Final Project Management Plan

Final Project Planmhpsa stem electrode redresser machine

MAN 4583 SUMMER 2016

STRATEGIC SAMURAISARCHI ADVANI

SHANNON COCHRANZACKARY JONES

JASON RAULERSONSPENCER STOLFO

Table of ContentsProject Charter:...........................................................................................................................................3

Project Scope...............................................................................................................................................5

Project Mission:.......................................................................................................................................5

Deliverable:.............................................................................................................................................5

Requirements:.........................................................................................................................................5

Limits and Exclusions:..............................................................................................................................5

Project Priorities:.....................................................................................................................................5

Project Change Request Form:................................................................................................................6

Key Assumptions:....................................................................................................................................7

Stakeholder Analysis:..................................................................................................................................8

Communication Plan:..................................................................................................................................9

Work Breakdown Structure.......................................................................................................................10

Work Breakdown Structure Dictionary:.................................................................................................11

Time & Cost Estimates:..............................................................................................................................15

Time Estimates:.....................................................................................................................................15

Network Diagram:.................................................................................................................................19

Critical Path:..........................................................................................................................................20

Direct Cost Estimates:............................................................................................................................20

Schedule & Budget:...................................................................................................................................24

Schedule & MS Project Gantt Chart:......................................................................................................24

Time Phased Budget:.............................................................................................................................25

Risk Management Plan:.............................................................................................................................26

Procurement Plan:.....................................................................................................................................27

Request for Quote:................................................................................................................................28

RFQ Response Form:.............................................................................................................................29

Responsibility Matrix:................................................................................................................................30

Quality Management Plan:........................................................................................................................36

Raw Materials & Outsources Parts:.......................................................................................................36

Final Machine Operation:......................................................................................................................37

Quality Assurance Log #1...................................................................................................................38

Quality Assurance Log #2...................................................................................................................38

2

Project Charter:Below is the official project charter for the MHPSA STEM Elecrode Redresser Machine. This Charter signifies the start of the project. The signatures required are those of the sponsors, the lead engineer at MHPSA, the academic advisor at the UCF’s College of Engineering, and as the signature of the project managers (Stategic Samurais). This Charter is an agreement of work that details the scope of the project. Changes to the scope will have to be done through a change request form (see page 5).

3

Project Scope Project Mission:The purpose of this project is to create a machine and establish a process to resurface titanium electrodes when they wear out during electrochemical machining (“ECM”). The machine will be used by Mitsubishi-Hitachi Power Systems America at their Orlando branch for their Shaped Tube Electrochemical Machining (“STEM”) Process. No alterations will be made outside of the intended use of the machine. The STEM machine is being created to alleviate reliance on outsourcing the electrode resurfacing to vendors. Not having to rely heavily on vendors will save time and money while increasing process confidence when manufacturing gas turbine engine components.

Deliverable:Strategic Samurai’s have been hired by the Engineering Senior Design group to help them create a project plan and manage the delegation of tasks during the designing of the MHPSA STEM Electrode Redresser Machine.

Although Mitsubishi-Hitachi Power Systems is a Japanese company, the project plan will be completed in English.

Requirements:The STEM machine will be able to redress titanium electrodes with a nonconductive coating with diameters between 1.5mm-1.75mm at a 30-degree angle.

Limits and Exclusions: The STEM machine will not be able to fix broken electrodes and will only redress titanium electrodes. Also, this machine will not be able to redress mass quantities.

Project Priorities:The triple constraint that we will be prioritizing throughout the duration of this project are scope, time, and cost in order to track the progress of the machine.

Cost has been accepted since certain parts that are required to create this machine will be purchased from vendors with set prices. Also, when referring to cost, no strict budget has been set by the project sponsor. Whatever costs the machine retains, will be accepted. Since this machine is being designed to reduce dependency on external resources, the scope must be optimized in order for the team to create the most efficient machine. Time is constrained (inflexible) because this project has to be completed by a deadline that has been set by the College of Engineering for graduating seniors and is a non-negotiable factor. The table below summarizes the project priorities.

4

Project Change Request Form:The project change request form is included in case a stakeholder wishes to make any changes to the project. Since this machine has to work flawlessly, scope will be enhanced and in order to make changes, there has to be a formal method of action in place to keep track of the changes and get approval from necessary stakeholders.

5

Key Assumptions: Below are the assumptions that were made to complete the project plan. These assumptions shaped the decisions made throughout the plan.

All electrodes that will be redressed are in good enough condition to handle the process. Mitsubishi-Hitachi Power Systems has space on the manufacturing floor to accommodate the

machine. Once a process is implemented, a worker will be assigned, by MHPSA, to use the machine. All approvals can be made in one day. Engineering team members work four days a week and 30 hours a week per head. Engineering team members are employed by Mitsubishi, they have other tasks that have been

allocated to them different from this project. Hence, we know that they do not commit all of their man hours to this project. Instead, we are assuming that three out of eight hours of a work day are devoted to this project.

None of the overhead costs such as existing machinery and operations will be included in the budget for this project.

6

Stakeholder Analysis: The table below entails all of the stakeholders in this project. A stakeholder is anyone who has influence or interest in the product and/or could be affected by the final product.

Stakeholder Register

Power High, medium, low

Interest(High/Low) Requirements

UCF College of Engineering Low Low

Accepted the project from Mitsubishi Hitachi Power Systems America (MHPSA) and is overseeing the quality and completion of the project.

UCF Engineering Senior Design Students

High High UCF engineering students are given the opportunity to design a project for the client, in exchange for experience, grade, or a job opportunity.

Mitsubishi Power Systems America (Orlando)

High High Sponsoring overall project throughout the duration of the project and are the ultimate client accepting the deliverable.

Lead Engineer High High MHPSA employee who is overseeing the entire project and is the direct supervisor to the UCF engineering students.

Operations Manager Medium High

MHPSA employee who oversees daily operations of Engineering Department. Initial advocate convincing UCF College of Engineer to accept project.

Professor Low Low

Assigned project and project requirements. However, they do not have an active role in the project.

Advisor High High

UCF College of Engineering employee that is assigned to advise student engineering team through the duration of the project. Advisor will receive weekly updates from student engineering team.

OperatorLow High

MHSPA employee that is responsible for operating the machine deliverable after completion of the project.

7

Vendors Low LowProvides components needed to complete the product.

End ConsumersLow High

The end consumer who will be purchasing the final gas turbine engine that the project’s deliverable helps create.

Communication Plan:The communication plan below details the type of communication needed, who it goes to and the method of delivery. This plan allows the team members and project managers to easily identify who needs to be notified for each type of update.

Information Type

Timing & Frequency

Sender Receiver Method of Communication

Status Reports

Weekly Senior Design Team Leader

Lead Engineer and Operations Manager

Face-to-face meetings and e-mail.

Milestone Reports

Twice a Semester

Senior Design Team Leader

Lead Engineer, Operations Manager and UCF Advisor

Face-to-face and E-mail

Team Status Reports

Weekly Senior Design Team Leader

UCF Advisor Face-to-face meetings

Deliverable Issues

As Needed Senior Design Team Leader

Lead Engineer Face-to-face meetings

Purchase Requests

As Needed Senior Design Team Leader

Lead Engineer Face-to-face meetings

Cost Updates Constantly Senior Design Team Leader

Lead Engineer, UCF Adviser, and Team Members

Constantly updated on shared drive that senders and receivers have access to.

8

Work Breakdown Structure. This work breakdown structure categorizes the type of work needed to complete the project and granulates the actual work packages that make up the project work. This structure will be the bases of time and cost estimates.

9

10

Work Breakdown Structure Dictionary:Taking the work breakdown structure one step further, a WBS dictionary was created. This dictionary details each work package and gives a brief description for each. This is a useful tool to reference if there are questions about what a work package entails.

Outline I.D.

Activity Name Description

1.0.0 Design Machine Parts In this phase, the team will identify the best option for each part of the machine, draw it using Solidworks CAD, and get approval from their Lead Engineer.

1.1.0 Design Frame The team will complete the necessary steps to design the frame that will hold up the entire machine. This also includes mounting the metallurgical polishing pad to the frame, since the frame will be built around it.

1.1.1 Brainstorm/Research Options

The first step in the design process is to brainstorm options for the design and then research what materials will be best to make it out of.

1.1.2 Select Best Design The second step in the design process is to select which design they want to move forward with.

1.1.3 Draw Design Using Solidworks CAD, the team will now draw each part that makes up the frame to bring the design to life.

1.1.4 Drawing Approval The final drawing needs approval from the Lead Engineer who closely looks over this project.

1.2.0 Design Electrode Holder Assembly

The team will complete the necessary steps to design the electrode holder assembly that will firmly hold the electrode at the intended angle during resurfacing.




1.2.3 Draw Design Using Solidworks CAD, the team will now draw each part that makes up the holder assembly to bring the design to life.


1.3.0 Design Z-axis The team will complete the necessary steps to design the Fastening

11

Fastening assembly assembly. This will be the branch stemming from the base of the machine that holds the electrode holder assembly at the proper angle and supports it during redressing.



1.3.2 Select Best Design The second step in the design process is to select which design they want to move forward with

1.3.3 Draw Design Using Solidworks CAD, the team will now draw each part that makes up the fastening system to bring the design to life.

1.3.4 Get approval The final drawing needs approval from the Lead Engineer who closely looks over this project.

1.4.0 Design Motor Assembly

The team will complete the necessary steps to design the motor and gear/pulley system that will move the polishing pad against the electrode tip and move the holder assembly at the proper height for redressing. This part also includes the design of all wiring and power components.




1.4.3 Draw Design Using Solidworks CAD, the team will now draw each part that makes up the motor assembly to bring the design to life.


1.5.0 Design Machine Enclosure

The team will complete the necessary steps to design the enclosure of the machine.





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1.6.0 Design Lubrication System

The team will complete the necessary steps to design the lubrication system that will push water onto the metallurgical polishing pad. This will keep the electrode tip lubricated to prevent damage during redressing.




1.6.3 Draw Design Using Solidworks CAD, the team will now draw each part that makes up the lubrication system to bring the design to life.


1.7.0 Write Machine Computer Code

The team will complete the necessary steps to write the computer code that will tell the machine what to do.


The first step is to brainstorm options for the design and then research what the code should look like and what functions it should have.

1.7.2 Write Code The team will use Microsoft Excel VBA Macro to develop the computer code

1.7.3 Code Approval The final code needs to be reviewed by the Lead Engineer and given approval. Run on G Code Sensor using chilipepper program.

2.0.0 Order Parts/Machine Parts

Identify what parts can be outsourced and which ones need to be machined in-house.

2.1.0 Order Materials to Make Machines Parts

If materials are not readily available, place orders with appropriate vendors.

2.2.0 Purchase Outsourced Parts

This step requires the team to identify all of their outsourced parts and place orders with appropriate vendors.

2.3.0 Machine parts The team will use materials ordered to machine the parts they designed.

3.0.0 Assemble Machine After all parts are machined or delivered it is now time to assemble the parts in phases to complete the machine.

13

3.1.0 Assemble Frame The frame is the first to be built. This will serve as the structure for the machine.

3.2.0 Assemble Z-Axis Fastening System

The z-axis is then constructed on top of the frame at the correct angle.

3.3.0 Assemble Electrode Holder Assembly

The electrode holder is built off of the z-axis frame to allow vertical movement of the electrode to the polishing pad on the frame.

3.4.0 Assemble Motor The motor and power source will need to be added to the frame next to give power to the machine

3.5.0 Assemble Lubrication System

The lubrication system will be added to the frame next to the polishing pad and connected to a water source.

3.6.0 Assemble Enclosure After the machine is assembled, the enclosure will need to be built around it.

4.0.0 Test Machine/Final Report

After the machine is built, testing will commence and a final report will be drafted.

4.1.0 Non-working dry run Initial testing of machine components to ensure proper function.

4.2.0 DOE Testing Through Computer Simulation

Design of Experiment (“DOE”) will occur and machine will undergo full testing.

4.3.0 Optical Microscopy Analysis

After a test is done, the team will analyze the test electrode to ensure proper function using a microscope.

4.4.0 Redesign After testing, the team has allotted time to revisit the design of the machine to make changes where appropriate.

4.5.0 Secondary DOE If a redesign has taken place, a new design of experiment will be drafted and the machine will be tested again.

5.0.0 Establish Process In order to implement the machine onto the manufacturing floor, an official process will be developed.

5.1.0 Develop SOP for Circular Electrode

In this step, the team will create a standard operating procedure (“SOP”) detailing instructions on how to use the STEM machine and redress a circular electrode.

5.2.0 Modify Circular SOP for “Racetrack” Electrode

In this step, the team will create a standard operating procedure (“SOP”) detailing instructions on how to use the STEM machine and redress a “racetrack” electrode.

5.3.0 Training Procedure for Operators

The team will develop a training procedure for training new employees on the machine.

14

5.4.0 Create HR Plan The team will help develop a plan to help HR train future workers.

6.6.0 Production Release Install STEM machine and begin integration on manufacturing floor.

Time & Cost Estimates:Time Estimates:Each work package has been assigned a time duration in days and each predecessor has been identified as below.

ID Work Package Duration Predecessors

1.1.1 Brainstorm/Research options (Frame) 5 Days None

1.1.2 Select Best Design (Frame) 1 Days 1.1.1

1.1.3 Draw Design (Frame) 3 Days 1.1.2

1.1.4 Drawing Approval (Frame) 3 Days 1.1.3

1.2.1Brainstorming/Research

options (Electrode Holder)

5 Days None

1.2.2 Select Best Design (Electrode Holder) 1 Days 1.2.1

1.2.3Draw Design

(Electrode Holder) 3 Days 1.2.2

1.2.4Drawing Approval

(Electrode Holder) 3 Days 1.2.3

1.3.1

Brainstorming/Research Options

(Fastening System) 5 Days None

1.3.2 Select Best Design 1 Days 1.3.1

15

(Fastening System)

1.3.3Draw Design

(Fastening System) 3 Days 1.3.2


(Fastening System) 3 Days 1.3.3

1.4.1

Brainstorming/research options

(Design Motor Assembly)5 Days None

1.4.2Select Best Design

(Design Motor Assembly) 1 Days 1.4.1

1.4.3Draw Design




1.5.1

Brainstorming/research options.

(Design Machine Enclosure)3 Days None


(Design Machine Enclosure) 1 Days 1.5.1

1.5.3Draw Design




1.6.1 Brainstorming/research options

5 Days None

16

(Lubrication System)


(Lubrication System) 1 Days 1.6.1

1.6.3Draw Design




1.7.1

Brainstorming/research options

(Write Machine Code)3 Days None

1.7.2Write Code

(Write Machine Code) 7 Days 1.7.1

1.7.3Code Approval

(Write Machine Code) 3 Days 1.7.2

2.1.0Order Material to Make

Machine Part 7 Days

1.1.4, 1.2.4, 1.3.4, 1.4.4, 1.5.4, 1.6.4, 1.7.3

2.2.0 Purchase Outsourced Parts 7 Days

1.1.4, 1.2.4, 1.3.4, 1.4.4, 1.5.4, 1.6.4, 1.7.3

2.3.0 Machine Parts 7 Days 2.1.0

3.1.0 Assemble Frame 2 Day 2.2.0, 2.3.0

3.2.0 Assemble Fastening System 1 Day 2.2.0, 2.3.0

3.3.0 Assemble Electrode Holder 1 Day 2.2.0, 2.3.0

17

3.4.0 Assemble Motor 1 Day 2.2.0, 2.3.0

3.5.0 Assemble Lubrication System 1 Day 2.2.0, 2.3.0

3.6.0 Assemble Enclosure 5 Day 2.2.0, 2.3.0

3.7.0 Assemble Entire Machine 3 Day

3.1.0, 3.2.0, 3.3.0, 3.4.0, 3.5.0, 3.6.0

4.1.0 Non-Working Dry Run 3 Days 3.7.0

4.2.0 DOE Testing 14 Days 4.1.0

4.3.0 Optical Microscopy Analysis 7 Day 4.2.0

4.4.0 Redesign 14 days 4.3.0

4.5.0 Secondary DOE 7 Days 4.4.0

5.1.0Develop SOP for circular

electrode. 7 Days 4.5.0

5.2.0Modify SOP for racetrack

electrode. 7 Days 5.1.0

5.3.0Training Procedures for

Operations 4 Days 5.2.0

5.4.0 Create H.R Management Plan 4 Days 4.5.0

6.0.0 Production Release 7 Days 5.3.0, 5.4.0

18

Network Diagram: The network diagram is a visual representation of each work package in order of completion. This is a useful tool when identifying predecessors and the critical path.

19

Critical Path:The critical path starts at activity 1.7.1 and travels through activities 1.7.2, 1.7.3, 2.1.0, 2.3.0, 3.6.0, 3.7.0, 4.1.0, 4.2.0, 4.3.0, 4.4.0, 4.5.0, 5.1.0, 5.2.0, 5.3.0 and ends at activity 6.0.0. This is the critical path because it’s the longest path on the network diagram; it contains zero slack time and therefore cannot be crashed. The total time it will take to complete the entire project is 105 days. The activities on the critical path consist of writing the machine code, ordering material and machine parts, assembling the enclosure and then the entire machine, conducting the experiment and finally, releasing the machine to production.

Direct Cost Estimates:Each work package has been analyzed to identify total direct costs. Indirect costs have not been accounted for because this is not the responsibility of the Engineering team to calculate and include. Most of the costs incurred come from labor. The total cost for this project is about $22,000.00.

ID Type of Skill Required

Number of

People Needed

Cost per day per

person

Duration in Days

Labor Cost of Work

Package

Materials or Other

Resources

Cost of Material

Work Package

Total Direct Cost

1.1.1

Basic Engineering Background 3 115 5 646.875 None 0 646.875

1.1.2


1.1.3

Basic Engineering Background 3 115 3 388.125 CAD

Solidworks 0 388.125

1.1.4

Advanced Engineering Background

1 350 3 393.75 None 0 393.75

1.2.1


1.2.2


1.2.3



1.2.4


1 350 3 393.75 None 0 393.75

20

1.3.1


1.3.2


1.3.3



1.3.4


1 350 3 393.75 None 0 393.75

1.4.1


1.4.2


1.4.3



1.4.4


1 350 3 393.75 None 0 393.75

1.5.1


1.5.2


1.5.3



1.5.4


1 350 3 393.75 None 0 393.75

1.6.1


1.6.2


21

1.6.3



1.6.4


1 350 3 393.75 None 0 393.75

1.7.1

Knowledge of Software

Development 3 115 3 388.125 None 0 388.125

1.7.2

Knowledge of Software

Development3 115 7 905.625

Excel ‘Chilipeppr’

Macro 0 905.625

1.7.3

Advanced Knowledge of

Software Development

1 350 3 393.75 None 0 393.75

2.1.0

Knowledge of Part Specifications 1 115 7 301.875

Multipurpose Aluminum (6061-T6)

200 501.875

2.2.0

Knowledge of Part Specifications 1 115 7 301.875

Water pump, polishing

pad, motor, electrical system, z-

axis, collett holder,

Computer.

1000 1301.875

2.3.0

Ability to Machine Parts 1 115 7 301.875 None 0 301.875

3.1.0

Knowledge of Machine Schematics 1 115 2 86.25 None 0 86.25

3.2.0


3.3.0


3.4.0


22

3.5.0


3.6.0


3.7.0


4.1.0

Knowledge of Machine Operation 3 115 3 388.125 None 0 388.125

4.2.0

Knowledge of Experimental

Process3 115 14 1811.25 MiniTab

Software 0 1811.25

4.3.0


Process3 115 7 905.625 Microscope 0 905.625

4.4.0

Knowledge of Machine Proper

Function3 115 14 1811.25 None 0 1811.25

4.5.0


Process3 115 7 905.625 None 0 905.625

5.1.0

Knowledge of Machine Operation and Knowledge of

Electrode Redressing Process

1 115 7 301.875 Microsoft Word 0 301.875

5.2.0

Knowledge of Machine Operation and Knowledge of

Electrode Redressing Process

1 115 7 301.875 None 0 301.875

5.3.0


23

5.4.0


6.0.0

Knowledge of Manufacturing Floor

Operations1 115 7 301.875 All Stainless

Steel Table 700 1001.875

Schedule & Budget:Schedule & MS Project Gantt Chart:Below is a schedule and Gantt chart created using Microsoft Project. This was created based off of the time estimates for each work package (see page 13). This shows the flow of tasks throughout the project’s life.

24

Time Phased Budget:Below is an excerpt of the time-phased budget for this project. This spreadsheet shows the distribution of cost throughout each day of the project with each work package. (See attached for full budget).

25

IDDur

.Tas

kBud

get1

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

2425

2627

2829

3031

3233

3435

36

1.1.1

5Bra

instorm

/Resea

rch opti

ons

(Frame

)646

.875129

.375129

.375129

.375129

.375129

.375

1.1.2

1Sele

ct Best

Design

(Frame

)129

.375129

.375

1.1.3

3Dra

w Desig

n (Fram

e)388

.125129

.375129

.375129

.375

1.1.4

3Dra

wing Ap

proval

(Frame

)393

.75131

.25131

.25131

.25

1.2.1

5Bra

instorm

/Resea

rch opti

ons

(Electro

de Holde

r)646

.875129

.375129

.375129

.375129

.375129

.375

1.2.2

1Sele

ct Best

Design

(Electro

de Hol

der)

129.375

129.375

1.2.3

3Dra

w Desig

n (Elect

rode H

older)

388.125

129.375

129.375

129.375

1.2.4

3Dra

wing Ap

proval

(Electro

de Hol

der)

393.75

131.25

131.25

131.25

1.3.1

3Bra

instorm

ing/Res

earch o

ptions

(Fasten

ing Sys

tem)

646.875

129.375

129.375

129.375

129.375

129.375

1.3.2

1Sele

ct Best

Design

(Fasten

ing Sys

tem)

129.375

129.375

1.3.3

2Dra

w Desig

n (Faste

ning Sys

tem)

388.125

129.375

129.375

129.375

1.3.4

3Dra

wing Ap

proval

(Fasten

ing Sys

tem)

393.75

131.25

131.25

131.25

1.4.1

3Bra

instorm

ing/Res

earch o

ptions

(Design

Motor)

646.875

129.375

129.375

129.375

129.375

129.375

1.4.2

1Sele

ct Best

Design

(Design

Motor)

129.375

129.375

1.4.3

4Dra

w Desig

n (Desig

n Moto

r)388

.125129

.375129

.375129

.375

1.4.4

3Dra

wing Ap

proval

(Design

Motor)

393.75

131.25

131.25

131.25

1.5.1

3Bra

instorm

ing/Res

earch o

ptions

(Design

Enclosu

re)646

.875129

.375129

.375129

.375129

.375129

.375

1.5.2

1Sele

ct Best

Design

(Design

Enc

losure)

129.375

129.375

1.5.3

3Dra

w Desig

n (Desig

n Enclos

ure)

388.125

129.375

129.375

129.375

1.5.4

3Dra

wing Ap

proval

(Design

Enc

losure)

393.75

131.25

131.25

131.25

1.6.1

3Bra

instorm

ing/Res

earch o

ptions

(Lubrica

tion Sys

tem)

646.875

129.375

129.375

129.375

129.375

129.375

1.6.2

1Sele

ct Best

Design

(Lubrica

tion

System

)129

.375129

.375

1.6.3

3Dra

w Desig

n (Lubr

ication

System

)388

.125

1.6.4

3Dra

wing Ap

proval

(Lubrica

tion

System

)393

.75

1.7.1

3Bra

instorm

ing/Res

earch o

ptions

(Write

Code)

388.125

129.375

129.375

129.375

1.7.2

7Wri

te Mach

ine Cod

e905

.625

Risk Management Plan:This chart details all of the risks associated with this project. Probability and impact have been assigned and a contingency plan has been created in an effort to deal with this risks if they arise. The impacts of high, moderate, and low have been assigned on the basis of the amount of time that the project will be pushed back if the risk occurs.

Risk ID Risk Title Risk Description Probabilit

y Impact Response Strategy Contingency Plan

1 Operating Errors

Risk involved with any errors during machining of raw

materials.

30% High Mitigate Re-machine parts.

2 Machine Failure

Experimental processes may have

to be revisited.90% High Retain Secondary DOE

3 Design ErrorsInitial designs could be incorrect or not

viable30% Moderate Mitigate

Lead Engineer approval before each design is

accepted. Redesign will occur if problem arises.

4 Outsourcing Receiving wrong, late or low quality parts 50% High Mitigate

Return parts to supplier or receive a refund.

5 Increase in Material Costs

Cost of raw materials may increase 20% Low Retain Re-evaluate the budget

6 Increase in Labor Costs

More labor hours could lead to higher

labor costs50% Low Retain

Add more labor hours per day to the forecasted

budget.

7Time

Allotment of Tasks

Certain aspects of the project could take

longer time.30% High Mitigate Submit change request.

26

Procurement Plan:The procurement needs for this project come from two work packages. In order to machine parts, raw materials have to be ordered. Also, any off the shelf parts need to be ordered to be included in the machine.

Work Package (WBS)

Procurement Needs

Time Frame

Order Date

Date Received

Notes

2.1.0 Raw Materials: Aluminum

7 days 4/25/16 5/4/16 Lead Time is built into the schedule to allow for shipping and receiving.

2.2.0 Outsourced Parts: Motor Metallurgic PolisherCNC Controller

7 days 4/25/16 5/4/16 Lead Time is built into the schedule to allow for shipping and receiving.

Request for Quote:The RFQ below is a hypothetical letter that could be sent by the Engineering team to request quotes for parts and materials from different vendors.

27

RFQ Response Form:This response form was included to allow possible suppliers to submit a formal quote. Ideally, it will be sent along with the RFQ at the time of procurement.

28

Responsibility Matrix:This responsibility matrix was included at the request of the Engineering team. Issues arose with the team members because work packages were not formally assigned to individuals. The chart below is similar to the work breakdown structure dictionary with a column added to assign the work to a team member.

Outline I. D

Activity Name Description Names Dates

1.0.0 Design Machine Parts In this phase, the team will identify the best option for each part of the machine, draw it using Solidworks CAD, and get approval from their Lead Engineer.

Team 4/21/2016

1.1.0 Design Frame The team will complete the necessary steps to design the frame that will hold up the entire machine. This also includes mounting the metallurgical polishing pad to the frame, since the frame will be built around it.

Team 2/11/2016



Raef, Aaron,Andrew

2/1/2016


Raef, Aaron,Andrew

2/2/2016


Andrew 2/8/2016


Jared 2/11/2016

1.2.0 Design Electrode Holder Assembly

The team will complete the necessary steps to design the electrode holder assembly that will firmly hold the electrode at the intended angle during resurfacing.

Team 2/23/2016



Raef, Aaron,Andrew

2/1/2016

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Raef, Aaron,Andrew

2/2/2016

1.2.3 Draw Design Using Solidworks CAD, the team will now draw each part that makes up the holder assembly to bring the design to life.

Aaron 2/17/2016


Jared 2/23/2016

1.3.0 Design Z-axis Fastening assembly

The team will complete the necessary steps to design the Fastening assembly. This will be the branch stemming from the base of the machine that holds the electrode holder assembly at the proper angle and supports it during redressing.

Team 3/3/2016



Raef, Aaron,Andrew

2/1/2016


Raef, Aaron,Andrew

2/2/2016

1.3.3 Draw Design Using Solidworks CAD, the team will now draw each part that makes up the fastening system to bring the design to life.

Raef 2/29/2016

1.3.4 Get approval The final drawing needs approval from the Lead Engineer who closely looks over this project.

Jared 3/3/2016

1.4.0 Design Motor Assembly

The team will complete the necessary steps to design the motor and gear/pulley system that will move the polishing pad against the electrode tip and move the holder assembly at the proper height for redressing. This part also includes the design of all wiring and power components.

Team 3/15/2016



Raef, Aaron,Andrew

2/1/2016

30


Raef, Aaron,Andrew

2/2/2016

1.4.3 Draw Design Using Solidworks CAD, the team will now draw each part that makes up the motor assembly to bring the design to life.

Andrew 3/9/016


Jared 3/15/2016

1.5.0 Design Machine Enclosure

The team will complete the necessary steps to design the enclosure of the machine.

Team 3/24/2016



Raef, Aaron,Andrew

2/1/2016


Raef, Aaron,Andrew

2/2/2016


Aaron 3/21/2016


Jared 3/24/2016

1.6.0 Design Lubrication System

The team will complete the necessary steps to design the lubrication system that will push water onto the metallurgical polishing pad. This will keep the electrode tip lubricated to prevent damage during redressing.

Team 4/5/2016



Raef, Aaron,Andrew

2/1/2016


Raef, Aaron,Andrew

2/2/2016

1.6.3 Draw Design Using Solidworks CAD, the team will now Raef 3/30/2016

31

draw each part that makes up the lubrication system to bring the design to life.


Jared 4/5/2016

1.7.0 Write Machine Computer Code

The team will complete the necessary steps to write the computer code that will tell the machine what to do.

Team 4/21/2016


The first step is to brainstorm options for the design and then research what the code should look like and what functions it should have.

Raef, Aaron,Andrew

1/27/2016

1.7.2 Write Code The team will use Microsoft Excel VBA Macro to develop the computer code

Raef, Aaron,Andrew

4/18/2016

1.7.3 Code Approval The final code needs to be reviewed by the Lead Engineer and given approval. Run on G Code Sensor using chilipepper program.

Jared 4/21/2016

2.0.0 Order Parts/Machine Parts

Identify what parts can be outsourced and which ones need to be machined in-house.

Team 5/17/2016

2.1.0 Order Materials to Make Machines Parts

If materials are not readily available, place orders with appropriate vendors.

Andrew 5/4/2016

2.2.0 Purchase Outsourced Parts

This step requires the team to identify all of their outsourced parts and place orders with appropriate vendors.

Aaron 5/4/2016

2.3.0 Machine parts The team will use materials ordered to machine the parts they designed.

Raef 5/7/2016

3.0.0 Assemble Machine After all parts are machined or delivered it is now time to assemble the parts in phases to complete the machine.

Team 6/9/2016

3.1.0 Assemble Frame The frame is the first to be built. This will serve as the structure for the machine.

Raef 5/19/2016

3.2.0 Assemble Z-Axis Fastening System

The z-axis is then constructed on top of the frame at the correct angle.

Raef 5/23/2016

3.3.0 Assemble Electrode Holder Assembly

The electrode holder is built off of the z-axis frame to allow vertical movement of the

Andrew 5/24/2016

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electrode to the polishing pad on the frame.

3.4.0 Assemble Motor The motor and power source will need to be added to the frame next to give power to the machine

Aaron 5/25/2016

3.5.0 Assemble Lubrication System

The lubrication system will be added to the frame next to the polishing pad and connected to a water source.

Andrew 5/26/2016

3.6.0 Assemble Enclosure After the machine is assembled, the enclosure will need to be built around it.

Andrew 6/6/2016

4.0.0 Test Machine/Final Report

After the machine is built, testing will commence and a final report will be drafted.

Team 8/29/2016

4.1.0 Non-working dry run Initial testing of machine components to ensure proper function.

Aaron 6/15/2016

4.2.0 DOE Testing Through Computer Simulation

Design of Experiment (“DOE”) will occur and machine will undergo full testing.

Raef 7/11/2016

4.3.0 Optical Microscopy Analysis

After a test is done, the team will analyze the test electrode to ensure proper function using a microscope.

Aaron 7/21/2016

4.4.0 Redesign After testing, the team has allotted time to revisit the design of the machine to make changes where appropriate.

Raef, Aaron,Andrew

8/16/2016

4.5.0 Secondary DOE If a redesign has taken place, a new design of experiment will be drafted and the machine will be tested again.

Raef 8/29/2016

5.0.0 Establish Process In order to implement the machine onto the manufacturing floor, an official process will be developed.

Team 9/28/2016

5.1.0 Develop SOP for Circular Electrode

In this step, the team will create a standard operating procedure (“SOP”) detailing instructions on how to use the STEM machine and redress a circular electrode.

Andrew 9/8/2016

5.2.0 Modify Circular SOP for “Racetrack” Electrode

In this step, the team will create a standard operating procedure (“SOP”) detailing instructions on how to use the STEM machine and redress a “racetrack” electrode.

Raef 9/21/2016

5.3.0 Training Procedure for The team will develop a training procedure Aaron 9/28/2016

33

Operators for training new employees on the machine.

5.4.0 Create HR Management Plan

The team will help develop a plan to help HR train future workers.

Team 9/5/2016

6.6.0 Production Release Install STEM machine and begin integration on manufacturing floor.

Jared 10/11/2016

Quality Management Plan:Quality for this project is defined by the Engineering Senior Design team in conjunction with the standards and specifications set by Mitsubishi Hitachi Power Systems America and engineering specification drawings published by the vendors of the parts. The purpose of this quality management plan is to define the specifications needed for the components of the machine, as well as define overall quality of the completed machine’s ability to redress worn electrodes.

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Raw Materials & Outsourced Parts:The chart below details raw materials and outsourced parts, the method of testing they will undergo, and the specifications needed to pass the quality check. The qualities detailed will assist in assuring the overall quality of the completed MHPSA STEM Electrode Redresser Machine. If quality is not maintained with these materials and parts, they will have to be exchanged and retested to ensure function.

Process Action Test Type Acceptable Process Standards Interval

Quality Check of Aluminum

Passive Test – Measurements Taken

(80mm x 70mm x 63.5mm) +5mm. Once

Quality Check of Motor Active TestRun motor on 12V

power, test connection to CNC Controller.

Once

Quality Check of Metallurgic Polisher Active Test

Connect to power to ensure it will run, Pad component needs to

be completely level +/- 0.0254mm

Once

Quality Check of CNC Controller Active Test

Connection to motor and computer had to

be established and functional.

Once

Final Machine Operation: The next chart details the qualifications needed at the completion of the project. The specifications will be for the final dimensions that will be accepted when an electrode is put through the machine. These tests will be done on the final MHSPA STEM Machine and the results will be analyzed using optical microscopy. If Quality is not reached in this testing, the machine will need to be analyzed and specifications will be changed at the discretion of the Senior Design Team until ideal quality is reached.

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Test Subject Process Phase Quality Specifications Assessment Interval

Circular Electrode Initial DOE Testing

Angle Tolerance: 30 degrees +/- 2 degrees

Visual: Identify presence of “burs” or uneven surfaces on

redressed electrode.Diameter: Verify

diameters are consistent on face of

electrode 2mm +/- .005mm for larger diameter; 1.75mm +/- 0.005mm for smaller

diameter.

100 Test Electrodes

“Racetrack” Electrode Initial DOE Testing

Angle Tolerance: 30 degrees +/- 2 degrees

Visual: Identify presence of “burs” or uneven surfaces on

redressed electrode.Diameter: Verify

diameters are consistent on face of electrode 3mm +/- 0.005mm for larger

diameter; 1.5mm +/- 0.005mm

100 Test Electrodes

Quality Assurance Log #1The log below can be used during the testing of each material and product. All quality tests need to be documented.

Item # Date Item measured

Required Value

Actual Measured

Acceptable (Y/N) Recommendation Date

ResolvedItem 1

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Item 2Item 3

Quality Assurance Log #2The logs below can be used during the testing of each type of electrode. All quality tests need to be documented.

Circular Electrode Date Process

MeasuredRequired

ValueActual

MeasuredAcceptable

(Y/N) Recommendation Date Resolved

Test 1Test 2Test 3

‘Racetrack” Electrode Date Process

MeasuredRequired

ValueActual

MeasuredAcceptable

(Y/N) Recommendation Date Resolved

Test 1Test 2Test 3

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Date post:	15-Apr-2017
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Final Project Management Plan

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