MANUFACTURING

OPTIMIZATION OF SMALL

SCALE COLOR IMAGING TARGETS

María Camila LunaPablo Santizo MatheuZachary BordenZachary Delurey

SENIOR

DESIGN

AGENDAProject Background

Alternatives Considered

Risk Management

Updated Schedule

Benchmarking

Functional Decomposition

Certain applications require smaller color targets Complications:

forming component parts customization requests final target assembly

Current process: hand assembled improper alignment low yields

The objective: optimize or redesign the manufacturing process lower costs higher yields improve customization ability

Problem Statement

Stakeholders

ISA Customers

SD Team

Don William

sOperato

r

Susan Farnand

Customer Need

Importance Description

CN1 3 Color materials are spectrally accurate.

CN2 2 Individual patches are blemish free to provide accurate measurements.

CN3 3 Individual patches are aligned.CN4 2 Durable base plate.

CN5 2 Logo of the company on the back of the plate.

CN6 3 Targets do not have burn marks or surface cracks.

CN7 1 Targets are resistant to alcohol and water.

CN8 3 Colors are easily and quickly customized.

CN9 1 Target sizes are easily customized.CN10 2 Fast production time.CN11 3 Low production cost.CN12 3 Low cost system redesign.CN13 3 High yield rates.

Customer Needs

Engineering Requirements

S# Source Functio

nSpecification

(Metric)Unit of Measur

e

Marginal

ValueIdeal Value

Comments/Status

S1 CN4 Base design Durability (drop test) Feet 3ft >3ft

Drop from 3ft without making the surface crack or target break

S2 CN9 Base design Target size # of Sizes 3 sizes inf. Only 3 sizes available

currently

S3 CN3 Individual patches

Positional accuracy with respect to tile size

% 5% <5%

S4 CN5 Base design Logo is present Pass/Fail Pass Pass

S5 CN2/CN6/CN7 Targets Percent damaged

surface % 5 0 Separate test for alcohol/water

S6 CN8 Individual patches

Number of patches that can be changed # 30 30

S7 CN8 Individual patches

Time to change color scheme Min. 5 5

S8 CN10 System Cycle time Min. 30 <15S9 CN11 System Production Cost Dollars 55 25S10 CN12 System System Redesign

Budget Dollars 1,500 >1,500S11 CN13 System Yield Rate % 90 95 Currently at 75%

MatrixEng. Requirements

S1 S2 S3 S4 S5 S6 S7 S8 S9 S10 S11

Customer NeedsPriority

Base Desi

gn Durability

Available Base Desi

gn Sizes

Individual Patc

h Alignmen

t

Base Desi

gn logo

is present

Target

percent

damaged surfa

ce

Individual patches that can be

changed

Time that

takes to

change

color

Syste

m Cycle time

System Production Cos

t

System

redesign

budget

System yiel

d rate

CN1Color materials are supplied from Munsell Div. of X-Rite, Inc. 3                    

CN2Individual patches are blemish free to provide accurate measurements. 2         x            

CN3 Individual patches are aligned. 3     x                CN4 Durable base plate 2 x                    CN5 Logo on back of plate 2   x   x              

CN6Targets do not have laser burns or surface cracks 3         x            

CN7 Targets are resistant to alchohol and water 1         x            CN8 Colors are easily and quickly customized 3           x x        CN9 Target sizes are easily customized 1   x                  CN10 Fast production time 2               x      CN11 Low production cost 3                 x    CN12 Low cost system redesign 3                   x  CN13 High yield rates 3                     x

Functional DecompositionProduce properly aligned, highly customizable, small scale color

targets

Obtain color papers

Choose specific

colors(customer request)

Cut paper to desired size

Position paper on cutter

Protect paper form cutting

process

Align patches within

tolerancesIdentify pattern

according to customer

order

Vertically and horizontally

align patches

Check quality

Secure colors in

place

Prevent patches from

shifting

Protect target from damage

Inspect final product

Benchmarking Circular Pockets

In order to cut the individual circular patches for the small targets without the burn marcs of the laser cutter:Loyalty punch -> 1/16” 1/4”$23.64

The production of the plate would be in the range of $30-50 John Bonzo, 2014

Benchmarking Grid Frame

Benchmarking Machine Slots

Alternatives Considered

Pick & Place

Machine Pocket

Machine slot

90 x 90 guide

Circle Tiles

Grid Frame

Circle Pockets

Mech Align Guide

Current Process

Low Cost - 0 0 - 0 0 0 - 0

Tech Availability + + + + + ? + + 0

Ease of Use + + + + + + + + 0Complexity - - - - - - - - 0Accuracy + + + + + + + + 0Size Flexibility + - - + + - - + 0Protect Color - 0 0 - 0 + 0 0 0Durable End 0 + + 0 0 - + 0 0Low Cycle Time 0 + + 0 + + + - 0Low Unit Cost + - - 0 + + + - 0Aesthetics + - - 0 - - - 0 0+ Total 6 5 5 4 6 5 6 4 0- Total 3 4 4 3 2 4 3 4 0

Cirle Pockets

Pros Cons

Easy alignment

Shorter Cycle Time

Higher Yiels

High Risk alternative

Less size flexibility

Cirle Pockets

Cut the circular patches on the laser cutter

Select the different colors needed for the target

Place adhesive paper and the patch in every pocket

Quality control check

Grid Frame

Medium risk alternative Sketch Pros Cons

Additional delivery: Prototype

Grid Frame

Architecture development Engineering analysis?

Machine Slots

Low risk alternative Sketch Pros Cons

Machine Slots

Architecture development Engineering analysis?

Risk Management

No. Risk Mitigation Plan

1Misunderstandings with the customer and within team members

Keep team members and customer informed of all decisions taken and any changes in scope

2 Unable to meet deadlines/milestones

Before each deadline meet before with sufficient time to solve any issues

3 Expensive alternatives to current process Innovate with lower cost technologies

4 Alignment or cutting system damage color surfaces

Test systems before committing resources to it. Change system if it is damaging surfaces

5 Process is not ergonomic Perform studies of the process and find alternatives to help the ergonomics for example new layout for tools

6 Adhesive does not allow for re-allignment

Perform a pass/fail test of alignment before putting the adhesive. Change the adhesive to allow for movement after applied (slow cure)

7Proposed product redesign (circles) are not well accepted in the market

Transfer risk to customer

8 Not able to review the current manufacture process Design a completely new process

Updated Schedule

Issues and Corrective Actions

Questions?