Redesign and Packaging of Adirondack Chair Team #58 Project # F07-58ADRNDKCH Team Members
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Redesign and Packaging of Adirondack Chair Team #58 Project # F07-58ADRNDKCH Team Members Craig Craddock William Fogerson Jason Hick John Mathews Mike Mayo Client: Center For Comprehensive Services Location: Carbondale, IL Problem: The Center for Comprehensive Services (CCS) provides after hospital rehabilitation for people with brain injuries. CCS requested that our team improve the strength of their current arm design and also find an effective packaging method so that they can sell more chairs. This problem is unique because of the nature of workforce and the unique manufacturing environment. Manufacturing Environment Solution: 1-FEA (Finite Elemental Analysis): Autodesk inventor was used to create a solid model of the current arm design. Then the Ansys Stress Analysis package was used to apply both a pressure and a couple. A pressure and a couple were applied to simulate the force of a person hand. This showed a maximum stress of over 190,000 psi at the rear screw hole. This model supports the statements made by CCS wherein they stated the arms were failing. Based on this information it is clear were redesign was needed. Both the original design and the revised design are shown below. With the addition of a brace rod and support the maximum stress was reduced to just over 9000 psi which is over a 21 times reduction. Original Design 190,000 psi Revised Design 9,000 psi Solution Con’t: 2-Physical Testing: To further verify the FEA results a four point bending machine was used to simulate the loading condition. A test stand was created to simulate the arm being mounted in the chair as shown in Figure #4. The load was constantly increased until the first sign of fracture occurred. This process was repeated for several designs. The results are recorded in Figure #1. Figure #1 shows the original design had a strength of 333 lbf and a range of 149 lbf whereas the revised design has a strength of 565 lbf and a range of 17 lbf. This data is expressed as a range is shown in Figure #2 which shows how the strength and the consistency of the product have been improved. 333.66 149.80 444.28 23.33 418.17 124.35 535.83 56.49 565.11 17.67 0.00 100.00 200.00 300.00 400.00 500.00 600.00 LB F #1 Load #1 R ange #5 #5 R ange #6 #6 R ange #7 #7 R ange #8 #8 R ange Figure #1 Strength 44.90 5.25 29.74 10.54 3.13 0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00 45.00 50.00 P ercen #1 #5 #6 #7 #8 Figure #2 Range 3-New Parts: The two additional parts that must be manufactured are shown in Drawing #1 and Drawing #2 along with a complete assembly which is shown in Drawing #3. Drawing #1 Drawing #2 Drawing #3 Solution Con’t: 4-Packaging and Shipping: In order for the chair to be shipped a set of instructions for the packager were created in addition to a directions for the end- user to reassemble the chair. A sample of these instructions is shown in Figure #3. A sample of the packaged chair is shown in Figure #5 Figure F-1.0 Packaging Instructions PACKING INSTRUCTIO NS PART1: Disassem bly Rem ove screw sshow n in boxesfrom both sidesofchair(1)(2). W ith thisstep com plete, you should have the follow ing in frontofyou (3)(4): 3 1 2 b a c e f g h d 4 Figure #3 Sample Directions Task# Action Day # A CutXXXXX asShown in Drawing ###### 1 B CutXXXXX asShown in Drawing ###### 1 C Assem ble Both partsasShown in Assem bly### 1 D Finish assem blyaspreviouslydone 2 E Follow packing instructionsasshown in AppendixF 2 F Include Assem blydirectionswith shipm entasShown in AppendixG 2 G Take Package to Shipping Vendor 2 Im plem entation Schedule Figure #4 Test Set-up Cost and Schedule: As shown in Table #3 the implementation time is short due to the similarities of the existing design. The greatest time is allotted for the adhesive to cure. As shown in Table#4 the total cost spent was just over $200 dollars and the amount spent on the prototype and testing was just slightly over $100 dollars Item Decription CostPer unit Quantity Purchased or Borrow ed Quantity Used Build Cost Total cost Source 1x6 CedarLum ber $1.16 45 8 $52.03 $9.25 6 2x6 CedarLum ber $1.31 8 8 $10.50 $10.50 6 Large Bubble W rap $0.65 50 16 $32.50 $10.40 11 Sm all Bubble W rap $0.40 50 3 $20.00 $1.20 11 Packing Tape $0.02 330 25 $5.95 $0.45 11 Box $11.95 2 1 $23.90 $11.95 11 Shipping Insurance $2.05 1 1 $2.05 $2.05 13 ShippingCosts $55.19 1 1 55.19 55.19 13 Total $202.12 $100.99 CostSpent Table #3 Implementation Schedule Table #4 Cost Figure #5 Sample Packaging
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Redesign and Packaging of Adirondack Chair Team #58 Project # F07-58ADRNDKCH Team Members Craig Craddock William Fogerson Jason Hick John Mathews Mike Mayo. Solution Con’t: - PowerPoint PPT Presentation
Transcript of Redesign and Packaging of Adirondack Chair Team #58 Project # F07-58ADRNDKCH Team Members
Redesign and Packaging of Adirondack ChairTeam #58
Project # F07-58ADRNDKCHTeam Members
Craig CraddockWilliam Fogerson
Jason Hick
John MathewsMike Mayo
Client:
Center For Comprehensive Services
Location:
Carbondale, IL
Problem:The Center for Comprehensive Services (CCS) provides after hospital rehabilitation for people with brain injuries. CCS requested that our team improve the strength of their current arm design and also find an effective packaging method so that they can sell more chairs. This problem is unique because of the nature of workforce and the unique manufacturing environment.
Manufacturing Environment
Solution: 1-FEA (Finite Elemental Analysis): Autodesk inventor was used to create a solid model of the current arm design. Then the Ansys Stress Analysis package was used to apply both a pressure and a couple. A pressure and a couple were applied to simulate the force of a person hand. This showed a maximum stress of over 190,000 psi at the rear screw hole. This model supports the statements made by CCS wherein they stated the arms were failing. Based on this information it is clear were redesign was needed. Both the original design and the revised design are shown below. With the addition of a brace rod and support the maximum stress was reduced to just over 9000 psi which is over a 21 times reduction.
Original Design 190,000 psi
Revised Design 9,000 psi
Solution Con’t: 2-Physical Testing: To further verify the FEA results a four point bending machine was used to simulate the loading condition. A test stand was created to simulate the arm being mounted in the chair as shown in Figure #4. The load was constantly increased until the first sign of fracture occurred. This process was repeated for several designs. The results are recorded in Figure #1. Figure #1 shows the original design had a strength of 333 lbf and a range of 149 lbf whereas the revised design has a strength of 565 lbf and a range of 17 lbf. This data is expressed as a range is shown in Figure #2 which shows how the strength and the consistency of the product have been improved.
333.66
149.80
444.28
23.33
418.17
124.35
535.83
56.49
565.11
17.67
0.00
100.00
200.00
300.00
400.00
500.00
600.00
LB
F
#1 Load
#1 Range
#5
#5 Range
#6#6 Range
#7
#7 Range
#8
#8 Range
Figure #1 Strength
44.90
5.25
29.74
10.54
3.13
0.00
5.00
10.00
15.00
20.00
25.00
30.00
35.00
40.00
45.00
50.00
Perc
ent
#1 #5 #6
#7 #8
Figure #2 Range
3-New Parts: The two additional parts that must be manufactured are shown in Drawing #1 and Drawing #2 along with a complete assembly which is shown in Drawing #3.
Drawing #1 Drawing #2 Drawing #3
Solution Con’t: 4-Packaging and Shipping: In order for the chair to be shipped a set of instructions for the packager were created in addition to a directions for the end-user to reassemble the chair. A sample of these instructions is shown in Figure #3. A sample of the packaged chair is shown in Figure #5
Figure F-1.0 Packaging Instructions PACKING INSTRUCTIONS
PART1: Disassembly Remove screws shown in boxes from both sides of chair (1)(2).
With this step complete, you should have the following in front of you (3)(4):
3
1 2
b
a
c
e
f
g
h
d
4
Figure #3 Sample Directions
Task # Action Day #A Cut XXXXX as Shown in Drawing ###### 1B Cut XXXXX as Shown in Drawing ###### 1C Assemble Both parts as Shown in Assembly ### 1D Finish assembly as previously done 2E Follow packing instructions as shown in Appendix F 2F Include Assembly directions with shipment as Shown in Appendix G 2G Take Package to Shipping Vendor 2
Implementation Schedule
Figure #4 Test Set-up
Cost and Schedule: As shown in Table #3 the implementation time is short due to the similarities of the existing design. The greatest time is allotted for the adhesive to cure.
As shown in Table#4 the total cost spent was just over $200 dollars and the amount spent on the prototype and testing was just slightly over $100 dollars
Item DecriptionCost Per
unit
Quantity Purchased
or Borrowed
Quantity Used Build Cost Total cost Source
1x6 Cedar Lumber $1.16 45 8 $52.03 $9.25 62x6 Cedar Lumber $1.31 8 8 $10.50 $10.50 6Large Bubble Wrap $0.65 50 16 $32.50 $10.40 11Small Bubble Wrap $0.40 50 3 $20.00 $1.20 11Packing Tape $0.02 330 25 $5.95 $0.45 11Box $11.95 2 1 $23.90 $11.95 11Shipping Insurance $2.05 1 1 $2.05 $2.05 13Shipping Costs $55.19 1 1 55.19 55.19 13
Total $202.12 $100.99
Cost Spent
Table #3 Implementation Schedule
Table #4 Cost
Figure #5 Sample Packaging
