)Candian Value Analysis Society judges - McGill CIMpaul/SkyfoldPost7Al.pdf · 2017-10-12 ·...

paul

Typewritten Text

paul

Typewritten Text

paul

Typewritten Text

Dean Di Georgio

paul

Typewritten Text

Jason Rutman

paul

Typewritten Text

paul

Typewritten Text

Milon Tsang

paul

Typewritten Text

Arcadia Chen

paul

Typewritten Text

Sean Fielding

paul

Typewritten Text

Daniel Wang

paul

Typewritten Text

Eric Cantin (Skyfold)

paul

Typewritten Text

Candian Value Analysis Society judges

P a g e |2

TableofContents

TableofFigures............................................................................................................................................4

TableofTables.............................................................................................................................................5

ExecutiveSummary.....................................................................................................................................6

Introduction.................................................................................................................................................6

ValueEngineeringDefinition...................................................................................................................6

CompanyHistory.....................................................................................................................................6

ObjectiveofStudyandContext...............................................................................................................8

OrganizationandInformationPhases.........................................................................................................9

Methodology.............................................................................................................................................10

FunctionAnalysis...................................................................................................................................10

FunctionalDiagram(FASTDiagram)......................................................................................................15

FlexibilityTable......................................................................................................................................16

CostAnalysisofCurrentSystem............................................................................................................19

CreativePhase...........................................................................................................................................19

EvaluationPhase........................................................................................................................................26

CaliperBrakingSystem..........................................................................................................................28

ReplacingSprocketswithTimingBeltsConcept....................................................................................29

ElectromagneticClutchSystem.............................................................................................................30

DrumBrake&BevelGearSystemConcept...........................................................................................30

SummaryoftheEvaluationphase.........................................................................................................30

DevelopmentPhase...................................................................................................................................30

Manifold.................................................................................................................................................31

AlignmentJig..........................................................................................................................................32

TensionPlate.........................................................................................................................................34

ElectricreleasebrakeActiveSystem.....................................................................................................36

Certa-StopCentrifugalBrakeSystem.....................................................................................................39

BenefitsCostAnalysis............................................................................................................................41

Conclusion.................................................................................................................................................46

Scenarios................................................................................................................................................46

ImplementationandFollowUp.............................................................................................................46

FinalRecommendation..........................................................................................................................48

Conclusion..............................................................................................................................................49

Appendices................................................................................................................................................50

APPENDIXA:FunctionalDiagram(FAST)...............................................................................................50

P a g e |3

APPENDIXB:DetailedCostAnalysis......................................................................................................51

APPENDIXC:ProductInformation(CertaStop)......................................................................................53

APPENDIXD:AlignmentJigUsageandInstallation...............................................................................54

APPENDIXE:ElectricReleaseBrakeCostBreakdown............................................................................56

APPENDIXF:Certa-StopCentrifugalBrakeCostBreakdown.................................................................58

P a g e |4

TABLEOFFIGURES

Figure1:SkyfoldWallDeploymentinOfficeSetting...................................................................................7Figure2:SkyfoldWallFullyExtendedinUniversityGymnasium.................................................................7Figure3:SkyfoldWallUnitwithMotorUnit................................................................................................8Figure4:MotorUnitofSkyfoldWall...........................................................................................................9Figure5:EnvironmentalAnalysisBreakdown...........................................................................................12Figure6:SequentialAnalysisBreakdown..................................................................................................13Figure7:MovementandEffortsAnalysisBreakdown...............................................................................13Figure8:SecondaryBrakeElements.........................................................................................................14Figure9:ReferenceProductAnalysisBreakdown.....................................................................................15Figure10:FASTDiagram(Excerpt)............................................................................................................16Figure11:CostDistributionofCurrentSystem.........................................................................................19Figure12:RotaryDashpot.........................................................................................................................20Figure13:One-WayClutch........................................................................................................................20Figure14:Swing-MassDesign...................................................................................................................20Figure15:CentrifugalBrake......................................................................................................................20Figure16:ACircularorDiskEddyCurrentBrake.......................................................................................21Figure17:MechanicalGovernor................................................................................................................21Figure18:EmergencyPullSwitches..........................................................................................................21Figure19:ShotinInserts(Closed).............................................................................................................22Figure20:ShotinInsert(Transition).........................................................................................................22Figure21:ShotinInsert(Open).................................................................................................................22Figure22:FrictionBelt...............................................................................................................................22Figure23:PressureDifferenceSeatBeltMechanism................................................................................22Figure24:ElectromagneticReleasedBrakes.............................................................................................23Figure25:ElectricallyReleasedBrakes......................................................................................................23Figure26:Car/CaliperBrake......................................................................................................................23Figure27:DrumBrakeExplanation...........................................................................................................24Figure28:DrumBrake...............................................................................................................................24Figure29:DrumBrakeAssemblyIllustration(thedrumbrakesarealltoobigtofitinthecurrentsystem)...................................................................................................................................................................24Figure30:ArmGrabsGrooveonWheel....................................................................................................25Figure31:TorsionalBar.............................................................................................................................25Figure32:Froude-ReynoldsHydraulicBrake.............................................................................................25Figure33:AxelWire...................................................................................................................................25

P a g e |5

Figure34:MajorParametersfortheFirstRoundofElimination...............................................................26Figure35:CaliperBrakingSystem.............................................................................................................29Figure36:ManifoldinAssembly................................................................................................................31Figure37:Manifold....................................................................................................................................31Figure38:AlignmentJig.............................................................................................................................33Figure39:Current2-TabTensionPlate.....................................................................................................34Figure40:ProposedBent,Laser-CutTensionPlate...................................................................................35Figure41:CurrentHydraulicBrakingSystem............................................................................................36Figure42:SideViewofProposedElectricReleaseBrakeSystem..............................................................37Figure43:ElectricReleaseBrakeSystem..................................................................................................37Figure44:CurrentHydraulicBrakingSystem............................................................................................39Figure45:ProposedCerta-StopBrake.......................................................................................................40Figure46:SideViewofCerta-StopBrake..................................................................................................40Figure47:Certa-StopCentrifugalBrake....................................................................................................40Figure48:BenefitsVersusCostDiagram...................................................................................................44Figure49:BenefitsVersusCostsDiagramofShortTermSolutions..........................................................45Figure50:BenefitsVersusCostsDiagramofLongTermSolutions...........................................................46Figure51:ImplementationProcessoftheJigSystem...............................................................................47Figure52:ImplementationProcessofLongTermSolutions.....................................................................48Figure53:RecommendedMethodologies.................................................................................................48Figure54:a)MountsonC-Channel;b)Sprockets.....................................................................................54Figure55:a)AlignedBrake;b)MisalignedBrake......................................................................................54Figure56:AlignmentJig.............................................................................................................................55Figure57:a)AlignmentJigInteractionwithShaftandMotor;b)JigAligningSprockets..........................55

TABLEOFTABLES

Table1:IntuitiveResearchBreakdown.....................................................................................................11

Table2:FlexibilityTable............................................................................................................................19

Table3:IdeaSummaryChart.....................................................................................................................28

Table4:PlanetaryGearboxCombinations................................................................................................30

Table5:CostAnalysisofShortTermSolutions..........................................................................................42

Table6:CostAnalysisofLongTermSolutions...........................................................................................42

Table7:BenefitsCostAnalysisWeightFactorDistribution.......................................................................43

Table8:BenefitCostAnalysisofAlltheRecommendations.....................................................................43

P a g e |6

EXECUTIVESUMMARY

Skyfoldhasestablisheditselfasaworldleaderinthefoldingwallsindustry.Theirproductsaredeployeddownwardsfromtheceiling,subdividingworkspaceswhileallowingclientsstorethemdiscreetlyandefficiently.Thesewallsystemsfeaturetwobrakingmechanismstosafeguardusersintheeventofamechanicalfailurethatcausesthewalltofall.Thecompanyhasaskedourgrouptoperformavalueanalysisofitssecondarybrakingsystemwiththeoverallgoalofimprovingitssafety,butwithoutcompromisingthecurrentoperatingenvironment.Thisreportprovidesadetailedwalkthroughofthevalueengineeringprocessusedtoassessthecurrentsystemaswellaswellasthegenerationandevaluationofvalue-addingconcepts.Thereportoverallrecommendsfivesolutionsandprovidesamethodologyforhowtoimplementeachone.Thesefivesolutionsincludethreesmallerchangestotheexistingmechanismthatcouldbeimplementedintheshorttermandtwoalternatedesignsthatwouldreplacetheexistingsystemandprovideaddedvalueinthelongterm.

INTRODUCTION

VALUEENGINEERINGDEFINITION

Valueengineeringisamethodologygearedtowardsensuringthattheclientissatisfiedwithaproduct,serviceorprocesswhileminimizingcostandthusoptimizingthevalue.Valuecanbedefinedasfollows:

𝑉𝑎𝑙𝑢𝑒 = !"#$%&"'#$() !" !""#$!"#$ !" !"#$%&'"#

(Equation1.1)

COMPANYHISTORY

Skyfolddesignsandmanufacturesfoldablewallunitsthatstowintheceilinganddeploywithatouchofabutton.Currently,Skyfoldhaswallunitsthatareapplicableforarangeofspacesfromsmallofficestolargegymnasiums.ThefollowingfiguresshowsomeexamplesofSkyfold’sproducts:

P a g e |7

Figure1:SkyfoldWallDeploymentinOfficeSetting

Figure2:SkyfoldWallFullyExtendedinUniversityGymnasium

P a g e |8

OBJECTIVEOFSTUDYANDCONTEXT

Tofigureoutwhattheobjectiveofthestudyis,wefirsthavetounderstandwhatbringsvaluetoSkyfoldandwhatthecurrentsystemactuallydoes.Skyfoldcurrentlyhasfoldingwallunits,ascanbeseeninFigure1andFigure2above.ThesefoldingwallunitsareactuatedbyamotorunitwhichislocatedabovethewallwhenitisfullyretractedasshowninFigure3below.

Figure3:SkyfoldWallUnitwithMotorUnit

ThismotorunitisfurtherbrokendownintosubcomponentsinFigure4.Number1inthefigureshowsthemotorthatactuatesthewall.Insidethismotorthereisagearboxwhichistheprimarysourceofbrakingforthewallunit.Number2isthesecondarybrakingsystem.Itisapurelymechanicalsystemthatreactstothemainshaftoverspeedingshouldthemainbrakingsystemfailandthewallbeginstofreefall.Asitdetectsthisoverspeeding,itprovidesacontrolleddescentofthewallatnomorethanthreetimesfasterthannormaloperatingspeeds.Skyfoldhasaskedustoinvestigateandaugmentthissecondarybrakingsystem.

P a g e |9

Figure4:MotorUnitofSkyfoldWall

AnimportantpartofthisphasewasfindingwhatSkyfold’sclientsvalue.Skyfold’sproductsoperatequietlyenoughtobeusedinanofficeenvironmentwhileprovidingeffectivesoundproofing.Sinceitcanoperateinapopulousenvironment,safetyisaprimaryconcernbothforSkyfoldanditsclients.Thecompanyisknownforprovidinganaestheticallypleasingproducttotheirclients.Thecompanyspecificallytoldusthattherewerethreemainwaysthattheyenvisionedvaluebeingaddedtothecurrentproduct:byreducingthecostofthesecondarybrakingunit,increasingitsreliabilityorstoppingthewallasopposedtoslowingitdown.

ORGANIZATIONANDINFORMATIONPHASES

Theorganizationphaseinvolvedclarifyingobjectives,establishingamandate,andconceptualizingpossiblesolutionstowardsthefinalidea.Tooutlinethegoalsoftheproject,wegatheredinformationaboutthecurrentproduct’sdesign.Tobetteridentifyandeliminateunwantedcostsweaccumulatedinformationfromboththeclientandvariousonlinesources.Thiswasalldonewiththemindsetofimprovingfunctionandqualitytooptimizethedesign.WeanalyzedindividualpartdimensionsthroughCADfiles.Wealsolookedatcomponentcostbreakdownsandassemblylaborcostforthecurrentsystem.Thisallowedustoperformadetailedanalysisandevaluationofindividualpartstoseekalternatives.

P a g e |10

Toanalyzecurrentdesignsofthehydraulicmotorandsprockets,thecompanyrepresentativeprovideduswithacompletecostbreakdownofthecurrentbrakesystemanddiscussedthecompany’scurrentmarketpositionwithus.Thisinformationallowedustoidentifypotentialcompetitorstoanalyze.

Toexpeditecalculations,ourteamwasprovidedwithproductdetailssuchastorquerating,weight,androtationalspeed.Wewerealsogiveninformationregardingthecurrentfailureratesofthehydraulicbrakingsystemcurrentlyinuse.Thisincludedinformationaboutthecostsofafailureincludingreplacementandshippingcosts.

Inordertobetterunderstandtheproductanditsmanufacturingenvironment,wevisitedSkyfold’sproductionfacility.Throughthistour,theteamassessedhowtheassemblylinewassetupincluding:theassemblyprocesswithdetailprocedures,theavailableproductionequipment(lathe,CNCetc.),andtheassemblyplantstorage.Thecompanyrepresentativealsodemonstratedseveralavailableproductdesignsonthemarketintermsofdifferentmaterials(layeredglassetc.),sizes,functions,andtechnologies.

Attheendofthisphasewehadacquiredalltheinformationfromourclientnecessarytocompletetheproject.Hereisalistofsomekeyspecificationsfromourclient.

ImportantDesignSpecifications:

• Maximumforcetobringtoequilibrium:2130lb • Maximumtorque:11488lb-in • Maximumrotationalspeed:15rpm • Maximummassofthewall:3120kg • Maximumheightofthewall:16ft • Maximumshafttorque:11488lb-in • Currentgearreductions:13:35(0.3714);13:40(0.325);13:45(0.2888)

METHODOLOGY

FUNCTIONANALYSIS

Inordertounderstandtheneedsthatthebrakingsystemfulfills,weperformedafunctionanalysis.Functionsaredescribedwithameasurablenounandanactionableverb.Thisallowsustoidentifythemainfunctionalityoftheproductfromthesecondary,sometimesnon-essentialandnon-valueaddingfunctions.Wewentaboutitusingaseriesoffunctionelicitationmethods.

1.INTUITIVERESEARCH

Theintuitivesectionisanon-systematicapproachtogeneratefunctionsbasedonintuitionandcommonsense.Themethodbreaksdowntheproblemintoitssimplestforms.Belowisalistofsomeofthetwowordcombinations:

Restrictmotion

Dissipateheat Savelives Providesafety Helpsales Improveconfidence

Controlspeed

P a g e |11

Operatesilently

Dissipatesenergy

Generatefriction

Containfluid Regulateacceleration

Decreasespeed

Protectusers

Facilitateinstallation

Minimizecost Limitweight

Simplifymanufacturing

Reducemaintenancecost

Maintainreliability

Supportmanifold

Resistdrop Providepeaceofmind

Createconfidence

Besubtle Reducevisibility

Remaininconspicuous

ProvidesFeedback

Table1:IntuitiveResearchBreakdown

2.ENVIRONMENTALANALYSIS

Thispartoftheanalysisdealswithidentifyingelementsoftheenvironmentwhichwillinteractwiththebrakingsystem.Welookedatinteractionswithboththebuiltenvironmentaswellaswiththestakeholders.Assuch,weweremoreeasilyabletocomeupwithelementsthatinteractwithourproductascanbeseeninFigure5below.

P a g e |12

Figure5:EnvironmentalAnalysisBreakdown

3.SEQUENTIALANALYSIS

Thissection’spurpose,asitistitled,istosequentiallygothroughthefunctionsoftheproduct.Wedecidedtogothroughthechainofeventsthatwouldneedtooccurforourbrakesystemtobeusedandevaluatewhyeachoftheseactionsneedtooccur.WeneedtodeterminewhatthegoalsofeachoftheseactionsareanddescribethemasfunctionswhichcanbeseeninFigure6below.

P a g e |13

Figure6:SequentialAnalysisBreakdown

4.MOVEMENTSANDEFFORTSANALYSIS

Themovementsandeffortsanalysislooksatthephysicalmovementsofthesystemandconvertsitintotwowordfunctions.Thewallsystemwearedealingwithhastwomodesofoperationandthuswehavedecidedtobreaktheanalysisintothreeparts:normalconditions,faultconditionsandgeneral/both.ThefullbreakdowncanbeseeninFigure7below.

Figure7:MovementandEffortsAnalysisBreakdown

5.REFERENCEPRODUCTANALYSIS

Duringthisstage,theproductwasanalyzedbystudyingthecurrentproductitself.Thereasonthiswasdoneasopposedtocomparingittoacompetitiveproductisduetothefactthatthisisaspecializedproductthatstandsaloneinthemarket;thereisnorealcompetitiontocompareto.ThusthevariouselementsofthecurrentsystemweredecomposedandthefunctionsofeachofthemweredeterminedascanbeseeninFigure8below.

NormalCondiions

• Rotatesfreely

FaultCondiions

• Providestorque

General/Both

• Fitinceiling• Maintainsenvelope

P a g e |14

Figure8:SecondaryBrakeElements

P a g e |15

Figure9:ReferenceProductAnalysisBreakdown

FUNCTIONALDIAGRAM(FASTDIAGRAM)

Afterhavinggonethroughtheabove-mentioned,functionanalysistechniques,wehadalistofoveronehundreditems.Thenext,crucialstepforourgroupwastosiftthroughthislisttoeliminateduplicatesandsubsequentlyorganizethemintoaFASTdiagram.Thisexercisehelpedustodefineaclearmissionstatementandtoidentifythemostimportantwaysthatitcouldbeachieved.Figure10showsasubsetofourFASTdiagram.ThecompletediagramcanbefoundinAPPENDIXA:FunctionalDiagram(FAST).

P a g e |16

Figure10:FASTDiagram(Excerpt)

Themissionforthisprojectistoprovidesafetywithoutcompromisingthecurrentoperatingconditions.Forourgroup,“operatingconditions”actuallyencompassesawiderangeoftopicsasshowninLevel1ofthediagram.Specificallywanttoensurecompatibilitybothwiththeenduser’senvironmentaswellasSkyfold’smanufacturing,servicingandoperatingsetup.Ourprimaryfunctionistoprovidesafetytotheuserintheeventthatthewallshouldenterfreefall.

FLEXIBILITYTABLE

Afterthefunctionshavebeenclearlyidentified(ascanbeseeninFigure10above),theycanbemeasuredintermsofperformance.Eachfunctionischaracterizedusingthefollowing:

• Criteria:Howafunctionisaccomplishedandmeasured

P a g e |17

• Level:Theacceptableresultforeachcriteria • Flexibility:Indicationonhowmuchalevelcanbenegotiated

Theflexibilitycanbeclassifiedbythefollowingsystem:

• F0noflexibility • F1littleflexibility • F2someflexibility • F3veryflexible

Thisgivesaclearindicationofwhichfunctionsmustberetainedandwhichcanbeadaptedastheanalysisdevelops.InthetablebelowwepresentaflexibilityanalysisofkeyfunctionsfromourFASTdiagram.

Category Function Criteria Level Flexibility Notes

ProvideSafety Engagemechanism

Successrate/reactiontime

100%/2shaftrotations

F0

Applytorque Torquevalue(N/m)

11488lbf*in F0 atleastgivenvalue

Operatesinconspicuously

Producenooutputs

VOClevel F0 tobeevaluatedwithclient

Dampenvibration vibrationlevel notperceptible

F1 continuousoperation

Avoidnoisymechanisms

Decibellevel <40dB F1 continuousoperation,one-timesystemmustbeunderthehumanthreshold

Fitinceiling Height 12" F0 atmost12"

Maintainenvelope

Width,length 17",35" F1

Coexistincurrentmanufacturingsystem

Simplifymanufacturing

#newprocesses none F2 Ifnewprocessneedbreakevenanalysis

Minimizerequiredpackaging

Volumerequiredtohold25units

1cubicfoot F3 Atmost

Resistroughhandling

Maxstaticforce 500N F2

Surviveminorshock

Maxsurvivableimpact

1kN F2

Survivetemperature

Survivabletemperature

Min5degrees

F2 Oilspecs

P a g e |18

shock range Celsius

Resistresiduebuildup

OperatingLife 10years F2 10,000cycles

Reduceweight kg <Currentweight

F1

Coexistwithcurrentservicingsystem

Reducesteps #additionalsetupsteps

1 F2

Resistroughhandling

Maxsurvivableforce

500N F2

Allowswapping #stepsrequiredforswapping

5steps F2

Provideaccess #stepsrequiredtoprovideaccess

1step F1

Displaystatus #tasksneededtoreadstatus

1step F1

Coexistwithoperatingsystem

Resistdust IPrating >=50 F1 Waterresistancenotimportant

Resistrusting Timetosignificantrusting

10years F1 10,000cycles

Resistcorrosion Timetosignificantcorrosion


Resistwear Timetosignificantwear


Allowsfreerotation

Appliedtorqueundernormaloperation

<185Nmondown

F1 ideally0Nmonup

Maintainenvelope

Width,length 17",35" F1

Accommodatepressure

Pressureupperlimits

80-120psi F0

Conformtoenvironmentalstandards

VOClevel F0 tobeevaluatedwithclient

AssureQuality Maintainproductionreliability

Failurerateinproduction

1/2500 F0

Simplifytesting Additionaltimefortesting

2min F1

P a g e |19

Table2:FlexibilityTable

COSTANALYSISOFCURRENTSYSTEM

Skyfold’scurrentbrakingsystemcosts$494.82incomponentsandassemblytime.Whenaddinginthecostoftestingandshippingthesystem,theoverallcostcomesto$627.24total.Inthisnextsection,wetriedtobreakdownthecostofeachcomponentintheassemblyintoacostforprovidingthefunctionswepreviouslyidentified.Foreachcomponent,weassignedascore0,1,3or9toeachfunctiontoidentifyifthefunctiondoesnotaffectthecomponentatall,ifitisatertiaryfunctionofthecomponent,ifitisasecondaryfunctionofthecomponentorifitisoneoftheprimaryfunctionsofthecomponent.Bytallyingupthepointsforeachcomponentwecouldthendistributeitscostamongsteachfunction.ThetablesshowingthisprocesscanbeseeninAPPENDIXB:DetailedCostAnalysis.Figure11belowsummarizestheseresults:

Figure11:CostDistributionofCurrentSystem

AsshowninFigure11above,weonlyspend30%ofthetotalcostonthebasicfunctionofprovidingsafety.Whileoverhalfofthetotalcostisonoperatinginconspicuouslyandcoexistingwiththecurrentoperatingsystem.Therefore,wewanttoreducethosetwocostsandallocatesomeofthemoneytowardsthebasicfunction.

CREATIVEPHASE

Aftercompletingtheinformationphase,weproceededtocreativephase.Themainfocusofthiscreativephaseisonbrainstormingsolutions.Weinitiatedtheprocessbyperformingbrainwritingasagroup.Followingtablesummarizestheideaswecameupwith.Thefourgroups:passivesystems,activesystems,triggeringmechanism,andimprovements.Passivesystemsrefertoamechanismthatwouldsloworstopthewallwithoutrequiringanelectricalsystemtofirstdetectanoverspeedandthentriggerabrakingmechanism.Conversely,activesystemswouldneedtobetriggeredbyanelectricalsignalafterhavingdetectedoverspeed.Inordertofacilitatetaskdistribution,weseparatedconceptsfordetectingoverspeedfromthebrakingmechanismitself.

P a g e |20

Group Examples BriefExplainationsPassiveSystem

RotaryDashpot

Figure12:RotaryDashpotAcontinuousrotarydashpotessentiallyprovidesatorqueproportionaltotheangularvelocityoftheinputshaftthatopposes

thedirectionofmotion.Theideawastocouplethissystemwithaone-wayclutchsothatasthewalldescendsthedashpotwillresistitsmotionbutasthewallrises,thedashpotwillnotspin.Figure13:One-WayClutch

SeatBeltMechanism(Eliminated)

Twopassivesysteminspiredbyseatbeltmechanismareshown:Thedesignusesanarmtocompleteacircuitthatsendsoutanelectricalsignal.Thearmisspunoutbythecentrifugalforcegeneratedunderoverspeed.

Figure14:Swing-MassDesign Centrifugal

BrakeRevolvingbrakeshoesaredrivenoutwardsbycentrifugalforceintocontactwithafixedbrakeunderexcessivespeed.Thesystemcanbe1)acentrifugalbrakewithplanetarygearboxandstandardgearingtoreducerpm2)designedtobealowrpmcentrifugalbrake.

Figure15:CentrifugalBrake

P a g e |21

EddyCurrentBrake

Eddycurrentbrakeproducesdragforcebyeddycurrentsinducedintheconductorthroughelectromagneticinduction.Figure16:ACircularorDiskEddyCurrentBrake

MechanicalGovernor

Asillustratedbythepicture,theflywheel(gray)hasacentrifugalArmsinside(lightblue)andthespringsthatholdthemin(yellow).Whenthewheelturnstoofast,thearmsflyoutward,trippingabrakingdevicethatappliesapairofspring-loadedarms(darkerblue)tothegovernorrope(brown)(no,spinningtoofast)

Figure17:MechanicalGovernorActiveSystems

ElevatorBrakes

Figure18:EmergencyPullSwitches

P a g e |22

DisposablePin

Figure19:ShotinInserts(Closed)

Figure20:Shotin Insert(Transition)

Figure21:ShotinInsert(Open)

FrictionBeltTimingBelt

Figure22:FrictionBelt

SealtBeltMechanism

Sealtbeltmechanismneedspressuredifferencegeneratedbyexplosion,combusition,orliquidtoinitiate.

Figure23:PressureDifferenceSeatBeltMechanism

P a g e |23

MoredetailswillbeaddressedinDevelopmentPhase

Figure24:ElectromagneticReleasedBrakes

ElectricallyReleasedBrakes

Figure25:ElectricallyReleasedBrakes

Car/CaliperBrake

Figure26:Car/CaliperBrake

P a g e |24

DrumBrake Figure27:DrumBrakeExplanation

Figure28:DrumBrake

Thedrumbrakewouldholdontotheshaftandpreventitfromrotating,thiswouldtransmittheforcetothewheelshaft.

Figure29:DrumBrakeAssemblyIllustration(thedrumbrakesarealltoobigtofitinthecurrentsystem)

P a g e |25

ArmGrabsGrooveOnWheel

Theclampwillbeactivatedwithanelectromagnetthatwillstoptheshaft.Thecoiledwirewillbeontheshaftitself.Figure30:ArmGrabsGrooveonWheel

TorsionalBar

Figure31:TorsionalBar

Froude-ReynoldsHydraulicBrake

Figure32:Froude-ReynoldsHydraulicBrake

TriggeringMechanism

UsingAxelAsAnElectricalWire

Figure33:AxelWire

DigitalCounterWheelSystem

Thesystemutilizescircuitlogical.

P a g e |26

Microaccelerometers

Improvement

Watermill Anideainspiredbywatermill,thedesignrequiresimmersingmultiplerotatingdisksinamagnetorheologicalliquid(highviscosity)fluidandanenclosedelectromagnettodissipatetheenergyandslowdownthefallingmotionofthewall.Whenpowersourceisappliedtotheelectromagnet,thecurrentchangesthefluidfromliquidstatetosolidstate.Thefluidsolidifiesasitsyieldstressvariesasafunctionofthemagneticfieldapplied.Thiscontrollableyieldstressproducesshearfrictionontherotatingdisks,generatingthebrakingtorque.

NewManifold

WillbediscussedinDevelopmentPhaseaboutthechangeofmanifoldblockmaterial

NewMotor AlignmentJig Facilitatingthealignmentofthesprockets LaserCutand

BendLasercutthepartasoncepiecethenusesheetmetalbendingmethodstoformthetabs.

EVALUATIONPHASE

Immediatelyfollowingthecreativephase,wemovedourfocustoamoredetailedfeasibilitystudy.Toensuresmootherimplementationandbetterfulfillourvariousrequirements,weenvisionedthatoursolutionsshouldbeoff-the-shelfandallthepartsmustbereadilyavailable.Afterlocatingspecificcompanies,wereadthroughproductcatalogsandcontactedcompanyrepresentativesanddistributorstoobtaincorrespondingdesignspecificationsandperformedcalculation.Severalsignificantparameterswetookintoconsiderationinthiscommencingeliminationstepare:

Figure34:MajorParametersfortheFirstRoundofElimination

P a g e |27

Afirstscreeningphasewasperformedontheideasgeneratedbythecreativityphase.Thisinitialscreeningwasasimplefeasibilityassessmentbasedonsomequicksearchesandquickcalculations.Thisallowedustoeliminatemorethanhalfofourideas.Thescreeningphaseissummarizedinthefollowingtable.

Ideas Feasibility BriefExplanations

ActiveandPassiveSystems

RotaryDashpot Low Continuousrotarydashpotshaveverylowdampingcoefficientsthatwereordersofmagnitudebelowwhatwouldbeneededforoursystem.

SeatBeltMechanism Low Theimplementationofthisideawouldrequirelargechangestotheexistingproduct.Therearenoofftheshelfcomponentsforthemagnitudeofforcesinvolvedhere

CentrifugalBrake High Worthfurtherinvestigation

EddyCurrentBrake Low

WheelRPMistoolowtogetsufficientbrakingtorque.Therequiredcurrentwouldbetoohighandwouldrequireexternalpowersources.Mountingthemagnetswouldalsorequireadditionalfixtures.

MechanicalGovernor Low

Significantlyincreasesthecomplexityofourproject.Also,atthelowRPMweneed,thereisnoproductthatcansupplysuchahightorque.Gearingoursystemupwouldincreasethecostbeyondourbudget.

Elevatorbrakes Low Theamountofforcerequiredtostopthecableistoohigh.Itwasalsooutofscope,asitwouldrequirethesystemtobeoutsideoftheenvelopeintheceiling.

HeenanFroudeWaterBrake Low

Abackoftheenvelopecalculationsshowsthatspacingwouldneedbeseriouslyconsideredinthedesign.Therearealsonoofftheshelfwaterbrakesystemsthatwecoulduse.Thiswouldneedtobedesignedandmanufacturedinhouse.

FrictionBelt Low Frictionbeltsdonothaveahighenoughdragcoefficienttostoporsignificantlyslowdownthewall.

ShotinDisposable Low

Weperformedanenergyanalysisbasedoffsteel’smaterialpropertiesandfoundthat,inordertostopthewallwithasafetyfactorof1,wewouldneedsomethingabout7timesstrongerthansteel.Duetotheenvelope,wealsocouldnotexceedthedimensionof2”x2”x1”

TorsionBarSpringConcept/ Moderate Worthfurtherinvestigation

P a g e |28

ElectromagneticClutch

ElectricReleasedBrakes High Worthfurtherinvestigation

CarBrake/CaliperBrake High Worthfurtherinvestigation

DrumBrake High Worthfurtherinvestigation

ArmGrabsGrooveOnWheel Low Asimplecalculationshowstheforceneededbythearmwould

betoohigh

TriggeringMechanisms

UsingAxelAsAnElectricalWire Low Potentiallyunreliableastheaxleitselfmaynotnecessarily

fracture.

DigitalCounterWheelSystem Low Needamechanismtolinkthedetectedoverspeedtotheactive

system.

Microaccelerometers Low

Off-the-shelfmicroaccelerometersaremostlygravimeterswhicharetooaccurateforourcase,thevaluetocostratioislow.Welookedatbuildingregularaccelerometerswhichcosts$20(materialcost)perdevice;however,accelerometersonlyoutputresultsinsteadofinitiatingtheactivesystem,weneedamechanismtolinkthedetectedoverspeedtotheactivesystem

Improvements

Watermill Low Unrealisticallyhighenergyneedstobedissipated.Nooff-the-shelfproductcomesunderoursizeorourbudgetlimit:thetrade-offbetweenperformanceandcostisnotoptimalatall.

NewManifold High Worthfurtherinvestigation

NewMotor Low Uponfurtherresearch,wefoundthattherewerenomotorsthatwereasbetterthantheonecurrentlyusedbySkyfoldforourbudget.

AlignmentJig High Worthfurtherinvestigation

LaserCutandBend Moderate Worthfurtherinvestigation

TimingBeltConcept High Worthfurtherinvestigation

Table3:IdeaSummaryChart

Otherthantheideaspresentedintheabovetable,severalideasrequiredmore-in-depthresearch,calculation,andanalysis.

CALIPERBRAKINGSYSTEM

P a g e |29

Oneconceptthatlookedverypromisingwasacaliperbrakingsystem.WewereincontinueddiscussionswiththeRowlandCompanyaboutacaliperbrakingsystem.OurcompanycontactproposedtheTwiflexMXEAcaliperbrakewithtwocalipersgrabbingontoasingle30cmdiameterflywheelascanbeseeninFigure35below.

Figure35:CaliperBrakingSystem

Oneofthemainbenefitsofthissystemwasthatitisdesignedtolockontothesystemwhenpowerislost.Thebiggestissuethatweranintowiththisconceptwasthatthepricewasmuchtoohigh.Thedistributorquotedusat16,000$evenafterweexplainedthatthiscouldturnintoarecurringorderofseveralhundredunitsperyear.Forthisreason,weeliminatedthisoption

REPLACINGSPROCKETSWITHTIMINGBELTSCONCEPT

Whenlookingtoreducethecostofindividualcomponents,itwasapparentthatthechainandsprocketscouldbecostlierthannecessary.Onealternativetothiswouldbetousetimingbeltsandpulleys.Itispossibletogettimingbeltsforrelativelylowprices.Oneproblemwiththisisthefactthatthetimingbeltsneedtowithstandveryhighlevelsoftorque.Thismeansthatthepulleysneedtobeofveryhighquality.Thiswastheultimatedownfallofthisideasincethequalitystandardsthatneededtobemetwereextremelyhigh.Almostallpulleysonthemarketwouldnotbeabletosupportthissystem.Apreliminaryquoteforthesetypesofpulleyswasnearly$100perunit.Anotherconsiderationthatisimportantforthissystemistheriskofslipandstretchwiththepulleys.Suddenjerksonthesystem,whicharelikelyifafailureweretooccur,cancauseslipiftheinitialtensionisnothigh.Ahighstatic

P a g e |30

tensionbringsontheriskofstretchthough.Ifthesystemneedstohaveawarrantyoftenyears,thenthisbecomesanotherseriousissue.Therefore,wehadtoeliminatethisidea.

ELECTROMAGNETICCLUTCHSYSTEM

Theelectromagneticclutchsystemwouldbeabrakethatwouldconnectthemaindriveshafttoafixedblockofmetalactingasaspringwhenoverspeedisdetected.Atthatpoint,theelectromagnetswoulddeactivateandthespringswouldprovideenoughforcetostoptherotationoftheshaft.Bydoingcalculations,itisnotpossibletodoasuddenstoponthecurrentmechanism.Theenergytobedispersedwouldrequiretoolargeofametalblocktofullyabsorbthedeformation.Wetriedtouseplanetarygearboxtoreducethetorque.Thetwomajorconsiderationsfortheplanetarygearboxesare--weightneedstobebelow20kg,diameterneedstobewithin12inches(305mm).Thetwofeasiblecombinationsareshowninthefollowingtable:

TorqueReduction MarketAvailability

Combination1

One100:1planetarygearbox

Reduce1300Nmtorqueto13Nm

Tooheavy*

Combination2

One45:13gearOne35:1planetarygearbox

Reduce1300Nmtorqueto376Nmthento11Nm

$4470.23CAD(taxincluded,considering600unites/year)**

Table4:PlanetaryGearboxCombinations

*AB220-100:goodfor1500Nmtorque,weightis600kg(tooheavy).**PriceprovidedbyNelsonPacheco([email protected])atBoschrexroth,manufacturedbyApex.

Thus,wedeterminedthatitwouldnotbefeasiblebasedonourcalculationsandweight/sizeconstraints.

DRUMBRAKE&BEVELGEARSYSTEMCONCEPT

Aftercarefulresearch,thePintschBubenzerdrumbrakeshavetorqueratingsthatmeetourclient’sneeds.However,thisideawasdiscontinuedfortwomainreasons:costandbevelgearprocurement.Tofindbevelgears,wecontactedindustryleadersingearmanufacturingsuchasBostonGears.Theyinformedusthatthereisnooff-the-shelfbevelgearinthemarketthatwouldfitourtorquespecifications.Lastly,thepricequoteswehaveobtainedforthePintschBubenzerbrakesindicateacostofseveralthousandsofdollarseach,whichisoutsideofourbudget.

SUMMARYOFTHEEVALUATIONPHASE

Attheendofthisphase,wewereleftwithfiveconcepts:with2ideasbeingnewbrakingsystemsand3beingimprovementsonthecurrentsystem.Weconductedfurtherresearchinthenextphase:development.

DEVELOPMENTPHASE

P a g e |31

Atthisstage,wewereleftwithconceptsthatweretechnicallyfeasibletotryandimplementforSkyfoldtoaddvaluetothesecondarybrakingmechanism.Inthissectionwe’llprovideadetailedoverviewofeachconceptincludingbenefitsandcosts.

MANIFOLD

Project:SkyfoldBackupBrakeSystem Preparedby:McGillValueEngineeringTeam

Item:ManifoldMaterialChange Date:Dec.2nd,2016 Presentedto:Skyfold

ActualDesignInthecurrentdesign,themanifoldismachinedoutofanaluminumblockandisusedtocontroloilflowintothehydraulicmotor.It’sattachedtothesystemasshowninFigure36.

Figure36:ManifoldinAssemblyProposedDesignWeareproposingasimplematerialswitchinthemanifold(Figure37)fromaluminumtogalvanizedsteel.

Figure37:ManifoldDiscussion Feasibility: -Easiertomachine -Justneedstoholdoil -Requirementsarelow

P a g e |32

-Availabletomostsuppliers -Nosizeordesignchangesneedtobemade -Galvanizedsteelisanexcellentreplacementasithassimilarphysicalpropertiestoaluminum Assumptions: -AluminumManifoldMass:13lbs -AluminumDensity:0.098lbs/in3 -AluminumCost:$1700/ton -GalvanizedSteelDensity:0.284lbs/in3 -GalvanizedSteelCost:$300/ton Pros: -Cheaperthanoriginalmaterial -Canbeimplementedwithonephonecall -Similarpropertiestoaluminum -Easytomachine Cons: -Possiblyunavailablefromthesupplier -Morethan2xheavier ImpactsandRisks: -Norealrisksorimpacttothesystem Investments,SavingsandCostJustifications:-Projecteddecreaseofthecostpermanifoldof$5totalingsavingsof$3000peryear

ALIGNMENTJIG


Item:AlignmentJig Date:Dec.2nd,2016 Presentedto:Skyfold

ActualDesign None.Theemployeeeyeballsthealignmentduringproduction. ProposedDesign Manufactureanalignmentjig.Thepiecewouldphysicallyconstrainandalignthesprockets.Theholeontheleftattachestothehydraulicmotor and the vice on the right clamps around the main shaft. A detailed analysis of the installationandusageofthealignmentjigisincludedinAPPENDIXD:AlignmentJigUsageandInstallation.

P a g e |33

Figure38:AlignmentJigDiscussion Feasibility: -Physicallyensuresreliability -Custompartwon’tbedifficulttomachine -Low,one-timeinvestmentforlargegainsinqualityconsistency Assumptions: -600unitssentayear -Jigcanbemanufacturedat$100 -10minassemblytimeincurrentsystem -+45seccorrectiontimein20%ofinstallations -8mintocorrectangularmisalignmentin2-3%ofunits -Jigwillsave1minperinterventionduetofastproblemidentificationandresolution -2%ofunitssentwitherrors(12units) -$500tofixeachunitsentout(shipping,correctionandreinstallation) Pros: -Simpletouse -Ensuresreliability -Uniformalignment -Facilitatesandstreamlinesassembly Cons: -Extrastep -Connectionpointtohydraulicbrakeisweak ImpactsandRisks: -Minimalriskasitsimplyassistsassembly -Maybeaccidentallyleftonsystem -Canbeeliminatedbyincreasingvisibility(ex.Paintitabrightcolor) Investments,SavingsandCostJustifications:-Initialinvestmentof$100perjig-Savingsduetoimprovedquality:$6000/year-$500/intervention*12faultyunits/year

P a g e |34

TENSIONPLATE


Item:TensionPlate Date:Dec.2nd,2016 Presentedto:Skyfold

ActualDesign Platewithtwotabsweldedon:

Figure39:Current2-TabTensionPlateProposedDesign Lasercutthepartasoncepiecethenusesheetmetalbendingmethodstoformthetabs. Thiswillsaveoncostsbycuttingmanufacturingtimeandfreeingupemployeesspecializedinweldingforothertasks.

P a g e |35

Figure40:ProposedBent,Laser-CutTensionPlateDiscussion Feasibility: -Simple -Lowcostforlasercutting -Clientisalreadyimplementingtechnologyformassivecostsavings Assumptions: -6000unitsayear -1800minofweldingtime(30hours) -$46.50/hourforwelding Pros: -Simple,cheap,effective -Uniformquality(strengthindependentofweldquality) -Potentialstrengthincreasetoplate -Reducesneedforspecializedlabor -Lasercuttingisaproventechnologyalreadybeingphasedintotheclient’sproductionline Cons: -Mayneedbendreliefs -Materialrestrictionsbecauseoflasercutting -Accuracyoflasercanaffecttolerances ImpactsandRisks: -Verylittleimpactbecausegeneralendgeometryandpiecearethesame -Inherentsheetmetalbendingproblems -Thesecanbeeliminatedbyoutsourcingthistoathirdparty -Localizedhardeningduetolaserheatintensity(problemforreaming) Investments,SavingsandCostJustifications:

P a g e |36

-Currentcostofplate:$7.19-Projectedsavingsduetodecreasedlaborcost:$1395/year-30hours’weldingtime*$46.50/hour-Optionprovidescostsavingsaslongasthepriceofthelasercutandbentsheetmetalpiecedoesnotexceed$9.52

ELECTRICRELEASEBRAKEACTIVESYSTEM


Item:ElectricReleaseBrake Date:Dec.2nd,2016 Presentedto:Skyfold

ActualDesign Thecurrentdesignusesahydraulicmotorattachedtoapairofsprockets,whichisattachedtothemainshaft.ACADimageisshownbelow.

Figure41:CurrentHydraulicBrakingSystemProposedDesign Theproposeddesignwouldremoveallthesprockets,chains,tensionplateandfasteners.Itwouldsimplyattachtheelectricreleasebrakedirectlyontothemainshaft.AproposedCADdrawingisshownbelow.

P a g e |37

Figure42:SideViewofProposedElectricReleaseBrakeSystem

Figure43:ElectricReleaseBrakeSystemThisshowstheWarnerElectricERDDVAR00HTsize1000bakesystem.Ithassimilardimensionstothe“yoyo”ensuringthatitwillsafelyfitinthewall.Asseen,itdoesnotrequireanysprocketsystemtoimprovethetorquerating.Therearetwochangesthatwouldneedtobemade. ThefirstisthereneedstobeanextensiontothecurrentC-channel.Thiswouldgiveroomtomounttheelectricreleasebrake.Thiswouldbesimilartothecurrent“tensionplate”partofthesystem,butwithfewermovingparts. Thesecondchangethatwouldneedtobemadewouldbetoconnecttheelectricreleasebraketothesystem’sencoderandasecondarybatterypack.Thereisalreadyanencoderonthemainshaft,soasimpleconnectionmustbemade.Thisisalsoanelectricsystem,soitmustbeconnectedtoabackupbattery.Thisisforsafetyreasons. Discussion Feasibility: -Simple;reducednumberofrequiredpiecesforassembly -Hightorquerating

P a g e |38

-Encodertodetectoverspeedisalreadymountedonothersideofsystem Specifications: -Torquerating:1600Nm -Maxdiameter:26.5cm -Weight:38.5kg -Singleunitquotedpurchaseprice:$7073.38 -Maxoperatingspeed:16.6RPM -Shaftdiameter:1.75-2in Pros: -Canbeactivatedinnon-faultconditionsprovidingaddedsafety -Bringsthewalltoacompleteandnearlyinstantaneousstop -Onlyusesofftheshelfcomponents -Doesnotrequireanygearingsystemtoachievedesiredtorquerating Cons: -Thecostofthesystemispotentiallytoohightomakethisviable -Thissystemweighsmorethanthecurrentsystem -Requiresabackupbatterysystem ImpactsandRisks: -Riskinreliabilitysincethisisnotapurelymechanicalsystem Backupbatteryproposal: Inordertousethissystem,itwouldbeadvisabletoincorporateabackupbatterysystemsothattheelectricreleasebrakecanremainfunctionalevenduringapoweroutage.Theproposedelectricreleasebrakerunsat150Wand103.5VDC.Withsizeandcostconstraintsinmind,afeasiblelonglastinguninterruptedpowersupply(UPS)couldbethemodelBE750G-CNfromAPC.Someofthisbatterypack’sspecificationsfollow: -Runtime:20min -Power:150W -Cost:$100 -Weight:4.8kg -Dimensions:9*18*36.5cm Investments,SavingsandCostJustifications: -Currentsystemcosts:$627.24 -ElectricReleaseBrakecost:~$1305.67

-Thisincludes~$1000forpurchaseoftheelectricreleasebreak -AdetailedbreakdownofthiscostestimatecanbefoundinAPPENDIXE:ElectricReleaseBrakeCostBreakdown

Contactinfo:WarnerElectric-GeneralSupport449GardnerSt.SouthBeloit,IL61080–USA

P a g e |39

Phone:1-800-825-6544Email:[email protected]

CERTA-STOPCENTRIFUGALBRAKESYSTEM


Item:Certa-StopCentrifugalBrake Date:Dec.2nd,2016 Presentedto:Skyfold

ActualDesign Aspreviouslydiscuss,thecurrentdesignusesahydraulicmotorattachedtoapairofsprockets,whichisattachedtothemainshaft.ThemotorACADimageisshownbelow.

Figure44:CurrentHydraulicBrakingSystemProposedDesign Theproposeddesignwouldremovethehydraulicbrakeandmanifold,replacingitwiththeCerta-Stopbrake.Itwouldbeasimplereplacementthatcouldfunctionwiththecurrentgearratios.AproposedCADdrawingandproductpictureareshownbelow.

P a g e |40

Figure45:ProposedCerta-StopBrake

Figure46:SideViewofCerta-StopBrake

Figure47:Certa-StopCentrifugalBrakeThisCerta-Stopbrakehassimilardimensionstothe“yoyo”ensuringthatitwillsafelyfitinthewall.Italsofitsdirectlyontothecurrentsprocketsystem,sothiswouldrequirelittlechanges.ThesystemrequiresamodifiedtensioningplateaswellasashaftwhichwillpassthroughtheCertaStopandholdthesmallersprocket.Thetensioningplatesupportstheshaftwithmountedbearingsoneithersideofthesprocket. Thisisacentrifugalbrake.Astheshaftspins,thearmsofthebrakewillextendoutwards.Oncetheshaftstartsspinningatahighenoughspeed,thearmswilllockintotherestofthebrakeandprovideanimpulsestoppingforce,bringingthewalltoacompletestop,andholdingitinplace. Thiscanthenberesetbyslightlyraisingthewallandreleasingthearmsofthebrake. Thissystemcanbemounteddirectlyontothetensionerplate,likethehydraulicmotorwas. Discussion Feasibility: -Systemispurelymechanical

P a g e |41

-Systemcanbeasimplereplacementforthehydraulicmotorontheoldsprocketsandtensionerplate -Reasonablyhightorquerating Specifications: -Torque:982Nm(systemusesthecurrentgearingratiotoreachahighenoughtorque) -Possibleengagementspeeds:5-250RPM -Shaftsize:1.75-2in -Height:12in -Weight:25kg Pros: -Offtheshelfsolutionthatcanbecustomizedtofitourclient'sneeds -Compatiblewiththecurrentsystem -Stopsthewallduringfaultconditions -Purelymechanicalsystem Cons: -Thereisanincreaseinweight -Thissystemdoesnothelpsimplifytheassemblyofthecurrentsystem ImpactsandRisks: -Sincethissystemisalreadyusedinsimilarapplications,thereislittlereliabilityrisk -Valueaddeddependslargelyontheabilitytonegotiatedowntheprice Investments,SavingsandCostJustifications: -Currentsystemcost:$627.24 -Certa-Stopcentrifugalbrakesystemcostestimate:~$869.88

-Thisincludes500USD(675CADwithtoday’sexchangerate)fortheCertaStop -AdetailedbreakdownofthiscostestimatecanbefoundinAPPENDIXF:Certa-StopCentrifugalBrakeCostBreakdown

Contactinfo:TannerBrants,ProductManagerCertaStop,LLCADivisionofProtechTheatricalNorthLasVegas,NV89030Email:[email protected]:702-639-0290Fax:702-639-0294

BENEFITSCOSTANALYSIS

Thefiverecommendations,dividedintoshorttermandlongtermcategories,aresummarizedpertheircostsinthefollowingtwotables.Forbettercomparison,thethreeimprovementstothecurrentsystemwe’veusedthecostsavingsofeachtodiscountthecurrentpriceofthebrakingsystem.

P a g e |42

Improvement YearlyCostSavings($)

Costsavingperunit($)basedon600units/year

Newcostofunit($)

Jig 6000 10 617.24

Bending 1395 2.33 624.92

Manifold 3000 5 622.24

Table5:CostAnalysisofShortTermSolutions

ReplacementSystem Costperunit($)

ElectricReleaseBrake 1305.67

CertaStop 869.88

Table6:CostAnalysisofLongTermSolutions

Akeycomponentofvalueengineeringisusingabenefitscostdiagramtoassesshoweachsolutionprovidesvaluetotheclient.BasedontheFASTdiagram,wecameupwithfivecriteriatoevaluateeachsolutionandassignedeachaweight.

Criteria Weight CriteriaDetails

Providessafety 10 Howwellthemodificationimpactstheprimarysafetyaspectofourdevice.

Operatesinconspicuously

6 Howwellthesystemavoidsgeneratingnoiseorproducinganydischargethatmightcompromisetheoverallaestheticoftheunitanditssurroundings.

Weight 3 Whattheimpactthateachchangewouldhaveontheweightoftheoverallsystem. (Decreasesinweightwouldessentiallyimpactshippingcostsandincreaseswouldonlybesignificantbeyondacertainthreshold.Forexample,iftheweightincreasestoomuchthentheclientmayneedtostartusingnewequipmentintheinstallationareaasthepiecescouldnolongerbeassembledpurelymanually.)

Impactoncurrentmanufacturingsetup/easeofintegration

5 Howthemodificationswouldimpactthecurrentassemblylinefortheclient. (Thiscriterionwouldencompasshowwellamodificationstreamlinesoperationsorcomplicatesthem.)

Reliability 8 Howreliablethesafetymechanismwillbe.

P a g e |43

Table7:BenefitsCostAnalysisWeightFactorDistribution

Basedontheabovecriteria,wecomparedeachproposedsolutiontothebaselinebrakingsystem.Thefollowingtableshowsthebenefitsscoreassignedtoeachsolution.

Criteria Weight Jig Bending Manifold CertaStop Electricreleasebrake

Baseline

Providessafety 10 5 5 5 9 10 5

Operatesinconspicuously 6 5 5 5 5 7 5

Weight 3 5 5 5 4 3 5

Impactoncurrentmanufacturingsetup/ease

ofintegration

5 7 7 5 5 4 5

Reliability 8 6.5 5 5 9 8.5 5

total 182 170 160 229 239 160

Table8:BenefitCostAnalysisofAlltheRecommendations

Thejigimprovesonthecurrentmanufacturingenvironmentbyfacilitatingthealignmentofthesprocketshencethescoreof7.WealsoassigneditapositiveimpactscoreforReliabilityasitwillhelptoimprovequalityassuranceatthecompanyandincreasetheoverallreliabilityoftheproductbeingsenttothecustomer.

Thesheetmetalbendingoperationimprovesonthecurrentmanufacturingenvironmentbyremovingastepintheoperation.Thissimplifiestheprocessandifproperlymanagedcouldavoidabottleneckinproduction.

Themanifoldmaterialchangedoesnotprovideasignificantimprovementinperformanceonanyofthesecriteriabutinsteadaddsvaluebyreducingcost.Weestimatethatanyincreaseinweightofthemanifoldfromthischangewouldnotbesignificantenoughtowarrantadecreaseinperformanceoftheunit.

TheCertaStopsystemwasgivenahighersafetyandreliabilityscoresinceitstopsthewallandeliminatestheneedforhydraulicfluidsystems.TheCertaStopispurelymechanicalanditsqualityisassuredbyanexternalcompanythatdesignsandmanufacturesit.Wefeltthatthiswouldrepresentabeneficialimprovementinreliability.Thesystemiscompatiblewiththecurrentmanufacturingenvironment.

Theelectricreleasebrakesystemscoredthehighestonsafetysinceitcanbeactivatedatanytimeeveninnon-faultconditionstoprovideaddedsafety.Theeliminationofpotentiallynoisychainsandsprocketshelpstheunitoperatemoreinconspicuously.Thisbrakingsystemissignificantlydifferentfromthecurrentonewhichwillimpacttheassemblylinesetup.Thereliabilityofthesystemifhighdue

P a g e |44

toitshightorquebutthisissomewhatdependentonthequalityoftheelectricalsystembeingusedwithit.

Usingthebenefitsscoresshownaboveaswellasthecostinformationpreviouslypresented,ourgroupgeneratedthefollowingbenefitscostdiagrams:

Figure48:BenefitsVersusCostDiagram

Figure48showsallfivesolutionsproposedinthisreportascomparedtothebaselinesystem.We’llnowdiscusstheseresultsconsideringfirstthethreeimprovementsolutionsandthenthetworeplacementsolutions.Figure49belowshowsacloserviewofthebenefitscostdiagramforthethreeimprovementsandthebaselinesystem:

P a g e |45

Figure49:BenefitsVersusCostsDiagramofShortTermSolutions

AsillustratedinFigure49above,allthreesolutionsaddvaluecomparedtothebaseline.Thethreelinesterminateintheupperleftquadrantindicatingthattheyprovideincreasedsatisfactionoftheclient’sneedswhilealsohelpingtoreducecosts.Noticehowthemanifoldmaterialchangesolutionstilladdsvaluedespiteprovidingnoincreaseinbenefitsasitdecreasescostsslightly.Figure50belowillustrateshowthetworeplacementsolutionsoutlinedinthisreportaddvaluetothecurrentsystem:

P a g e |46

Figure50:BenefitsVersusCostsDiagramofLongTermSolutions

Boththesesolutionslieintheupperrightquadrantofthechartindicatingthattheyincreasebenefitstotheclientbutalsoincreasecost.WecanseethoughthattheslopeoftheCertaStoplineissteeperthanthebaselinesolutionindicatingthatitstillprovidesvalue.Theelectricreleasebrakesolutionthoughhasamuchlowerslopethanthebaselineindicatingthatatitscurrentpricepointitdoesnotaddvalue.It’simportanttokeepinmindthoughthatthepricingofeachofthesesolutionsisverypreliminaryandreliesonsomesignificantassumptionsatthisstage.Ourgrouphadonlyalimitedabilitytonegotiatepriceswithsuppliersandtheclientmaywellbeabletonegotiateamorefavorablepricegivenitscurrentmarketpositionandthevolumeofpartsitwillbeordering.

CONCLUSION

SCENARIOS

Inordertocarryoutthesolutionsoutlineabove,thereareseveralpossiblecombinationsofcompatibility.Themostobviouscombinationofsolutionsthatcanworktogetheristhethreesmallimprovementsolutionstogether(jig,manifoldandbend).Thisispossibleastheyareallworkingtowardsimprovingthecurrentsystem.TheCertaStopsolutionandtheElectricReleaseBrakesolutionarebothindependentofthefirstscenario.Thecompanywouldneedtoselectoneofthesetwoideastodevelop.

IMPLEMENTATIONANDFOLLOWUP

P a g e |47

Inordertoimplementtherecommendationspresentedabove,itisusefultobreakthemdownintoshortandlongtermgoals.Intheshorttermwerecommendimplementingthejig,thesheetmetalbendingandthematerialchangeforthemanifold.InthelongtermwerecommendimplementingtheCertaStopsolution.

We’veprovidedapreliminaryCADrenderingofthejigsystemalongwithalistofofftheshelfcomponentsrequiredtoimplementit.Givenourclient’smachiningcapabilities,itshouldbefeasibletocreateafirstprototypeofthesystematlittleinitialinvestment.Thejigcouldthenbephasedinaspartofaninitialpilotproject.Thejigsystemfunctionswiththecurrentproductionlineandrequiresminimaltrainingtouse.Itshouldnotsignificantlyimpacttheproductionlineandcanbejustremovedfromtheenvironmentshoulditnotproveuseful.Basedonfeedbackfromtheassembler,adjustmentscouldbemadetothejig’sdesignoritcouldbeabandonedentirely.

Figure51:ImplementationProcessoftheJigSystem

Changingthematerialsforthemanifoldwouldinvolvenegotiatingwiththecurrentsupplierofthehydraulicbrakesystem.Oneavenueforimplementingthissystemcouldbetohaveaprototypebuiltwiththenewmetalandhaveitundergoatrialperiodoftestingintheresearchanddevelopmentarea.Ifthefunctionprovestobesatisfactoryfortheprototypeandifthemanufactureragrees,thenthenewdesigncouldbeprogressivelyphasedintothefleet.Itwouldbeadvisabletokeepabufferofthepre-existingsolutiononhandinordertofacilitatethetransition.

Thesheetmetalbendingprocesscouldberefinedinhouseasaresearchanddevelopmentprojectandthenoutsourcedafterwardsoncethedesignhasbeenrefinedsufficiently.Thetransitionfromthecurrentweldedpiecestothebentmetalpiecesshouldnotbeoverlytaxingonthecurrentproductionlinegiventhefactthatthemetalpiecescanbeweldedinbulkbeforehandorpurchasedinbulkandthenusesasneeded.Ananalysisofthecurrentproductionenvironmentshouldbedoneinordertoensurethattheassemblylineisnotheldupbythischange.

TheERDDandCertaStopsystemsrepresentmuchmoresignificantmodificationstothecurrentsystem.Weattemptedtoprovideanobjectiveassessmentofbothsystemsinthisreportbutwerecognizethatadoptingeitherwouldrepresentasubstantialinvestmentofcapitalandwouldsignificantlychangethedesignofthesystem.Forthesereasons,wewouldrecommendadoptingthefollowingmethodologyforimplementingoneofthetwosolutions.

P a g e |48

Figure52:ImplementationProcessofLongTermSolutions

Tostartwith,werecommendadvancingalongtwoavenuesinparallelasdescribedinthefollowingfigure.

Technicalreevaluation Initialpricenegotiation

Afeasibilityassessmentofthesetwosystemshavebeenperformedinthisreport,howeverbecausethisisasafetysystemforthewall,asecondindependentevaluationofeachoptionshouldbedonebySkyfoldEngineers.

WecontactedthemanufacturersoftheCertaStopandERDDbrakesandtriedtoobtainalowpricebyaskingaboutbulkorders.However,giventhefactthatwearestudents,webelievethatSkyfoldcannegotiatealowerpriceduetoitsreputationandexpertiseinsupplierrelations.WerecommendthatSkyfoldshouldstartthenegotiationprocesswithbothcompanies.

Figure53:RecommendedMethodologies

Attheendofthisfirststage,Skyfoldwillhaveamorecompletepictureofthetechnicalandeconomicfeasibilityofpursuingeitheroptionthancouldbeprovidedbythisreportalone.

Aprototypesystemwouldberequiredforeithersystemtovalidatetheperformanceofthesafetysystem.Skyfoldshouldtrytoprocuresamplesfromthecompaniesfortestingpurposes.FortheERDDsystem,thiswillbeespeciallyimportantasitsadoptionwouldmarkatransitionfromapurelymechanicalsystemtoanelectromechanicalsystem.Theelectricalsideofthissystemwouldneedtoberigorouslytestedtoensureitsreliability.TheCerta-Stopoptionisalsohighlycustomizabledependingontheapplication.Potentially,Skyfoldcouldorderamodelthatcouldfunctionasadirectreplacementofthecurrenthydraulicbrake,whichcouldsimplifytheprototypingphase.

Aftertesting,eithersystemcouldbeeitherkept,modifiedorabandoned.Thefunctionalprototypewouldthenserveasastartingpointfortheintegrationofthesystemintotheproductionenvironment.

FINALRECOMMENDATION

Overall,webelievethatintheshorttermallthreeofourproposalsarefeasible.AchangeinmanifoldmaterialwouldbethesimplestmodificationtomakeandwouldlikelyrepresentagoodstartingpointasitrequiresnodirectinterventiononthepartofSkyfoldtoitsproductionline.Thejigprojectwouldrequireanupfrontinvestmentofcapitalanditssuccesswillalsodependonbuyingfromstakeholderssuchastheassemblers.Itwouldprobablybebeneficialtoexploretheideawiththemandgettheirfeedbackaboutthejigsystembeforeadvancing.Webelievethoughthatengagingassemblersinthisprocesswouldbebeneficialandcouldilluminateotherareasofthecurrentassemblylinewherejiggingorothertechniquescouldimproveproductionefficiency.

P a g e |49

Intermsofthelongtermgoals,webelievethatmoreattentionshouldbefocusedontheCertaStopsolution.Themechanismisthemostsimilartothecurrentsystemintermsoffunctionanditdoesnotsubstantiallyaltertherestofthewall’sdesigninthatitstillreliesonthesameCchannelandsprocketsystemcurrentlybeingused.Thesystemismechanicalanddoesnotrelyonanyelectricalcomponentstoprocessdataandtriggerasafetymechanism.Themajorchangesthatwouldneedtobemadewouldbetointegrateanewaxleandtensioningplatesystemontothesprocketstomakethebrakecompatible.TheERDDsystemoffersthepotentialtosignificantlysimplifythemechanicalsystemofthebrakebyremovingthesprocketsentirelybutwerecognizethatthissolutionhassomepotentialdrawbacks.AdoptingtheERDDsystemwouldrepresentamajorshiftinhowthecompanybuildsitsproductandthismaynotbejustifiablesincethisisasecondarybrakingsystem.Furthermore,partialadoptionofthesystemorevenjustphasingitinwouldaddincreasingcomplexitytotheproductionenvironment.TheaddedelectricalsystemandthelackofsprocketsessentiallymeansthatERDDbrakingsystemswouldformaforkintheproductionline.TheCertaStopsystemoffersthebenefitofbeingmorecompatiblewithatransitionfromthecurrenthydraulicmotorsystemasbothusethesamesprockets.

CONCLUSION

Insummary,ourteamhasappliedtheVEprocesstoassessSkyfold’ssecondaryhydraulicbrakingsystem.Weperformedadetailedanalysisofthecurrentsystemwhichhelpedtoinformourrecommendations.Intheend,wegeneratednumerousconceptswhichweeventuallypareddowntofivefeasiblevalueaddingsolutions.ThreeofthesesolutionsrepresentshorttermmodificationstoSkyfold’sexistingdesignwhichprovidemoderateaddedvalue.Ourremainingtwosolutionsarelongtermdevelopmentprojectswhichwouldcompletelyreplacethecurrentsystemandpotentiallyaddsignificantvalue.We’rerecommendingthatthecompanyimplementallthreeofourshorttermsolutionsandthattheyfocusondevelopingtheCertaStoplongtermsolution.

P a g e |50

APPENDICES

APPENDIXA:FUNCTIONALDIAGRAM(FAST)

P a g e |51

APPENDIXB:DETAILEDCOSTANALYSIS

BasicFunction OperatesInconspicuously

Component/\Function Totalpiececost

Retard/Stopwall

Producenooutputs

OperatesSilently

PreserveRoomaesthetics

Key $1.60 $0.96 $0.00 $0.00 $0.00

Sprockets $33.78 $25.34 $0.00 $2.82 $2.82

Chains $13.46 $9.32 $0.00 $1.04 $0.00

Fasteners $10.79 $0.00 $0.00 $0.00 $0.00

PressureGauge $19.00 $0.00 $0.00 $0.00 $0.00

ManifoldBlock $57.00 $0.00 $15.55 $5.18 $15.55

Flowcontrolvalve $35.00 $0.00 $8.08 $0.00 $0.00

Hydraulicmotor $315.00 $113.40 $37.80 $37.80 $0.00

Adjustmentplate $7.19 $0.00 $0.00 $0.86 $0.00

Hydraulicoil $2.00 $1.80 $0.00 $0.00 $0.00

Total $494.82 $150.82 $61.42 $47.70 $18.36

$150.82 $127.48

30.48% 25.76% Manufacturing Servicing

Component\Function Totalpiececost

Simplymanufacturing

FacilitateAssembly

FacilitateTransportation

FacilitateInstallation

Facilitatemaintenance

Key $1.60 $0.11 $0.11 $0.00 $0.11 $0.32

Sprockets $33.78 $0.00 $2.82 $0.00 $0.00 $0.00

Chains $13.46 $0.00 $1.04 $0.00 $1.04 $0.00

Fasteners $10.79 $0.00 $10.79 $0.00 $0.00 $0.00

PressureGauge $19.00 $0.00 $0.00 $0.00 $0.00 $11.40

ManifoldBlock $57.00 $0.00 $5.18 $5.18 $1.73 $1.73

Flowcontrolvalve $35.00 $0.00 $2.69 $0.00 $0.00 $8.08

Hydraulicmotor $315.00 $0.00 $0.00 $0.00 $0.00 $0.00

Adjustmentplate $7.19 $0.00 $2.59 $0.00 $2.59 $0.86

P a g e |52

Hydraulicoil $2.00 $0.00 $0.00 $0.00 $0.00 $0.00

Total $494.82 $0.11 $25.21 $5.18 $5.46 $22.39

$30.49 $27.84

6.16% 5.63%

CoexistencewithOperating QualityAssurance

Component\Function

Totalpiececost

Doesn'tinhibitoperation

Conformtoenvironmentalstandards

Maintainproductionreliability

Simplifytesting

Key $1.60 $0.00 $0.00 $0.00 $0.00

Sprockets $33.78 $0.00 $0.00 $0.00 $0.00

Chains $13.46 $0.00 $1.04 $0.00 $0.00

Fasteners $10.79 $0.00 $0.00 $0.00 $0.00

PressureGauge $19.00 $0.00 $0.00 $3.80 $3.80

ManifoldBlock $57.00 $1.73 $5.18 $0.00 $0.00

Flowcontrolvalve $35.00 $0.00 $0.00 $8.08 $8.08

Hydraulicmotor $315.00 $113.40 $0.00 $12.60 $0.00

Adjustmentplate $7.19 $0.00 $0.00 $0.00 $0.29

Hydraulicoil $2.00 $0.00 $0.20 $0.00 $0.00

Total $494.82 $115.13 $6.42 $24.48 $12.16

$121.54 $36.64

24.56% 7.41%

P a g e |53

APPENDIXC:PRODUCTINFORMATION(CERTASTOP)

P a g e |54

APPENDIXD:ALIGNMENTJIGUSAGEANDINSTALLATION

Figure54:a)MountsonC-Channel;b)Sprockets

WithSkyfold’scurrentproductionsystem,sprocketalignmentisacommonissue.Thesesprockets,mountedontheC-channelasshowninFigure54a),andontheshaftinFigure54b),translatetorquemomentsfromthehydraulicmotor.Ifthesearemisaligned,itwillinterferewiththeoperationsofthesecondarybrake,creatingnoiseandexcesswear.

Figure55:a)AlignedBrake;b)MisalignedBrake

ThemisalignmentofthesprocketsstemsfromamisalignedC-channel.InFigure55a),theC-channelisalignedproperly,ensuringthatthesprocketisintheproperorientationaswell.However,smalldeviations,exaggeratedinFigure55b),thatoccurduetohumanerror,negativelyimpactsprocketalignment.

P a g e |55

Figure56:AlignmentJig

Thuswe’reproposingtheimplementationofanalignmentjigsuchasshowninFigure56.Theholeandboltontheleftwouldattachtothehydraulicmotor,theviceontherightgripsthecentralshaftandthebarontopisusedbothtokeepthesystemtogetherandtoallowalignmentalongitsparallels.Inaddition,theslotsinthetopbarallowforlengthadjustmentsasnecessary,enablingthisjigtobeusedacrossmultiplevariationsofthesamesystem.

Figure57:a)AlignmentJigInteractionwithShaftandMotor;b)JigAligningSprockets

TheboltedendofthejigissecuredtothehydraulicmotorandtheviceendisclampedtothemainshaftuntilthefinalsideviewoftheassemblylookslikeFigure57a).Byadjustingthesprocketssothatthey’reflushwiththesidesofthetopbarsuchasinFigure57b),aperfectalignmentcanbeachievedquicklyandconsistently.Oncethesprocketsaresecured,simplyunclampandunboltthealignmentjigfromtheassemblyandthealignmentprocesswouldbecomplete.

P a g e |56

APPENDIXE:ELECTRICRELEASEBRAKECOSTBREAKDOWN

ThetotalcostoftheElectricReleaseBrakeis$1305.77.Thiscanbeseeninthefollowingtable.

Component Price($)

Electricreleasebrake 1000

BatteryBackup 100

ShaftAdapter 30

Metalplate 10

AssemblyCost 13.43

TestingCost 3.88

ShippingCost 148.36

Total 1305.67

Thefollowingtableoutlinesthecurrentstepsforinstallingthehydraulicmotorassemblyandthesprocketstoillustratethecostsavingsintheformofreducedlabortime:

Parts Time(Seconds) LaborCost($)

HydraulicMotorAssembly 500 6.46

MotorSprocket 240 3.1

Chain 420 5.43

Total 15

Intermsoflaborcost,wesave$1.57/assembly(includingalltheaccessories).Thefollowingtablesummarizesthecostofthenewdesign.

Parts SizingInfo Time(s) Cost($)

Installation

ShaftAdapter Withrecessedscrew 60 0.775

ERDD Compressspringswithreleasescrews; Mountthehubandfitthedrivingkey; Fitthefrictionplate Installthefrictiondisc Slidethemovingarmature; Removereleasescrews

500 6.458

Adjustment AirGap 60 0.775

P a g e |57

WearCompensation 60 0.775

Mounting ShippingScrews FourM12Screws 60 0.775

PowerSupplyCBC140-5

71mm(Length)90mm(Width)58(Height)lessthan1lb

120 1.550

Dustcover 249mmdiameter 60 0.775

HandRelease 60 0.775

SilentBrake 60 0.775

Total 13.43

Shippingcostcanbecalculatedasfollows:

-Weight=38+4.8kg -Thisrepresentsanincreasein50lbofweight -Withacurrentpriceof$850for550lbofshipping,thenewcostcanbecalculatedto$148.36

Currentshaftradiusis18.26mmwhereas1000VAR00HighTorquehasradiusof15mm,weneedtoinstallastepdownshaftadapter.Thequoteweobtainedfor600unitsperyearisroughly$30perstepdownshaftadapter.

P a g e |58

APPENDIXF:CERTA-STOPCENTRIFUGALBRAKECOSTBREAKDOWN

CostbreakdownoftheCerta-StopCentrifugalBrake

Component Price($)

CertaStop 500USD(675CADtoday)

Bearingsx2 20

Tensioningplateandaxle(rawmaterial+machining) 31.59

AssemblyCost 15.77

TestingCost 3.88

ShippingCost 123.64

Total 869.88

ThelaborcostofusingtheCerta-Stopsystemwouldincreasethelaborcostby$0.77(comparedtotheoriginallaborcostof$15perpieceoutlinesinAPPENDIXE:ElectricReleaseBrakeCostBreakdown)perpiece.Thebreakdownisshownbelow.

Parts Time(s) Cost($)

MotorSprocket 240 3.1

Chain 420 5.43

Mounting 60 0.78

Installation Certa-Stop 500 6.46

Total 1520 15.77

TheCertaStopsystemhasashippingweightof55lb.Addingthistothecurrentweightofthe.Basedonaweightof25lbforthesprockets,adjustmentplate,axleandbearingsthisbringsthetotalweightestimateto80lb.Basedonacostof$850for550lbofshipping,thenewcostcanbecalculatedto$123.64

)Candian Value Analysis Society judges - McGill CIMpaul/SkyfoldPost7Al.pdf · 2017-10-12 ·...

Documents

Transcript of )Candian Value Analysis Society judges - McGill CIMpaul/SkyfoldPost7Al.pdf · 2017-10-12 ·...