Module 4B – Design Continued
Module 4B: Overview
- Module Objective 1: Students will be able to prepare engineering drawings using engineering graphics/CAD software for the final design (CLO1)
- Module Objective 2: Students will identify the appropriate manufacturing/assembly processes for building a functional prototype (CLO1)
- Module Objective 3: Students will create a purchase order for outsourced materials within approved budgetary constraints for prototype (CL01)
- Module Objective 4: Students will develop a plan for manufacturing and distributing with estimated associated costs based on prototype (CLO1)
- Module Objective 5: Students will be able to function effectively in selected role (CLO2)
- Module Objective 6: Students will be able to evaluate (give examples of good) teamwork contribution and collaboration (CLO2)
- Module Objective 7: Students will be able to justify own (self) teamwork contribution and collaboration (CLO2)
- Module Objective 8: Students will be able to prepare structured summaries of design tool use and results that possess appropriate structure, grammar and tone (CLO3)
- Module Objective 9: Students will identify locally sourced materials to use in the final engineering design prototype(CLO4)
- Module Objective 10: Students will be able to generate an expected profit and loss analysis using estimate costs and sales revenue (CL01)
Module Highlights
In this module, students will review/read the content, including watching videos. Students will watch quiz-based/activity-based videos and complete test for understanding activities. This will prepare students for the teamwork activities of completing. Prior to fabrication/manufacture, the prototype design package must be reviewed to ensure manufacturability and costing are aligned with constraints provided (prototype fits in rubber/tote container). Prior to fabrication/assembly, a full design-drawing package and corresponding fabrication plan MUST be reviewed and approved by Boyd Lab and Instructor/TA. Additionally a final prototype cost needs to be completed, along with a final BOM. Purchased parts must be approved and then entered into the Purchase Order form. A written draft of this section (structured summary) of the final report will be completed, as well as Peer Review 2. All student teams will need to be focused on utilizing roles/responsibilities and workload allocation per project plan. An industry perspective video (Vermeer Co.) on the design tools is included in this module.
Materials, Activities and Assignments
- Read/review module content in sequential order as setup in Canvas
- Watch embedded and associated module videos
- Discuss in-class and on MS Teams the work progress to ensure work is completed and submitted per Canvas due date
- Utilize Canvas templates to complete work as outlined in assignment document
- Utilize Solidworks to complete CAD work as outlined in assignment document
- Consult with and obtain approval from Boyd Lab on final prototype design review package that includes prototype drawings AND MPIs
- Perform research and utilize cost analysis to complete P/L statement
- Submit module assignment(s):
The team must be focused on roles/responsibilities to complete this assignment. The subassembly design, MPIs and BOM with initial purchase order completed in Module 4A are critical input into this assignment. The Boyd Lab is the reviewer and approver of the engineering design drawing package. Consult with Boyd Lab as much as needed in order to obtain the final approval, without this, the prototype cannot be built. The team will need fully utilize the roles/responsibilities to complete this assignment, which includes the approval of the final design package. The final prototype cost will be completed and will be used as input into the P/L statement for the prototype to determine profit or loss, as well as manufacturing and distribution plan.
In order to successfully complete this assignment , teams will need to allocate work, considering roles/responsibilities. This interaction may take place in the classroom and on Microsoft Teams. The team will complete the DMADVR toolbox template(s) and submit it to Canvas. This assignment will require teams to work together to get the major tasks completed. A key to success is consultation with the Boyd Lab on the engineering drawings and MPIs. As the experts in the Boyd Lab manufacturing equipment and capabilities, they will assist all teams in ensuring success during this process. Without Boyd Lab approval, the assignment is incomplete and no prototype building can be done. Consult with the Boyd Lab during class time as much as needed, based on availability of personnel. The teams will need to be respectful of other team sections, and do the consulting with Boyd only during this section, unless Boyd Lab allows it at another time. There are multiple sections and teams consulting with Boyd during their own sections class time, so please be aware of this constraint. It is important to focus on getting the design package completed and approved! The prototype build depends upon this! Time management is critical and the final report draft of this section (structured summary) is a component of the assignment that must be planned for as well!
This activity will help you to develop…
- Module Objective 1: Students will be able to prepare engineering drawings using engineering graphics/CAD software for the final design
- Module Objective 2: Students will identify the appropriate manufacturing/assembly processes for building a functional prototype
- Module Objective 5: Students will be able to function effectively in selected role (CLO2)
- Module Objective 8: Students will be able to prepare structured summaries of design tool use and results that possess appropriate structure, grammar and tone
- Module Objective 9: Students will identify locally sourced materials to use in the final engineering design prototype
Task
In this assignment the teams will create engineering drawing package for final prototype design, follow the design package review process with Boyd Lab, develop final bill of materials (BOM) needed to build/fabricate prototype, and determine final prototype cost (material and manufacturing costs), profit and loss, manufacturing & distribution plan. Prior to fabrication/manufacture, the prototype design package must be reviewed to ensure manufacturability and costing are aligned with constraints provided (prototype fits in rubber/tote container). Prior to fabrication/assembly, a full design-drawing package and corresponding fabrication plan MUST be reviewed and approved by Boyd Lab and Instructor/TA. Additionally a final prototype cost needs to be completed, along with a final BOM. Purchased parts must be approved and then entered into the Purchase Order form. The teams will prepare a written draft of this section of their final report.
Grading Criteria
Grading is based on the “Submission Deliverables Expectations” outlined in the assignment document. This is reflected in the grading rubric available to students on the Canvas once the assignment is opened.
Student teams will utilize their roles/responsibilities in this assignment to develop a plan for manufacturing and distribution of your product, estimate associated costs of running the business, estimate sales volumes needed to realize a net profit in the fourth year of the business, evaluate the sustainability of the business venture, and develop a draft of the final report for this section. The profit and loss statement summary will require teams to write about changes they would make to reduce costs and the how the current prototype supports the three pillars of sustainability.
In order to successfully complete this assignment, the teams must interact/discuss both in-class and on MS Teams (if needed) the roles/responsibilities that will lead to workload allocation in this assignment. The previous work in Modules 4A and 4B will be key inputs into this assignment, and completing the DMADVR toolbox template by utilizing the instructions outlined in the assignment document will be critical to success. Developing the manufacturing and distribution plan will rely heavily on research about the target market and area from previous assignments in Modules 1 and 2. Also manufacturing equipment needed will also rely on previous Modules 4A and 4B.
This activity will help you to develop…
- Module Objective 3: Students will be able to generate an expected profit and loss analysis using estimated costs and sales revenue
- Module Objective 4: Students will develop a plan for manufacturing and distributing with estimated associated costs based on prototype
- Module Objective 5: Students will be able to function effectively in selected role
- Module Objective 8: Students will be able to prepare structured summaries of design tool use and results that possess appropriate structure, grammar and tone
- Module Objective 9: Students will be able to generate an expected profit and loss analysis using estimate costs and sales revenue (CL01)
Task
Teams will complete a Profit and Loss statement utilizing the DMADVR toolbox templates. This template will require input from work in this module, as well as Module 4A on costing. Teams will make calculations based on the inputs, volumes are estimated which result is a profit by year 3 of production, and net prof and units sold are plotted versus years (See sample plot in the assignment). For the final report draft, the profit and loss template is analyzed, and an analysis of the sustainability of the design and the proposed business. The manufacturing and distribution plan is also discussed. In addition the team will need to discuss what changes they would make to reduce the total cost. The assignment requirements for all components is outlined in Parts A and B, as well as the Expectations of Assignment Deliverables.
Grading Criteria
Grading is based on the “Expectations of Assignment Deliverables” outlined in the assignment document. This is reflected in the grading rubric available to students on the Canvas once the assignment is opened.
Students will be assessing themselves and their team colleagues in Peer Review 2. The same set of evaluation questions as Peer Review 1. This Peer Review 2 assumes students have read through and reviewed the results from Peer Review 1. The students can address comments and the quantitative evaluation portions of the assessment. The students have the opportunity to discuss with the instructor at any time once they receive their results from any Peer Review. Peer Reviews are an important component of professional/team development.
This activity will help you to develop…
- Module Objective 5: Students will be able to function effectively in selected role (CLO2)
- Module Objective 6: Students will be able to evaluate (give examples of good) teamwork contribution and collaboration (CLO2)
- Module Objective 7: Students will be able to justify own (self) teamwork contribution and collaboration (CLO2)
- Module Objective 10: Students will to seek assistance for teamwork and conflict resolution (CL02)
Task
Students will individually complete the CATME peer review online and follow the instructions outlined in the email sent to their ISU account from catme.org. The quantitative assessment must be completed, as well as, the qualitative assessment comments. The qualitative comments justify/explain the quantitative ratings for both team colleagues and self. Professional comments are important and need to be connected to the quantitative assessment given to all.
Grading Criteria
Grading is based on the “Expectations Deliverables” outlined in the assignment document. This is reflected in the grading rubric available to students on the Canvas once the assignment is opened.
