Revised 1/2/2014

ME 428-429-430 Senior Design Project

Instructor: Peter Schuster Office Hours (Fall): M: 4:10-5:50 Office: 13-256 T: 1:10-2:00 in 13-107 Phone: 756-2976 W: 12:10-1:00 F: 10:00-10:50 Lecture: ME428-01 M 6:10-7:00 14-249 Labs: ME428-02 TR 8:10-12:00 192-120 Schuster ME428-03 TR 12:10-3:00 192-132 Rossman ME428-04 TR 8:10-11:00 192-132 Rossman Course Learning Outcomes:

1. Apply an engineering design process to solve open-ended engineering design problems. 2. Work effectively on an engineering team. 3. Develop, analyze, and maintain an engineering project schedule using a Gantt chart. 4. Use Quality Function Deployment (QFD) to evaluate customer requirements. 5. Formally define an engineering problem. 6. Generate an engineering specification document. 7. Apply creative techniques to generate conceptual design solutions. 8. Apply structured decision schemes to select appropriate engineering concepts in a team environment. 9. Design subsystems within constraints of strength, size, materials, performance, cyclic loading, etc. 10. Evaluate potential design solutions through the use of appropriate analysis techniques and tools. 11. Apply current industrial design practice and techniques such as DFX, FMEA and/or TQM in

engineering design. 12. Develop and implement a design verification plan and report. 13. Construct and test prototype designs. 14. Communicate and present engineering design project results orally, graphically, and in writing. 15. Discuss and take a stand on open-ended topics involving engineering ethics and product liability. 16. Discuss engineering professionalism and its responsibility to society. 17. Understand the codes of ethics and their implications in engineering practice. Prerequisites: ME 329, ME 318, ME 343 Text: ME 428-429-430 Senior Project Student Success Guide

(at http://me.calpoly.edu/cpr/senior-project-student-info/) Materials: You are required to keep a written record of all your project activities. This

should be kept in a bound, 8.5x11 inch logbook. You will need a minimum of 150 pages. See the Student Success Guide for more details.

Additional Resources (not required, but good references): Shigleys Mechanical Engineering Design, Budynas & Nisbett

Creative Design of Products and Systems, Niku Total Design, Stuart Pugh The Mechanical Design Process, Ullman Engineering Design, Dieter & Schmidt

Revised 1/2/2014

ME428 Schedule (SUBJECT TO CHANGE) WK DATE TOPIC & ACTIVITIES ASSIGNMENTS DUE 1 1/6 M

Lab T TH

Course Intro, Expectations, & Process Sponsor Presentations - Meet in 197-104 Team Building Activities

1/8 - Project Preference Form

2 1/13 M Lab T TH

Travel, Research, Teams Team Building / Background Research Define Problem / Team Meetings

1/14 - Register for IDEALS 1/16 - Team Contract, Intro letter

3 1/21 T Lab T TH

Problem Definition & QFD No Tuesday Lab (Monday Schedule!) Background Research / Team Meetings

1/23 - Sponsor e-Visit,

Problem Statement 4 1/27 M

Lab T TH

Creativity & Idea Generation Requirements (QFD House of Quality) Prepare Project Proposal / Team Meetings

1/30 - QFD House of Quality

5 2/3 M Lab T TH

Concept Modeling & Idea Evaluation Ideation Ideation / Team Meetings

2/4 - PROJECT PROPOSAL ** 2/7 - Team Evaluation in IDEALS

6 2/10 M Lab T TH

Design of Experiments & DVP Concept Model Building - Meet in 197-104 Idea Evaluation / Team Meetings

2/11 Reflection in PolyLearn 2/13 - Concept Models

7 2/17 M Lab T TH

NO LECTURE (HOLIDAY) Design & conduct a simple experiment Idea Evaluation / Team Meetings

By 2/21 - Schedule Design Review

w/sponsor 8 2/24 M

Lab T TH

Entrepreneurship & Intellectual Property Write Concept Design Report Concept Design Review Presentations

2/25 - Decision Matrix 2/28 - Yellow Tag

9 3/3 M Lab T TH

Project Planning & Budget Concept Design Review PresentationsProject Planning

3/4 - CONCEPT DESIGN REPORT ** By 3/7 - Concept Design Review

w/sponsor 10 3/10 M

Lab T TH

FMEA & Safety Design FMEA & DVP Design Analysis

3/11 - Design Analysis Plan Project Gantt Chart 3/13 - Design FMEA & DVP Team Evaluation in IDEALS 3/14 Reflection in PolyLearn

Lab attendance is mandatory ME 428 Grading (3 units): You will initially receive an RP (Report in Progress) grade for ME428. This will be changed to the appropriate letter grade after you complete your Critical Design Review with your sponsor during the 6th week of ME 429. Design Logs/Weekly Activities/Teamwork 15% Project Proposal 10% Conceptual Design Report and Review 25% Final Design Report and Critical Design Review 50%

Revised 1/2/2014

ME429 Schedule (SUBJECT TO CHANGE) WK DATE TOPIC & ACTIVITIES ASSIGNMENTS DUE

1 4/1 4/3

Design for Manufacturing & Assembly Design Analysis / Team Meetings

2 4/8 4/10

Design Analysis Design Analysis / Team Meetings

3 4/15 4/17

CAD Modeling / BOM BOM / Team Meetings

By 4/18 Schedule CDR with Sponsor

4 4/22 4/24

CAD Modeling / BOM Prepare Design Report / Team Meetings

5 4/29 5/1

Critical Design Review (CDR) Presentations Critical Design Review (CDR) Presentations 5/2 FINAL DESIGN REPORT **

6 5/6 5/8

Engineering Ethics Awareness Training Team Meetings

5/6 Team Evaluation in IDEALS 5/8 Reflection in PolyLearn By 5/9 Critical Design Review w/Sponsor

7 5/13 5/15

Part Ordering Part Ordering / Team Meetings

5/13 Individual Ethics Memo

8 5/20 5/22

Ethics Case Study Presentations Ethics Case Study Presentations

By 5/23 All Parts & Materials Ordered

9 5/27 5/39

NO LAB (Monday schedule) Global Competency

10 6/3 6/5

Manufacturing & Test Review Presentations Prepare Quarter Report / Team Meetings

6/6 - End of Quarter Report Team Evaluation in IDEALS Reflection in PolyLearn

Lab attendance is mandatory ME430 Schedule (SUBJECT TO CHANGE) WK DATE TOPIC & ACTIVITIES ASSIGNMENTS DUE

1 9/22 Prototype Construction / Team Meeting 2 9/29 Prototype Construction / Team Meeting By 10/3 - Project Update Memo to Sponsor 3 10/6 Prototype Construction / Team Meeting 4 10/13 Prototype Construction / Team Meeting SENIOR EXIT EXAM (day TBD) ** 5 10/20 Project Testing / Team Meeting By 10/24 - Project Hardware Demo 6 10/27 Project Testing / Team Meeting 10/31 Team Evaluation / Reflection 7 11/3 Project Testing / Team Meeting By 11/7 - Complete Senior Survey (TBD) 8 11/10 Prepare for Expo / Team Meeting 9 11/17 Prepare for Expo 11/ 20 - SENIOR DESIGN EXPO (4-7pm) **

10 11/24 Prepare Final Report 11 12/1 Prepare Final Report 12/5 - FINAL PROJECT REPORT **

Team Evaluation / Reflection Project work & meetings at mutually agreed times for each team. ME 429 / ME 430 Grading (3 units): You will initially receive an RP (Report in Progress) grade for ME 429. At the end of ME 430, you will receive the appropriate letter grade for BOTH ME 429 & ME 430. Design Logs/Weekly Activities/Teamwork 10% Ethics Activities 10%

Manufacturing and Test Review 10% Senior Exit Exam 10%

Final Project Design Expo & Report 60%