Lucky Charms Marbit Separation Critical Design Review May 16, 2003 Gregory Dickman Roy Mitchell...

Lucky Charms Marbit SeparationCritical Design Review

May 16, 2003

Gregory Dickman

Roy Mitchell

Karen Palumbo

George Simmonds

Scott Walker

Andy Wang

© 2002 Lucky Charms Senior Design Team 2

Agenda

• Background• Objective• Intricacies and Constraints• Deliverables• Concept Development• Preliminary Testing• Concept Selection• Fabrication• Final Testing• Proposed Design

© 2002 Lucky Charms Senior Design Team 3

Background

• Lucky Charms Cereal Consists of 2 main components, Marbits and Base Cereal.

• Currently General Mills employs an offline check to ensure the marbit percentage per box.

• The process is performed by separating marbits by hand.

• The marbits are discarded after this process, and the base cereal is utilized for further testing.

© 2002 Lucky Charms Senior Design Team 4

Objective

• General Mills requested that we develop a device, method and procedure to replace the current separation method.

• The process must…– Be statistically repeatable– Be Accurate within 1% of the current method– Be robust and straightforward– Be completed in 5 minutes or less by 1 lab technician– End with sample of base cereal that can be crushed and

used for further testing

© 2002 Lucky Charms Senior Design Team 5

Intricacies and Constraints

• Marbits and base cereal are approximately the same size, weight and density.

• Special promotional marbits are often added to the cereal.

• A budget of $1500 was allotted to the group for research, testing and prototype.

© 2002 Lucky Charms Senior Design Team 6

Concept Development

• A series of concepts ideas were developed, a few were chosen for further analysis.

Concept Development

© 2002 Lucky Charms Senior Design Team 7

Preliminary Testing

• Tests were performed in the chemistry lab.

• Simple prototypes were assembled in order to assess the feasibility of ideas.

• Ideas were analyzed and synthesized to find optimal design.

• Two most feasible designs were chosen to be fabricated as prototypes.

© 2002 Lucky Charms Senior Design Team 8

Concept Selection

Heat Tray design Pin Press design

Common components were utilized to enable both designs to be fabricated under the allotted budget.

© 2002 Lucky Charms Senior Design Team 9

Fabrication

100% Team Fabricated (Except Heating Element)

Similar Designs

Identical Sub-Frames

Modifications Made to Press Plates

© 2002 Lucky Charms Senior Design Team 10

Pin Press Testing

© 2002 Lucky Charms Senior Design Team 11

Heat Tray Testing

© 2002 Lucky Charms Senior Design Team 12

Heat Tray Testing (Destruction)

198 g separated by hand198 g separated with heat tray prototype

Base cereal was tested for Vitamin C and Moisture

Hypothesis tests were conducted and showed no

significant difference

5 boxes of cereal tested

Base cereal was tested for Vitamin C and Moisture

© 2002 Lucky Charms Senior Design Team 13

Heat Tray Testing (Temperature)

• Various studies performed to determine optimal temperature of hot plate and pressure time.

• Plate surface varies within +/- 10 degrees Celsius due to crude dial and nature of heating element.

© 2002 Lucky Charms Senior Design Team 14

Heat Tray Testing (Repeatability)

• A gage study was performed to determine differences between operators, within operators and between batches.

• Difficulties resulted due to the non-uniform distribution and randomness of the hot plate.

© 2002 Lucky Charms Senior Design Team 15

Heat Tray Testing (Time)

• Based on time study analysis, it is estimated that separation would take 6.54 min with a hot plate of the same effectiveness.

• Based on 100% accuracy (error times included in study)

• With incorporation of a higher caliber hot plate, it estimated error rates can be reduced by approximately 50% yielding a total process time of 4.80 minutes.

© 2002 Lucky Charms Senior Design Team 16

Proposed Design

• Based on a 12 by 24 inch proportional controlled hot plate

© 2002 Lucky Charms Senior Design Team 17

Budget

Part Description Supplier Part Number Qty Price SubtotalHeat Element Aluminum Hot Plate McMaster- Carr 3271K14 1 $216.11 $216.11Springs Precision Compression Springs McMaster- Carr 94340K142 1 $9.40 $9.40Plate Insert Perforated Sheet McMaster- Carr 9232T181 1 $36.36 $36.36Bearings Linear Ball Bearing McMaster- Carr 6483K13 8 $25.26 $202.08Shafts Precision Ground Shafts Metal Supermarkets n/a 1 $28.62 $28.62Base and Top Aluminum Plate (12"x12") Metal Supermarkets n/a 3 $95.00 $285.00Tray Aluminum Plate (8"x8") Metal Supermarkets n/a 1 $21.00 $21.00Foam Foam McMaster-Carr 8882K1 1 $1.70 $1.70Pins Spring Pins Donated n/a 900 $0.00 $0.00Assembly Misc Nuts and Bolts (estimate) Shop / Local Retailer n/a 1 $25.00 $25.00

TOTAL $825.27

Budget (Heat Tray and Pin Press Design Prototypes)

Part Description Supplier Part Number Qty Price SubtotalHeat Element Aluminum Hot Plate Wenesco HP 1224 D 1 $1,450.00 $1,450.00Bearings Linear Ball Bearing McMaster- Carr 6483K16 4 $53.30 $213.20Shafts Precision Ground Shafts Metal Supermarkets 60345K45 1 $145.54 $145.54Raw Material Aluminum Plate MSC 2255800 1 $224.84 $224.84Raw Material Aluminum Plate MSC 9425455 1 $17.52 $17.52Foam Foam McMaster-Carr 8882K1 2 $1.70 $3.40Assembly Misc Nuts and Bolts (estimate) Shop / Local Retailer n/a 1 $10.00 $10.00

TOTAL $2,064.50

Estimated Budget for Proposed Full Scale Model

© 2002 Lucky Charms Senior Design Team 18

Questions