Safety protocols

METerm Project: Reverse Engineering and Redesign220 points

Learning objectives

Engineered products are not created out of serendipity or accidental bursts of creativity. They are meticulously designed and optimized to deliver functions and features to address society’s needs and to create value for the stakeholders. In order to create successful products, your knowledge of science and technology must be guided by an understanding of the interplay between these aspects and their influence on engineering.

The objectives of this project are two:

1. Learning how to examine technical products to understand the role of customer needs, functionality, solution principles, and components in creating value for the stakeholders.

2. Learning the design tools and methods for capturing these elements in models and reports.

Teams

This is not a team project. All effort should be of the student’salone.

Safety protocol

Within this project, you may need to plug in and operate the consumer products that you examine. You may operate them only in the original condition in which they were sold and if you have the necessary training and license to operate them. Under no circumstances should you plug in or try to operate a product that has been altered or disassembled, even if partially.

Product categories

The following product categories are included in this project.

1. Consumer products, such as coffeemakers, toasters, juicers, blenders, can openers, food processors, rice cookers, electric kettles, electric shaving razors, electric toothbrushes, vacuum cleaners, clothes washers, clothes dryers, etc.Only electric and battery-operated products are allowed. Fuel-powered products are prohibited.

2. Passive products, such as dishes, water bottles, chairs, windows, toothbrushes, clocks, etc.

3. Infrastructural products, such as traffic lights, lampposts, highway signs, billboards, sidewalks, parking lots, bike racks, etc.

Project tasks

All deadlines are on Saturday midnights of the week # mentioned.

#TaskActivityDeliverable and deadlines
1Product selection10 pointsSelect one product from each category that you wish to examine (total 3). You are free to select products that are not listed as examples. All selections are pending approval by the GSAs.Find specific real-life instances of these products from the world around you. Then take multiple photographs of those objects from various angles.Select the consumer product so that you could obtain a physical copy of it for disassembly.1-page report.Your name, course section number, contact info.Three sections: one for each product. Include name, photographs, brief description (~50 words), source, location, etc.
2Obtainphysical product as benchmark10 pointsObtain a physical copy of the product selected under the consumer product category. It can be new or used, but it must be in functional condition. You will disassemble it in this project, so recognize it may not remain usable after the project.Also procure the tools that you may need for disassembly.You will use only this product for Tasks 4-15.Show the physical product to your GSA during the lab meeting.Due:lab.One-page report on the product: name, photo, source, price. (10)Due:
3Customer and end-user needs30 pointsIdentify the customer needs and end-user needs for each of the three products using the tools and methods taught in class (checklist).Customer and end user needs document. At least ten needs per product is expected. No page limit.Due:
4Subtract and operate20 pointsUse the subtract and operate procedure (SOP) taught in class to disassemble the product, take photographic record, and uniquely name the components and subassemblies.Photographic record of the SOP, step numbers, and component names.Due:
5Assembly tree10 pointsBuild a tree structure, showing how the components are collected into the subassemblies and they are collected into the product.Assembly tree. Make the model as detailed as you can, based on your SOP results.Due:
6Connectivity model10 points(extra credit)Build a graph, as shown in class, showing how the components and subassemblies areconnected to each other and the types of joints.Connectivity model. Make the model as detailed as you can, based on your SOP results.Due:
7Function models20 pointsIdentify the functions of the components and subassemblies in the verb-noun format. Then connect them to form a function tree and a function graph for the whole system.Individual subfunctions, Function tree, and function graph for the components and the whole system.Due
8Design requirements15 pointsReexamine the customer and end-user needs. Update the table by adding new needs and editing the existing ones. (5)Create a new SMART table to capture the design requirements from all other stakeholders. (10)Updated customer and end-user needs. Design requirements from all stakeholders.Due:
9Value analysis10 pointsBased on the detailed requirements, perform a value analysis of the product using the methods shown in class.Value analysis of the benchmark product.Due:
10R-F mapping10 pointsUsing a design structure matrix (DSM) as shown in class, describe how the requirements and needs are connected to the functions of the device.Requirements to function mapping using a DSM.Due:
11F-C mapping10 pointsUsing a design structure matrix (DSM) as shown in class, produce a mapping between the functions of the product and the physical components.
12Morphological analysis10 pointsUse a morph chart to develop multiple working principles for each major function of the product.Morphological analysis of the benchmark product using a morph chart.Due
13Concept presentation20 pointsCompose at least one new product variant from the morphological analysis.Present your new concept in form of freehand sketches with labels. (10)Write a short paragraph on how the product will work, how it is different from the benchmark, and calculate its value. (10)Freehand sketch and text (Rube Goldberg style) for the new variant design.Due:
14CAD models20 pointsCreate CAD models of components and assemblies as approved by your GSA, from the benchmark product or your new concept.Creo models for parts and assemblies (*.prt) and their screenshots in document format (*.docx).Due
15Final report25 pointsAssemble the results of the entire project in a report form. All deliverables should be updated based on feedback received from the GSAs. The deliverables from the project should become different sections. All external media such as sketches, photographs, hand calculations, etc. should be scanned and pasted into the document using the same format and template as the remainder. (10)Write a one-page reflective essay summarizing what you learned from this project, in as much detail as you can.(10)Write a brief paragraph on how we could improve this experience for future students. (5)Final report.

Professional formatting

1. All submitted document files should be in DOC or DOCXformat compatible to MS Word.

2. Paper-based content such as freehand sketches and hand calculations should be scanned in to the document file. Spreadsheets must be converted into tables in the document. Supplemental files such as images or CAD files can be submitted in their native formats such as JPG or PRT, but they must also be captured as screenshots within the document format.

3. All documents including the final report must be written using the same template so that they look uniformly formatted. Templates, styles, cross referencing, and citation formats must be used appropriately to ensure uniformity, professional appearance, and legibility.

4. The font size should be comparable to 11 point Calibri in print, even though the files are submitted online. Fonts that are too small to read or unnecessarily large will cost points.

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