Damian Ashmead Adam Binkley Angela Huenerfauth Beth Miller Jonathan Rashidi

Ion Selective Paste Dispenser Current Dispense Process -Laser Scan to Measure Electrode Elevation -Dispense Paste using Stitch Pattern Onto Electrode -Move to Next Laser Read Location Apparent Design Flaws Stitch Pattern Excess Movement Human Interaction Outdated Control Device ········

Sponsor Goal Dispense Machine is the bottle-neck in the electrolyte test cartridge production line. Increase productivity of paste dispense process.

Project Focus Developed Top 5 Wants->Metrics Productivity – Manufacture Rate Productivity – Manufacture Rate Simplicity – Minimal Hardware Changes Simplicity – Minimal Hardware Changes Paste Quality – Stay Within Existing Tolerances Paste Quality – Stay Within Existing Tolerances Low Cost - $ Low Cost - $ Accuracy – Number of Paste Lines Within Tolerances Accuracy – Number of Paste Lines Within TolerancesInvestigation Record Video Footage of Existing Process Record Video Footage of Existing Process Analyze Time Breakdown Analyze Time Breakdown

Process Time Breakdown

Concept Selection Based Upon the Time Breakdown Total Time ~ 218 seconds Total Time ~ 218 seconds Areas of Focus: Paste Stitch Time ~ 146 seconds (67%) Paste Stitch Time ~ 146 seconds (67%) Laser Reads ~ 38 seconds (18%) Laser Reads ~ 38 seconds (18%) Initial Concepts More dispense apparatuses More dispense apparatuses Use dispense manifold Use dispense manifold Alter dispense method Alter dispense method Altering laser read process Altering laser read process Buy new dispense machine Buy new dispense machine

Concept Selection - Benchmarks Both Show Potential for Faster Dispense Methods Both Show Minimal or More Advanced Laser Scans I&J Fisnar Inc.

Project Components Project Scope Broken Down Into 2 Parts. Maximize Speed and Accuracy For Both Parts Increase Process Capacity Part #1 Alter Dispense Method Part #2 Decrease Number Of Laser Reads

Part #1 - Dispense Method Reduce Dispense Time - 16 lines of paste 5 seconds per line currently 5 seconds per line currently Increase speed while maintaining accuracy Increase speed while maintaining accuracy How Will We Accomplish This? Develop new paste dispense methods using offline test device. Develop new paste dispense methods using offline test device. “Toothpaste” method Validation Time – Video Footage Time – Video Footage Accuracy – Light Microscope Accuracy – Light Microscope

Offline Test Device

Time Results “ Toothpaste” Method – 1.4s per electrode

Accuracy Results Tolerances: 0.024” to 0.036” Paste Lines Examined with Light Microscope Max Width – 0.029” Min Width – 0.026” Max Width – 0.029” Min Width – 0.026”

Part #2 – Decrease Laser Reads Decrease Laser Read Time Reduce Number of Laser Reads Reduce Number of Laser Reads How will we accomplish this? Prove electrodes are at same height Prove electrodes are at same height Hold ceramic plates flat under vacuum Scan electrodes using CCM laser scanner Analyze data to show electrodes are at consistent elevation

Vacuum Plate Design Current Design Square Design Vacuum Area ~ 4in ” Thick Vacuum Channel Experimental Design Circular Design Vacuum Area ~ 6.75in ” Thick Vacuum Channel

CCM Laser Scan Test.. Collect Plates from Variety of Batches Good Test-bed Hold Plates in Same Position Assures Accurate Repeatable Data Collection Scan Individual Rows of Electrodes Compare Electrode Elevation Variables 1.Vacuum Plate 2.Batch Numbers

Data from multiple scans of single line were averaged. Electrodes located from graph of data. Heights averaged over each electrode in line (Six per line). Difference was calculated between maximum and minimum electrode height on plate. Laser Scan Data Analysis

Laser Scan Results Electrode Elevation Data Variation using current vacuum plate: ” Variation using experimental vacuum plate: ” Electrode Elevations Over Single Plate in Electrodes Elevation (in)

Time Reduction Analysis 218s 170s 124s

Prototype / Experiment Cost Offline Test Device$110 Hardware $60 Aluminum MIC-6 $50 Aluminum Vacuum Plates$100 Vacuum Plates Total Cost$210

Process Summary Dispense Method Decrease Dispense Time Decrease Dispense Time Maintain Accuracy Maintain Accuracy Laser Reads Decrease Laser Reads Decrease Laser Reads ACCOMPLISHED ACCOMPLISHED ACCOMPLISHED

Implementation “Toothpaste” Dispense Method “Toothpaste” Dispense Method Software Engineer – alter control code Software Engineer – alter control code Replace vacuum plate with new plate design Replace vacuum plate with new plate design Decrease laser reads to 1 per plate Decrease laser reads to 1 per plate Software Engineer - alter control code Software Engineer - alter control code Conduct further calibrations and on-line tests 2-3 months, $20,000 – $30,000

Questions?