Lip Balm/Hand Salve Production Line Ohimai Aisiku Stephanie Bloechl Kenneth Costello Jessica Dill Jeff Lariviere 1

1

Lip Balm/Hand Salve Production Line

Ohimai Aisiku

Stephanie Bloechl

Kenneth Costello

Jessica Dill

Jeff Lariviere

2

Agenda

Problem Definition

Problem Statement, Customer Requirements, Engineering Requirements, House of Quality

System Design

Functional Decomposition, Morphological Chart, Concepts, Pugh Chart, Selected Concept, Risk Assessment

Detailed Design

Feasibility

Test Plan

Questions

3

Problem Definition

4

Problem Statement

Original State of Production

Very long process – not safe for student use

Cant keep up with customer demand

Desired State of Production

Process is safe for students to participate in

Process is able to keep up and exceed customer demand

Main Constraints

Student Safety

Easy to Clean

5

Customer RequirementsCustomer Rqmt. #

Category Importance Description

CR1 Teaching 1 Follow Healthy Urban Food System Model

CR2 Teaching 1 Maximizes STEM input

CR3 Teaching 2 Involves student in each step of process

CR4 Physical Constraints 3 Fit in allotted classroom space

CR5 Physical Constraints 1 Maximizes use of recycled material

CR6 Physical Constraints 2 Portable

CR7 Ease of Use 3 Easy to clean

CR8 Ease of Use 2 Easy to set up and tear down

CR9 Diversity 1 For ages 8 and up

CR10 Diversity 1 Can be used at multiple schools and locations

CR11 Cost 3 Within budget

CR12 Cost 1 Multipurpose

CR13 Cost 3 Financially self-sustaining

CR14 Safety 3 School safe

CR15 Safety 3 Sanitary

1: preference only2: nice to have3: must have

6

Customer RequirementsCustomer Rqmt. #

Category Importance Description

CR16 Safety 3 Too large to choke on (based on safety standards)

CR17 Engage Students 1 Fun

CR18 Engage Students 1 Team Oriented

CR19 Durable 2 Resistant to vandalism

CR20 Durable 2 Long product life

CR21 Durable 2 Easy to repair

CR22 Durable 2 Low maintenance

CR23 Product Creation 3 Makes usable product

CR24 Product Creation 2 Adjusts to different ingredients

CR25 Product Creation 2 Adjusts to different containers

CR26 Process Related 2 Process is quick

CR27 Process Related 3 Can heat beeswax to liquid

CR28 Process Related 3 Can strain product to mostly particulate-free

CR29 Process Related 2 Dispensing of hot liquid is automated

1: preference only2: nice to have3: must have

7

Engineering Requirementsrqmt. # Source Engr. Requirement (metric)

Unit of Measure

Marginal Value Ideal Value

S1 PRP Footprint Size sq ft 12'x3.5’ S2 PRP Weight - individual components lb 30 15S3 CUSTOMER Elapsed Process Time hr 6 4S4 CUSTOMER Yield Size Capability oz 130 200S5 PRP Adjustable Height Range ft 2-3.5 S6 PRP Prototype Cost $ 800 S7 PRP Manufacturing Cost $ S8 CUSTOMER Heating Element Temperature Range °F 140-160 S9 CUSTOMER Number of Students Involved students 20

S10 PRP Time to clean min 30 15S11 CUSTOMER Percentage of single use material that is compostable % 50% 95%+S12 CUSTOMER Degree of automation of pouring process degree Partially automated Highly automatedS13 PRP Storage Size sq ft 6'x6' S14 PRP Breaktown/set up time min <60 <30S15 CUSTOMER % acceptable products based on oz % 90% 95%S16 PRP Maximum particle size after straining in 0.01" 0.005"

S17 PRP Minimize student contact with heating source/hot liquids binary N/A S18 CUSTOMER Degree of automation of capping process degree Partially automated Highly automatedS19 PRP No parts smaller than lip balm cap in 0.61" x 0.67" 0.61" x 0.67"

8

S1 S2 S3 S4 S5 S6 S7 S8 S9 S10 S11 S12 S13 S14 S15 S16 S17 S18 S19

House of Quality footp

rint size

weight

elapsed

process

time

yield size

capability

adjustable heig

ht rang

e

prototype cost

manufacturing cost

heating

element

temperatu

re rang

e

number

of students involved

time to

clean

% of singl

e use mate

rial that

is compostable

pouring

system is auto

mated

Storage

Size

breakdown/set

up time

% acceptabl

e products

visual - is prod

uct clear after straining

minimize student contact

with heating

source/hot liquids

capping is auto

mated

avoid

choke

hazards

CR1 Follow Healthy Urban Food System Model x CR2 Maximizes STEM input x CR3 Involves student in each step of process x CR4 Fit in allotted classroom space x CR5 Maximizes use of recycled material x CR6 Portable x x x CR7 Easy to clean x CR8 Easy to set up and tear down x CR9 For ages 8 and up x x

CR10 Can be used at multiple schools and locations x x CR11 Within budget x x CR12 Multipurpose x CR13 Financially self-sustaining x x CR14 School safe x CR15 Sanitary x x CR16 Too large to choke on (based on safety standards) xCR17 Fun x x CR18 Team Oriented x CR19 Resistant to vandalism x CR20 Long product life x CR21 Easy to repair x CR22 Low maintenance x x CR23 Makes usable product x x CR24 Adjusts to different ingredients x CR25 Adjusts to different containers x CR26 Process is quick x CR27 Can heat beeswax to liquid x CR28 Can strain product to mostly particulate-free x x CR29 Dispensing of hot liquid is automated x

9

System Design

10

Function DecompositionMake Lip Balm/Hand Salve

Gather Ingredient

s

Infuse Oil

Pick Plant

s

Dry Materials

Buy Ingredient

s

Strain Oil

Combine Ingredient

s

Measure Ingredie

nts

Heat Ingredie

nts

Stir Ingredients

Regulate Temperature

Add Fragranc

e

Pour into containers

Secure Container

s

Fill Container

s

Dispense

Liquid

Cool Liquids

Cap Container

s

Label Container

s

Clean Product

Line

Clean Heating Element

Clean Pouring Element

11

Morphological Chart

12

Morphological Chart

13

Morphological Chart

14

Considered Concepts Current Concept A Concept B Concept CFunctions

Pick plants Students Students Buy Students

How to dry ingredients Let sit Drying rack Place in jar Spread on table

Determine source of heat for ingredients

Natural light Natural light Heat lamp Natural light

Strain the oil Tiered straining Tiered straining Cheese cloth Multiple strainers

Measuring the dry ingredients

Weigh Weigh Measuring cup Weigh

Measuring the wet ingredients

Measuring cup Beaker Gatorade cooler with fill line Measuring cup

Heating the ingredients Crockpot Engineered crockpot Crockpot Double boiler

Secure containers Two planks of wood Tray with holes Two planks of wood Chuck

Adding fragrance Manual Manual Manual Automated

Dispensing liquid Pipette Engineered crockpot Pipette Pump

Cooling containers Let sit Let sit Fan Water bath

Capping containers Manual Pen dispenser Vacuum pressure Manual

Labeling containers Manual Manual Tape dispenser Roll container over label to apply adhesion force

Cleaning heating element Soap and water Beeswax proof material Pot liner Beeswax proof material

Cleaning pouring element Soap and water Soap and water Dispose Beeswax proof material

15

Pugh Chart Concepts Current A B C Selection Criteria safety

DATUM

+ S -

process speed + + +easy to clean - + +ease of use + + -engaging + S +cost - - -simplicity to build - - -sustainability S - +low maintenance - - -container security + - +repeatability + S Syield size S S -amount of automation + + +

Sum + 's 7 4 6Sum 0's 2 4 1Sum -'s 4 5 6

16

Pugh Chart Concepts Current A B C Selection Criteria safety -

DATUM

- -process speed - - -easy to clean + + +ease of use - - -engaging - - Scost + + +simplicity to build + + +sustainability - - +low maintenance + + Scontainer security - - Srepeatability - - Syield size S S -amount of automation - - - Sum + 's 4 4 4Sum 0's 1 1 4Sum -'s 8 8 5

17

Pugh Chart Concepts Current A B C Selection Criteria safety S +

DATUM

-process speed - + +easy to clean - - -ease of use - + -engaging S + Scost + - -simplicity to build + - Ssustainability + + +low maintenance + - -container security S + +repeatability S + +yield size S S -amount of automation - + + Sum + 's 4 8 5Sum 0's 5 1 2Sum -'s 4 4 6

18

Pugh Chart Concepts

Current A B C

Selection Criteria

safety + + +

DATUM

process speed - - -

easy to clean - - +

ease of use - + -

engaging S S -

cost + + +

simplicity to build + - +

sustainability - S S

low maintenance + S +

container security - S -

repeatability S + +

yield size + + +

amount of automation - + -

Sum + 's 5 6 7

Sum 0's 2 4 1

Sum -'s 6 3 5

19

Selected ConceptPlants

are grown in scho

ol 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 mater

ial out of

oil.

Measure strained oil

using measuring cups.

Use triple beam

balance to weig

h beeswax.

Combine ingredients in

homemade

crockpot

.

Heat mixture

to at least 140° - do not

allow to

exceed

160°.

Use automati

c stirring

arm to

keep liqui

d from scalding.

Add fragrance once

mixture

becomes

homogenou

s. Continue to monit

or temperature

.

Open crockpot

spigot to

allow liquid

to flow throu

gh tubing to nozzl

e

Select

nozzle

based on product

type (Han

d salve or lip balm

)

Fill containers.

Allow to sit for 30

minutes or until cool to

the touch

.

Place cap on container

Place

labels on

finished product.

Clean all components.

20

System Level Risk Assessment

ID Risk Item Effect CauseLikelihoo

d

Severit

y

Importance

Action to Minimize Risk

1 Over BudgetCannot build prototype that matches design

Grants do not get funded 2 2 4Have functionally similar backup designs, track spending throughout project

2 Student Burns Themselves

Student needs to visit nurse, parents may be upset

Insufficient barrier between students and heating element

1 3 3Safeguard heating elements and keep students from hot liquids

3Conflicting Team Schedules

Late completion of deliverables, team conflict

Overlap in class schedules, other class work

2 2 4Maintain group meeting times, assign individual work as needed

4Product does not match Customer Requirements

Customer is upset, project does not get used

Insufficient budget, unrealistic expectations

1 2 2

Maintain open line of communication with customer, obtain approval at project milestones

21

System Level Risk Assessment

ID Risk Item Effect CauseLik

elihood

Severity

Importan

ceAction to Minimize Risk

5 Conflicts with CustomerCustomer is upset, expectations are not met

Unrealistic expectations, poor communication

1 3 3

Maintain open line of communication with customer, obtain approval at project milestones

6Insufficient knowledge to create automated system

Level of automation does not meet customer expectation

Team members have not taken appropriate classes

2 1 2Meet with professors to ascertain necessary information

7Ingredients are measured incorrectly

Product is not sellable or undesirable

User error, poor implementation of measuring tools

1 1 1Provide clear instructions and easy to use measuring tools

8System inadequately cleaned


User error, difficult to clean equipment

2 3 6Provide easy to clean equipment, ensure cleaning methods are properly documented

22

Detailed Design

23

System Layout

24

Straining System

ID Risk Item Effect CauseLik

elihood

Severity

Importan

ceAction to Minimize Risk

S1 Petals/leaves in final product


Insufficient straining, user error

1 3 3Ensure tiered straining mechanism meets engineering requirement for particle size

S2Strainers do not stay securely together

Oil spills all over everything

Strainers not securely fastened together

1 3 3

Ensure students are taught to correctly assemble strainers. If strainers seem unsecure during testing, add security measures.

25

Preliminary Bill of Materials

Item

Description Vendor QuantityPrice (ea.)

S1 3070-6 Screen Sieves Set American Educational through Amazon 1 $75.35

26

Heating System – Low Risk

ID Risk Item Effect CauseLikelihoo

d

Severit

y

Importance


H1 Overheating of productProduct boils and is unusable

Insufficient temperature regulation

2 3 6Measure temperature throughout process, adjust heat source as needed

H2 Stand tips overProduct spills everywhere and burns everyone

Reckless kids/poor design 1 3 3Secure base to table. Move assembly away from edge of table.

H3 Stirring Arm FailsProduct scalds and becomes unusable.

Poor design. Motor used inappropriately.

1 1 1Robust motor. If motor does fail, stir by hand.

27

Bill of MaterialsItem


H1 Lumber Hardware store 1 $20

H2 Plexiglas Machine Shop 1 $0

H3 1300Watt Countertop Induction Cooktop in Silver Home Depot 1 $57.99

H4 Pot Wegmans 1 $20

H5 L-Brackets & Suction Cups Hardware Store 6 ~$10

H5 Motor Sears 1 $34

28

Heating System- Changes since last review

Improved Base stand

Design of the mixing system Holder sits on top of Plexiglass

Motor has spoon attached and plugs in to an outlet

Connect a thermometer to end of system

Designed holder for Plexiglas Hinges connect each piece to each other

Track in Base to stand the pieces up

29

Dispensing System – High Risk

ID Risk Item Effect CauseLikelihood

Severity

Importance


D1Over-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

2 1 2Create robust and repeatable pouring system

D2 Tubing/Nozzle clog Cant fill productProduct cools too rapidly. Poor cleaning.

2 2 4Insulated tubing. Maintain temperature in pot. Ensure proper cleaning techniques

D3 Insufficient Insulation Kids burn themselvesTubing reaches unsafe temperatures for handling of components.

1 3 3Thorough heat transfer analysis of components.

30

Dispensing System Design

1 Lip Balm = 0.15 fl oz

1 Hand Salve = 1.95 fl oz

Selected Syringe could hold:

31 lip balms

2 hand salves

31

Dispensing System Bill of MaterialsItem Description Vendor Quantity Price (ea.)

D1 HFSLT No-drip faucetUnited States Plastic Corp 1 $3.9

D2PVC Tubing – ¼” ID x ½” OD * 25' length McMaster Carr 1 $14.25

D3Foam Rubber Pipe Insulation – ½” ID x 3/8” thick x 6' length McMaster Carr 1 $2.54

D4 Plastic Check Valve 47245k18 McMaster Carr 2 $14

D5 Syringe 7510a805 McMaster Carr 1 $12.5

D6 Tee-Fitting 5116k36 McMaster Carr 1 $4.75

32

Container Trays – Low Risk


Severity

Importance


T1 Railing system cracks/breaksContainers cannot be filled, possible damage to product/containers

Railings too small, students use excessive force 1 2 2Create robust trays and railings, perform

fatigue analysis

T2 Over-pouring or mis-pouring of product

Additional time required to clean outside of containers and tray

Poor implementation of pouring system, user error, misalignment of tray

2 1 2Create robust and repeatable pouring system, use easy to clean materials for trays

T3 Pinched fingers Injured kids = grumpy parents Not large enough handle on railings. User error 1 3 3

Ensure handles are large enough. Encourage students to pay attention to what they are doing.

33

Container Trays - Design

Base will be made of PVC, rails will be made of aluminum

2 socket head cap screws at each corner for stability, 4 in center for lip balm tray

34

Container Trays – Stress Analysis

Lip balm:

Max P = 687.5 lbf

Max RA = 5625 lbf

Hand salve:

Max P = 1379.2 lbf

Max RA = 5625 lbf

35

Container Trays – Preliminary BOM

Have decided to use PVC sheets

May purchase small sample to test machinability

Item Description Vendor Quantity Total Price

T1 Rigid PVC sheets Curbell Plastics 2 $302.02

T2 Socket head cap screws – various sizes Bolt Depot 40 $9.82

T3 6061 Aluminum bar stock – various sizes Metals Depot 5 $96.08

36

Container Trays – Detailed Drawings

37


38


39


40


41


42

Capping System – Medium Risk


Severity

Importance


C1 Contamination of product during capping

Product is unsanitary, unsellable

Student gets hands in product, capping system not used properly

2 3 6Create easy to use and repeatable capping system

C2Capper dispenses multiple caps at once

Additional cap must be set aside for later use, capping process slowed.

Spring provides too much force, stops fail, user error

2 1 2Ensure spring strength is appropriate, stop mechanism is strong enough

C3Students are not strong enough to load caps

Only some students or teachers can load capper

Spring provides too much force

1 2 2Ensure spring strength is appropriate

C4Cap “misses” lip balm container during capping

Need to try again, slows down capping process

User error, capper barrel is too large compared to lip balm container

1 1 1 Select appropriate sized barrel

C5Capper design is not feasible to produce

Need to change design Unrealistic design 1 3 3Use standard parts, discuss design with machine shop

43

Capping System – Design

Features soft plastic/rubber slotted disc at bottom to allow for insertion of lip balms and retention of remaining caps

Locking top to keep contents inside

44

Capping System – Detailed Drawings

45

Capping System – Detailed Drawings

46

Capping Force Feasibility – Testing

Testing performed to determine force required to put cap on lip balm

Container with cap lightly on top placed on scale, force gradually applied

Capping force, lbs

4.865.704.146.044.766.385.315.335.004.85

Max6.38lbs

Avg.5.24lbs

47

Capping Force Feasibility – Spring Selection

Use 7 lbs as a conservative required capping force

Worst case for spring force will be when there is only one cap in capper (spring least compressed at this point).

Spring will have 1.5” to compress in this case

= 4.67 lb/in required spring constant

48

Spring Selection

11.4” Free Length

11 lb/in spring constant

3.8” suggested max deflection

With ½” long caps, each capper will fit 7 caps

Estimate that the capper will take roughly the same amount of time to load and unload so two will be made

Corresponds to less than 40 lbs of force which is reasonable for a 5th/6th grader without assistance

There is another similar length spring with a 3.8 lb/in spring constant and 6.2” max deflection

Would fit 12 caps in each capper but provides slightly less force than calculated to be required

However, calculations are conservative, so may purchase both and test

49

Preliminary Bill of Materials

Item


C1 Compression Spring Axcess Springs 2 $15.38

C2 Nylon 6/6 Tubing – 7/8” OD x 3/4” ID – for barrel McMaster Carr 5 ft (only

length sold) $11.80

C3Nylon 6/6 Tubing – 1” OD x

7/8” ID – for top McMaster Carr 5 ft (only length sold) $15.38

C4 Neoprene Rubber sheets for top & bottom disc – 1/8” thick McMaster Carr 6” x 6” $6.89

50

Bill of Materials

51

52

Feasibility

53

Time to melt beeswax Initial feasibility done to calculate

how much improvement could be made over customer’s current crockpot method:

% improvement Flux, W/m^2Time to heat and

melt, min10% 437.26 117.23420% 477.02 107.46530% 516.77 99.19840% 556.52 92.11350% 596.27 85.97260% 636.02 80.59970% 675.77 75.85880% 715.52 71.64390% 755.27 67.873

100% 795.03 64.479

Time Improvement w/ % increase in heat flux

Have now selected hot plate and modified batch size (lip balms and hand salves made separately):

These times do not seem realistic

A test will be done to determine actual heat transfer rate from hot plate to product

Need heat flux of crock pot, know the followingBeeswax 3.985 fl. oz.Time to melt, T 3000 secondsHeating area of crock pot, A 329.87 in^2 Assume 12" x 8" x 8" high oval

0.21 m^2Energy Required to heat mixture 237407 J mCΔTEnergy Required to melt beeswax 16385 J m*HfTotal Energy Input, E 253792 JHeat Flux of Crock Pot 397.51 W/m^2 Q=E/(T*A)

Hot Plate Heat Flux CalcsHeating Surface Diameter 7.25 in = 0.184 mHeating Area 0.02659 m^2Power Rating 1300 WEffi ciency 25%Heat Flux 12222.44

Hand Salve Batch Size (50 x 1.95 oz): 97.5 fl. oz.Time to Heat and Melt 16.36426 min

Lip Balm Batch Size (250 x .15 oz): 37.5 fl. oz.Time to Heat and Melt 6.293948 min

54

Time to melt beeswax, cont. For now, have reiterated previous calculations with new smaller batch

sizes for lip balm and hand salves:


melt, min10% 104.92 91.60620% 114.46 83.97230% 124.00 77.51340% 133.54 71.97650% 143.08 67.17860% 152.62 62.97970% 162.16 59.27580% 171.69 55.98290% 181.23 53.035

100% 190.77 50.383

Time Improvement w/ % increase in heat flux - Lip Balm


melt, min10% 227.63 109.78320% 248.33 100.63530% 269.02 92.89440% 289.72 86.25850% 310.41 80.50860% 331.10 75.47670% 351.80 71.03680% 372.49 67.09090% 393.19 63.559

100% 413.88 60.381

Time Improvement w/ % increase in heat flux - Hand Salve

55

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

56

Are students insulated from hot liquids? Hot Plate Approach:

Avg Height of 12 year old Male: 60.6 inches

Avg Height of 12 year old Female: 61.7 inches

Results:

Total fixture would have to be about 3.5 feet tall.

System Designed to be 3’ tall

Heating element 2’ off table

Plexiglass 1’ tall blocking student access to heat source

Tube Flow AnalysisProblem Setup:

Equations:

Given an amount of time to fill a lip balm container, find required elevation H. Model as assumed laminar flow through standard ¼” (.125” ID) tubing of length L+H.

Results:Time to fill (s) Q (m^3/s) V (m/s) Re f major HL (m) minor HL (m) H (m)

0.1 4.44E-05 1.401 982.894 0.065 1.139 0.060 1.3990.2 2.22E-05 0.700 491.447 0.130 0.569 0.015 0.6340.3 1.48E-05 0.467 327.631 0.195 0.380 0.007 0.4080.4 1.11E-05 0.350 245.723 0.260 0.285 0.004 0.3010.5 8.87E-06 0.280 196.579 0.326 0.228 0.002 0.2380.6 7.39E-06 0.233 163.816 0.391 0.190 0.002 0.1970.7 6.34E-06 0.200 140.413 0.456 0.163 0.001 0.1680.8 5.55E-06 0.175 122.862 0.521 0.142 0.001 0.1460.9 4.93E-06 0.156 109.210 0.586 0.127 0.001 0.130

1.00 4.44E-06 0.140 98.289 0.651 0.114 0.001 0.1161.25 3.55E-06 0.112 78.631 0.814 0.091 0.000 0.0931.50 2.96E-06 0.093 65.526 0.977 0.076 0.000 0.0771.75 2.53E-06 0.080 56.165 1.139 0.065 0.000 0.0662.00 2.22E-06 0.070 49.145 1.302 0.057 0.000 0.0582.25 1.97E-06 0.062 43.684 1.465 0.051 0.000 0.0512.50 1.77E-06 0.056 39.316 1.628 0.046 0.000 0.046

58

Are students insulated from hot liquids?Hose connecting pot to nozzle To prevent students from

burning a safe surface temperature of the hose material would have to be 91F.

59

Are students insulated from hot liquids? – Tubing calculations/material selection Start by modeling internal forced convection of beeswax almond oil

mixture through ¼” tubing to determine convection coefficient

Internal Forced Convection of Beeswax/Almond Oil Mixture

Density ρ= 929.34 kg/m^3

Dynamic Viscosity μ = 8.41E-03 kg/m*s

Kinematic Viscosity v = 9.05E-06 (m^2/s)

Volumetric Flow Rate V.= 1.48E-05 m^3/s

Pipe Mass Flow Rate m. = 1.37E-02 kg/s

Pipe Diameter d = 0.25 in 0.00635 m

Pipe Area A = 3.17E-05 m^2

Pipe Speed u∞ = 0.46691 m/s

Reynolds number ReD = 327.6312 Laminar

Nusselt Number Nud = 3.66

Conduction Coefficient of Mixture kf = 0.186 W/m*K

Convection Coefficient h = 107.2063 W/m^2*K

60

Are students insulated from hot liquids? – Tubing calculations/material selection

hi, Ti

T1

T2

T3ho,To

kT

kI

61

Approximate Process Time

Original Process

Time

Target Process

Time

straining oil 15 15

heating oil/beeswax mixture 180 75

filling containers 120 60

cooling containers 30 30

labeling containers 60 60

Total: 405 240

Material Selection Tested: Steel, Pyrex, Stoneware, and Porcelain

Compared room temperature wax removal to cooled ice removal

Preferred method of cleaning pot

Let residual mixture cool

Use ice to loosen residual (edge of ice quickly loosens material)

Wipe clean with paper towels

Hand wash with cold water

Tubing

Run through with cold water

Use bottle brush to clean out

63

Test Plan

64

Test Plan

ER 1 – Footprint Size (Marginal 12’x3.5’ (double check number))

Set up entire process

Measure dimensions of set up on lab bench

ER 2 – Weight of individual components (marginal: <30 lbs; ideal < 15 lbs)

Weigh each component to ensure meet engineering requirement

ER 3 – Elapsed Process Time (marginal: 6 hrs, ideal: 4 hrs)

Using a stopwatch measure time to make a batch from beginning to end

Also measure time duration of each subsystem to identify any issues

65

Test Plan

ER 4 – Yield Size Capacity

Not testing – used in design

ER 6 – Prototype Cost

Not testing – monitor spending throughout process

ER 7 – Manufacturing Cost

Not testing

66

Test Plan

ER 8 – Heating Element Temperature Range

Obtain thermometer

Compare thermometer readings with hot plate display

Provide detailed list for users limiting which settings should be used

ER 9 – Number of Students involved

ER 10 – Time to clean

Once process has been run to completion; time duration of cleaning

67

Test Plan

ER 11 – Percentage of single use material that is compostable

At current point, there are no single use materials

If any begin to be used, record which type of materials are being used

ER 12 – Degree of automation of pouring process

Not testing – used in designed

ER 13 – Storage Size

Disassemble set up and measure space requirement for storage

68

Test Plan

ER 14 – Breakdown/set up time

Allow typical user to practice how to assemble components

Time typical user setting up

ER 15 – Percent acceptable products based on oz

Allow users to become familiar with set up

For each batch, record amount of product being placed in pot and number of

ER 16 – Maximum particle size after straining

Have students test each strainer to visually see what oil looks like after straining

Design will include small enough holes to meet requirement

69

Test Plan

ER 17 – Minimize student contact with heating source/hot liquids

Once system is in use, measure temperature at points of concern

ER 18 – Degree of automation of capping process

Not testing – used in design

ER 19 – No parts smaller than lip balm cap

Measure any parts that appear smaller than safe for students

Test heating element at various set points with set amount of water to determine flow of heat into system for use with feasibility analysis

70

MSD 2 Project Plan

71

Questions?

Documents

Lip Balm/Hand Salve Production Line Ohimai Aisiku Stephanie Bloechl Kenneth Costello Jessica Dill Jeff Lariviere 1