Embedded Files
Client in industry
Renishaw presented a problem regarding their glue application process for a range of components.
A key problem in the current process is the accuracy of glue application. If the adhesive is applied too high, that leads to a cosmetic failure. If it is applied too low, then that leads to a functional failure. The workpiece would likely be scrapped leading to wastes in resources and financials.
The key problem stems from the entire gluing operation being done manually. As a result, the process is heavily reliant on the user’s manual ability and vision which limits the available work force and requires funded skill training.
The solution must ensure that glue is applied evenly and accurately. The solution must be able to improve the success rate of the current process and minimize the current working time. This could be done through automation of the process. The improved efficiency and ease-of-use can help to reduce labour and training cost. Greater control of the glue dispensing could also result in significant cost savings due to reduced waste.
Thorough process from Day One
A systematic approach to solving the problem given by Renishaw.
Project plan
Set out key objectives, deliverables, breakdown of activities
Early brainstorm
Broke the problem down into its constituent parts
Literature review
Record various findings on a literature review matrix, building a better understanding of the different aspects of the problem
Gantt chart
Timeline of activities, ensuring steady progress
Storyboard
Visualizing how the product will be used
Agendas and minutes
Keeping track of regular meetings
Product Design Specification
List the requirements of the final product
Workflow - Concept development funnel
The project workflow closely followed the concept development funnel with alternating periods for concept generation and evaluation.
Initial ideas
Members are responsible for at least 4 ideas each.
Pugh matrix evaluation
Ideas get evaluated in a Pugh matrix.
Newly added ideas
Following initial evaluation and group discussion, new ideas were generated.
Revised Pugh matrix evaluation
Parameters and the scoring process were refined to be more specific and thorough.
Ideas that stand out
Ideas that stand out from the revised Pugh matrix were chosen as primary candidates for development.
Early testing - anything goes
Testing was conducted to verify the fundamentals of the concepts. Does the concept behave in the same way or have the desired performance as expected.
Techniques as simple as cardboard models were used along with mock workpieces in testing.
New ideas from testing
Valuable information, such as shortcomings and ease-of-use, gained from early testing led to new ideas generated.
More testing - Rapid prototyping
Rapid prototyping and testing of the latest ideas generated helped to narrow down the concepts to a final concept moving forward in development.
Proposal - key features
The latest design is mainly based on the best performing concepts in testing.
Spring clip and turntable
Secure workpiece holding with quick and easy reloading method
Needle guide
Correctly positions the needle for glue dispensing
Glue dispenser holder
Slight tilt keeps the dispenser correctly postioned
Extensive use of standard components
For ease of manufacturing and adjustability
Automation
Workpiece rotating and glue dispensing automated to improve efficiency, ease-of-use and success rate
Aluminium components
For ease of manufacturing and reduced tooling costs
Proposal Development
The development of the proposal began after receiving the approval from Renishaw in a presentation.
Plans to develop
Highlighting the key areas for development
Updated Gantt chart
Updated timeline of activities
Control electronics
Normal operation flowcharts, components selection and microcontroller programming
Component selection
The selection of standard components
Component refinement
Geometric changes for various improvements such as ease of use, setup or manufacturing
Viewing of the gluing process
Exploring ways to aid the viewing of the gluing process
REVISED PROPOSAL - Key features
The revised proposal retained the key features of the proposal with additional key features added.
Spring clip and turntable
Secure workpiece holding with quick and easy reloading method
Needle guide
Correctly positions the needle for glue dispensing
Glue dispenser holder
Slight tilt keeps the dispenser correctly postioned
Extensive use of standard components
For ease of manufacturing
Automation
Automated workpiece rotating and glue dispenser actuation
Aluminium components
For ease of manufacturing and reduced tooling costs
Calibration slits
Quick and easy initial setup of the needle guide
User interface
User can adjust relevant parameters easily
Process Viewing/Verification
Devices can be added and mounted easily on the frame
FInal TEsting and Evaluation
A physical proof of concept was created.
FINAL Testing
Testing shows satisfactory results, inline with expectations during the design process.
COST Analysis
Cost analysis showed great savings can be made due to the greatly improved success rate and speed.
EVAluation aGainst PRODUCT DESIGN SPECIFICATION (PDS)
18 out of 23 metrics either fully met or have evidence to suggest to have met with the specification.
Reflection
This project presented a great opportunity to work for a client in industry. As expected from companies like Renishaw, the expectations and the standards were set exceptionally high.
This project was a great challenge and practice of soft skills. This was especially apparent after assuming a leadership role following concept generation, driving the team to reach high standards as the project progresses. Technical skills like CAD and rapid prototype were also developed and ultilized as well.
Ultimately, this led to a final product which highly satisfied Renishaw during presentations.
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