Engineering Projects In Community Service

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Engineering Projects In Community Service
in partnership with
Wabash Center Greenbush Industries, WCGI
Final Presentation May 2, 2008
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WCGI
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Wabash Center Greenbush Industries
WCGI is a local non-profit organization

• Mission of WCGI
• To create living and working opportunities for
  people with disabilities in and around the
  Lafayette area
• About WCGI
• Provides commercial subcontracting services for
  a variety of corporations, from banking to
  medical industries
• Most jobs simple, repetitive tasks such as
  placing rivets, cutting vial tips, etc.
• OUR Team Mission
• Design devices that increase worker safety,
  improve efficiency, and increase
  productivity at WCGI

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Medical Tube Cutting TeamDelivery Review

• 28 March, 2008
• ARMS 1098C

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WCGI
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Team Members
Medical Tube Cutting Project

• Ratan Rego, Sophomore EE
• Phillip Bush, Freshman ME
• Jeffrey Rieger, Junior EE
• Leonard Jackson, Sophomore IDE
• Ankit Singhania, Junior EE

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WCGI
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Introduction to the Project

• Ratan Rego

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WCGI
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Project History
Medical Tube Cutting Project

• Origins of project
• Start semester Fall 2006
• Requirement A device that would enable people
  with disabilities (Consumers) working at WCGI to
  cut tubing to different lengths

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WCGI
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Community Need
Medical Tube Cutting Project

• Relevance to the project partner
• What is the need that is being addressed?
• WCGI provides jobs for people with disabilities
• What is the current situation?
• Use of temporary workers who measure out tube and
  cut it with a razor blade
• Safety and accuracy can be improved

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WCGI
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Community Need
Medical Tube Cutting Project

• Why should the need be addressed?
• To enhance the lives of Consumers by providing
  them with living and working opportunities
• To help the Consumers eventually transition into
  active jobs in the community

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WCGI
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Goals of the Project
Medical Tube Cutting Project

• To provide a device that will enable the
  Consumers to cut Medical Tubing safely
• To improve the speed and efficiency of the
  current process
• To stay within the following tolerance range
• Length 1/8?
• Angle 5

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WCGI
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Goals of the Project
Medical Tube Cutting Project

• Tube Lengths
• Tube Diameters

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Goals of the Project
Medical Tube Cutting Project

• What are the deliverables
• 1 Cutting Device
• 5 Inserts
• Attachment that measures tube length

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WCGI
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The Cutting Device

• Phillip Bush

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WCGI
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Project Specifications
Medical Tube Cutting Project
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WCGI
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Design Overview
Medical Tube Cutting Project

• The tube cutter is designed to cut medical tubing
  of different diameters efficiently and safely.
• The tube cutter is able to cut the tubing with a
  guillotine effect using a razor blade. The
  tubing is held firmly in the insert.

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WCGI
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Operational Overview
Medical Tube Cutting Project
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WCGI
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Functional Decomposition
Medical Tube Cutting Project

• Base Holds the insert in place and has rods for
  blade holder
• Blade holder Holds the blade and slides down
• Cover Encloses the blade to protect consumer
  from harm
• Insert Fits around the tube tightly to allow
  the tube to be cut
• Insert Tab Holds insert in base

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WCGI
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Design Overview Subsystem 1
Medical Tube Cutting Project

• Base

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WCGI
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Design Overview Subsystem 2
Medical Tube Cutting Project

• Blade Holder

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WCGI
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Design Overview Subsystem 3
Medical Tube Cutting Project

• Cover

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WCGI
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Design Overview Subsystem 4
Medical Tube Cutting Project

• Insert

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WCGI
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Design Overview Subsystem 4
Medical Tube Cutting Project
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WCGI
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Design Overview Subsystem 5
Medical Tube Cutting Project

• Insert Tab

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WCGI
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Tube Measuring System

• Jeffrey Rieger

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WCGI
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Tube Cutter Measurement System
Medical Tube Cutting Project

• Overview and description
• Problem To effectively measure and store a piece
  of tubing
• Solution To connect a piece of piping to the
  Tube Cutter insert and place a stopper at the
  required distance within the piping

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Tube Cutter Measurement System
Medical Tube Cutting Project

• Measurement System Usage
• The Piping will be placed perpendicular to the
  floor
• When the stopper is removed the tube will fall
  (due to gravity) into a basket or collector

Tube Cutter
Piping with stoppers
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Tube Cutter Measurement System
Medical Tube Cutting Project

• Drawbacks
• The tube cutter needs to be held firmly in place
  to assure a cut is made
• Four different steps
• 1. Feed the tube into the tube cutter/pipe
• 2. Make the cut
• 3. Remove the stopper
• 4. Replace the stopper

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Measurement Prototypes
Medical Tube Cutting Project

• Grooved Table
• Use a table to cradle the tube as it fed through
  the tube cutter
• Drawbacks
• Does not insure the tube will
• be cut to the specification
• Requires operator to determine
• when the length is correct

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Measurement Prototypes
Medical Tube Cutting Project

• Grooved Stand
• A grooved block of wood is set on a stand, which
  allows for mobility
• Drawbacks
• Difficult to remove the cut tube
• from within the groove
• Does not guarantee a cut within
• the specifications

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Tube Cutter Testing Plan
Medical Tube Cutting Project

• Overview and description
• Purpose To determine the repeatability and
  consistency of the Tube Cutter
• Procedure
• Using the given tube cut ten pieces to be ten
  inches in length
• Compare these ten pieces to a sample measuring
  exactly ten inches in length
• Compute the percent error with each cut

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WCGI
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Tube Cutter User Training
Medical Tube Cutting Project

• Overview and description
• Purpose To teach prospective users the proper
  way to operate the Tube Cutter.
• Process Select an insert that appropriately
  matches the diameter of the tube to be cut
• Select the appropriate size Tube Holder (this
  matches the length of tube that will be cut)
• Set the sensor system up by placing it at the end
  of the Tube Holder

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WCGI
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Project Schedule Budget

• Leonard Jackson

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WCGI
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Project Schedule
Medical Tube Cutting Project

• Current week Week 11
• Order Cutting Device Week 12
• Order Attachment Week 13
• Complete Testing and Training Package Week 14
• Project Delivery Week 15/16

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Team Budget
Medical Tube Cutting Project

• The total cost for the Cutting Device is
  1,000-1,250. The break up is as follows
• Cutting Device 1 Insert 1,000
• Cutting Device 3 Inserts 1,250
• This cost includes the following
• Machine shop cost
• Labor for the machine shop
• Materials

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WCGI
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Progress Roadblocks

• Ankit Singhania

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WCGI
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Semester Progress
Medical Tube Cutting Project

• Designs and drawings were updated corrections
  were made and completed
• A new design of the measuring attachment was
  created
• An order will shortly be placed for the Cutting
  Device
• Began Testing Plan and Training Package

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WCGI
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Team Roadblocks
Medical Tube Cutting Project

• Team had to work off a prototype that isnt fully
  functional
• No one on the team knew how to use AutoCAD
• Only one returning team member on the continuing
  project

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WCGI
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Questions?
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Scheduling ProjectDesign Review

• 28 March, 2008
• ARMS 1098C

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WCGI
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Team Members
Scheduling Project

• Vikrant Vikram Singh, Junior EE
• Dhruv Saxena, Junior EE
• Ankit Singhania, Junior EE

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WCGI
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Introduction to the Project
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WCGI
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Project History
Scheduling Project

• Origins of project
• Start semester Spring 2007
• Requirement A scheduling template that would
  enable the client (Mr.Chuck Jansen) working at
  WCGI to efficiently organize and schedule weekly
  production.

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WCGI
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Project Need
Scheduling Project

• Relevance to the project partner
• What is the need that is being addressed?
• Simplify the use of already developed scheduling
  template.
• What is the current situation?
• The client currently uses an excel file which is
  not automated, requiring manual entry.

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WCGI
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Goals of the Project
Scheduling Project

• To increase the ease of use of constructing the
  daily and weekly production and shipping schedule
  for each of WCGIs customers.
• Create a simplified tabular help file.
• Create a weekly updated database for the goods in
  hand.

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WCGI
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Goals of the Project
Scheduling Project

• What are the deliverables
• 1 Modified User Friendly Scheduling Template.
• Simplified Tabular Help Guide.

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WCGI
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The Scheduling Template
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WCGI
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Design Overview
Scheduling Project

• The tools include automated calculations,
  categorized information using color coding and
  logically organized spreadsheets.
• The spreadsheet operates on real time, meaning
  that when determining outputs, the functions
  automatically take into account the current day
  and time as well as the preceding days actual
  activity and update based on these variables.

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WCGI
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Project Specifications
Medical Tube Cutting Project
TRW Corcoran Endowment
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WCGI
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Functional Decomposition
Scheduling Project

• Inputs a unique identifier is created by
  combining the customer information with their
  requested product for each order.
• Weekly Schedule Quantity to produce is
  determined by subtracting the quantity on hand
  from the customer order, and the amount of days
  to produce is determined based on the ship date.

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WCGI
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Project Specifications
Medical Tube Cutting Project
TRW Corcoran Endowment
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WCGI
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Design Overview Subsystem 4
Medical Tube Cutting Project

• Insert

TRW Corcoran Endowment
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WCGI
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Functional Decomposition
Scheduling Project

• Production Schedule - Extracts and displays
  relevant information from the weekly schedule by
  matching the current day with the corresponding
  day from the weekly schedule tab.
• Shipping Schedule - same concepts as the
  production schedule except that the information
  is based on the orders that need to be sent out
  on a particular day.

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WCGI
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Design Overview Subsystem 4
Medical Tube Cutting Project
TRW Corcoran Endowment
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WCGI
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Template Help Guide
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WCGI
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Tube Cutter Measurement System
Medical Tube Cutting Project

• Overview and description
• Purpose To effectively measure and store the cut
  piece of tubing.
• Using predetermined lengths of wood, grooving a
  hole within the wood will allow the precise
  measurements to be made.

TRW Corcoran Endowment
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WCGI
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Tube Cutter Measurement System
Medical Tube Cutting Project

• Overview and description
• The wooden Tube Holder will be placed equally
  leveled with the Tube Cutter to assure proper
  assignment.

TRW Corcoran Endowment
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WCGI
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Progress Roadblocks
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WCGI
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Semester Progress
Scheduling Project

• The team gained valuable insight into the
  problems with the template.
• Identified the need for a simplified tabular help
  file.
• Designed and Documented the help file.
• Resolved the inherent issues with the scheduling
  template.

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WCGI
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Team Roadblocks
Scheduling Project

• Entire Team comprised of new members
  necessitating extra time to familiarize with the
  project.
• Immense time was devoted in understanding the
  complex excel spreadsheet codes and hidden
  templates.

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WCGI
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Where Were Going...
Scheduling Project

• Since the errors with the template have been
  resolved and the functioning is satisfactory we
  intend to
• Carry out a test survey from multiple users and
  the client testing the template.
• Collect the feedback from the survey and after
  making any required rectifications deliver the
  project to WCGI.
• Develop a training module to train the client on
  using the template.

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Questions?
Scheduling Project
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Screw Packing Project (WCGI)Project Review

• 28 March, 2008
• ARMS 1098C

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Introduction
Screw Packing Project

• Leonard Jackson, Sophomore IDE
• Benjamin Brown, Freshman IE

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Community Need
Screw Packing Project

• Relevance to the project partner
• What is the need that is being addressed?
• Allow a task to be done by Consumers with varying
  abilities
• Why should the need be addressed?
• Provide the Consumers with living and working
  opportunities, help them eventually transition
  into active jobs in the community

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Community Need
Screw Packing Project

• How did the team become aware of the need?
• Informed by project partner, discussed previous
  groups work
• Benefits of addressing the need to
• Project partner creating more opportunities for
  Consumers
• Those served by the project partner creating
  tools and devices that allow more Consumers to
  perform the task

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Goals of the project
Screw Packing Project

• What aspects of the need will the project
  address?
• Consumers with varying abilities will be able to
  perform the task
• Safety and reliability of the device
• What aspects of the need will not be addressed by
  the project?
• The amount of items that each Consumer will be
  able to pack in a given time

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Goals of the project
Screw Packing Project

• Constraints or overall objectives that are
  critical to the project success.
• Design utility, so that many Consumers with
  different skill sets can use the device
• Design versatility, so that the device can be
  used for different screw combinations
• Design safety

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Goals of the Project
Screw Packing Project

• What is the success criteria?
• Production levels should increase for Consumers
  performing this task with our device
• What are the deliverables?
• Base and funnel, universal bottom plate, variety
  of top plates

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Project Specifications
Screw Packing Project
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Background Research
Screw Packing Project

• Currently the research that has been conducted
  was by another Industrial Engineering Team (in IE
  486) that had a similar problem. Their paper is
  the primary source in which we got our ideas
  from. So far this is one of very few sources that
  we found, that had a big impact on our project.

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Functional Decomposition
Screw Packing Project

• Top Plate Contains holes that sorts screw set
  to be packed
• Bottom Plate Holds the screws from top plate,
  top plate shifts to align to holes in bottom
  plate
• Base Holds the plates in place when plates are
  aligned, screws fall through into an attached
  funnel and their bag

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Operational Overview
Screw Packing Project

• The only operational concern is the movement of
  the top plate

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Top Plate Overview
Screw Packing Project

• Overview of Top Plate
• Different layout for each screw package
• Up to nine slots for screws of each length, caps,
  or plugs (max 18 slots)
• Slot size and placement a concern for utility,
  ease of use
• Once our device is completed we will develop a
  testing plan

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Top Plate Proposed Solutions
Screw Packing Project

• Explanation of first proposed solution
• One universal base plate aligns with multiple top
  plates
• Different top plate can be substituted for
  different package combination
• Attached example of screw/cap/plug to be inserted
  in each group of slots provides visual, tactile
  recognition

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Preliminary Budget
Screw Packing Project
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Discussion of future plans
Screw Packing Project

• Design and machine universal bottom plate
  prototype
• Design and machine top plate prototype for most
  common combination (BM II DH/SH 6 screw set)
• Return to project partner with prototypes to test
  utility

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Discussion of future plans
Screw Packing Project

• If prototype design proves successful, develop
  more top plates for different packaging
  combinations
• Develop bases as directed by consumer necessity
• Estimated delivery date Fall 2008

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Questions?
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