P10041 Managerial Review

MSD 2 Primary Objectives Finalize Designs Prototype Designs Finalize Bill of Materials Make and follow a budget Test all kits following test plans Mitigation of kit risks Creation of kit documentation Determine fulfillment of customer needs Evaluate successes and failures Create a team project poster Write technical paper Update EDGE

MSD II Project Plan

Project Plan Evaluation• All MSD1 action items closed (finalize kit designs, BOMs, test plans)• Last minute design changes caused some parts to be ordered late• Prototyping successfully completed on time• Kit documentation still in development

– Some lesson plans in progress, some assembly plans need refinement

• Testing not completed fully due to failure to attain access to classroom• All completed testing has been documented• Poster and technical paper both completed on time• EDGE continuously and fully updated

Causes

• Most of these deviances result from the delay caused by being behind in MSD1– Needing to reconfigure activity hardware at the

beginning of MSD2– Not enough time to build multiple kits– Kits weren’t finished with enough time to

schedule classroom visitation

What we would do differently

• Contact teachers regardless of kit completion so that it would be feasible to schedule an appointment for in-class testing

• Try to interface more to work collectively on each kit, this was a challenge though due to the amount of work required for each kit and the limited time available due to our other full-time job (School).

• Before ordering materials have a meeting to discuss ordering common parts for each kit.

Customer Needs Checklist

Kits must operate safely in a classroom environment

Kits must relate music and sound to engineering concepts and design

Kits must be portable and durableKits must be usable by groups of up to 30

studentsQuick set up and storageKits must be well documented

Xylophone Kit Individual Project Status

• Testing– Completed: dB level, life expectancy, weight and dimension,

turnover time– Not Completed: classroom implementation, time to familiarizeAll completed testing is documented but needs to be updated to

EDGE by Wednesday night• Kit Documentation

– Completed: lesson plan, activity handouts, assembly plan, visit checklist

– In Progress: creating pdfs of all documents• Hardware

– Products for Science Industries is assembling and when completed I will be picking them up.

Xylophone Kit Individual Project Status

• Personal responsibilities– Project organization (EDGE, templates)– Xylophone Kit

• Bar construction• Base construction• Kit documentation• Kit testing

– Starting the tech paper• Compared to the original project plan

• I am behind schedule with the testing since it was not all completed

• I am behind on completing all of the micro-kits since an outside company is assembling them

Xylophone kitDesign Strong Points• Highly Portable• No small parts that can go

missing• Zero replenishment cost

barring damages• Offers multiple test scenarios• Acrylic base looks

professional and has more of a “wow” factor

Design Weak Points• Sounds produced were not

designed to be harmonic in nature as focus was on material properties

• Base material is more brittle and has a slightly higher possibility to break

Electronic Keyboard Kit Individual Project Status

• Personal responsibilities– Help update project plan, and various group document templates– Electronic Keyboard Kit

• Microcontroller Integration and Programming• Oscillator Testing• Filter Design• Amplifier Design• Synth Shield Design, Plan of Layout

• MSD1 Project Plan– Plan was too ambitious; I did not have enough time to finalize the kit

design, plus it was requested that I change design• MSD2 Project Plan

– I am following the team MSD2 plan, with my own testing requirements

Electronic Keyboard Kit Individual Project Status

• Plan for MSD2– Finish up all MSD1 action items– Follow project plan to complete all testing, building, and

document writing• Test Plan Completed• What I would have done differently– Not wasted time on Analog design since it is not the

industry standard anyway– Made a meeting agenda/action item template to maximize

efficiency of the team’s time together

Electronic Keyboard kitDesign Strong Points

Highly Portable Offers multiple test scenarios Offers multiple design variables Stresses engineering principles

of design, testing, and teamwork

Allows a meshing of creativity and ingenuity

Limited interaction with required circuit components ensures durability

Design Weak Points

Batteries drain disproportionately due to +9V rail also powering microcontroller

8 keys do not allow for playing a multitude of songs

Lack of quality enclosure leaves kit potentially vulnerable to fall or misuse damage.

Vulnerable to damage if incorrect battery lead plugged into Synth. Shield

Will require some replenishment funds to purchase new batteries after several uses

Hearing Aid Kit Individual Project Status

• Testing– Completed: dB level, life expectancy, weight and

dimension, turnover time– Not Completed: classroom implementation, time to

familiarizeAll completed testing is documented

• Kit Documentation– Completed: lesson plan, activity handouts, assembly

plan, visit checklist• Hardware– Completed: all

Hearing Aid Kit Individual Project Status

• Personal responsibilities– Project organization (EDGE, templates)– Hearing Aid Kit

• Speaker stand design and construction• Circuit assembly and verification• Kit documentation• Kit testing

– Starting the Poster• Compared to the original project plan

• I am behind schedule with the testing since it was not all completed

• I am on track with everything else

Hearing Aid kit

Design Strong Points• Highly Portable• Kid Friendly

– Ease of circuit manipulation– Durable

• Snap Circuit has “wow” factor when compared with a breadboard circuit

• Zero replenishment cost barring damages

• Maximum output level not as high as other kits– Activity won’t be overwhelmingly

loud when in a classroom

Design Weak Points• Maximum output level

not as high as other kits– Changes in volume may

be hard to hear

• Snap Circuits are not customizable– Can’t add resistor values

to create a bigger range of volumes

Testing Engineering Specs Engr. Spec. # Specification (description) Unit of

Measure Marginal Value Ideal Value Pass /Fail

ES1 Flame Retardant Y/N None Y PASSES2 Toxicity Rating Rating None IV PASSES3 Explosive Material Rating Rating None TBD PASSES5 Shock Hazards # 1 0 PASSES6 Emergency Shut Down Y/N None Y N/AES7 Temperature Limit °F 100 <90 PASSES8 Decibel Rating dBs 90 <80 FAILES9 Laceration Hazards # 2 0 PASS

ES10 Follows learning objectives #/kit 2 3 PASSES11 Sound & Music Related Y/N None Y PASSES12 Total Activity Time min 25 30 TBDES13 Hands on Time % 60 75 TBDES14 Students engaged in hands on activity % 50 100 TBDES15 Life Expectancy Years 6 10 PASSES16 Class Size # 25 30 PASSES17 Number of Groups Each Kit can Accommodate # 5 6 PASSES18 Weight - Total Kit lbs 45 35 PASSES19 Weight - Individual Activities lbs 10 7.5 PASSES20 Dimensions - Total Kit in TBD TBD TBDES21 Handles on Carrying Bin Y/N None Y PASSES22 Time to Assemble/Disassemble min 10 <5 PASSES23 Relys on Presence of Computer or Software Y/N Y N PASSES24 Kit Turnover time min 30 15 PASSES25 Parts coming off shelf % 75 100 PASSES26 Related learning standards #/kit 2 3 PASSES27 Number of Kits # 3 4 PASSES28 Documents Included Y/N None Y PASSES29 Time to Familiarize min 90 <60 TBDES30 Avg. Length of Lesson min 55 45 TBDES31 Lesson Plan Adaptable to Other Age Groups Y/N N Y TBDES32 Kit Replenisment cost $/use 20 0 PASS

Budget Overview

$2,250 Allotment Some unnecessary

purchases were made, decreasing budget performance

Still anticipate being under budget (Shipping costs omitted but have little effect)

Electronic Keyboard Kit (8 μKits) $655.86Hearing Aid Kit (6 μKits) $464.30Xylophone Kit (6 μKits) $239.46Unneccessary Expenditures $230.58Container/Supplies Expense $150.00Xylophone Construction Expense $300.00

Total Expenditures $2,040.20Total Budget Allotment $2,250.00

Deviance $209.80

Project wrap-up

Successes Created 3 functional kits Met the majority of customer

needs/specs See Completed Test Plans on

Edge (Seperated By Kit) Assembly Plans Have a Strong

Foundation Stayed within budget Improved quality of kits by using

kid-friendly hardware i.e. PCB with sockets, snap

circuits

Failures Electric Guitar Kit Unable to complete in-class

testing Never found a solution for

having to work individually Overall quality reduced as

a result Did not manage budget

perfectly due to limited group interfacing and rushed design fabrication

Possible Future Work• In-class testing of activities and lesson plans• Xylophone Kit

– Add more bar materials– Add more types of mallets– Replace 3” bar with an 8” bar– Obtain more scales so each group can have one

• Electronic Keyboard Kit– Expansion into polyphonic tone generation to demonstrate harmonic

combinations– Physical Key Integration– Professional Style Enclosure Integration– Expansion of number of keys to allow higher function

• (Multiplexing Input Push Buttons)• Hearing Aid Kit

– Design a new amplifier to allow for a greater volume gain– Improve snap to speaker connection

Lessons Learned

• Document everything• Have a realistic project plan and stick to it• Working together is a lot more productive and

beneficial than working separately• Sometimes the most familiar method is not

the best method, thus it is intelligent to perform thorough concept generation