María Camila Luna Pablo Santizo Matheu Zachary Borden Zachary Delurey ENIORDESIGNENIORDESIGN.

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?