Workstation Redesign Subsystem Design Rachele Floeser Project - - PowerPoint PPT Presentation

P16718 Micropen Workstation Redesign

Subsystem Design

Rachele Floeser Project Manager Alex Langkamp Project Manager Sabrina Caliri Facilitator/Engineer Nick Accuosti Engineer Matt DePalo Engineer Mike Everett Engineer

Updates

Customer Requirements Engineering Requirements House of Quality Review of Project Deliverables Open Items from System Design Review

Customer Requirements

Added CR12 Ensure intellectual property is secure

Customer

• Rqmt. #

Importance Description CR1 9 Accommodates both CR100611-00 and CR110623-00 part diameters CR2 9 Allows “touch-up” procedure so the contact pads can be connected to the helix CR3 9 Allows operator to visually confirm “touch up” procedure is complete CR4 3 Modify workstation to accommodate a left handed operator CR5 9 Allows for workstation adjustability to accommodate variations in operator size CR6 9 Reduce ergonomic issues for the operator CR7 1 Improves upon or retains current cell throughput CR8 1 Improves upon or retains current scrap rate CR9 9 Maintains current printing system hardware CR10 9 Maintains critical dimensions/features on the part CR11 3 Utilizes space occupied by existing workstation CR12 9 Ensure intellectual property is secure

Engineering Requirements

Added ER36 Password protected

House of Quality

CR12 Ensure intellectual property is secure ER36 Password protected

Review of Project Deliverables

• Design alternatives by subsystem
• Functional prototype of complete system design
• User guides for operation
• Appropriate design, test, manufacture, and supply chain documentation
• Improved workstation that eliminates or at least reduces the ergonomic risk

factors for the operator

Open Items from System Design Review

Issue: Input is needed from the operators about the current process and what types of solutions they would be interested in implementing Action Taken: Created, finalized, and distributed operator background and function chart questionnaires to each operator Current Situation: Received feedback from the operators. Began discussing the feedback and how it will influence the design Issue: Specific information about the location and type of discomfort is important to ensure the team is designing to eliminate the true challenges with the process Action Taken: Created, finalized, and distributed discomfort survey questionnaires to each operator Current Situation: The operators are filling out the surveys as they are working at the workstation. We will be receiving documents once all operators have rotated through the workstation

Open Items from System Design Review

Issue: Making adjustability easy for the operators Action Taken: Identified components of the complete system that can be adjusted and then determined a measurement system for the components Current Situation: The need is identified and a solution is available, once the components are determined the measurement system can be scaled for the component Issue: Allowing for sitting and standing positions Action Taken: Determined sitting and standing position requirements for each component to identify solutions that can accommodate both positions and those that can not Current Situation: Using the requirements to verify solution feasibility

Design Ideas

Actuating the Opener Using the Keypad Viewing the Painted Part Operator Tooling Arm and Elbow Support Holding the Painted Ceramic Part WIP Fixture Operator Orientation Position Back Support Discussion with Subject Matter Experts

Actuating Opener - Current Condition Plus Possible Modifications

Possible modifications to CC:

• Shortening the 180 deg throw

from full open to full close

• Lubrication of the lever

control

• Lengthening the lever to

decrease the amount of force required to actuate the valve

Actuating Opener - Solenoid Controlled Air Valve

Pros:

• Reduces the need to move RH

shoulder for part placement and removal

• Allows for consolidation of operation

control buttons

• Reduced amount of strain on the

wrist of the operator Cons:

• Operator loses modulation of the air

flow unless a much more expensive valve and control system are used

Actuating Opener - Vertical Lever Controlled Valve

Pros:

• all the benefits of the current

condition valve

• reduces the wrist pain, more of a

natural movement rather that 180 deg of twisting motion

• maintains modulation of airflow

Cons:

• very similar to CC to spend money

to make change

• could use a mounting block to create

essentially the same thing with the current air control valve

• amount of pressure required to

actuate the valve is unknown

Using the Keypad

• Standardized keys
• Possible combination of all keyboards onto one
• Coloring of keys for easy identification

○ New keyboard ○ Transparent Colored Keyboard Cover

• Pros

○ Minimizes distance of operator arm to initiate keyboard functions ○ Simplification of keys

• Cons

○ Possibility of too many controls in one area

http://www.bhphotovideo.com/bnh/controller/home? O=&sku=1040111&gclid=CMTU9ILizsgCFdCQHwodzo0HbQ&is=RE G&A=details&Q=

Viewing the Painted Part via Microscope

• Current setup produces large amounts of back, neck, and eye strain
• Due to the height restraints that cannot be modified (work surface to part),

replacing the current microscope with a new model would likely not solve the issue

○ Current setup Pros: easily adjustable zoom Cons: strain large enough to warrant complaints, limited position adjustability

Viewing the Painted Part Without Microscope

• Eliminating the microscope and installing a camera connected to a viewing

screen in the station will reduce strain from the microscope use

• An adjustable monitor stand can be introduced for operator preference
• The current camera could be adjusted to move with the part
• A DinoXcope or similar product could be set up to view the part, with a key on

the keyboard to switch views

○ Pros: Less strain, relatively cheap to implement ○ Cons: There will be a learning curve with looking at a screen while doing precise work

Operator Tooling - Dental Pick

Pros

• Ability to dispense micro amounts onto part

○ Does not require smearing of ink on part from Operators POV

• Maintains current Touch-Up Process - No Training
• Simple and Easy to use

Cons

• Dangerous if sharpened based on operator feedback
• May require smearing if it does not dispense material
• Requires use of microscope to connect points

Example Tooling Tips:

Operator Tooling - “Stamping”

• Tooling designed to contour edge of ceramic part
• Injects micro amount of material into the 90 degree corner of the part
• Sliding tray or hand held tooling (possibility of simple automation)

○ Arduino boards Pros

• Simplifies process
• Potential to increase throughput through simplification of process
• Reduction of ergonomic issues - Does not require microscope

Cons

• Retraining will be required for New Touch-Up Procedure
• Possibility of smearing part (in comparison to current process)
• Tooling tip specificity for each part number (3 different tools)

Operator Tooling - “Pantograph”

https://en.wikipedia.org/wiki/Pantograph

• Control Touch-Up through indirect movements from operator
• nto the ceramic part to manipulate the cermet ink

Pros

• Simple for operators to connect points with larger scale

drawing

• Ability to dispense micro amounts onto part
• Does not require microscope to complete process

Cons

• Possible issue of design - Can this idea be used with this type
• f system? 3D? Difficulty of Design?
• Requires visual check to ensure part is correct

Forearm Support

“Wedge - Ease Ergonomic Forearm Supports”

• From UCLA Ergonomics

Pros:

• Cheap ($21 - $31 each) - Come in various sizes
• Safe for use in clean rooms (Vinyl material doesn’t form any particulates)
• Has a non - slip base.

Cons:

• Has no adjustability.
• Would have to adjust / rearrange the workstation

○ Platform would need to be lowered (i.e. dimension B)

Forearm Support

“Morency Forearm Support for Microscopes”

• From UCLA Ergonomics

Pros:

• Adjustability - angle can be altered.
• Safe for use in clean rooms (Vinyl material doesn’t form any particulates)
• Clips to a desk in between ¾” and 1 ½”

Cons:

• More expensive than previous option (around $200)
• Would have to adjust / rearrange the workstation

○ Platform would need to be lowered or removed.

Potential Elbow Support

Note: We would only need to implement an elbow support if the chair that is implemented does not properly support the elbow. Option #1: Ergoguys Ergonomic Adjustable Computer Arm Rest

• Allows adjustability for operators
• Affordable: Costs $60
• Was a favored choice in operator feedback survey

Option #2: Ergonomic, Adjustable Computer Desk Extender

• Can rotate once attached to the desk
• Cheaper, but more limited option - costs $20

1 2

Holding the Ceramic Part

Wire with Kink Pros

• Reduces amount of scrap from dropping

parts

• Simplifies transfer of parts to machine
• Possible improvement of throughput

Cons

• Possible higher costs from current

process Bobby Pin Example Pros

• Reduces amount of scrap from dropping

parts

• Simplifies transfer of parts to machine

Cons

• Possible higher costs from current

process

• Time to remove part from final product

tray after furnace could increase

• Wire would be specific to each part

number (3 different types)

WIP Fixture

Action Pros Cons Decreasing the number

• f holes in the WIP tile

by spacing the holes farther apart Decrease the batch size Require the operator to bring the fixture to get fired more often (This will force the operator to get up and walk around, which is good for them) Help to prevent components from coming in contact with each other causing scrap Allow for ease of part placement for the operator A single WIP tile will hold less parts Adjusting the angle the WIP tile sits in the WIP tile stand Reduce occurrence of having parts fall forward - fall off, slide backward - get smudged The operators will need to adjust to the change

Operator Orientation Position

• Straight-on to the work
• Supported upper and lower back
• Operator may use workstation standing
• Work is moved into working range, rather than

the operator moving to the work

Back Support: Saddle Chair

Pro

• Allows for closest positioning to the workstation when

legroom is an issue

• Places the pelvis in a near-neutral, stress-free position,

thus naturally balancing the spinal curves.

• Helps relieve strain on neck muscles and vertebrae, which

can help reduce headaches, and pain in arms or hands and improves shoulder posture Con

• Adapting to a saddle chair takes some effort. "Saddle

soreness" in the butt and inner thighs as well as tiredness in the back muscles lasts 2-14 days. As a return you get better posture, higher productivity, improved quality of work and more satisfying years at work.

Back Support

WaterFall Seat Stool

• The deeply contoured seat forces you to sit all

the way back in the seat, ensuring that the sculptured backrest is in firm contact with the lumbar regackbackion of your back. Zackback

• forward-leaning work posture, no lumbar

support is possible. Zackback allows the microscope/microtome user to still obtain sacral support in a forward-leaning posture.

Stretching Handouts for the Operators

Discussions with Subject Matter Experts

• Richard Langkamp

○ Manager of New Product Development at Southco Inc. ○ Also volunteers as head coach for Robotics team

• Because most of the issues involved come from working with parts so small for operators, automation

would be best option ○ Believes a robot could be created and programmed under $20,000

• Other Benchmarking Ideas: Microsurgery tools
• Microsoft/Xbox controller for cheap standardized keyboard
• Developed idea of injecting micro amount of material into 90 degree angle and/or develop fixture to

fill out “Touch-up” of ceramic part

• Pantographing Idea: Look into possible 3D version and the adaptability for this specific process

Operator Feedback

Operator Background Survey Operator Functional Chart Survey

Operator Background Survey

• Height ranges from 60” - 72”
• 7 out of 10 operators wear glasses/contact lenses
• Range of work experience from 6 months (0.5 years) to 10 years
• Operators did not feel a “kink” in the wire would improve the process
• Space is not an issue for the current operators when loading and unloading the part as

well as during the touch-up procedure

• Placing parts into the finished product tray is an issue for 4 of the 10 operators
• 9 out of 10 operators are not opposed to changing the current shift rotation schedule

and have noted a preferred rotation schedule

Operator Functional Chart Survey

Categories # Possibilities Circled/ Commented on in each category Possibility with the greatest number of circles in each category Accessing/ Grabbing the stiff wire to load part 8 Operator's Hand Actuate Opener (Open/ Close Chuck) 13 Push Button Operator Tooling for Touch-up Procedure 13 Non-slip, Compressible Material Around Handle Forearms Supports 21 Adjustable Forearm Support Back Support 8 Mesh Backrest to Straighten Posture Modification for Proper Seating Position 15 Adjustable Workstation Height Using a Hydraulic Lift Viewing the part during the touch up 22 Adjustable eyetube angle, length, height… Transporting part after printing process 6 Wire with Kink Using the control pad or keys 11

• Allow for Additional Freedom in the Position of the Current Controls
• Hand Held Remote

Circle the tooling tip 5 2, 2, 2, 3, 3, 5

Management

Risk Management Project Plan and Next Steps

Risk Management

Project Plan and Next Steps

• Receive and analyze

Discomfort Survey feedback from the operators

• Narrow down design

choices based on feedback and operator surveys

• Research implementation

and costs of design choices

• Purchase/produce the

prototypes for each component of the system

• Develop test plans and test

prototypes with the

• perators

Questions?