Group E1:

Helena Chia, Pey-Hua Hwang,

Gregory Padilla, Cameron Wheeler

Choosing the Design &

Making the Molds

Things we had to consider:

Consensus

Performance

Aesthetics

Time constraints

Difficulties we encountered:

Tool Limitations

Draft Angles

Red BaseRed Base Shewhart Chart

1.995

1.996

1.997

1.998

1.999

2

2.001

2.002

2.003

0 5 10 15 20 25

Run Num ber

Av

era

ge

(o

f 5

sa

mp

le)

dia

me

ters

[i

nc

he

s]

• UCL=2.000”• LCL=1.997”• Cp=4.767

• Range=0.04”

0

5

10

15

20

25

Inches

Nu

mb

er

of

Pa

rts

Black Cover

0

2

4

6

8

10

12

14

16

Inches

Nu

mb

er

of

Pa

rts

• UCL=2.004”• LCL=1.99”• Cp=1.303

• Range=0.04”

Black Cover Shewhart Chart

1.98

1.985

1.99

1.995

2

2.005

2.01

0 5 10 15 20 25

Run Num ber

Ave

rag

e (o

f 5

sam

ple

) d

iam

eter

s [i

nch

es]

Thermoform Insert

0

2

4

6

8

10

12

Inches

Nu

mb

er

of

Pa

rts

• UCL=1.324”• LCL=1.302”• Cp=1.02

Therm oform Insert Run Chart

1.29

1.295

1.3

1.305

1.31

1.315

1.32

1.325

1.33

1.335

0 50 100 150

Parts Num ber

Crit

ial

Dim

en

sio

n [

Inc

he

s]

1.02

What would we have done differently?

• Alternative method/design of creating thermoform windows

• Additional complexity of designs (ie injector pins)

What if there were no rules?• Different design without thermoform part

• Tried to break machines, play with pressure profiles, incorporate “mistakes” into design

Dave and Patrick,

THANK YOU!