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Background 39/30/2014P System Design Review
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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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P15420 - System Design Review 3
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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P15420 - System Design Review 6
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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P15420 - System Design Review 7
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
P15420 - System Design Review 9
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
P15420 - System Design Review 12
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
P15420 - System Design Review 14
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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P15420 - System Design Review 15
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.
P15420 - System Design Review 16
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
P15420 - System Design Review 18
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
P15420 - System Design Review 20
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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P15420 - System Design Review 21
Concept Development
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Morphological Chart
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P15420 - System Design Review 23
Morphological Chart cont.
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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
P15420 - System Design Review 30
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
P15420 - System Design Review 31
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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P15420 - System Design Review 32
Selected Concept: Measuring the ingredients
Measure strained oil using measuring cups.
Use triple beam
balance to weigh beeswax
. 9/30/2014
P15420 - System Design Review 33
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
P15420 - System Design Review 34
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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P15420 - System Design Review 35
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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P15420 - System Design Review 36
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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P15420 - System Design Review 37
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
P15420 - System Design Review 38
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
Risk AssessmentID Risk Item Effect Cause
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
Risk AssessmentID Risk Item Effect Cause
Likelihood
Severity
Importance
Action to Minimize Risk
11 Ingredients are measured incorrectly
Product is not sellable or undesirable
User error, poor implementation of measuring tools
1 1 1 Provide clear instructions and easy to use measuring tools
12 System inadequately cleaned
Product is not sellable or undesirable
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
P15420 - System Design Review 42
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
P15420 - System Design Review 44
Questions?
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