EDGE™EDGE™

Concept Level Project PlanP0860X (1-5)

Eula Dozier’s “Tile Measurer”

Paul Gaylo (ME)Ryan Hellems (ME)Cortney Ross (ME)

Jeremy Schiele (ME)Reid Williamson (ME)

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Original Prototype BackgroundDescription

This product is a device that can mark and/or cut tiles for cutting that are to be laid against a wall. It enables many tiles to be marked at once, and marks them according to the exact contour of the wall. Currently it is only for linoleum tile, but expansion to ceramic time is expected.

Key Business Goals The primary business goals of this prototype are to -enable contractors and users of the device to mark tile more efficiently, cutting down on the time needed to finish a job.-increase the profitability of a tiling job to the company that its contracted to. -become a source of revenue for the prototype’s inventor: Eula Dozier.-make it easier for the average person to get clean and correct cuts the first time, every time.

Primary Market This prototype’s primary market is composed of professional contractors who lay large quantities of tile on a regular basis.

Secondary Market P08601, P08603: The secondary customer base contains all other types of people who could be laying tile- this includes the “do-it-yourselfers,” smaller scale contractors, and remodelers.P08602, P08604, P08605: Hardware rentals, professional tilers

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How the Prototype Functions

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Common Tile Types

Vinyl Composition (VCT)

Ceramic Luxury Vinyl

Laminate Glazed Porcelain Natural Stone

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InterviewsPrimary Customers

Eula Dozier (inventor)Inspired to develop prototype after observing a tile layer as a general contractor with no tiling experience. This 2nd generation prototype is patent pending and functions to mark linoleum tiles accurately to a wall profile. Patent info, CAD files, prototype, and testing fixture are in RIT hands and accessible to all tile project teams.

Flooring BusinessesTile Shop – Tile Showroom (Jefferson Rd.)

Toured extensive showroom of ceramic tiles and natural stone. No VCT products. Business specializes in DIY customer and provides clinics. Introduced to preparation requirements and limited array of tools available. Received list of recommended contractors.

Sail-On Carpets – Residential Flooring (Rt. 15)Met with Joe Rizzo and Brian. Introduced to wide variety of flooring choices and installation procedures. Majority of business is residential. Passed on to Jim Pavone @ Premier. Coordinating interview.

United Carpet Brokers – Commercial Flooring (Winton Plazza)Met with Kevin Nasser to discuss innovation opportunities. Introduced to carpet tiles and parallel installation procedure. Business is 90% commercial. Opportunity to interview installation crew.

Other StakeholdersPrivate Home Contractor

Provided insight on the needs of home installation by a professional. Expressed interest in a “light” version that was cheap, quick and easy.

Private Home ContractorExpressed a willingness to try a machine that would speed up the marking process. Cost shouldn’t be more than $30.00. Expressed a significant interest in the usefulness. Must be adjustable for designer tile variations. For sale at home centers?

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Manufacturing Needs Benchmarking

•In the process of making 5 examples of Eula’s original prototype

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Concept Level Plan Feedback

• How to the needs of professionals and D.I.Y’s differ?– f(robustness, value, price accessibility)

• Is there an application to wood flooring?– Need to observe installation procedure– Adaptability to other flooring is possible

• What was the prototype cost?– $200 to build five

• Why no electrical engineers?– Prototype is purely mechanical

• Why Constrain to only marking and not cutting?• How are projects related?

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Project Breakdowns

• P08601 (Paul) – Improve Eula’s original design; make product ready for manufacturing; documentation/manual; business plan; life cycle

• P08603 (Jeremy) – Improve Eula’s original design; not necessarily manufacturing ready; “perfection” of design for future market; conceptual design (mold?); ergonomics

• P08604 (Cortney) – Tile measurer with data storage and data retrieval

• P08602 (Ryan) – Tile cutter and data uploader

• P08605 (Reid) – Electro-mechanical measuring and cutting device

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Concept Level Project Plan – P08601/3• Project Name

– Dozier Tile Layout Tool• Project Number

– P08601, P08603• Project Family

– Construction Industry Technology• Track

– Entrepreneurship and Business Development Track• Start Term

– 2007-2• End Term

– 2007-3• Faculty Guide

– John Wellin (ME) pending• Faculty Consultant

– Timothy Landschoot (ME) confirmed• Faculty Consultant

– Dr. Mark Kempski (ME) confirmed• Primary Customer

– Mr. Eula Dozier, Original Inventor - confirmed

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P08601Commercial Venture

Project Goals• Create a commercialized version of Mr. Dozier’s prototype • Re-design and improve as necessary to create polished consumer

product by the end of SD-2.• Design and build all necessary jigs and fixtures for manufacture and

assembly• Mark ceramic and linoleum floor tiles• Engage in a production run or be ready to do so• Create user documentation (manual)• Construct a business plan

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Staffing Requirements – P086015 member team

Mechanical Engineers (3)ME1 - Potentially the project leader. This member of the team will be responsible for the management of the project and assist in an ADHOC fashion with other aspects of the projectME2 - This person will focus on the development side of this project. They will specialize in the drafting needs and any mechanical redesign of the prototype.ME3 - This person will be primarily responsible for the production side. They will be in charge of any CNC programming and work holding design. In the early stages of this project, they will assist ME2 with redesign considerations.

Industrial and Systems Engineers (1)ISE - This person will have two primary roles. Firstly, the parts chain and secondly the user documentation/ product manual(s). This person should be skilled in technical writing and will have a significant role in the redesign of the prototype for assembly and manufacture.

Business (1)Bus - This person will specialize in the business plan and market research. Information gained from this research is expected to affect the final design. This person will develop a detailed business plan to market this product upon the completion of the first production run.

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Preliminary Work Breakdown Plan – P08601

Weeks 1-2 Weeks 2-3 Task to be completed

ME1

Project Introduction Begin Brainstorming for redesign Use information brought to the group from new members to organize a progression for future group discussion

Meet with Mr. Dozier Present project history of all known info

Review team values and grading scheme  

ME2

Project Introduction Begin Brainstorming for redesignPick a drafting program and draft the nylon block of the prototype.

Meet with Mr. Dozier Review customer interviews project history

Review team values and grading scheme

Begin drafting the prototype with alterations

ME3

Project Introduction Begin Brainstorming for redesign Write a CNC program in a software package compatible to RIT machines. Create a profile of the pen holder of the prototype

Meet with Mr. Dozier review customer interview project history

Review team values and grading scheme

Investigate what will be needed CNC at RIT

ISE

Project Introduction Begin Brainstorming for redesign Locate 3 user manuals of general hand tools and create a two lists. One list of the similarities and another of the differences

Meet with Mr. Dozier Review customer interviews

Review team values and grading scheme Locate potential parts vendors

Bus.Project Introduction

Investigate a previous specialty tool business plan

Locate a business plan from another specialty construction tool and create a list of similarities and differences

Meet with Mr. Dozier Review history of developmentReview team values and grading scheme  

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Group Grading Scheme – P08601Requirements

AExcellent

Met the primary project goal of production preparation.Meets all of the project goals.Able to present a polished consumer product to Eula Dozier.Able to market the product effectively.

B Good

Nearly met production deadline.Fully operational prototype design exists and has much improved functionality.

C Fair

Design was not able to be manufactured.Design has flaws that reduce its effectivenessPrototype has been much improved.

D Not Good

Design is improved over the original but not fully functional or ready for production.

FFail

Design is not improved over the original prototype

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Potential Issues and Risks - P08601

• Acceptance in the market place

• Overall Cost – Ultimate cost to the consumer

• Reaching the project goal of a production ready prototype by the end of SD-2

• Assembly and Production Constraints

• Where is the money going to come from?

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P08603Stylized Tile Measuring Tool

Project Goals • Use the same principles of functionality as Eula Dozier’s prototype,

with the aide of industrial designers, design a tile marking tool that is appealing but tough enough for commercial usage

• The tool should have flawless function in marking multiple types of tiles

• The design should keep the ability to be transferred to a medium-high production line after senior design.

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Staffing Requirements – P08603Mechanical Engineers (3)

ME1: Project Manager responsible for planning and execution of project and required deliverables for senior design. Other responsibilities include assuring proper design for manufacture and the manufacturing techniques chosen to the end product.

ME2: Engineer will be responsible for mechanical design work pertaining to functionality of product and assisting in materials selection. Should be familiar with CAD software and proper design considerations for large scale manufacturing. If group size requires it, they will be the Engineering Lead for the group.

ME3: Will be responsible for functionality of mechanical systems that allow the tile measurer to function properly, will also be responsible for keeping EDGE website up to date, and any major changes to website. They should class background or work experience in machine design and be familiar with CAD software.

Industrial and Systems Engineers (1)ISE: Engineer will be in charge of meshing work between industrial designer and mechanical

design engineers, production and execution of customer perception testing protocols/reports, and aide in hypothesized production flow. Industrial Engineer is also eligible for position as Project Manager.

Industrial Designers (1)ID: Design of exterior shell of tile marking product focusing on aesthetic appeal and

manufacturability, while keeping functional requirements under consideration. Will provide the mechanical engineers an envelope do design within. Should be knowledgeable about ergonomics and plastic product design and materials selection (desired but not required).

NOTE: For all positions, a knowledge or interest in tiling/home finishing is a plus, but not required.

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Preliminary Work Breakdown Structure – P08603MemberMember Week 1Week 1 Week 2Week 2 DeliverableDeliverable Week 3Week 3

M.E. (PM)M.E. (PM)

Familiarize team with project background and begin to distinguish individual's areas of strength.

Update any deliverables, set regular meeting times, and collect schedules from team members.

Formulate 11 week schedule and give to team, have individual’s specific responsibilities finalized.

Find what rapid prototyping is available. Continue to update essential documents.

M.E. 2M.E. 2

Research techniques for marking/laying tile and begin decision on which CAD platform is preferred.

Begin to look at methods for marking multiple types of tile and what kinds of tile are most common.

List of possible marking methods on 3 most common types of tile.

Begin design of wall following and marking ends.

M.E. 3M.E. 3

Familiarize yourself with how prototype works and learn how tile is marked/laid.

Learn how to use EDGE website and Tortoise SVN.

Educate rest of group on how to use wiki language, EDGE website and Tortoise SVN application.

Begin design of internal components, based on Eula’s prototype.

I.S.E.I.S.E.

Familiarize yourself with how prototype works and learn how tile is marked/laid.

Investigate the ergonomic concerns associated with product.

Tech. brief for group on ergonomic considerations.

Help ME 1 maintain documentation, begin protocols.

I.D. (1-2)I.D. (1-2)Look into how tile is marked/laid, familiarize yourself with requirements of device.

Investigate proper design considerations for plastic product design.

Technical brief on plastic product design considerations.

Begin housing concept generation.

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Group Grading Scheme – P08603Requirements

AExcellent

Level B requirements satisfied plus:•Manufacturing techniques for larger scale production (100-10,000 unites) have been finalized•Tile marking tool is able to efficiently switch between tile on point and square laid tile•Customer perception findings have been conducted and results incorporated into final design

B Good

Level C requirements satisfied plus:•Manufacturing techniques capable of small scale production (1-10 unites) have been selected•Physical prototype (3D printed, machined, etc.) that provides proof of function and can be shown to Mr. Dozier as a deliverable•Some customer perception testing has been conducted, but not finalized

C Fair

•Completed 3D models and assemblies of final product•Mechanical function is proven on square laid tile•Complete BOM that identifies parts that need special attention (off site manufacturing, long lead time, etc.)

D Not Good

•Have designs and 3D models of all required components of product necessary for basic function•Almost complete BOM•Conceptual manufacturing techniques

FFail

•No design or 3D models•No BOM•No conceptual manufacturing techniques

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Potential Issues and Risks – P08603

• Maintaining fluent channels of communication between other tile teams.

• Maintaining differentiation between the 2 projects spun off of Eula’s original prototype.

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P08601 vs. P08603Design for Manufacturing

Business PlanProduction Ready

Attention to Industrial DesignJigs and FixturesProduct Testing

Customer Appeal TestingPart Supply Chain

ErgonomicsMulti-sized TileTile-On-PointUser ManualEnd Product

Production Ready, Run

of 5-100

Optimized Functional Prototype

1-100 units >5,000 units

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Concept Level Project Plan - P08602/4• Project Name

– Automated Tile Measurer and Cutter• Project Number

– P08602, P08604• Project Family

– Construction Industry Technology• Track

– Entrepreneurship and Business Development Track• Start Term

– 2007-2• End Term

– 2007-3• Faculty Guide

– Mr. Tim Landschoot (confirmed)• Faculty Consultant

– Dr. Kempski, ME (confirmed)• Faculty Consultant

– CSE or EE professor, unconfirmed• Primary Customer

– Mr. Eula Dozier, Original Inventor - confirmed

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P08604Automated Tile Measuring Device

Project Goals • A device that will go along the edge of the tile and measure the

distance it is from the wall• Log and store that data• Send that data to an automated tile cutting device (P08602)

+

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Staffing Requirements – P08604Mechanical Engineers (3)

ME1 (Leader): The project leader will make sure that the rest of the members are doing their work efficiently and effectively.

ME2: The first mechanical engineering student will mainly be working on the design of the product. They will also be working with a solid modeling program (Pro-E, SolidWorks, etc.). After design is done, they will help with the assembly of the prototype during SDII.

ME3: The second mechanical engineering student will be assisting with the design of the product. Their main function will be machining the parts for that design. After design is done, they will help with the assembly of the prototype during SDII.

Industrial Designers (1)ID: The Industrial Design student would be needed to make the device look aesthetically

pleasing. They will need to be able to work with the mechanical engineers that are working on the design to help make the device compact and ergonomic.

Electrical Engineers (1)EE: The Electrical Engineer will need to be able to come up with a battery power supply to run

the device that will measure the distance the device is from the wall, and to run the device that will log, store and send the data to the cutter.

Industrial and Systems Engineers (1)ISE: The Industrial and Systems Engineering student will be needed on either this project or

P08602 to integrate the two systems together. They will need to be able to make sure that the tile cutter communicates correctly with the measurer.

Computer Engineers (1)CE: The computer engineering student will be working with the data logging, storing and

retrieval for the design. They will need to be able to write, read and understand some coding program. They will need to able to manipulate that code to retrieve data from the measuring device and send it to the cutting device (P08602).

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Preliminary Work Breakdown Structure - P08604MemberMember Week 1Week 1 Week 2Week 2 Week 3Week 3

ME1ME1LeaderLeader

Familiarize group with project Gather questions and comments and go over themMake sure brainstorming is productive

Bring together all designs and go over themGive next weeks assignments

ME2ME2Familiarization of projectBring back questions and comments on design Week2Meet with P08602

Brainstorm ideas for a first generation design based of comments and questions

Bring back a hand sketched or 2D/3D model of their own first generation mechanical design for Week 3 – individual or group

Group sketched MUST show that ALL members worked together to make sketch

Research different solid modeling programsBring back pluses and minuses for Week 4

ME3ME3Familiarization of projectBring back questions and comments on design Week2Meet with P08602

Research different materials for first generation mechanical designResearch different mechanical or electrical components that can be used on the first generation designBring back pluses and minuses for Week 4

IDIDFamiliarization of projectBring back questions and comments on design Week2Meet with P08602

EEEEFamiliarization of projectBring back questions and comments on design Week2Meet with P08602

Brainstorm ideas for a first generation design based of comments and questions

Bring back a hand sketched or computer sketch of their own first generation design for the data logging, storing and sending device for Week 3 – individual or group

Group sketched MUST show that ALL members helped

Research different battery/power supply optionsBring back pluses and minuses for Week 4

ISEISE

Familiarization of projectBring back questions and comments on design Week2Meet with P08602

Research different wireless communication systemsBring back pluses and minuses for Week 4

CECEFamiliarization of projectBring back questions and comments on design Week2Meet with P08602

Research different coding/data sending programsBring back pluses and minuses for Week 4

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Group Grading Scheme - P08604Requirements

AExcellent

Make a design and a prototype that will be able to measure the distance the device is away from the wallMake a device that can log this data and store itMake a device that can send the data to the cutter

B Good

Make a design and a prototype that will be able to measure the distance the device is away from the wallMake a device that can log and store data, but not send to cutter

C Fair

Make a design, but not a prototype that will be able to measure the distance the device is away from the wallMake a device that can log and store data, but not send to cutter

D Not Good

Make a design, but not a prototype that may be able to measure the distance the device is away from the wallNo device that can log, store or send data

FFail

No new design or prototype that can measure the distance the device is from the wallNo device that can log, store or send data

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Issues and Risks – P08604

• Must have great amount of integration with P08602

• Has some wireless system on a small device• Wireless/electrical system(s) should be

contained and/or kept safe from users, but still be easily accessible

• Shouldn’t be too expensive• Must be fairly accurate

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P08602Automated Tile Cutter

(P08604)

Device Does cuts Vinyl Tiles to fit provided wall profile, without user input. Device cuts accurately and quickly.

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Staffing Requirements – P08602Mechanical Engineers (4)

ME1: Team Leader. Plans teams progress, work scope, and focus of efforts. Ensures that design gives proper consideration to 2nd generation (ceramic). Assists ME3 with tile securing efforts.

ME2: Design and develop positioning system for cutter using linear actuators.ME3: Design and develop system to hold tiles securely in place for cutting, without interfering

with the cutter.ME4: Create designs for frame to tie in 2&4’s systems, with respect for 2nd generation. Assist

ME2 with designing.

Electrical Engineers (1)EE: Design and implement power supply from wall to control box, to cutter/router and linear

actuators. Return feedback signals from Actuators back to control box to monitor locations.

Industrial and Systems Engineers (1)ISE: Make sure all systems come together, help design device to be more easily

manufactured, help control visual appeal to some extent.

Computer Engineers (1)CE: Share CE’s w/ 604 to ensure highly usable data is collected, which would create best cuts

based on data. Develop an easy to use interface to control cutting or re-cutting of every tile. Use actuators feedback to record where cutter really is and how to control that.

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Preliminary Work Breakdown Structure - P08602MemberMember Week 1Week 1 Week 2Week 2 Week 3Week 3

ME1ME1Project Project

ManagerManager

Review EDGE website, set up a group meeting with Eula Dozier. Facilitate discussion based on different methods, and problems associated with each.

Familiarize self with CAD software that most in group are experienced with. Create a rough assembly of a standard wet-saw.

Develop week 4 WBS, thoroughly review previous weeks research.

ME2ME2PositioningPositioning

Review EDGE website, research topic online. Bring back comments on at least 2 installation videos, DIY guides, or preferably a novel/uncommon tile cutting techniques. Comments for both vinyl and ceramic tile techniques.

Research differences in linear actuators, and make recommendations of our needs

Familiarize self with CAD software. Create a rough assembly of a wet saw.

ME3ME3ClampingClamping

Familiarize self with CAD software. Create a rough assembly of a simple vise.

Experiment with cutting vinyl tile, max unsupported length

ME4ME4FrameFrame

Familiarize self with CAD software. Create a rough assembly of a simple vise.

Experiment with cutting vinyl tile, max unsupported length

EEEEInvestigate power load's/differences in cutting tools and routers. Create spreadsheet to summarize.

Discuss with ME1 choices in actuators and cutting tools based on power.

ISEISEInvestigate alternatives to linear actuators. Develop spreadsheet of pros and cons of different options.

Perform comparative benchmark/time study on time of tile cutting on an actual installation job

CECE

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Group Grading Scheme - P08602Requirements

AExcellent

Working device that cuts tilesTiles fit within a 0.25” gap on Eula’s test stand

B Good

Device that can cut simple shape of tilesComprehensive BOMAll deliverables met.

C Fair

Full designs and plans for tile cutterNo device that actually cuts

D Not Good

Nearly complete BOMIncomplete design of how system would work

FFail

No BOMNo working deviceNo design

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Potential Issues and Risks – P08602

• Design Issues: – How to take measurements that will be usable– Tiles other then 12” square.– What to do about tile-on-point– Unknown solution for supporting flexible tile without cutting

under• Unknown Factors:

– Budget: RotoZip/router (150 or 40), Linear actuators (150+, each), Support frame ($200-300). Who pays?

– Materials for control system/computer box are unknown. – Seamless integration with programming between projects– Material selection based on design choices, no pre-ordering.

Can only pre-order extra tiles.

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Concept Level Project Plan - P08605• Project Name

– Dozier Tile Layout Tool • Project Number

– P08605 • Project Family

– Construction Industry Technology• Track

– Entrepreneurship and Business Development Track• Start Term

– 2007-2• End Term

– 2007-3• Faculty Guide

– T.B.D.• Faculty Consultant

– Timothy Landschoot (ME) confirmed• Faculty Consultant

– Dr. Hoople (EE) confirmed• Primary Customer

– Mr. Eula Dozier, Original Inventor

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P08605Dual-Function Tile Perimeter Layout

Tool• On-the-spot cutting of tiles for perimeter voids

– Reduce secondary tile layout time– Cut tiles utilizing real-time data

• Couple measuring function with cutting function that was previously performed by hand

• Implement design of electrical components • Design product to function with VCT

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Process Needs Map – P08605

DUAL-FUNCTION TILE PERIMETER

LAYOUT TOOL

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Staffing Requirements & ResponsibilitiesP08605

Mechanical Engineers 3-4Design & execution of structure, measuring device, motors, functionality, data acquisition, and additional mechanical components.

Electrical Engineers 3-4Design & execution of sensors, power sources, data acquisition, data processing, and additional electrical components.

Computer Engineers0-2Definite opportunity to be involved with an electro-mechanical product. Uncertain of priority and possible role.

Industrial and Systems Engineers0Process integration and efficiency, ergonomic concern, and management of systems are limited and tasks will be spread among team.

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Preliminary Work Breakdown Structure P08605

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Grading Scheme – P08605

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Potential Risks and Issues – P08605

• Unknown budgetary restriction• Multiple components necessary to achieve

combined function results• Maturity of technology in measuring and cutting

components are unknown• Potentially grand electrical systems• Operating speed of product and electronic lag• Utilization of mechanical engineers beyond

rugged case design• Challenged to find acceptance of technology

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Resource Requirements – P08601-5People

-Eula Dozier (inventor)-SD Team (4-8 members)-Faculty Advisor & Guide (consultants)-Tile Contractors (industry contacts)

Environment -SD cubby-Open floor testing space-Construction site (onsite testing)

Equipment-Machine shop-Computers with design software-Rapid prototyping equipment-Mr. Dozier’s prototype-Mr. Dozier’s testing fixture-Challenging wall profile testing fixture

Materials-Variety of tiles-Tile laying materials-Standard machining materials -Vendor components

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Outstanding Items – P08601-5

• Patent Considerations (Eula Dozier holds patent for original prototype)

• Final Product Ownership• Budget• Finish prototypes for each group