Automatic Dental Bur Automatic Dental Bur LoaderLoader

NCDADental Products Development Group

Design Concept Design Concept ReviewReview

Team 99.06:Team 99.06:Jason Dickey, Greg Frantz,Jason Dickey, Greg Frantz,

Allison Martin, Nancy MeyerAllison Martin, Nancy Meyer

Sponsor:Sponsor:Dave Berezowski, Dave Berezowski,

Dentsply/CaulkDentsply/Caulk

Advisor:Advisor:Dr. Jim GlanceyDr. Jim Glancey

1 December 19981 December 1998

Mission & ApproachMission & Approach

MissionMission::To develop a cost effective dental bur automatic loading and unloading device, while fulfilling as many of the customer and team wants as possible, within the specified time and budget constraints.

ApproachApproach::Using the SSD process, we will determine our customers, their wants and constraints, associated metrics, and benchmarks, which will lead into the conceptual design and prototyping of the automatic dental bur loader.

Presentation OverviewPresentation Overview

Project Description & BackgroundProject Description & Background Customers -- Constraints & WantsCustomers -- Constraints & Wants Wants -- Metrics -- Target ValuesWants -- Metrics -- Target Values Concept Generation & SelectionConcept Generation & Selection Final Concept DetailsFinal Concept Details Overview of Project ManagementOverview of Project Management

Project Description & Project Description & BackgroundBackground

Automate Unload / Load Cycle of Bur Automate Unload / Load Cycle of Bur GrinderGrinder

Currently 3 Operators Per Shift to Currently 3 Operators Per Shift to Manually Unload / Load 27 GrindersManually Unload / Load 27 Grinders

Looking to Reduce Labor Costs Through Looking to Reduce Labor Costs Through Complete Automation of GrindersComplete Automation of Grinders

Estimate Only One Operator Per Shift Will Estimate Only One Operator Per Shift Will be Required for the Automated Processbe Required for the Automated Process

Economical if Firm Budget is MaintainedEconomical if Firm Budget is Maintained

CustomersCustomers

Dave BerezowskiDave Berezowski• Bur Area ManagerBur Area Manager

Gene AnthonyGene Anthony• Grinder MechanicGrinder Mechanic

Dave BrownDave Brown• ManagerManager

Kevin BarkleyKevin Barkley• Grinder OperatorGrinder Operator

Brian HuntingtonBrian Huntington• Safety & HAZMAT Safety & HAZMAT

OfficerOfficer James AgnewJames Agnew

• ISO AuditorISO Auditor Brian MelonakisBrian Melonakis

• General ManagerGeneral Manager Dr. Donald BondDr. Donald Bond

• DentistDentist

Project ConstraintsProject Constraints

Must Be Under BudgetMust Be Under Budget Must Load 4 Bur FamiliesMust Load 4 Bur Families Quality of Burs Produced Must Not Quality of Burs Produced Must Not

DecreaseDecrease Cycle Time Must Not IncreaseCycle Time Must Not Increase Must Have Operation InterlockMust Have Operation Interlock Must Perform Design & Equipment Must Perform Design & Equipment

ValidationValidation Voltage and Air Pressure RequirementsVoltage and Air Pressure Requirements

Top Ten Wants & Related Top Ten Wants & Related MetricsMetrics

Minimize Per Unit CostMinimize Per Unit Cost• Prototype CostPrototype Cost• Per unit cost Per unit cost

Simplify operation of grinderSimplify operation of grinder• Number of steps needed by operatorNumber of steps needed by operator

Increase consistency of operationIncrease consistency of operation• Percentage of incorrect loadsPercentage of incorrect loads• Ratio of interlocks to positionsRatio of interlocks to positions

Easy to Adjust, Diagnose, and Repair Easy to Adjust, Diagnose, and Repair ProblemsProblems• Number of status Indicators (amount of Number of status Indicators (amount of

feedback)feedback)• Completeness of documentation and drawingsCompleteness of documentation and drawings

Minimize Unscheduled Down TimeMinimize Unscheduled Down Time• Cycles between FailureCycles between Failure• Completeness of documentation and drawingsCompleteness of documentation and drawings• Ratio of interlocks to positionsRatio of interlocks to positions

Comply with RegulationsComply with Regulations• Noise LevelNoise Level• Completeness of documentation and drawingsCompleteness of documentation and drawings

Reduce bur Production CostReduce bur Production Cost• Number of steps needed by operatorNumber of steps needed by operator

Complete DocumentationComplete Documentation• Completeness of documentation and drawingsCompleteness of documentation and drawings

Match Caulk Engineering PhilosophyMatch Caulk Engineering Philosophy• % of parts from Standard Vendors or made in house% of parts from Standard Vendors or made in house

Decrease Bur Unloading / Loading Cycle TimeDecrease Bur Unloading / Loading Cycle Time• Unload/Load Cycle TimeUnload/Load Cycle Time

Metrics & Target ValuesMetrics & Target Values

Prototype Cost . . . . . . . . . . . . . . . . . . . . . . . . . . < Prototype Cost . . . . . . . . . . . . . . . . . . . . . . . . . . < $25,000$25,000

Per unit cost. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Per unit cost. . . . . . . . . . . . . . . . . . . . . . . . . . . . . < $8,000 < $8,000

Number of steps needed by operator. . < 7Number of steps needed by operator. . < 7 Percentage of incorrect loads . . . . . . . . . < 0.02%Percentage of incorrect loads . . . . . . . . . < 0.02% Ratio of interlocks to positions . . . . . . . . = 1/1Ratio of interlocks to positions . . . . . . . . = 1/1 Number of status Indicators . . . = # of IndicatorsNumber of status Indicators . . . = # of Indicators

Metrics & Target Values, Metrics & Target Values, cont.cont.

Completeness of documentation Completeness of documentation and drawings . . . . . . . . . . . . . . . . . . . . . . . . = 100%and drawings . . . . . . . . . . . . . . . . . . . . . . . . = 100% Cycles between Failure . . . . . . . . . . . . . > 250,000Cycles between Failure . . . . . . . . . . . . . > 250,000 Noise Level . . . . . . . . . . . . . . . . . . . . . . . . . . . < 80 dBNoise Level . . . . . . . . . . . . . . . . . . . . . . . . . . . < 80 dB % of parts from Standard Vendors % of parts from Standard Vendors or made in house . . . . . . . . . . . . . . . . . . . . .= 100%or made in house . . . . . . . . . . . . . . . . . . . . .= 100% Unload/Load Cycle Time . . . . . . . . . . . . . < 13 Unload/Load Cycle Time . . . . . . . . . . . . . < 13

secondsseconds

System BenchmarksSystem Benchmarks

Yamaha Automatic LoaderYamaha Automatic Loader Machine CentersMachine Centers Current Manual LoadingCurrent Manual Loading

ProcessProcess

Initial ConceptsInitial Concepts

Linear Screw DriveLinear Screw Drive Swing ArmSwing Arm Linear PistonLinear Piston Eliminate Head Unit -- Grippers OnlyEliminate Head Unit -- Grippers Only Robotic ArmRobotic Arm Four-Bar MechanismFour-Bar Mechanism

Initial Concepts, cont.Initial Concepts, cont.

Replace Steady Rest with GrippersReplace Steady Rest with Grippers MonkeyMonkey Rear Load Push RodRear Load Push Rod Rear Load Chain DriveRear Load Chain Drive Top LoaderTop Loader Conveyor BeltConveyor Belt

Initial Iteration of Initial Iteration of SelectionsSelections

Linear Piston ArmLinear Piston Arm

Linear Lead Screw Drive ArmLinear Lead Screw Drive Arm

Swing ArmSwing Arm

System FunctionsSystem Functions

Bur DeliveryBur Delivery

Collet ControlCollet Control

Steady Rest Steady Rest ControlControl

Bur TransferBur Transfer

Type of GrippersType of Grippers

Final Bur StorageFinal Bur Storage

Control SystemsControl Systems

Functional BenchmarksFunctional Benchmarks

Collet ControlCollet Control• Pneumatic PistonPneumatic Piston• Pneumatic ScrewPneumatic Screw• Electro MagnetElectro Magnet• Electro Servo MotorElectro Servo Motor• Pneumatic Lever ArmPneumatic Lever Arm

Final Bur StorageFinal Bur Storage• BasketsBaskets• x-y Indexed Trayx-y Indexed Tray

Type of GrippersType of Grippers• Pneumatic Grippers Pneumatic Grippers

& Actuators& Actuators• Magnetic “Grips”Magnetic “Grips”• Vacuum “Grips”Vacuum “Grips”

Control SystemsControl Systems• PLCsPLCs• LabVIEWLabVIEW• CamsCams

Second Iteration of Second Iteration of SelectionSelection

Quality Metrics Linear Piston

Linear Screw Drive

Swing Arm

Yamaha Automatic

LoaderHuman

Design Cost 4 3 2 5 1

Initial Per Unit Cost and Setup 4 3 2 5 1

Number of Steps Required by Operator

1 1 1 1 5

Percentage of Incorrect Loads 2 2 1 5 4

Number of Status Indicators 1 2 1 5 4

Cycles Between Failure 3 2 2 5 1

Noise Level 3 2 2 3 1

Continuation of SelectionContinuation of Selection

Quality Metrics Linear Piston

Linear Screw Drive

Swing Arm

Yamaha Automatic

LoaderHuman

Labor Cost 1 2 1 4 5

(# of interlocks)/(# of positions)

1 2 1 1 5

Contains SOPs, PM Plan, Tech. Drawings, Component List, and Training Aids

1 2 1 5 1

% of Parts from Standard Vendors or made in-house

1 2 1 5 1

Unload/Load Cycle Time 1 2 1 4 5

Total Points 23 25 16 48 34

Advantages Of Swing ArmAdvantages Of Swing Arm

Bur Transfer has One Degree of FreedomBur Transfer has One Degree of Freedom

Minimal Redesign of Current SystemMinimal Redesign of Current System

Fewer PartsFewer Parts

Easier to Diagnose and Repair Problems.Easier to Diagnose and Repair Problems.

Cheaper to Design Cheaper to Design

Cheaper to ImplementCheaper to Implement

Collet ExtensionCollet Extension

Normal ColletNormal ColletExtension ~1/8”Extension ~1/8”

Extended ColletExtended ColletExtension ~1/4”Extension ~1/4”

Final DesignFinal Design

Head Unit

Swing Arm

Grippers

Collet ControlPiston

Bur Tray &Feed Tube

Range ofMotion

Materials ListMaterials List

Quantity Item1 Omron C60 PLC 1 Numatics 6 Station Mark III6 Numatics Station1 Numatics Cord w/ lead (6') 5163--10100001 Meto-Fer Grippers KZ12D1 Bimba Air Cylinder PT-006270-A1MR2 Bimba Air Cylinder 0070.5-D1 Bimba Air Cylinder FO-170.375-3FMNTEE0.3751 Bimba Air Cylinder FT-041.25-3FMEE0.3751 Bimba Air Cylinder MRS-041-DXP4 Bimba Hall Effect Switch4 Bimba Magnetic Reed Switches4 Standard Lever Switch

Division of LaborDivision of Labor

Report, Slides, Schedule - JasonReport, Slides, Schedule - Jason AutoCAD, Design, Liaison - GregAutoCAD, Design, Liaison - Greg Report, AutoCAD - NancyReport, AutoCAD - Nancy Spread Sheet Design, Budget, Report - Spread Sheet Design, Budget, Report -

AllisonAllison

All other aspects such as customer, want, All other aspects such as customer, want, constraint, and metric determination was constraint, and metric determination was completed equally as a group.completed equally as a group.

Actual Schedule to DateActual Schedule to Date

Planned schedule:Planned schedule: Receive grinder by mid Receive grinder by mid

OctoberOctober 2 weeks of concept 2 weeks of concept

generation after generation after grinder unit receivedgrinder unit received

2 weeks of concept 2 weeks of concept selectionselection

1 week on the report1 week on the report

Actual Schedule:Actual Schedule: Receive head unit Receive head unit

November 13November 13 Less than one week of Less than one week of

generation due to time generation due to time constraintsconstraints

Less than one week Less than one week concept selection concept selection

A few days on the A few days on the reportreport

Schedule of Future EventsSchedule of Future Events

Submit design to Caulk for review in mid Submit design to Caulk for review in mid DecemberDecember

Begin ordering and making parts in early Begin ordering and making parts in early JanuaryJanuary

Begin building prototype early in FebruaryBegin building prototype early in February Continue testing and improving prototype Continue testing and improving prototype

through Marchthrough March Work on finalizing documentation in AprilWork on finalizing documentation in April

Preliminary Prototype Preliminary Prototype BudgetBudget

Materials Materials $3,800 $3,800

Engineering hoursEngineering hours 600 @ 600 @ $0.00/hr$0.00/hr

Shop hoursShop hours 100 @ 100 @ $0.00/hr$0.00/hr

Engineering ContingencyEngineering Contingency $2,400$2,400

Total CostTotal Cost $6,200$6,200