1. System Design Review P15420: Rochester Roots Lip Balm/Hand Salve Production Line Ohimai Aisiku Stephanie Bloechl Kenneth Costello Jessica Dill Jeff Lariviere

2. Agenda  Background  Current Process  Problem Statement  Customer and Engineering Requirements  Benchmarking  System Analysis  House of Quality  Functional Decomposition  Feasibility Analysis  Concept Development  Morphological Chart  Concepts Considered  Pugh Chart  Concept Selected  Engineering Analysis  Risk Assessment  Test Plan  Project Plan 29/30/2014P15420 - System Design Review

3. Background 39/30/2014P15420 - System Design Review

4. Current Process 49/30/2014P15420 - System Design Review

5. Problem Statement  Current State  Small batches made with minimal student involvement  Desired State  Students active in as many steps of the process as possible  Faster process able to keep up with demand  Constraints  Safe process for students to use  Easy to clean 59/30/2014P15420 - System Design Review

6. Problem Statement  Deliverables  Straining system  Heating and pouring system  Capping and labeling process  Instruction and Maintenance Manual  Stakeholders  Rochester Roots  Jan McDonald  Montessori School and students  RIT and our MSD team 69/30/2014P15420 - System Design Review

7. Action Items from last review  Update Engineering requirements with specifics - quantify  Clean up requirements to look more professional  Customer requirements importance scale  Add Benchmarking 79/30/2014P15420 - System Design Review

8. Customer Requirements Customer Rqmt. # CategoryImportanceDescription CR1Teaching1Follow Healthy Urban Food System Model CR2Teaching1Maximizes STEM input CR3Teaching2Involves student in each step of process CR4Physical Constraints3Fit in allotted classroom space CR5Physical Constraints1Maximizes use of recycled material CR6Physical Constraints2Portable CR7Ease of Use3Easy to clean CR8Ease of Use2Easy to set up and tear down CR9Diversity1For ages 8 and up CR10Diversity1Can be used at multiple schools and locations CR11Cost3Within budget CR12Cost1Multipurpose CR13Cost3Financially self-sustaining CR14Safety3School safe CR15Safety3Sanitary 1: preference only 2: nice to have 3: must have

9. Customer Requirements Customer Rqmt. # CategoryImportanceDescription CR16Safety3Too large to choke on (based on safety standards) CR17Engage Students1Fun CR18Engage Students1Team Oriented CR19Durable2Resistant to vandalism CR20Durable2Long product life CR21Durable2Easy to repair CR22Durable2Low maintenance CR23Product Creation3Makes usable product CR24Product Creation2Adjusts to different ingredients CR25Product Creation2Adjusts to different containers CR26Process Related2Process is quick CR27Process Related3Can heat beeswax to liquid CR28Process Related3Can strain product to mostly particulate-free CR29Process Related2Dispensing of hot liquid is automated 1: preference only 2: nice to have 3: must have 99/30/2014P15420 - System Design Review

10. Engineering Requirements rqmt. #SourceEngr. Requirement (metric) Unit of Measure Marginal ValueIdeal ValueComments/Status Test (how are you going to verify satisfaction) S1PRPFootprint Sizesq ft12'x13' Measuring Tape S2PRPWeightlb5030 Scale S3CUSTOMERElapsed Process Timehr64 Timer S4CUSTOMERYield Size Capabilityoz130200 Measure Output S5PRPAdjustable Height Rangeft2-3.5 Measuring Tape S6PRPPrototype Cost$800 S7PRPManufacturing Cost$ S8CUSTOMERHeating Element Temperature Range°F140-160 Thermometer S9CUSTOMERNumber of Students Involvedstudents20 Observation S10PRPTime to cleanmin3015 S11CUSTOMERPercentage of single use material that is compostable%50%95%+ S12CUSTOMERDegree of automation of pouring processdegreePartially automatedHighly automated S13PRPStorage Sizesq ft6'x6' fits in back of truckMeasuring Tape S14PRPBreaktown/set up timemin<60<30 Timer S15CUSTOMER% acceptable products based on oz%90%95% Scale/Measure Output S16PRPMaximum particle size after strainingin0.01"0.005" Smallest strainer mesh S17PRP Minimize student contact with heating source/hot liquidsbinaryN/A S18CUSTOMERDegree of automation of capping processdegreePartially automatedHighly automated S19PRPNo parts smaller than lip balm capin0.61" x 0.67"

11. Benchmarking Benchmark parametersCurrent Product Martha Stewart Homemade lip balmCommerical ChapstickBurt's Bees Ingredients 2 cups infused almond oil 4 oz beeswax 4 tsp honey 10-15 drops vanilla fragrance oil 3 teaspoons grated beeswax 5 teaspoons oil (carrier, sunflower, castor, or jojoba) 6 or 7 drops essential oil 1 teaspoon honey camphor beeswax menthol petrolatum phenol vitamin E aloe oxybenzone sunflower seed oil coconut oil beeswax flavor castor seed oil list continues Shelf life6 months does not expire suggested use within 1 year should be good for 3 years suggest use within 1 year Batch Size20.67 oz1.33 oz continual666K oz Heating apparatuscrockpotdouble boilergiant pot Ease of Cleaning very difficult, scrap out remaining beeswax then run through industrial dishwasher use very hot water to clean off beeswax mixtures continuous process, cleaning not explained Power Sources requiredplug for crockpotstovecommercial plant

12. System Analysis 129/30/2014P15420 - System Design Review

13. S1S2S3S4S5S6S7S8S9 S10S11S12S13S14S15S16S17S18S19 House of Quality footprint size weight elapsed process time yield size capability adjustable height range prototype cost manufacturing cost heating element temperature range number of students involved time to clean % of single use material that is compostable pouring system is automated Storage Size breakdown/set up time % acceptable products visual - is product clear after straining minimize student contact with heating source/hot liquids capping is automated avoid choke hazards CR1Follow Healthy Urban Food System Model x CR2Maximizes STEM input x CR3Involves student in each step of process x CR4Fit in allotted classroom space x CR5Maximizes use of recycled material x CR6Portable xx x CR7Easy to clean x CR8Easy to set up and tear down x CR9For ages 8 and up x x CR10Can be used at multiple schools and locations x x CR11Within budget xx CR12Multipurpose x CR13Financially self-sustaining x x CR14School safe x CR15Sanitary x x CR16Too large to choke on (based on safety standards) x CR17Fun x x CR18Team Oriented x CR19Resistant to vandalism x CR20Long product life x CR21Easy to repair x CR22Low maintenance x x CR23Makes usable product x x CR24Adjusts to different ingredients x CR25Adjusts to different containers x CR26Process is quick x CR27Can heat beeswax to liquid x CR28Can strain product to mostly particulate-free xx CR29Dispensing of hot liquid is automated x

14. Functional Decomposition Make Lip Balm/Hand Salve Gather Ingredients Infuse OilPick PlantsDry Materials Buy Ingredients Strain Oil Combine Ingredients Measure Ingredients Heat Ingredients Stir Ingredients Regulate Temperature Add Fragrance Pour into containers Secure Containers Fill Containers Measure amount Dispense Liquid Cool Liquids Cap Containers Label Containers Clean Product Line Clean Heating Element Clean Pouring Element 149/30/2014P15420 - System Design Review

15. Feasibility Analysis: How much can we improve the time to melt beeswax? 15P15420 - System Design Review

16. Feasibility Analysis: Extrapolating to a full batch… Conclusion: 16P15420 - System Design Review

17. Feasibility Analysis: Engaging  Pick plants - Yes  Students currently pick the plants  Dry materials - Yes  Students can place them on drying rack or in jars  Strain - Yes  Students can pour liquid into straining system, may require some help  Measure - Yes  Students can measure wet and dry ingredients  Heat - No  Heating system and hot parts will be insulated  Secure containers - Yes  Students can place lip balm containers in rack Students can be at least partially involved in 9 out of the 11 steps of the process.  Dispense liquid - Yes  Students can be at least partially involved as long as pouring system is insulated  Cool containers - No  Students must wait for liquid to cool  Cap containers - Yes  Students can use spring loaded capping system  Label containers - Yes  Students currently label containers  Cleaning - Yes  Students can clean parts, but may not be necessary 17

18. Feasibility Analysis: Safety vs. Speed  Assumptions  Increasing cooking time, higher heat  Increasing automation, less contact time  Solution:  Prototyping  By creating the process, we can see where the holes in the process where the students can be exposed to safety risk  Increasing automation could lead to other safety risks, such as fingers being caught inside the automatic capping system 189/30/2014P15420 - System Design Review

19. Feasibility Analysis: Process Time Current Process Process Time (min) Marginal ER Process time = 360 mins Ideal ER process time = 240 mins Realistic Target %reduction from original required time reduction to meet requirement 0.8890.593 straining oil1513.38.9150 heating oil/beeswax mixture 180160.0106.77558.33 filling containers120106.771.16050 cooling containers3026.717.8300 labeling containers6053.335.6600 Total:405360240

20. Feasibility Analysis: How to effectively dispense heated liquid from heating mechanism without contamination?  Assumptions:  Must be able to fill lip balm and hand salve containers  Must not overflow containers  Must minimize hand contact with top of containers.  Solution:  Prototyping  Create different attachments for both lip balm and hand salves that fit over the nozzle attached to the engineered crockpot that will include a spacer to allow for the overflowing of liquid and a cap to regulate the amount of overflow. 209/30/2014P15420 - System Design Review

21. Concept Development 219/30/2014P15420 - System Design Review

22. Morphological Chart 229/30/2014P15420 - System Design Review

23. Morphological Chart cont. 239/30/2014P15420 - System Design Review

24. Morphological Chart cont. 249/30/2014P15420 - System Design Review

25. Concepts Considered CurrentConcept AConcept BConcept C Functions Pick plantsStudents BuyStudents How to dry ingredientsLet sitDrying rackPlace in jarSpread on table Determine source of heat for ingredients Natural light Heat lampNatural light Strain the oilTiered straining Cheese clothMultiple strainers Measuring the dry ingredientsWeigh Measuring cupWeigh Measuring the wet ingredientsMeasuring cupBeakerGatorade cooler with fill lineMeasuring cup Heating the ingredientsCrockpotEngineered crockpotCrockpotDouble boiler Secure containersTwo planks of woodTray with holesTwo planks of woodChuck Adding fragranceManual Automated Dispensing liquidPipetteEngineered crockpotPipettePump Cooling containersLet sit FanWater bath Capping containersManualPen dispenserVacuum pressureManual Labeling containersManual Tape dispenser Roll container over label to apply adhesion force Cleaning heating elementSoap and waterBeeswax proof materialPot linerBeeswax proof material Cleaning pouring elementSoap and water DisposeBeeswax proof material

26. Pugh Chart Concepts CurrentABC Selection Criteria safety DATUM +S- process speed+++ easy to clean-++ ease of use++- engaging+S+ cost--- simplicity to build--- sustainabilityS-+ low maintenance--- container security+-+ repeatability+SS yield sizeSS- amount of automation+++ Sum + 's 746 Sum 0's 241 Sum -'s 456

27. Pugh Chart Concepts CurrentABC Selection Criteria safety- DATUM -- process speed--- easy to clean+++ ease of use--- engaging--S cost+++ simplicity to build+++ sustainability--+ low maintenance++S container security--S repeatability--S yield sizeSS- amount of automation--- Sum + 's4 44 Sum 0's1 14 Sum -'s8 85

28. Pugh Chart Concepts CurrentABC Selection Criteria safetyS+ DATUM - process speed-++ easy to clean--- ease of use-+- engagingS+S cost+-- simplicity to build+-S sustainability+++ low maintenance+-- container securityS++ repeatabilityS++ yield sizeSS- amount of automation-++ Sum + 's48 5 Sum 0's51 2 Sum -'s44 6

29. Pugh Chart Concepts CurrentABC Selection Criteria safety+++ DATUM process speed--- easy to clean--+ ease of use-+- engagingSS- cost+++ simplicity to build+-+ sustainability-SS low maintenance+S+ container security-S- repeatabilityS++ yield size+++ amount of automation-+- Sum + 's567 Sum 0's241 Sum -'s635

30. Concept Refinement  Concept A looked best from Pugh chart  Few changes made to make better product  Measuring system  Addition of stirring mechanism and thermometer  Capping Technique  Change to beeswax resistant material – easier to clean Functions Pick plants How to dry ingredients Determine source of heat for ingredients Strain the oil Measuring the dry ingredients Measuring the wet ingredients Heating the ingredients Secure containers Adding fragrance Dispensing liquid Cooling containers Capping containers Labeling containers Cleaning heating element Cleaning pouring element Concept A’ Students Drying rack Natural light Tiered straining Weigh Measuring Cup Engineered crockpot with stirring arm and thermometer Tray with holes Manual Tube from pot to filling nozzle Let sit Pen dispenser Manual Beeswax proof material Bottle brush and hot water/soap 309/30/2014P15420 - System Design Review

31. Plants are grown in school garden. Students pick the plants and place them on the drying rack. After plants are dried, students mix oil and plants in a large jar. Using a stackable strainer, filter plant material out of oil. Selected Concept: Pre-Cooking Procedure 319/30/2014P15420 - System Design Review

32. Selected Concept: Measuring the ingredients Measure strained oil using measuring cups. Use triple beam balance to weigh beeswax. 329/30/2014P15420 - System Design Review

33. Selected Concept: Heating the Mixture Combine ingredients in homemade crockpot. Heat mixture to at least 140° - do not allow to exceed 160°. Use automatic stirring arm to keep liquid from scalding. Add fragrance once mixture becomes homogenous. Continue to monitor temperature. 339/30/2014P15420 - System Design Review

34. Selected Concept: Pouring the solution into the containers. Open crockpot spigot to allow liquid to flow through tubing to nozzle. Select nozzle setting based on product type (lip balm or hand salve). Place containers (lip balm or hand salve) into tray holes to secure them. Fill containers. 349/30/2014P15420 - System Design Review

35. Allow to sit for 30 minutes or until cool to the touch. For lip balm: use spring loaded capper to place cap. For hand salves: cap will be placed by hand. Place labels on finished product. Selected Concept: Finalizing the product 359/30/2014P15420 - System Design Review

36. Selected Concept: Cleaning the equipment The homemade crockpot will be made out of a beeswax resistant material providing an easier clean up The tube and nozzle will need to be run through with hot water to prevent beeswax buildup. 369/30/2014P15420 - System Design Review

37. Engineering Analysis Needed  Wattage required  Want to decrease process time but cannot boil beeswax/oil mixture  Automation  Research professional automated dispensing systems  Beeswax resistant materials  Glass (Pyrex), stainless steel, ceramic, Teflon coating  Does ice or heat make it easier to remove residual wax?  System layout  Ergonomic and functional layout of system that allows for simple flow of product through system  Max Batch Size  Batch size cannot exceed amount of secured containers available 379/30/2014P15420 - System Design Review

38. Risk Assessment  Likelihood Scale:  1 - unlikely to happen  2 – could conceivably happen  3 – very like to happen  Severity Scale:  1 – impact very minor but will cause extra work  2 – noticeable impact; unmet Engineering requirements  3 – severe impact; not able to deliver product that meets customer needs 389/30/2014P15420 - System Design Review

39. Risk Assessment IDRisk ItemEffectCause Likelihood Severity Importance Action to Minimize Risk 1Overheating of productProduct boils and is unusable Insufficient temperature regulation 236 Measure temperature throughout process, adjust heat source as needed 2Over Budget Cannot build prototype that matches design Grants do not get funded224 Have functionally similar backup designs, track spending throughout project 3Student Burns Themselves Student needs to visit nurse, parents may be upset Insufficient barrier between students and heating element 133 Safeguard heating elements and keep students from hot liquids 4Conflicting Team Schedules Late completion of deliverables, team conflict Overlap in class schedules, other class work 224 Maintain group meeting times, assign individual work as needed 5 Product does not match Customer Requirements Customer is upset, project does not get used Insufficient budget, unrealistic expectations 122 Maintain open line of communication with customer, obtain approval at project milestones

40. Risk Assessment IDRisk ItemEffectCause Likelihood Severity Importance Action to Minimize Risk 6 Failure of Automated Systems Certain processes need to be done manually or cannot be done Poorly designed systems, user error 326 Include repair instructions in documentation 7Conflicts with Customer Customer is upset, expectations are not met Unrealistic expectations, poor communication 133 Maintain open line of communication with customer, obtain approval at project milestones 8 Necessary Technology not available for budget allocation Level of automation does not meet customer expectation Insufficient budget, unrealistic expectations 212 Have functionally similar backup designs with safety improvements to make up for lack of automation 9 Insufficient knowledge to create automated system Level of automation does not meet customer expectation Team members have not taken appropriate classes 212 Meet with professors to ascertain necessary information 10 Petals/leaves in final product Product is not sellable or undesirable Insufficient straining, user error 133 Ensure tiered straining mechanism meets engineering requirement for particle size

41. Risk Assessment IDRisk ItemEffectCause Likelihood Severity Importance Action to Minimize Risk 11 Ingredients are measured incorrectly Product is not sellable or undesirable User error, poor implementation of measuring tools 111 Provide clear instructions and easy to use measuring tools 12 System inadequately cleaned Product is not sellable or undesirable User error, difficult to clean equipment 236 Provide easy to clean equipment, ensure cleaning methods are properly documented 13 Over-pouring or miss-pouring of product Product is unusable or additional time required to clean outside of containers Poor implementation of pouring system, user error 212 Create robust and repeatable pouring system 14 Contamination of product during capping Product is unsanitary, unsellable Student gets hands in product, capping system not used properly 236 Create easy to use and repeatable capping system

42. Test Plan Outline  Create our own batch  Check for pitfalls in selected concept  Compare different materials for ease of cleaning  Test designed process  Ensure usable by students  Capping Methods  Pouring methods  Straining efficiency 429/30/2014P15420 - System Design Review

43. Schedule

44. Questions? 449/30/2014P15420 - System Design Review