Dfss Design Project Details Fall 2010
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A semester long design project for a graduate level engineering course in Design for Six Sigma
Transcript of Dfss Design Project Details Fall 2010
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Objectives of Design Project• Provide an opportunity for students to gain hands-on Design for Six Sigma
experience with the application of the Concept, Design, Optimize and Validate (CDOV) process through the engineering, manufacture and practical demonstration of a new product design.
1. Project Planning and Risk Management
2. VOC analysis and Requirements Generation (QFD, KJ, Kano)
3. Concept generation & Pugh Selection
4. Design FMEA
5. P-Diagram
6. Critical Parameter Management and Capability Growth Index
7. Design Optimization of multiple responses (Taguchi Robust Parameter Design and/or Response Surface Methods)
9. Monte Carlo Simulation and Optimization
10. Design for Manufacturing and Assembly
11. Tolerance design
12. Design Validation
• Demonstrate ability to apply course content in a practical context within the scope of a one semester graduate level class.
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The Milk Run Challenge• Your design team has been hired by the worlds foremost producer of mouse
trap powered vehicles to design a new mouse trap powered vehicle kit to be marketed through the company’s internet website, hobby stores, and educational product distributors.
• Mouse trap powered cars are used by high school physics teachers and undergraduate engineering professors to teach basic physics, mechanics and engineering principles.
• Your sponsor desires to grow their market and is looking for a new product which students and teachers can buy, build and use to compete in a new competition: the Milk Run Challenge.
• Your design could be sold as a complete kit or as set of instructions
http://www.docfizzix.com/about-doc-fizzix.shtml
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VOC - Customer Needs• Safe to build and operate
• Low cost: Target cost < $15
• Easy for high school students to build and operate
• Simple packaging – easy to ship
• Budget 150 man hours for entire project
• Reliable, durable and repairable
• Additional customer needs must be elicited by each team
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Milk Run Challenge
OBJECTIVE: Be the first team to transfer 2 gallons of liquid payload from square A to squares B and C using a fleet of 3 mouse trap powered vehicles The competition will end when the first team successfully transports the given quantity of liquid (fills up the milk jugs at squares B and C and returns all vehicles to square A) or after 30 minutes, which ever occurs first.Points will be awarded in proportion to the amount of payload that is successfully transported by your team at the end of the challenge. The first team to fill up the milk jugs will earn 10 points. Other teams will be awarded points determined by the total volume of liquid successfully transported.
A B
10 --- 9 ---8 ---7 ---6 ---
5 ---4 ---3 ---2 ---1 ---
Points
C
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Competition Rules
1. Each square is 4 ft on each side
2. Squares B and C may be anywhere from 6 to 16 feet away from square A
3. Payload liquid will be provided in 1 gal. milk jugs supplied at square A
4. Payload must be transferred into milk jugs at squares B and C
4 ft 6 to 16 ft
4 ftA B C
6 to 16 ft
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Competition Rules5. Vehicles must travel under their own power from square A to squares B
and C and then back again to square A6. Cars may not be handled or manually repositioned when moving in either
direction between squares A and B7. Vehicles may be picked up and handled before departing a square and after
the vehicle comes to a complete stop8. Vehicles must be positioned completely within a square when starting and
must stop completely within square (defined by point of contact of wheels with ground)
9. Anytime a car stops outside either square the car and any payload it is carrying must be carried back to the starting square and restarted
A B/C
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1. The vehicles will be powered by the mouse traps provided by the professor at the beginning of the semester
2. The vehicles will be representative of your product design as built by the intended customer
3. All three vehicles will be produced from the same basic product design/kit, though individualized customization is allowed
4. All propulsive power for each car must come solely from one standard mouse trap provided by your instructor. No other sources of stored energy may be used to propel the vehicle.
5. The spring cannot be rotated more than normal design limit of 180 degrees.
6. Vehicles must be self-starting. No pushing allowed.7. No operator intervention allowed once trap is activated.
Vehicle Design Rules
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7. Vehicle design must incorporate a cup holder sized to contain and carry common cups, bottles and other beverage containers – just like in real cars
8. Payload will be transported in Commercial Off The Shelf (COTS) beverage containers supplied by your team
9. Beverage containers must be representative of cups, bottles etc. intended for serving individual consumers
10. The beverage container must fit securely and be carried in the vehicle’s cup holder
11. Vehicles must be loaded before starting off from square A and unloaded only after successfully reaching square B or C
Vehicle Design Rules
10http://www.victorpest.com/store/rodent-control/m150
Victor® Metal Pedal Mouse Trap Model M150
• For clean and quick trapping
• Made environmentally responsible from Forest Stewardship Council Certified wood
• Provides visible proof of rodent capture
• Can be used around kids and pets
• Packaged in convenient 2-packs
• Easy to use
• Made in the U.S.A.
• Easy disposal
• Non-toxic
• Trap measures 4"L x 1 3/4"W
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Some Online Resources• http://www.docfizzix.com/
• http://www.docfizzix.com/about-doc-fizzix.shtml
• http://www.victorpest.com/store/rodent-control/mouse-traps
• http://www3.towerhobbies.com/cgi-bin/wti0002p?&M=DFX
• http://www.mousetrap-cars.com/project-plans.htm
• http://shop.pitsco.com/store/default.aspx?CategoryID=102&by=9&c=1&t=0&l=0
• http://hubpages.com/hub/How-to-Build-a-Mouse-Trap-Car---A-Step-by-Step-Guide
• http://www.codecooker.com/howto/mousetrap/instructions.htm
• http://mtcarschallenge.homestead.com/
• http://web.isp.cz/web/science/mousetrapcar/mousetrapcar.htm
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Former Student Consultants• Nancy Poisson
Hamilton SundstrandWindsor Locks, CTW: 860-654-6546M: 860-371-4226 [email protected]
• Jim RoachPratt & WhitneyMiddletown, CTW: (860) 704-7285 [email protected]
• Alexis Vargas-MartinezPratt & [email protected]
• Dave RustonHamilton SundstrandRockford, IlM: [email protected]
• Shari BugajPratt & WhitneyMiddletown, CTW: (860) [email protected]
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