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
Customer Requirements Engineering Requirements Updates House of Quality Review of Project Deliverables Open Items from System Design Review
Customer Importance Description Rqmt. # Customer CR1 9 Accommodates both CR100611-00 and CR110623-00 part diameters Requirements 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 Added CR12 CR5 9 Allows for workstation adjustability to accommodate variations in operator size Ensure intellectual CR6 9 Reduce ergonomic issues for the operator property is secure 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: Issue: Input is needed from the operators about the current Specific information about the location and type of process and what types of solutions they would be discomfort is important to ensure the team is designing interested in implementing to eliminate the true challenges with the process Action Taken: Action Taken: Created, finalized, and distributed operator background Created, finalized, and distributed discomfort survey and function chart questionnaires to each operator questionnaires to each operator Current Situation: Current Situation: Received feedback from the operators. Began discussing The operators are filling out the surveys as they are the feedback and how it will influence the design working at the workstation. We will be receiving documents once all operators have rotated through the workstation
Open Items from System Design Review Issue: Issue: Making adjustability easy for the operators Allowing for sitting and standing positions Action Taken: Action Taken: Identified components of the complete system that can Determined sitting and standing position requirements be adjusted and then determined a measurement system for each component to identify solutions that can for the components accommodate both positions and those that can not Current Situation: Current Situation: The need is identified and a solution is available, once Using the requirements to verify solution feasibility the components are determined the measurement system can be scaled for the component
Actuating the Opener Using the Keypad Viewing the Painted Part Operator Tooling Arm and Elbow Support Design Ideas 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 Example Tooling Tips: ● 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
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” ● Control Touch-Up through indirect movements from operator onto 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 of system? 3D? Difficulty of Design? ● Requires visual check to ensure part is correct https://en.wikipedia.org/wiki/Pantograph
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.
1 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 2
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