52 71.64390% 755.27 67.873

100% 795.03 64.479

Time Improvement w/ % increase in heat fluxBatch Size: 200 fl. oz.Beeswax pellets 39.9 fl. oz. = 1134.831 gAlmond oil 160.1 fl. oz. = 4363.258 gSpecific Heat of Mixture 2.70708 J/g*K

Melting beeswax occurs in two stages:Energy Required to heat mixture from room temperature to melting 490020 JEnergy Required to melt beeswax 164551 J mCΔTTotal Energy Input, E 654571 J m*Hf

Typically crockpots are rated at 200-300W of power. There are electric hotplates and other heating solutions rated at upwards of 1000 W. Taking into account losses, the heat fluxes shown should be feasible considering we are going with a proprietary heating solution.

Conclusion:

17

Feasibility Analysis: Engaging Pick plants - Yes

Students currently pick the plants Dry materials - Yes

Students can place them on drying rack or in jars

Strain - Yes Students can pour liquid into straining

system, may require some help Measure - Yes

Students can measure wet and dry ingredients

Heat - No Heating system and hot parts will be

insulated Secure containers - Yes

Students can place lip balm containers in rackStudents can be at least partially involved in 9 out of the 11 steps of the process.

Dispense liquid - Yes Students can be at least partially

involved as long as pouring system is insulated

Cool containers - No Students must wait for liquid to cool

Cap containers - Yes Students can use spring loaded

capping system Label containers - Yes

Students currently label containers Cleaning - Yes

Students can clean parts, but may not be necessary


Feasibility Analysis: Safety vs. Speed Assumptions

Increasing cooking time, higher heat Increasing automation, less contact time

Solution: Prototyping

By creating the process, we can see where the holes in the process where the students can be exposed to safety risk

Increasing automation could lead to other safety risks, such as fingers being caught inside the automatic capping system

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Feasibility Analysis: Process TimeCurrent Process

Process Time (min)

Marginal ER Process time =

360 mins

Ideal ER process time =

240 mins Realistic Target

%reduction from originalrequired time reduction

to meet requirement 0.889 0.593

straining oil 15 13.3 8.9 15 0heating oil/beeswax

mixture 180 160.0 106.7 75 58.33

filling containers 120 106.7 71.1 60 50cooling containers 30 26.7 17.8 30 0labeling containers 60 53.3 35.6 60 0

Total: 405 360 240 240


Feasibility Analysis: How to effectively dispense heated liquid from heating mechanism without contamination?

Assumptions: Must be able to fill lip balm and hand salve containers Must not overflow containers Must minimize hand contact with top of containers.

Solution: Prototyping

Create different attachments for both lip balm and hand salves that fit over the nozzle attached to the engineered crockpot that will include a spacer to allow for the overflowing of liquid and a cap to regulate the amount of overflow.

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Concept Development

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Morphological Chart

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Morphological Chart cont.

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Concepts Considered Current Concept A Concept B Concept CFunctions Pick plants Students Students Buy StudentsHow to dry ingredients Let sit Drying rack Place in jar Spread on tableDetermine source of heat for ingredients

Natural light Natural light Heat lamp Natural light

Strain the oil Tiered straining Tiered straining Cheese cloth Multiple strainersMeasuring the dry ingredients

Weigh Weigh Measuring cup Weigh

Measuring the wet ingredients

Measuring cup Beaker Gatorade cooler with fill line Measuring cup

Heating the ingredients Crockpot Engineered crockpot Crockpot Double boiler

Secure containers Two planks of wood Tray with holes Two planks of wood ChuckAdding fragrance Manual Manual Manual AutomatedDispensing liquid Pipette Engineered crockpot Pipette PumpCooling containers Let sit Let sit Fan Water bathCapping containers Manual Pen dispenser Vacuum pressure ManualLabeling containers Manual Manual Tape dispenser Roll container over label to apply

adhesion forceCleaning heating element Soap and water Beeswax proof material Pot liner Beeswax proof material

Cleaning pouring element Soap and water Soap and water Dispose Beeswax proof material

Pugh Chart Concepts Current A B C Selection Criteria safety

DATUM

+ S -process speed + + +easy to clean - + +ease of use + + -engaging + S +cost - - -simplicity to build - - -sustainability S - +low maintenance - - -container security + - +repeatability + S Syield size S S -amount of automation + + +

Sum + 's 7 4 6Sum 0's 2 4 1Sum -'s 4 5 6

Pugh Chart Concepts Current A B C Selection Criteria safety -

DATUM

- -process speed - - -easy to clean + + +ease of use - - -engaging - - Scost + + +simplicity to build + + +sustainability - - +low maintenance + + Scontainer security - - Srepeatability - - Syield size S S -amount of automation - - - Sum + 's 4 4 4Sum 0's 1 1 4Sum -'s 8 8 5

Pugh Chart Concepts Current A B C Selection Criteria safety S +

DATUM

-process speed - + +easy to clean - - -ease of use - + -engaging S + Scost + - -simplicity to build + - Ssustainability + + +low maintenance + - -container security S + +repeatability S + +yield size S S -amount of automation - + + Sum + 's 4 8 5Sum 0's 5 1 2Sum -'s 4 4 6

Pugh Chart Concepts Current A B C Selection Criteria safety + + +

DATUM

process speed - - -easy to clean - - +ease of use - + -engaging S S -cost + + +simplicity to build + - +sustainability - S Slow maintenance + S +container security - S -repeatability S + +yield size + + +amount of automation - + - Sum + 's 5 6 7 Sum 0's 2 4 1 Sum -'s 6 3 5


Concept Refinement

Concept A looked best from Pugh chart Few changes made to make better product

Measuring system Addition of stirring mechanism and thermometer Capping Technique Change to beeswax resistant material – easier to clean

FunctionsPick plantsHow to dry ingredientsDetermine source of heat for ingredientsStrain the oil Measuring the dry ingredientsMeasuring the wet ingredientsHeating the ingredients

Secure containersAdding fragranceDispensing liquidCooling containersCapping containersLabeling containers

Cleaning heating element

Cleaning pouring element

Concept A’ StudentsDrying rack Natural light

Tiered strainingWeigh

Measuring Cup

Engineered crockpot with stirring arm and thermometerTray with holesManualTube from pot to filling nozzleLet sitPen dispenserManual

Beeswax proof material

Bottle brush and hot water/soap9/30/2014


Plants are grown in scho

ol garden.

Students pick the

plants and

place them on the drying rack.

After plants

are dried, students mix oil and plants in a

large jar.

Using a

stackable

strainer,

filter plant material out of oil.

Selected Concept: Pre-Cooking Procedure

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Selected Concept: Measuring the ingredients

Measure strained oil using measuring cups.

Use triple beam

balance to weigh beeswax

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Selected Concept: Heating the MixtureComb

ine ingredients in

homemade crockpot.

Heat mixture to at least

140° - do not allow

to excee

d 160°.

Use autom

atic stirring arm to keep liquid from

scalding.

Add fragrance once mixture become

s homoge

nous. Continu

e to monitor tempera

ture.9/30/2014


Selected Concept: Pouring the solution into the containers.Open

crockpot spigot to allow liquid

to flow through tubing

to nozzle.

Select nozzle setting based

on product type

(lip balm

or hand

salve).

Place containers (lip balm or

hand salve) into tray

holes to

secure them.

Fill containers.

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Allow to sit for 30 minute

s or until

cool to the

touch.

For lip balm: use

spring loaded

capper to place cap.For hand salves: cap will

be placed by hand.

Place labels

on finish

ed produ

ct.

Selected Concept: Finalizing the product

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Selected Concept: Cleaning the equipment

The homemade crockpot will be made out of a

beeswax resistant material

providing an easier clean up

The tube and nozzle will

need to be run through with hot water to

prevent beeswax buildup.

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Engineering Analysis Needed Wattage required

Want to decrease process time but cannot boil beeswax/oil mixture Automation

Research professional automated dispensing systems Beeswax resistant materials

Glass (Pyrex), stainless steel, ceramic, Teflon coating Does ice or heat make it easier to remove residual wax?

System layout Ergonomic and functional layout of system that allows for simple flow of

product through system Max Batch Size

Batch size cannot exceed amount of secured containers available9/30/2014


Risk Assessment

Likelihood Scale: 1 - unlikely to happen 2 – could conceivably happen 3 – very like to happen

Severity Scale: 1 – impact very minor but will cause extra work 2 – noticeable impact; unmet Engineering requirements 3 – severe impact; not able to deliver product that meets customer

needs

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Risk AssessmentID Risk Item Effect Cause

Likelihoo

d

Severit

y

Importance

Action to Minimize Risk

1 Overheating of product Product boils and is unusable

Insufficient temperature regulation 2 3 6

Measure temperature throughout process, adjust heat source as needed

2 Over Budget Cannot build prototype that matches design Grants do not get funded 2 2 4

Have functionally similar backup designs, track spending throughout project

3 Student Burns Themselves

Student needs to visit nurse, parents may be upset

Insufficient barrier between students and heating element

1 3 3 Safeguard heating elements and keep students from hot liquids

4 Conflicting Team Schedules

Late completion of deliverables, team conflict

Overlap in class schedules, other class work

2 2 4 Maintain group meeting times, assign individual work as needed

5 Product does not match Customer Requirements

Customer is upset, project does not get used

Insufficient budget, unrealistic expectations 1 2 2

Maintain open line of communication with customer, obtain approval at project milestones


Likelihood

Severity

Importan

ceAction to Minimize Risk

6 Failure of Automated Systems

Certain processes need to be done manually or cannot be done

Poorly designed systems, user error 3 2 6 Include repair instructions in

documentation

7 Conflicts with Customer Customer is upset, expectations are not met

Unrealistic expectations, poor communication 1 3 3

Maintain open line of communication with customer, obtain approval at project milestones

8Necessary Technology not available for budget allocation

Level of automation does not meet customer expectation

Insufficient budget, unrealistic expectations 2 1 2

Have functionally similar backup designs with safety improvements to make up for lack of automation

9 Insufficient knowledge to create automated system

Level of automation does not meet customer expectation

Team members have not taken appropriate classes

2 1 2 Meet with professors to ascertain necessary information

10 Petals/leaves in final product

Product is not sellable or undesirable

Insufficient straining, user error 1 3 3

Ensure tiered straining mechanism meets engineering requirement for particle size


Likelihood

Severity

Importance

Action to Minimize Risk

11 Ingredients are measured incorrectly


User error, poor implementation of measuring tools

1 1 1 Provide clear instructions and easy to use measuring tools

12 System inadequately cleaned


User error, difficult to clean equipment 2 3 6

Provide easy to clean equipment, ensure cleaning methods are properly documented

13 Over-pouring or miss-pouring of product

Product is unusable or additional time required to clean outside of containers

Poor implementation of pouring system, user error

2 1 2 Create robust and repeatable pouring system

14 Contamination of product during capping

Product is unsanitary, unsellable

Student gets hands in product, capping system not used properly

2 3 6 Create easy to use and repeatable capping system


Test Plan Outline

Create our own batch Check for pitfalls in selected concept

Compare different materials for ease of cleaning Test designed process

Ensure usable by students Capping Methods Pouring methods Straining efficiency

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Schedule


Questions?

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system design review p15420: rochester roots lip balm/hand salve production line ohimai aisiku...

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