1. Engineering Design Process GK12 Module 6 th Grade Science Traci Abney

2. Module Overview Encourages students to think like engineers by following a design process common throughout engineering The Design Process 1.Define the problem 2.Develop Ideas 3.Make a Sketch 4.Do some Math 5.Build 6.Test 7.Deliver

3. Module Overview Introduction to engineering Beam building activity Catapults Engineering drawing Kanban paper airplane Uranium transport vehicle design competition

4. Kanban Paper Airplane Activity Using engineering to solve manufacturing problems Objective: Students find optimal method to produce paper airplanes –Quantity –Cost –Quality Kanban(Japanese) means sign or placard, and comes from the cards used on assembly lines to signal that parts are needed. “Pull” manufacturing is a visual replenishment of goods, where only is produced what is demanded by the next work center.

5. Learning Objectives Students should be able to: Apply engineering methods to manufacturing Understand a “pull” manufacturing process Use engineering concepts to design an optimal process

6. Procedure (Before Activity) Have stacks of about 75 pages of scrap paper per group ready Prepare a correctly completed paper airplane example as shown below Split the class into groups of about 8-10 students

7. Procedure (With Students) 1.Number off students 1-7 in each group (manufacturing company) 2.Demonstrate how to build the paper airplane 3.Ask the students to perform their task as fast as they can for 5 minutes 4.After the 5 minutes, count how many airplanes each group has completed 5.Regroup and promote discussion about what could be done to make the process more efficient

8. Important Discussion Topics Goal is to create the most airplanes, at the lowest cost, with good quality Introduce students to pull manufacturing –Reduces waste and creates a smoother flowing assembly line Teamwork, efficiency, and bottlenecks –An assembly line where students are in order of folds is quickest –Extra students should be doubled up on the harder folds because they tend to take longer Some students were sitting idle while others were backed up with inventory (bottlenecks) –Entire group works together to create a final product –Waste should be minimized because every time a material is scrapped it costs the company money –Quality is vital because if the plane cannot fly, the company will lose both time and money Scrapped planes

9. 6.Separate and rerun activity using pull manufacturing 7.Students can only perform their task when there are no planes waiting for the next person in line to fold (absence of a plane can be considered the Kanban signal) 8.Implement any other ways discussed to increase the efficiency of the process and have a quality check upon completion 9.Again give the groups 5 minutes to produce the most airplanes 10.After the 5 minutes, count the number of paper airplanes produced and the number of unfinished airplanes or scrapped airplanes Procedure (With Students) Fold 1Fold 2Fold 3Fold 4 Fold 5Fold 6Fold 7 Quality Check Kanban Signal

10. Procedure (With Students) 11.Use a spreadsheet (shown below) to calculate a representative profit made by each company (group of students) Each finished airplane is worth 5 million dollars Wasted material costs the company 3 million dollars 12.Regroup and discuss the differences in the two systems and how the improvements worked

11. Questions? Contributors: Adam Nathan, Don Knobbe, Lisa Picker