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Capstone Design Mechanical, Industrial, and Manufacturing Engineering

Capstone Design Mechanical, Industrial, and Manufacturing Engineering. M.I.M.E. Capstone Design Engineering Methods. House of Quality (Parmigiani) Purpose in Capstone Design Template and Components Timeline Examples Responsibility *(Funk) Requirements (Funk)

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Capstone Design Mechanical, Industrial, and Manufacturing Engineering

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  1. Capstone Design Mechanical, Industrial, and Manufacturing Engineering

  2. M.I.M.E. Capstone DesignEngineering Methods • House of Quality (Parmigiani) • Purpose in Capstone Design • Template and Components • Timeline • Examples • Responsibility *(Funk) • Requirements (Funk) • Project Awarding (Funk)

  3. House of QualityPurpose in Capstone Design • Provides a concise diagram of project requirements • Translates vague, imprecise requirements from sponsor into measurable specifications (CRs and Ers) • Prioritizes project requirements and provides grading criteria for winter term (Weightings) • Documents specifically how the implementation will be tested (Testing Plans) • Documents, concisely, how the specified design meets requirements (Design Links) • Documents agreement of faculty advisor, sponsor mentor, course instructor, and student team (Signatures) • Helps you succeed! If HoQ is new to you, see The House of Quality by Hauser and Clausing (available on course web site)

  4. HoQ: Template and Components Approval (print name, sign, and date): Team member 1: Faculty Advisor: Team member 2: Sponsor Mentor: Team member 3: Course Instructor: • Modification of HoQ from Hauser and Clausing (ME 382) • Use this format for your project’s HoQ • Add more rows for CR’s and columns for ER’s as necessary (likely will add many) • Use a fold-out on large paper as necessary for your reports (must be legible!) • More information when report templates are discussed in a later lecture • Let’s have a look at each component of this HoQ …

  5. Approval (print name, sign, and date): Team member 1: Faculty Advisor: Team member 2: Sponsor Mentor: Team member 3: Course Instructor: • Approvals • Indicates agreement of what is to be accomplished and how it will be tested • No credit for unapproved HoQ • Complete, fully approved HoQ is required to take ME498-001 / IE 498 • It may take several days to obtain signatures from out-of-town sponsors • HoQ is the contract between you, the sponsor, and MIME of what must be accomplished. It is the most important document in Capstone Design!

  6. Approval (print name, sign, and date): Team member 1: Faculty Advisor: Team member 2: Sponsor Mentor: Team member 3: Course Instructor: • Customer Requirements (CRs) • A complete listing, in the “language of the sponsor”, of what must be done • Each CR deals with one concept (e.g don’t group “Small” and “Lightweight”) • Example: “Device must be lightweight” • One sponsor requirement may generate several CR’s (e.g. “Portable”) • Must be approved by team, sponsor mentor, faculty advisor, course instructor • Project scope defined in CR's ... pay close attention!

  7. Approval (print name, sign, and date): Team member 1: Faculty Advisor: Team member 2: Sponsor Mentor: Team member 3: Course Instructor: • Weightings • Indicate relative importance of each CR (greater weighting  more important) • Total of 250 points to distribute among CRs (i.e. sum of all weightings = 250) • Example: “Device must be lightweight” given weighting of 50. • Low Technical Effort (LTE) CRs: Not given numerical weighting, but must be met. • Must be approved by team, sponsor mentor, faculty advisor, course instructor • Very important in grading Evaluation 1 and Evaluation 2 in winter term

  8. Approval (print name, sign, and date): Team member 1: Faculty Advisor: Team member 2: Sponsor Mentor: Team member 3: Course Instructor: • Engineering Requirements (ERs) • Define CRs in terms of technical, measurable specifications • Generated from Customer Requirements (One CR may generate several ERs) • Example: CR “Device must be lightweight” maps to ER “Weighs less than 20 lb” • Used in specifying and evaluating design concepts • Must be approved by team, sponsor mentor, faculty advisor, course instructor • Ability to properly test and satisfy ERs constitutes 50% of winter term grade

  9. Approval (print name, sign, and date): Team member 1: Faculty Advisor: Team member 2: Sponsor Mentor: Team member 3: Course Instructor: • Target (w/ tolerance) • The Target is the design-to value for an ER (value to use in calculations) • The Tolerance (+/- value, <>, etc.) defines the amount of permissible variation • Example: ER “Weighs less than 20 lb” has Target “15lb”, Tolerance “<20lb” • ER satisfied if test result = target value within tolerance • Must be approved by team, sponsor mentor, faculty advisor, course instructor • Don’t use the extreme-permitted ER value as the design-to value!

  10. Approval (print name, sign, and date): Team member 1: Faculty Advisor: Team member 2: Sponsor Mentor: Team member 3: Course Instructor: • Testing Plan • A technically convincing description of how an ER will be proven to be satisfied • A number in the HoQ corresponds to a textual description later in the report • Example: ER “Weighs less than 20 lb” might have TP “Place on certified scale” • Every ER must have a corresponding test plan • Must be approved by team, sponsor mentor, faculty advisor, course instructor • Think about feasibility, you must execute the plan exactly as you specify!

  11. Approval (print name, sign, and date): Team member 1: Faculty Advisor: Team member 2: Sponsor Mentor: Team member 3: Course Instructor: • Design Link • A one paragraph description of how the design meets an ER • A number in the HoQ corresponds to a textual description later in the report • Example: ER “Weighs less than 20 lb” has DL “ … fabricate with aluminum …” • Every ER must have a corresponding design link • Must be approved by team, sponsor mentor, faculty advisor, course instructor • DL’s should arise naturally from your design process

  12. Approval (print name, sign, and date): Team member 1: Faculty Advisor: Team member 2: Sponsor Mentor: Team member 3: Course Instructor: • Penalty • Deductions from Evaluation 1 and/or Evaluation 2 scores • Incurred due to winter term, partially unjustified, changes to HoQ • Examples given in later lecture • HoQ-change requests in winter term are via petition process (later lecture) • Penalty is determined by course instructor associated with your project • Avoid penalties by giving careful thought to the HoQ in fall term!

  13. Approval (print name, sign, and date): Team member 1: Faculty Advisor: Team member 2: Sponsor Mentor: Team member 3: Course Instructor: • Evaluation 1 • E1 measures extent to which the "build" is done and testing can begin • Must be able to fully execute testing plan (passing test not required for E1) • Must be good-faith effort to pass test • E1 grade is based on CR weightings • Can execute testing plan for all ER's mapped to a CR, E1 score for CR = weighting • Can't execute testing plan for all ER's mapped to CR, E1 score for CR = zero • Must be able to test all ER’s mapped to LTE CR’s to conduct E1 (else E1 grade = zero) • E1 grade = sum of scores (zero to 250 points), 25% of winter term course grade

  14. Approval (print name, sign, and date): Team member 1: Faculty Advisor: Team member 2: Sponsor Mentor: Team member 3: Course Instructor: • Evaluation 2 • E2 measures extent to which CR’s are met • Must be able pass tests • E2 grade is based on CR weightings • Pass tests (w/ tolerance) for all ER's mapped to a CR, E2 score = weighting • Don't pass tests for all ER's mapped to CR, E2 score = zero • Must pass tests for all ER’s mapped to LTE CR’s to conduct E2 (else E2 grade = zero) • E2 grade = sum of scores (zero to 250 points), 25% of winter term course grade

  15. HoQ: Timeline • Part 1*: • CR's and Weightings due week 3 fall term • Include in Background Report • Part 2*: • ER’s, Targets, and Tolerances due week 5 fall term • Include in Preliminary Proposal • Part 3*: • Testing Plan and Design Links due week 10 fall term • Include in Final Proposal • Any element of the HoQ can be changed, with approvals (all signatures), in fall term without penalty • Any changes made during winter term will still require approvals but may incur a penalty (more on this next lecture) * Each part requires signatures of students, mentor, advisor, and instructor

  16. House of QualityProduct Example • Original requirement from Sponsor  Portable • Customer Requirement  One person can easily carry across a room • Weighting  20 • Engineering Requirements  Weighs < 20 lbs, no sharp edges, no dimension > 12” (3 ER’s) • Target  15 lb, largest dimension of 10” • Tolerance  +5/-15 lb, +2/-10" OR < 20lb, < 12" (include units!) • Test Plan (Summary, you’ll need more detail)  1. Weigh, 2. Inspect for sharp edges, 3.Measure • Design Link (Summary, you’ll need more detail)  1. Material selection, 2. Fabrication method, 3. Component sizing

  17. House of QualityProduct Example • Requirement from Sponsor  All control knobs labeled in English, German, and French • Customer Requirements  All control knobs labeled in English, German, and French • Weighting  LTE (Low Technical Effort) • Engineering Requirements  All control knobs labeled in English, German, and French • Target & Tolerance  N/A • Test Plan (Summary)  4. Professor from German / French depts. verifies labels meet needs • Design Link (Summary)  4. Describe how label material selection and size are appropriate

  18. House of QualityProduct Example • Requirement from Sponsor  Water flow rate of 10 in3/min • Customer Requirements  Water flow rate of at least 10 in3/min within 1 sec. of activation, never a flow rate greater than 20 in3/min (2 CRs) • Weighting  30, 35 • Engineering Requirements  Flow > 10 in3/min within 1 sec, Flow < 20 in3/min (2 ERs) • Target  12 in3/min in 0.8 sec, maximum flow of 17 in3/min. • Tolerance  >10 in3/min , <1 sec, <20 in3/min • Test Plan (summary)  5. Using flow meter and timing device, measure flow rates. • Design Link (summary)  5 & 6 Describe how piping, pump, and valve selection satisfies these ERs

  19. House of QualityProcess Example • Requirement from Sponsor  Design a process that maximizes manufacturing flexibility • Customer Requirements  Maximize Volume Flexibility, Maximize Product Mix Flexibility • Weighting 80, 70 • Engineering Requirements  Some ERs are unique to a CR; whereas, others are common • Targets  Mix of types of target measures • Tolerance  Vary depending on type of measure • Test Plan  1. Count/Audit, 2. Sample for 3 days, 3.Measure, 4. Audit, 5. Sample for 2 weeks • Design Link  For each ER, explain how your process design meets this requirements

  20. House of QualityProcess Example • Requirement from Sponsor  The process must be worker-centered • Customer Requirements  High Worker Autonomy, High Worker Satisfaction, High Worker Safety • Weighting  30, 50,70 • Engineering Requirements Some ERs are unique to a CR; whereas, others are common • Targets Mix of types of target measures, including perceptual measures • Tolerance Vary depending on type of measure • Test Plan  1. Count/Audit, 2. Measure, 3.Audit, 4. Survey with LikertScale • Design Link  For each ER, explain how your process design meets this requirements

  21. Course InformationProject Manager • Project Manager • Required for each project team • Should be available fall, winter, and spring term • Single point of contact for team • Responsible for Expo display Send an email to your project instructor’s GTA with your project number and team manager’s name

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