Digital Doorbell Team 2 Tyler Blaker, Mike Woessner, Jose Pina, Bill Kessler, Jesse Yanik, Justin Bayham, Brandon Roberts, Mike Goggins, Ralph Voltz
Project Goals • Doorbell Prototype • Two moving parts • Multiple processes • Multiple materials • Under 25 dollars apiece • Mass produce 10 products • Learn and apply technologists’ management Skills • Meet consumer demands
Kit and Prototype • We used an Electronics Learning Lab to design the circuit • We transferred the circuit to our PC Board to make our prototype
Final Product • From our prototype and improvements, we made our final product • This product has a speaker to omit sound, LED to omit light, and potentiometer to alter pitch
How It Works • The current travels through the resistors to the speaker and the LED • The frequency can be adjusted by turning the potentiometer • The potentiometer alters the amount of current that runs through the circuit
Problems and Improvements • Problems • The kit had 5 holes and the prototype had 3 holes • We used jumps that made things confusing • We shorted some components by soldering them together • Improvements • We had to use extra wires to “create” more holes • Used long jumps to show where things were going • We spread out the entire circuit to eliminate unwanted solder connections
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Tool #1 • Dealt with basic teamwork fundamentals • Communication skills, emphasis on quality, preparations as a team. • Allowed first opportunity for our team’s proposal idea in actual writing.
Tool 2 • Materials • The toolkit explains the refinement and classification of materials, their structures and characteristics for each of the materials talked about in the presentation. • Processes • Some of the processes talked about where Forming, Cutting, Fastening, and Conditioning.
Tool #3 • “Process Engineering, Design And Innovation” • Has to do with Product Development, the Design Process, Research, and Improving the overall product. • The SDA’s completed in Tool #3 were the MMA, CA (Cost Analysis), DSD, and BSOP.
“Process Engineering, Design And Innovation” • Process Engineering • Identify, analyze, and solve any problems which would improve quality and productivity. • The Design Process • The entire process from basic ideas to production. • Innovation • Changing an existing design or product to make it better and more competitive.
MMA and CA (Cost Analysis) • Man Machine Analysis • Looked at issues and problems that occurred using the machines like cutting the acrylic or soldering the circuit. • Cost Analysis • Concentrates on Direct Costs with a breakdown of all individual part costs and Labor.
DSD and BSOP • Documentation System Design • The Discussion board on Blackboard is very organized and can be easily accessed by any group member on the computer. • Basic SOP • Helped with writing SOP’s for all tools used in production. • Soldering Iron • Band Saw • Hand Drill • Drill Press
Tool 4 - Cost analysis and Productivity • The forms in Tool 4, Break Even, Cost Analysis, Standard Operation General Analysis and the Time and Method Analysis all deal with cost analysis and productivity • Manufacturing Industries constantly deal with costs and productivity of their workers
Cost Analysis • The BEA and the CA both have to deal with calculating costs and determining what can be improved. • With our product we calculated our CA with the materials we purchased, and calculated our own analysis
Productivity • SOGA and TAMA are both productivity forms for calculating the number of parts produced • In our case we used our lab time to calculate how our time was spent and we kept track of what process we used to log on the SOGA
Productivity • Companies should take into consideration man labor vs. machines. • After so long a service a machine should be replaced with a new machine that could increase productivity
Tool 5 “Quality Systems” • Designed to introduce technologists to quality improvement systems and to help them better understand how to put these tools in motion • Quality is taking systems which help conformance and taking them to meet the market demands
Quality • Quality has the perspectives of total quality movement, quality functions deployment, quality costs, quality value analysis and global quality issues.
ISO 9000 • World wide effort to improve quality • Used in all technical and business fields • Purpose is to keep the technical standards around the world consistent so all parties can do business with each other
Assembly line idea • We split apart the team into two groups. • One group did the circuits • Place components on to board • Checked by quality technician • Passes or fails • Soldered components on to board • Checked by quality technician • Passes or fails
Assembly line idea cont’ • Continued: • The other group did the casing • Cut pieces out of the acrylic • Checked by quality technician • Passes or fails • Glued the pieces together • Checked by quality technician • Passes or fails
Tool 6 • Automation • Devices to accomplish specific tasks in a technological work place. • Computer Integration • Computers have paved the way for many new opportunities in the manufacturing world.
Automation • Less manual labor • Repeatability and precision production methods • Usually skill levels are required • Increases in energy and non-human resources • Increase in productivity • Reduced cost in price
Computer Integration • Always plan ahead for growth within the company • This is a very serious thing, always plan for hidden factors • Always set realistic goals that can be obtainable • Always being thinking of new ways to improve, but start off realistically • Never go through the middle man
Computer Integration • There has been a lot of computer integration over the years, we even used it in our doorbell. - The PC board is an easier way to solder components. - Another useful product of computer integration is our 555 IC Timer chip. - Computer Integration gave us a lot of our components for doorbell.
Conclusion • We have achieved our goals of: • Building a working prototype. • Replicating mass production on a smaller scale. • Working together as a team to obtain a common goal. • Become more educated in the processes and fundamentals that will allow us to become more successful in a technologist’s world.
