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Pierre-Carl Dion Louis-Pierre Dorval Marie Nancy Dorvil Marie-Eve G.Desaulniers Luis R. Jimenez Gomez Wei Xu PDT #3.

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Presentation on theme: "Pierre-Carl Dion Louis-Pierre Dorval Marie Nancy Dorvil Marie-Eve G.Desaulniers Luis R. Jimenez Gomez Wei Xu PDT #3."— Presentation transcript:

1 Pierre-Carl Dion Louis-Pierre Dorval Marie Nancy Dorvil Marie-Eve G.Desaulniers Luis R. Jimenez Gomez Wei Xu PDT #3

2 Outline Team Presentation Team Presentation Product Description Product Description Manufacturing Plan Manufacturing Plan Unit Cost Unit Cost Prototype Prototype Testing Testing Marketing Strategies Marketing Strategies Financial Projections Financial Projections Challenges Challenges Lessons Learned Lessons Learned

3 Project Manager Louis Dorval Product Manager Pierre-Carl Dion Project Engineer Wei Xu Product Designer M. Nancy Dorvil Marketing Manager Marie-Eve Desaulniers Production Manager Rafael Jimenez

4 Product Description Device that measures juice concentration based on the changing properties of water Device that measures juice concentration based on the changing properties of water Customer needs list: Device is reusable, is reusable, is worth between $1 and $10, is worth between $1 and $10, is easy to use, is easy to use, is precise, is precise, is easy to maintain, is easy to maintain, is small, and is small, and indicates the concentration quickly indicates the concentration quickly

5 Product Description 4 possible concepts were generated: 1. Disposable pH paper 2. Reusable pH spoon 3. pH digital reader spoon 4. Digital reader device that would hold on a cup

6 Product Description Selected Concept: reusable pH spoon Raw Material Choices: Plastics: polystyrene, polyethylene, polypropylene Metals: silver or 18/8 stainless steel Wood: different kinds

7 Product Description Functionality Use litmus dye to detect pH level of juice Use litmus dye to detect pH level of juice Litmus is extracted from fermented lichens Litmus is extracted from fermented lichens Active component of litmus: erythrolitmin Active component of litmus: erythrolitmin

8 Raw Materials Body of the spoon Bapolan® Grade PS6060 General Purpose Polystyrene Injection Molding Resin Body of the spoon Bapolan® Grade PS6060 General Purpose Polystyrene Injection Molding Resin Litmus Litmus Powder Litmus dyes (erythrolitmin) Powder Litmus dyes (erythrolitmin) Packaging Packaging Material Cost Availability of suppliers Ease to Manufacture Customer Perception Environmental Impact / Recycling Plastics Metal (stainless steel) Wood Chemical Name composition ISO 1043 Density [g/cm 3 ] Processing temperature [  ] Flowability* Shrinkage in processing [%] Polystyrene PS g0.3 – 0.8 Polyethylene PE0.91– g m p1.2 – – 2.5 Polypropylene PP m p0.5 – 1.2r** Best Alternative: Plastic Plastified starch materials, Aliphatic polyesters, Cellulose? Best option

9 Vendor Selection Criteria Selection, Evaluation and Development of Suppliers Quality Quality Reliability in deliveries Reliability in deliveries Cost Cost References – goodwill References – goodwill Technology Technology Location Location Financial strength Financial strength Continuous improvement efforts Continuous improvement efforts Raw MaterialSupplier Bapolan® Grade PS6060 Polystyrene Bapolan® Grade PS6060 Bamberger Polymers Powder Litmus dyes (erythrolitmin) Microessential laboratory Miscellaneous (Boxes, Bags)Alliance Packaging

10 Manufacturing Cycle Raw materials Stocks reception Injection Molding Coating to impregnate litmus solution InspectionPackagingWarehouse Shipping Customers

11 Injection Molding Machines Characteristics Characteristics

12 Manufacturing Principles FMEA FMEA SPC SPC TPM TPM QUALITY ASSURANCE QUALITY ASSURANCE ENVIRONMENTAL RESPONSIBILITY ENVIRONMENTAL RESPONSIBILITY DFSS DFSS ProblemPotential Causes Short shots or surface wrinkles Low injection pressure, low mold temperature, inadequate mold venting, small runner or gates Surface streaking Low mold temperature, material not dry enough, high injection rate, short corners around the gates Warping of parts Abrupt section variations, high mold temperature, high material temperature, low ram pressure time Dimensions too large High injection pressure, low mold temperature Dimensions to small High mold temperature, high material temperature, low injection pressure Shot-to shot dimension variation Mold temperature not constant, material temperature not constant, injection pressure variation COMPUTER INTEGRATED MANUFACTURING Process planning Data, tool & document management

13 Unit Cost -I A. Material cost Part material weight: 30g Part material weight: 30g Part weight adjusted for yield (90%) and scrap (8%) = 30g x 1/0.9 x 1/(1-0.08) = 36.23g Part weight adjusted for yield (90%) and scrap (8%) = 30g x 1/0.9 x 1/(1-0.08) = 36.23g Cost of Polystyrene: $0.8/kg Cost of Polystyrene: $0.8/kg Material cost = g x $0.8/kg (polystyrene) Material cost = g x $0.8/kg (polystyrene) Cost = $0.0289/part B. Setup cost Unit setup cost = $200hr x 2hr/4000 parts Unit setup cost = $200hr x 2hr/4000 parts Cost = $0.1000/part

14 Unit Cost -II C. Molding Cost Molding Cost = $25/hour x 15sec/3600sec/hour = $ 0.104/molding cycle Number of Part per Cycle : 4 parts/cycle Molding Cost = $0.104 cycle/ 4 parts/cycle Cost = $ /part D. Labor cost Manpower: $20/hr Labor Cost = $20/hr x 15 sec/cycle x 1cycle/4parts x 1hr/3600 sec Cost = $ /part

15 Unit Cost -III E. Coating Costs Cost = $ /part F. Inspecting, Packing, Shipping Cost = $ /part TOTAL UNIT COST:$0.376

16 Prototype Process: FDM (Fused Deposition Modeling) Process: FDM (Fused Deposition Modeling) FDM builds parts by depositing semi-liquid thermoplastic material in ultra thin layers, one on top of the other Parts Specifications Parts Specifications Material: ABS Plastic (Acrylonitrile Butadiene Styrene)Material: ABS Plastic (Acrylonitrile Butadiene Styrene) Precision: .015’’Precision: .015’’ Parts can be drilled, sanded, painted…Parts can be drilled, sanded, painted…

17 Prototype Material Specifications P400 ABS Tensile Strenght (psi) 5000 Flexural Strenght (psi) 9500 Tensile Modulus (psi) Flexural Modulus (psi) Specific Gravity (lb/in 3 ) 0.038

18 Prototype Pro-E Drawing: 3-D

19 Prototype Pro-E Drawings: 2-D      

20 Prototype Pro-E Drawing: 3-D Dimensions of the prototype : 5.775’’: FITS IN THE PACKAGE !!!!!      

21 Testing ADD WATER  PERFECT TASTE PERFECT TASTE ADD POWDER 

22 Marketing Size of the Market Juice Beverage: 10B$US/year (NA) Juice Beverage: 10B$US/year (NA) Powder juice products: 5% Powder juice products: 5% Cost of powder juice products: 4$US Cost of powder juice products: 4$US TOTAL: 125 million units/year TOTAL: 125 million units/year Target: 30% of units sold Target: 30% of units sold SALES: 40 million units/year SALES: 40 million units/year

23 Marketing - Partners

24 Launch Timing: Summer Timing: Summer Market (1 st year): Segment of North America (12.5 million units) Market (1 st year): Segment of North America (12.5 million units) Market (2 nd year): Total North America + segment of Asia/Latin America (40 million units) Market (2 nd year): Total North America + segment of Asia/Latin America (40 million units) Market (3 rd year): Asia/Latin America (40 million units) Market (3 rd year): Asia/Latin America (40 million units)

25 A) Development Cost $ 43, Labour Salary 6Engineers$36000/year/engineer Time invested 20%$7200/engineer Total $ 43, Prototypes $ Miscellaneous $ B) Marketing cost10% of the volume of the sales Financial Projections -I

26 Financial Projections -II C) Ramp up costs $ 540, Location Rent (source: The Montreal Real Estate Page / La Page Immobilière de Montréal) Warehouse and office areas of s.f. Cost per monthRamp up 6 months $10,000$60,000 Adequation of the warehouse $40,000 Machinery and production devices Cost per machine10 machines Injection machines $ 12, $120, Molds $ 4,000.00$40, Another machinery (forklifts, etc) $100, Materials, Training & miscellaneous $180, D) Unit Production Cost $ 0.376

27 Financial Analysis Sales Revenues Unit sale price = $ 0.60 Sales Volume: 12.5 million spoons in year 2 40 million spoons in year 3 40 million spoons in year 4 Net Present Value (r = 8%) for 4 years = $ 7, 525, 000

28 1. Scheduling We need to get the product out BEFORE the summer Challenges

29 2. Manufacturing Large scale process of Litmus incorporation to plastic Challenges

30 3. Testing What is the durability of this device? Challenges

31 Lessons Learned Primary goal is to achieve best cost/quality products Primary goal is to achieve best cost/quality products CE can be used to reduce the TTM CE can be used to reduce the TTM Do tasks simultaneously Do tasks simultaneously Full team participation and involvement Full team participation and involvement

32 Lessons Learned Feedback is the key of success Feedback is the key of success Weekly meetings are mandatory Weekly meetings are mandatory Design cannot be done by s !!! Design cannot be done by s !!!

33 Lessons Learned T each E mpathize A sk questions M otivate T ogether E veryone A ccomplishes M ore There is no “I” in TEAM!

34 QUESTIONS?!? Thank You!


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