1 of 16

DESIGN REVIEW - 2

  • Name – Akash Milind Kolte
  • Date – 11/22/2021

​

2 of 16

3 of 16

Name : John (ME Senior, SPD Club, Undergrad student)

    • GOAL:
      • To build prototypes to pitch idea to clients, develop proof of concept and visualize CAD in reality.

Name: Aaryan (Grad student)

    • GOAL:
      • Apply prototyping for day to day life problems.

​

Name: Ryan (Lab Manager)

    • GOAL:
      • To guide students about prototyping processes and help them in building prototypes.

Stakeholders

4 of 16

Key Insights

  • Low hands on experience(needed to gain proficiency) leads to:
    • Students making general errors
    • Machine breakdown(e.g. ~60 hours service time for VMC)
    • Tool breakdown(leading to procurement delay)
    • Delay in overall project completion time
    • Lack of understanding of machine, and processes to be followed(table saw breakdown, high feed rate – band saw)

​

AFFINITY DIAGRAM

5 of 16

Problem Statement

  • How might we increase the hands-on experience of students in prototyping?

https://www.google.com/url?sa=i&url=https%3A%2F%2Fqualityinspection.org%2Fsteps-goals-prototype%2F&psig=AOvVaw2Ul62VRmnzI6L9AfC1rvCm&ust=1637633699243000&source=images&cd=vfe&ved=0CAwQjhxqFwoTCJDK14rzqvQCFQAAAAAdAAAAABAD

6 of 16

Generating solutions using Mindmap, C-Sketch, Ask Nature

7 of 16

Design Solution

8 of 16

What is BUDDY SYSTEM?

  • Peer learning system
  • Knowledge-sharing method used to onboard beginners
  1. Buddy system in corporate organizations.

2. University of Southern Alabama Engineering jag Buddy program(for freshmen to navigate college life): https://www.southalabama.edu/colleges/engineering/engineeringjagbuddy.html

9 of 16

What is BUDDY SYSTEM?

  • Peer learning system
  • Knowledge-sharing method used to onboard beginners

10 of 16

Existing systems!

  • Buddy system in corporate organizations.

11 of 16

How does it work?

Command station:

  • Group of students qualified to mentor students.
  • Skilled students either from technical clubs like 3d printing club, Baja or students with experience.
  • Will help peers understand the high level understanding of process/machine, layout of process, tips and tricks(WILL NOT SPOONFEED!)
  • Students can reach out to command stations and book the slots through them.

12 of 16

How does it help?

  • Students understand the high level working of process/machine, layout of process, tips and tricks from buddy.
  • Students can reach out to buddy when stuck at specific step.
  • Active learning of students. Reduces load on Lab managers, TAs (more peer to peer learning.)
  • Develop teaching and communication skills.
  • Reduce probability of student making general errors and complete tasks efficiently.

​

​

​

13 of 16

Site analysis

1. MACHINE SHOP: MILLS

2. MACHINE SHOP: CNCs, VMCs

3. PROTOTYPING LAB (3D PRINTING CLUB)

4. WOODSHOP

~25 students/term, ~3-18 hours to build prototype

Machine not cleaned before use.

~ 30 students/term, MFGE 436 class

Conductive material present in wood.

Students ~ 100/term

Service time ~ very high(60 work hours)

Students ~ 50 students/day, weekly servicing.

Measurement: #students/term; Servicing time and frequency.

14 of 16

SITE ANALYSIS

  • Operated and serviced by 3D printing club.
    • ~25 students this term.
    • Students from College of Engineering and College Of Business.
    • ~3 hours: for small components (example- small gears).
    • ~ 18 hours: for large components (example – Large bolt).
  • Observations:
    • Qualification seminar required.
      • Canvas modules and practical exam.
    • Machines not serviced regularly.
      • Incident: The bolt(in figure) had failed because the machine was not serviced for long time and presence of dust.
  • MFGE 436 class:
    • Machine reserved via MPRL site.
    • #Students ~ 30 students per term.
  • Observations:
    • Qualification seminar required.
    • Table saw blade breakdown reason- Conductive material present in wood while using machine.
    • Band saw ~ frequently used.
    • Blade gets dull because of high feed rate.

​

  • ME 250 class
    • #Time: Monday through Wednesday 8-6pm (2 hrs batch).
    • Remainder week machine reserved via MPRL site.
    • #Students ~ 50 students/day
  • # Service frequency
    • Weekly, between 6-9pm (Mon-Wed) or Thu-Sun.
    • Full factory service in summer.
  • Observations:
    • Students don’t go through canvas notes thoroughly before practical.
    • Lathe machine temporarily out of service due to high level of backlash.
  • # Students: ~100 every term.(mostly capstone and technical clubs like BAJA,GFR…).
  • # Service time ~ very high(example- 60 work hours required to align the tool header).
  • Observations:
    • Qualification seminar required.
      • High learning curve.
      • 8 hours of Canvas modules followed by practical exam.
      • Training modules mostly are safety oriented. Need more hands on experience to gain machining skills.
    • Fadal 4525(VMC) temporarily out of service(wrong input given by student).

15 of 16

Prototyping Results: Buddy System

Key insights(feedback from stakeholders)

Results:

  • Quantitative:
    • ~1-2 hours of run around time (where tools are kept, whom to ask, troubleshooting, cleaning of machine etc.) of students saved.
    • ~60 hours of maintenance time saved(incase of FADAL machine) by avoiding breakdown due to common errors.
  • Qualitative:
    • Technical skills and increased understanding of machine working.
    • Communication and teaching skills.

​

  • Likeability = 8 out of 10
  • Low cost and easy implementation, testing
  • Solution to serve undergrad and graduate students (large group).

16 of 16