Trapped With A Kupholder Verify

Please download to get full document.

View again

All materials on our website are shared by users. If you have any questions about copyright issues, please report us to resolve them. We are always happy to assist you.
 3
 
 

Slides

  Final presentation from one of my student teams in my Design for Six Sigma class at RPI. Excellant application of DFSS to the design of a mouse trap powered vehicle.
Related documents
Share
Transcript
  • 1. “Trapped With A Kupholder” The Greatest Mousetrap Car Yet! Ayoob Ahmed Osvaldo Colon-Sandoval Amanda Learned December 14th, 2010 DSES-6960 H13 Design for Six Sigma Instructor: Bob Shemenski
  • 2. Agenda Background of our vehicle concept Why customers want this kit Using CDOV process to enhance the car Packaging & Assembly Critical Parameters Accuracy & Precision of the vehicle Ease of use & Enjoying the beverage…
  • 3. Background: The Team Ayoob Ahmed – Electrical Engineer in Non-Destructive Testing – Hoping to become a Lean/6 Black Belt to enhance test rig design & manufacturing – Loves optimizing for a challenge, especially one consisting of drink deliveries! Amanda Learned – Mechanical Engineer in Aero/Thermo Part Durability – Learning to apply DFSS concepts for proactive durability KPC monitoring in her route to hold a Lean/6 Black Belt title – As a true P&W Engineer, loves to see a gear added into the mix! Osvaldo Colon-Sandoval – Project Engineer in F119 Program - Exhaust System CIPT – Becoming a Lean/6 Black Belt to finally develop a logical & achievable scope, schedule, & cost for the company‟s most important engine program – Just happens to have an inner love for mousetrap powered vehicles!
  • 4. Background: The Mission A frequent customer of DocFizzix tapped us on the shoulder, due to our love for mousetrap vehicles, optimization of drink delivery, and passion for creative solutions With the challenge in hand, our team spent countless* hours to develop just the right new kit to be marketed through the company‟s website, hobby stores, & educational product distributors Our sponsor desires to grow their market and is looking for a new product which customers, including students, teachers & hobbyists, can buy, build and use to compete in a new competition: “The Milk Run Challenge” * Actually not countless, please see actual schedule in the back-up slides
  • 5. Customers: Why This New Kit Will Sell They talked… Simple mechanics We listened… - No strings/tangles - A gear driveNo more than a and followed through! - A screw-on break - Simple tools for build day to build, Interchangeable parts maybe even Something fairly - Customizable bodyjust a few hours simple to put - Multiple wheel choices together, but at the use only simple - Repairable same time somewhat mechanics in Easy to use open ended. design… yet make - Breaking independent of it technically drivetrain I‟d like to challenge my interesting.. but - Reliable for multiple uses technical skills… must doable in a day… - Safe to operate be more than just put a Design “Built to win!” couple blocks together. - Delivers large beverages - Consistent & quick - Abides by ground rules
  • 6. CDOV: The Better Way to Design Since we are Black Belts in training, the first step taken to develop the new kit was to decide on a process to follow: – Concept: linking our product to the market – Design: translating the VOX into creative prototypes – Optimize: Concentrating the design to meet design goals – Verify: Ensuring our product is buildable, reliable, & marketable Our product has the customer in mind, with critical features optimized & verified in order for them to win “The Milk Run Challenge” Our team strongly believes that keeping the definition of our „Customer‟ open from the start and following the CDOV process with this base, has really helped us to create an innovative product that will be marketable, even amongst the many other Doc Fizzix mousetrap powered vehicle options
  • 7. CDOV: How it Enhanced “Trapped With a Kupholder” During the concept & design phases we generated some great creative ideas to meet the customer‟s need; however, we kept a back-up concept just in case the lead design was overcome by new failure modes; repetitive testing was done to ensure “the gear” would be user-friendly & reliable At times, there may have been some “heated discussions” in regards to „what next?‟ OK, to verify, we need a GR&R with 3 users, 3 cars, and total distance No, we need the 3 cars, breaking, & wheels… … But “CDOV” pulled us together and kept us moving forward, which reduced R&D costs associated in the new kit & let us meet customer needs & desires Pull up our Critical Parameters to refer to, to answer this one!
  • 8. Project Plan:Actual hours spent on the project…Schedule Analysis for “Trapped With a Kupholder”Phase Schedule Actuals VarianceConcept 36.5 31 5.5Design 27 37 -10Optimize 37 50 -13Verify 47.5 46 1.5 180Totals 148 164 -16 160 140200 120 100150 80 60100 40 50 20 0 0 Concept Design Optimize Verify Totals Concept Design Optimize Verify CUM Schedule CUM Actuals Schedule Actuals
  • 9. Packaging & Assembly:Getting StartedItems in your package Standard TWAK 57 individual pieces Kit contains 57 individual A Manual for assembly & operation Pieces Delivered in a priority mail small flat-rate shipping containerTools required for assembly Wood glue & Super glue 2 adjustable clamps Pliers Wire cutters A 5/8” drill bit Ruler
  • 10. Packaging & Assembly:BOM, Part and “TWAK” Kit CostSale Price per kit @ $14.89 with a Profit Margin of 30% Description Size Location Qty Cost Total Cost Platform 3"x12"x.25" www.hobbylinc.com 1 $ 0.76 $ 0.76 Siderail 1.25"x12"x.25" www.hobbylinc.com 2 $ 0.65 $ 1.30 Front/Rear Axles 0.25" Brass www.hobbylinc.com 2 $ 0.39 $ 0.78 Metal Washers 4 x0.25"ID www.appliancepartspros.com 4 $ 0.10 $ 0.40 Chasis Plastic Washers 12x0.25"ID www.grainger.com 22 $ 0.04 $ 0.88 Mouse trap standard www.acehardware.com 1 $ 0.60 $ 0.60 Axle Gear Plastic www.SmallParts.com 1 $ 0.80 $ 0.80 Main Drivetrain Plastic www.SmallParts.com 1 $ 1.30 $ 1.30 Main Gear Brackets Plastic www.SmallParts.com 2 $ 0.25 $ 0.50 Drive Shaft 0.25"x 3" Brass www.hobbylinc.com 1 $ 0.39 $ 0.39 Drivetrain Gear Support Balsa 0.25" Square www.hobbylinc.com 1 $ 0.10 $ 0.10 Threaded Rod 1.25" of 8-32 Threaded Rod www.hardwareandtools.com 1 $ 0.05 $ 0.05 Wing nut 8-32 Wing Nut www.grainger.com 1 $ 0.40 $ 0.40 Balsa wood .125" x0.5"x3" www.hobbylinc.com 1 $ 0.10 $ 0.10 Braking System Balsa Rod 0.25" Rod www.hobbylinc.com 1 $ 0.02 $ 0.02 Cds 6 Standard CDs www.meritline.com 6 $ 0.12 $ 0.72 Empty Roll of tape www.rhinomart.com 1 $ 0.87 $ 0.87 Rubber Gromet 0.25" to CD ID www.docfizzix.com 4 $ 0.30 $ 1.20Wheels & Cupholders Balloons Assorted 6 www.amazon.com 4 $ 0.07 $ 0.28 Totals 57 $ 11.45 Sales Price per kit @ a Profit Margin of 30% $ 14.89
  • 11. Packaging & Assembly:Simple Steps for a Fun Project This kit comes with clear, illustrated, step-by-step instructions for assembly and operation – Getting Started (1-3) – Building the frame (4-14) – Assembling the large gear (15-22) – Modifying the Mousetrap (23-29) – Fabricating the chassis (30-35) – Making Customizations (36) – Adding Wheels & a Cup Holder (37-46) – Affixing the break (47-52) – Using the Vehicle
  • 12. Packaging & Assembly:The Final Product Drawing with critical features & dimensions – All critical features, like plastic gears and mouse trap, will be provided to the customer as part of the package. – Key assembly dimensions (drawing) will be provided to the customer on the assembly instructions to ensure proper performance of the car.
  • 13. Critical Parameters:Design Score CardDesign score card documenting minimum of 3 system level Critical Parameters Critical Parameters Units LSL Target USL Mean Std Dev Cp Cpk Stop Distance (+/- 1 ft of desired distance) in -12 0 12 -0.61 2.13 1.87 1.78 Ultimate Distance (Able to move car min 16 ft.) ft 16 20 24 17.89 0.49 2.73 1.29 Straight Drive "Alignment" (+/- 1 ft after 16 ft.) in -12 0 12 2.97 5.79 1.18 0.97 Able to move 2 gal to dist of 16 ft in less than 30 min min 0 15 30 14.81 5.36 1.11 1.09 ˆ USL LSL Cp ˆ Min USL x , x LSL C pk 6ˆ 3ˆ 3ˆ
  • 14. Critical Parameters:Capability Growth Index (CGI)• A CGI completed to account for overall subsystems(braking, stop, distance, time) and target Cp = 2• Cpi = min(Cp, 2) n 100 C p iCGI (%) i 1 n 2CGI (%) = 100/4*((1.87/2)+(2/2)+(1.18/2)+(1.11/2))CGI (%) = 77.0%
  • 15. Accuracy & Precision:Design Validation Cpk‟s for the highest priority critical parameters, etc… – Optimized weight capability was set at… 32oz.  Distance traveled > 16ft… 18 ft.  Braking capability ± 12” … ± 2” from target.  Alignment capability ± 12”… ± 4” from axis.  Competition Time < 30min… 15 minutes.
  • 16. Accuracy & Precision:Validation of All Design Requirements Process Capability of Distance Traveled (using 95.0% confidence) Distance: LSL USL P rocess Data WithinLS L 16 Ov erall Cpk of 1.29Target *USL 24S ample M ean 17.8906 P otential (Within) C apability Cp 2.73 Cp of 2.73S ample N 16 Low er C L 1.77S tDev (Within) 0.487589 U pper C L 3.70S tDev (O v erall) 0.598392 C PL 1.29 C PU 4.18 Overall Performance: C pk 1.29 Low er C L 0.80 0.08% total population to U pper C L 1.78 O v erall C apability be out of Limits Pp 2.23 Low er CL 1.44 U pper CL 3.02 PPL 1.05 PPU 3.40 16.25 17.50 18.75 20.00 21.25 22.50 23.75 P pk 1.05O bserv ed P erformance E xp. Within P erformance E xp. O v erall P erformance Low er CL 0.64 % < LS L 0.00 % < LS L 0.01 % < LS L 0.08 U pper CL 1.46 % > U S L 0.00 % > U S L 0.00 % > U S L 0.00 C pm * % Total 0.00 % Total 0.01 % Total 0.08 Low er CL *
  • 17. Accuracy & Precision:Validation of All Design Requirements Process Capability of Stop Distance (using 95.0% confidence) LSL USL Stopping : P rocess Data WithinLS L -12 Ov erallTargetUSL * 12 P otential (Within) C apability Cpk of 1.78 Cp 1.87S ample M ean -0.611111S ample N 18 Low er C L 1.25 Cp of 1.87S tDev (Within) 2.13809 U pper C L 2.49S tDev (O v erall) 3.07052 C PL 1.78 C PU 1.97 C pk 1.78 Low er C L 1.16 Overall Performance: U pper C L 2.39 0.01% total population to O v erall C apability Pp 1.30 be out of Limits Low er CL 0.87 U pper CL 1.74 PPL 1.24 PPU 1.37 -12 -8 -4 0 4 8 12 P pk 1.24O bserv ed P erformance E xp. Within P erformance E xp. O v erall P erformance Low er CL 0.79 % < LS L 0.00 % < LS L 0.00 % < LS L 0.01 U pper CL 1.68 % > U S L 0.00 % > U S L 0.00 % > U S L 0.00 C pm * % Total 0.00 % Total 0.00 % Total 0.01 Low er CL *
  • 18. Accuracy & Precision:Validation of All Design Requirements Process Capability of Alignment P rocess D ata LSL USL Within ALIGNMENT:LS L -12 Ov erallTarget *USLS ample M ean 12 2.13889 P otential (Within) C apability Cp 1.18 CPK of 0.97 C P L 1.39S ample NS tDev (Within) 18 3.38965 C P U 0.97 CP of 1.18S tDev (O v erall) 3.35106 C pk 0.97 O v erall C apability Pp 1.19 PPL 1.41 Overall Performance: PPU 0.98 P pk 0.98 0.16% total population to C pm * be out of Limits -12 -8 -4 0 4 8 12O bserv ed P erformance E xp. Within P erformance E xp. O v erall P erformance % < LS L 0.00 % < LS L 0.00 % < LS L 0.00 % > U S L 0.00 % > U S L 0.18 % > U S L 0.16 % Total 0.00 % Total 0.18 % Total 0.16
  • 19. Accuracy & Precision:Validation of All Design Requirements Process Capability of Time_Total (using 95.0% confidence) Time: LSL USL P rocess D ata WithinLS L 0 Ov erall CPK of 1.09Target *USL 30S ample M ean 15.3467 P otential (Within) C apability Cp 1.11 CP of 1.11S ample N 20 Low er C L 0.76S tDev (Within) 4.49173 U pper C L 1.46S tDev (O v erall) 5.24807 C PL 1.14 C PU 1.09 Overall Performance: C pk 1.09 Low er C L 0.71 0.43% total population to U pper C L 1.46 O v erall C apability be out of Limits Pp 0.95 Low er CL 0.65 U pper CL 1.25 PPL 0.97 PPU 0.93 0 5 10 15 20 25 30 P pk 0.93O bserv ed P erformance E xp. Within P erformance E xp. O v erall P erformance Low er CL 0.60 % < LS L 0.00 % < LS L 0.03 % < LS L 0.17 U pper CL 1.26 % > U S L 0.00 % > U S L 0.06 % > U S L 0.26 C pm * % Total 0.00 % Total 0.09 % Total 0.43 Low er CL *
  • 20. Ease of Use:Operation & Delivery In-person demo to be performed.
  • 21. Ease of Use:Customization Deliver the beverage of your choice – Cup-holder fits all standard sizes – Steady enough to drive even with a Double Big Gulp! – Easily swap out cup-holder for “small glasses” Wheels easily swap out – Add balloon-wrap Bushing simply – Add rubber band wrap pops off of axel & – Double-up the CD‟s out of CD center Frame can be customized – Paint it with markers, crayons, pens, or paint – Add your logo! – Lengthen or shorten or make cut-outs in frame as desired
  • 22. Ease of Use:Enjoying the Beverages For just $14.89 + $4.95 S&H you too could be winning “The Milk Run Challenge” Wow your friends & party guests! Draw a crowd into your business $$ Let students have fun & learn at the same time …Then you can relax and enjoy the beverages too!
  • 23. Back-Up Slides GOOD BAD UGLY
  • 24. Phase 4 RequirementsAction from Optimize Phase Updated design score card including Transfer Functions, predicted Capabilities and Capability Growth Index (CGI) for minimum of 3 system level Critical ParametersVerify Drawing with critical features and dimensions Satisfaction of VOC, both customer and stakeholder needs Validation of all design requirements generated in Concept phase BOM and parts cost Description of assembly, tools and process Demonstrate operating procedure Design Validation – Cpk for highest priority critical parameters Updated Design score card Critical Parameters, Capability Growth Index (CGI) Specific details: How DFSS tools and CDOV process influenced the development of your product design Project Plan (actual hours spent on Concept, Design, Optimize and Verify phases) Three working prototypes, materials and instructions for in-class competition. Verify phase gate scorecard
  • 25. Verify Phase Scorecard
  • 26. A Missing Anecdote from the Optimize Phase Report: The Original Cup Holder was to carry 2 beverage containers, on either side of chassis Market research was completed to determine standard cup holder sizes & requirements: 4.25” & 3.75” diameter should fit most all cups (except “Nalgene” bottle type) As the design evolved, we were able to optimize the design by carrying more beverage in a single cup holder, in the center of the chassis Testing & analysis showed small cups needed no further support than what the 4.75” standard cup-holder delivered: stability was consistent with repetitive testing A cylinder provides simpler assembly than a 4- or 3-sided design, which requires multiple pieces and more locations for failure (FMEA) Design 1: Design 2a: Design 2b:
  • 27. Packaging & Assembly:The Final Product Drawing with critical features & dimensions
  • 28. Packaging & Assembly:The Final Product Drawing with critical features & dimensions
  • 29. Accuracy & Precision:Validation of All Design Requirements Process Capability Sixpack of Distance Traveled I Chart Capability Histogram LSL USL UCL=19.353 19 S pecificationsIndividual Value LS L 16 _ 18 X=17.891 U S L 24 17 LCL=16.428 1 3 5 7 9 11 13 15 16.25 17.50 18.75 20.00 21.25 22.50 23.75 Moving Range Chart Normal Prob Plot 2 A D: 0.855, P : 0.021 UCL=1.797 Moving Range 1 __ MR=0.55 0 LCL=0 1 3 5 7 9 11 13 15 16 18 20 Last 16 Observations Capability Plot 19 Within Within O v erall S tDev 0.487589 S tDev 0.598392Values 18 Cp 2.73 Pp 2.23 O v erall C pk 1.29 P pk 1.05 17 C pm * S pecs 5 10 15 Observation
  • 30. Accuracy & Precision:Validation of All Design Requirements Process Capability Sixpack of Alignment_1_1 Xbar Chart Capability Histogram LSL USL UCL=9.19 S pecifications Sample Mean 6 _ _ LS L -12 X=2.14 U S L 12 0 LCL=-4.91 -6 1 2 3 4 5 6 7 8 9 -12 -8 -4 0 4 8 12 R Chart Normal Prob Plot UCL=12.25 A D: 0.328, P : 0.489Sample Range 10 5 _ R=3.75 0 LCL=0 1 2 3 4 5 6 7 8 9 -10 0 10 Last 9 Subgroups Capability Plot Within Within O v erall 5 S tDev 3.32484 S tDev 3.35106 Values Cp 1.2 Pp 1.19 0 O v erall C pk 0.99 P pk 0.98 C pm * -5 S pecs 2 4 6 8 Sample
  • 31. Accuracy & Precision:Validation of All Design Requirements Process Capability Sixpack of Stop Distance Xbar Chart Capability Histogram 1 5 LSL USL UCL=4.35 S pecificationsSample Mean _ LS L -12 0 _ X=-0.61 U S L 12 -5 LCL=-5.57 1 2 3 4 5 6 7 8 9 -12 -8 -4 0 4 8 12 R Chart Normal Prob Plot UCL=8.613 A D: 0.781, P : 0.034 8 Sample Range 4 _ R=2.636 0 LCL=0 1 2 3 4 5 6 7 8 9 -10 0 10 Last 9 Subgroups Capability Plot Within Within O v erall 5 S tDev 2.33692 S tDev 3.07052Values Cp 1.71 Pp 1.3 O v erall 0 C pk 1.62 P pk 1.24 C pm * -5 S pecs 2 4 6 8 Sample
  • 32. Accuracy & Precision:Validation of All Design Requirements Process Capability Sixpack of Time_Total I Chart Capability Histogram LSL USL 30 UCL=30.90 S pecificationsIndividual Value LS L 0 _ 15 X=14.81 U S L 30 0 LCL=-1.27 1 3 5 7 9 11 13 15 17 19 0 5 10 15 20 25 30 Moving Range Chart Normal Prob Plot 20 UCL=19.76 A D: 0.179, P : 0.905Moving Range 10 __ MR=6.05 0 LCL=0 1 3 5 7 9 11 13 15 17 19 0 10 20 30 Last 20 Observations Capability Plot Within Within O v erall 20 S tD ev 5.3627 S tDev 6.03241Values Cp 0.93 Pp 0.83 O v erall 10 C pk 0.92 P pk 0.82 C pm * 0 S pecs 5 10 15 20 Observation
  • 33. “Trapped With A Kupholder” Build InstructionsParts, Assembly, & Usage Manual for your new mousetrap powered vehicle* *Proprietary information of Ayoob Ahmed, Osvaldo Colon- Sandoval & Amanda Learned
  • 34. What is Standard TWAK Kitincluded in contains 57 individualyour kit Pieces2 chassis side rails (balsa wood sheet)2 chassis spacers (balsa wood blocks) 1 large gear with spokes (plastic)1 chassis platform (balsa wood sheet) 1 small gear (plastic)4 reinforcing blocks (balsa wood rectangles) 1 bent metal tube1 break arm (thin wood piece) 2 wheel axels (long metal tubes)1 round wooden rod 1 gear axel (short square metal rod)4 standard CDs 1 threaded rod (round metal)2 balloons (std 8”, optional for assembly) 2 gear mounting feet (plastic)1 cardboard flattened roll (packing tape 20 spacers (plastic disks)size) 4 bushings (rubber)1 mousetrap (standard “Victoria” brand) 4 washers (optional for assembly)1 wing nut
  • 35. Assembly steps 1-3: Getting Started1. Lay out the entire contents of your kit2. Check that all of the parts listed in the “What is Included in Your Kit” section are accounted for  If any parts are missing, please visit our website and submit a communication; please include your kit bar code and the name of the specific missing kit piece(s)3. Gather the required equipment needed for assembly, not included in your kit: a. Wood glue b. 2 adjustable clamps c. Pliers d. Wire cutters e. A 5/8” drill bit f. Ruler g. Super glue h. Cup of your choice to carry liquid
  • 36. Steps 4-14: Building the Frame4. Insert a wheel axel through one hole 9. Slide one end of the 2nd wheel axel of each chassis side rail through the hole at the other end of5. Stand the side rails on their edges, as a chassis side rail shown and align short ends with a 10. When the inserted end is in the secure straight edge or T-square middle of the 2 side rails, slide the6. Place a chassis spacer between the small gear onto this end of the axel two bars, up against the straight edge 11. Continue pushing axel through the and ensure it is not touching the axel last chassis side rail pre-drilled hole7. Glue the chassis spacer ends to the 12. Push the small gear towards the inner side of each chassis side middle of the assembly, until the rail, with the wood glue back axel looks similar to that shown8. Secure a clamp on the outer edges of in the picture the chassis side rails, aligned with the 13. Follow steps 5. through 8. again, for glued intersections this end of the assembly 14. Set Frame aside to let the
  • Related Search
    We Need Your Support
    Thank you for visiting our website and your interest in our free products and services. We are nonprofit website to share and download documents. To the running of this website, we need your help to support us.

    Thanks to everyone for your continued support.

    No, Thanks