P16718 Micropen Workstation Redesign Detailed Design Rachele Floeser Project Manager Alex Langkamp Project Manager Sabrina Caliri Facilitator/Engineer Nick Accuosti Engineer Matt DePalo Engineer Mike Everett Engineer
Review and Updates Operator Feedback Outline Test Plan Design Models Project Management
Review and Updates
Review of Project Deliverables ● Design alternatives by subsystem or component ● Develop functional prototype of complete system design ● Create user guides for operation ● Create appropriate design, test, manufacture, and supply chain documentation ● Create an improved workstation that eliminates or at least reduces the ergonomic risk factors for the operator
Open Items from System Design Review Issue Issue The viewing apparatus solution of using a screen Tooling solutions used for the touch-up procedure potentially causes different ergonomic challenges for the creates more challenges for the operator, outside of the operator known challenges Action Taken Action Taken Performed initial testing using the DinoXcope at the Researched precise tooling operations. Sketched ideas Micropen workstation. Identified some software and and created solidworks documents of potential solutions hardware requirements of the viewing apparatus solution Current Situation Current Situation Developed multiple solutions that vary in difficulty to Continuing to identify requirements and additional testing implement and also in simplicity of the operation for the methods for the subsystem operator
Customer Requirements
Updates to Engineering Requirements ● House of Quality Updated ● Added two new engineering requirements: Marginal Ideal Requirement # Rank Function Metric Unit Value Value All measured stresses are within a S36 9 Testing FOS 3 >5 FOS for the given part geometry cycles/ All tests do not fail within avg. hourly S37 9 Testing 50 >60 output rate hour
Operator Feedback
Operator Survey - Daily Discomfort - Overview ● Time Increments Recorded ● Operator Comments Summary Morning Attributed some discomfort to arthritis ○ ○ ○ Before Lunch ○ Recorded more detail in type and Evening ○ location of discomfort ● Collected Data for Each Body Part ● Expressing Discomfort Frequency ○ Type of Discomfort ○ Variable ○ Level of Discomfort Intermittent ○ ○ Frequency of Discomfort ○ Stable
Operator Daily Discomfort Survey - Feedback Average Discomfort Intensity Discomfort Frequency
Operator Daily Discomfort Survey - Feedback (continued) Highest Point Amount of Issues Recorded Average Discomfort Levels Left Side is a Big Issue
Test Plan
Test Type Test Description Test Plan Ergonomics Test Take image of worker performing task for each specific component. Compare to Engineering Requirements. May have to be performed for multiple operators Workstation Measure current and finished workstation. May have to be performed for multiple Measurements operators Operator Survey Gather operator survey from both current and future system Survey of Measurement of throughput from current and future system Throughput Survey of Scrap Measurement of scrap from current and future system Stress Test Solidworks simulation Endurance Test Continuous use over a certain amount of time (Pass/Fail) Functionality Ensure components are working as expected (Pass/Fail) Test
Component Phases ● Based on operator survey feedback ● Diagram is used to determine when decisions about subsystem components will be made Phase 1 - Focuses on initially ○ identified ergonomic challenges Phase 2 - Requirements are ○ dependent on Phase 1 decisions Phase 3 - Additional opportunities for ○ improvement and based on Phase 1 and Phase 2
Design Models
Final Design Model - No Updates ● Material Handling Place kink in wire ○ ■ Creates the need to develop a kink tool ● Actuating the Opener (Open/Closing Chuck) ○ Solenoid Air Valve ● Stretching & Exercises Provide stretching sheets at workstations ○ ○ Decrease WIP to increase flow ● Arm & Elbow Support During the “Touch-Up” Procedure ○ Adjustable Elbow & Forearm Support ■ Operator’s preferences are different so adjustability will be key ○ Will depend on the choice for back support
Final Design Model - Viewing the Part High Cost Option: O.C. White TKMACZ Prolite Macro-Zoom ● Adjustable focal length, zoom and stand ● HD 1080p resolution ● Cost: $2785 Medium Cost Option: Hitachi KP-d20 ● Compact, easy to mount out of the way ● Higher resolution than existing camera ● Already used in the company ● Cost: $600-$900
Final Design Model - Viewing the Part Dino-Lite Microscope ● Cheaper model not strong enough for our purposes ● More advanced models have much higher specs ● Costs can go up to $1200 based on features wanted ● Easily adjusted by operators ● Very small and easy to mount and manipulate
Final Design Model - Viewing the Part Humanscale Monitor Arm OmniMount OC40FMX ● Full range of motion ● Not quite as flexible ● Multiple mounting attachments available ● Wall mount only ● Integrated cable control ● Integrated cable control ● $239 ● $36
Final Design Model - Viewing the Part Monitors ● Selection is entirely dependant on camera and stand chosen ● Ergonomics comes from placement more than monitor specs
Final Design Model - Operator Tooling ● Operator Tooling for the “Touch-Up” Procedure Modify the handle of the tooling based on operator feedback ○ ○ Develop mechanical system to assist in the use of a screen ■ 2D tooling ■ 3D tooling ● “Pantographing” design to allow operator to control tooling at more natural level ○ Redesign plastic shielding used to block rotation of chuck set screw Plastic Clip/Clamp in field of view of screen for holding the tooling when not in use ○ ● 5 Main Options - Following slides
Final Design Model - Tooling for “Touch-Up” ● Option 1 - Touch up Tooling Clip (Pen Clamp) ○ Placed in Operator’s field of view while completing touch up procedure. Helps to “find” tooling.
Final Design Model - Tooling for “Touch-Up” ● Option 2 - Slotted Touch Up Tooling Fixture ○ 2 degrees of freedom ○ Tool Tip modification may be necessary for functional implementation Can add a single drive system which will ○ stop the vertical input from being inverted ○ Also has the ability to be easily controlled by a remote linkage system to allow the operator to manipulate the tool from a more ergonomically safe position
Final Design Model - Tooling for “Touch-Up” ● Option 3 - Steady Hand Tooling Arm Fixture Based on Da-Vinci-Surgical- System ● The surgeon's fingers grasp the master controls below the display with hands and wrists naturally positioned relative to his or her eyes - The system seamlessly translates the surgeon's hand, wrist and finger movements into precise, real-time movements of surgical instruments
Final Design Model - Tooling for “Touch-Up” ● Option 4-Steady Hand Tooling Arm Fixture ● Developed by benchmarking surgical guided robotic systems ● Using a fixture to help support and stabilize the tooling dramatically increases the precision and accuracy of the operator. ● The seven degrees of freedom of the open kinematic chain allow the systems to inherent motion resembling the actions performed by the operator.
Final Design Model - Tooling for “Touch-Up” ● Option 5 - Simplified Steady Hand Tooling Fixture with Constrained Ranges ● A Ball Joint possess zero translational degrees of freedom. Therefore, rails are used to facilitate the linear translation of the tooling fixture sub assembly. Two rails permit precise positioning of the subassembly along the selected axis without allowing rotation. ● A ball joint possesses three rotational degrees of freedom. This Allows for smooth motion to maintain precision alignment and handling of the touch up tool. The ball joint can be heat treated, have lubricated fittings and coated with Teflon, to enhance endurance and increase component life. ● Range of motion is constrained to the desire dimensions required to perform the touch up. Simple way to limited rotation angles and range of motion
Final Design Model - Tooling for “Touch-Up” ● Touch Up Tooling Arm Extension
Final Design Model - Proper Seating Position RGP 400D Hybrid Global Microsurgeon ● Facilitates the same desirable ● Specifically designed for use with leg position as a saddle stool, microscopes Without the groin ● Fully adjustable armrests ○ compression and also ● Seat fully rotates with your seating offers a backrest. posture ● It was found that medium-to-tall ● provides firm lumbar and back support dentists and hygienists best fit in multiple positions this stool. ● Rated 'excellent' on comfort and support by evaluators over 5' 5" ● Cost not available
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