SeniorDesignProjectHandbook

MechanicalEngineeringDepartment

LafayetteCollege

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TableofContents1.CourseInformation page32.ImportantDeadlines page53.ProjectPlanningandCommunication page64.EngineeringDesignProcess page95.Professionalism&Policies page106.ASMECodeofEthicsofEngineers page157.DepartmentSafetyRulesandProcedures page16Appendix:RelevantForms

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1.CourseInformationThefollowingisthecoursecatalogdescriptionofME497/8,SeniorDesignProject:

Projectof thestudent'schoice iscarriedthroughfromproblemformulationtocompletion.Thissequencerepresentsthestudents'majordesignexperienceandisbasedonknowledgeand skills acquired in earlier courses. Design criteria and objectives are formulated, andrealistic constraints including economic, environmental, sustainability, manufacturability,ethical, health and safety, social, and political are considered. Engineering analysis andsynthesistechniquesareappliedanditeratedtoobtainanoptimaldesignsolution.Studentsdesign and conduct experiments to verify design performance. Students document theirachievementsthroughoralandwrittenpresentations.

ME497/8isacapstonedesignexperience,providingstudentswiththeopportunitytoapplyknowledgegainedinpreviouscoursesandtoextendthatknowledge.Theeducationalobjectivesofthisyearlongprojectarethatstudentswill:Gainexperiencewiththenature,demands,andramificationsofreal-worldproblems:

● Decisionsandtradeoffs ● Adequatereporting ● Projectcontrolviascheduleandbudget ● Vendorrelations ● Resourcelimitations ● Confidentialityandclient-specificconcerns

Developleadershipandteamworkskills:

● Divisionsofwork ● Delegation ● Authority/responsibility/accountability ● Resolutionofconflict ● Utilizationofavarietyoftalentsandskills ● Personnelevaluationandconstructivecriticism

Increaseunderstandingoftheengineeringdesignprocess:

● Proposal,negotiation,execution,evaluation ● Feasibilitystudy ● Preliminarydesign ● Detaildesign ● Revision ● Fieldtest ● Manufacturing

Applyandsynthesizecoursematerial:● Recognizeapplicationsandlimitations ● Realityvs.model ● Predictionofperformance ● Optimization ● Communicationoftechnicalconcepts

Gainreal-worldinsights:

● Professionalpractice

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● Standardsandregulations TheABEToutcomesassociatedwiththisyearlongcourseare:

● Abilitytoworkonmulti-disciplinaryteams(outcomeD) ● Abilitytounderstandprofessionalandethicalresponsibility(outcomeF) ● Abilitytocommunicateeffectively(outcomeG) ● Developarecognitionoftheneedfor,andanabilitytoengagein,life-longlearning

(outcomeI) TheprimaryrequirementoftheSeniorDesignProjectisthesuccessfulexecutionoftheproject.Thestudentsinateamarejointlyresponsibletothefacultyadvisor,tothe ME department and to each other for organizing, scheduling, budgeting,implementing,time-managing,andreporting.Additionalcourserequirementsinclude:● Weeklymeetingswiththefacultyadvisor ● Weeklymeetingsoftheteam ● PresentationstotheMEdepartmentthroughouttheyear ● InterfacingwithEngineeringtechniciansandsupportstaff

Gradesareassignedbythefacultyadvisor.Gradingcriteriaareasfollows:1.TechnicalContribution● Adequacy and appropriateness of analyses, syntheses, tests, conclusions –

includeslibrary,field,laboratory,computer,andshopwork

2.ProjectManagementandCollaboration● Initiativeandimaginationintakingresponsibilityasaleaderorvolunteering

asateammember ● Givingandreceivingcriticismeffectively ● Keepingteamandadvisorinformedofprogress ● Qualityofwritten,graphic,andoralcommunication ● Meetingdeadlines ● Attendanceandparticipationatteammeetings

3.OverallContributiontoProjectSuccessTeammembers will be asked to complete self- and team-evaluations. A samplerubricforthisevaluationcanbeviewedhere..

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2.ImportantDeadlinesSeniordesignprojectsinMEatLafayettetypicallyinvolvethefollowingmajordeliverables.● ConceptualDesignReport(~3pages,week3)● PreliminaryDesignStudy(~5pages,week5)● DesignProposal(Week7)● ProgressReport(Week14)● MidtermPresentation(Week15)

3.ProjectPlanningandCommunicationPlanningEffective timemanagement is THEKEY to successful completion of SeniorDesignProjects. Various tools are available to assist in planning your time, settingschedules,andassigningresources;softwareprogramscanbeusedtopreparetheseprojectmanagementtools.(a)WorkBreakdownStructure(WBS)diagramsphasesofthedesignprocess(b)LinearResponsibilityChartdescribestheparticipationbyvariousrolesincompletingtasks(c)GanttChartrepresentsdurationoftaskswithbarchart(d)DescriptionofProgressMonitoringiswhatitsoundslikeEachofthesetoolshasadvantagesanddisadvantages;teamsshouldworktogetherandwiththeirfacultyadvisorstoselecttheprojectmanagementstrategythatworksbestforthem.Thefollowingaresomeexamples:

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Figure1.SampleWorkBreakdownStructure.Source:CornellUniversity

Figure2.SampleGanttChart.Source:AndersenConsulting

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KeepingRecordsSomerecordshouldberetainedofalltransactionsofteammeetingsthroughouttheyear.Therecordshouldincludemajordecisionsandbasicassumptionsmade,andshouldclearlyidentifyactionitemstobecompletedandbywhom.Keepmeetingagendas and minutes is encouraged; they are a record of what your team haslearned,decided,andaccomplished;andwhatyouhaveplannedtodoandhowyouplantoaccomplishit.Minutesshouldinclude:● Date,location,time,andpeoplepresent ● Itemsaccomplishedsincethelastmeeting ● Individualresponsibilitiesfornextweek’swork ● Newfactsanddata;changedworkplan;problemsorquestions,etc.

CommunicationThe effective communication of technical ideas is a critical skill for engineers. Bygivingcareful consideration to theneedsofyouraudience, thepurpose(s)ofyourwriting, and the relevance of yourwork, youwill bemost effective. Organization,writingandrevisionareallimportantaspectsofthewritingprocess.PleaseconsultyourFYStextbook,TheSt.Martin’sHandbook,forthefundamentals;youmayalsobeinterested in the ideasandstrategiespresentedbymore focusedmanualssuchasThe Chicago Guide to Communicating Science (ScottMontgomery), andA Guide toWritingasanEngineer(Beer&McMurrey).ProjectManager/TeamLeaderResponsibilitiesDesignProjectTeamsare student-led. Facultyadvisorsarenotprojectmanagers,but academic advisors for these student projects. The responsibility for projectmanagementandproductionofdeliverableslieswiththeteam,andwiththeteam’sproject manager. Successful supervision of engineering projects involves thefollowingongoingtasks:● Clarifyrolesandresponsibilities ● Defineobjectives ● Provideinformation(toandfromteam,facultyadvisor,andothers) ● Monitorprogress ● Solvetheunsolvableproblems ● Motivate(praiseandblame) ● Evaluateresults ● Selltheproduct

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Theprojectmanagershouldhaveamentalplanforthegoalsofeachteammeeting.Thisplanmaybedocumentedintheformofawrittenagenda.TeamBuildingHowwellstudentsworktogetherasateamcorrelatesstronglywithprojectsuccess.It iscriticalthattheteammemberscommunicatewitheachother,andensurethatallmemberscontributemeaningfullytoeachmeetingandtotheprojectasawhole.Youalldependoneachother,andtheproject’ssuccessdependsonallofyou.Conflicts and disagreements often arise during team projects. Conflicts must befaced and resolved, whether by compromise, discussion, or through an externalarbitrator. Thesoonerearlyconflicts canberesolved, thesooneryourgroupwillfunctionasatrueteam.Whena team isperformingeffectively,members trusteachotherenough tovoiceopposing opinions, and to accept both positive and negative feedback from othermembers.Thisshouldbeyourgoal!TerminationThis project requires a team effort to be successful. Members of the team whodemonstratethattheycannotworkontheteammaybeterminatedfromtheteam.Beforeterminationoccurs,theinstructorwillprovidethestudentwithadocumentexplaininghowtheireffortislacking.Ifthestudentcontinuestoperformatalevelbelow that ofwhich is required, the studentwill be terminated.Once terminated,thestudentwillswitchintoanindependentstudywiththefacultymemberastheiradvisor.Thefacultymemberhassolediscretiontoterminateastudent.

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4.EngineeringDesign

Figure3.AnengineeringdesignmethodologyFigure3showsoneuseful illustrationof theengineeringdesignprocessbywhichengineerssolveproblems. Studentsarefamiliarwiththisprocessfromtheirpriorexperience in ME 210 and other courses. This process is iterative, involvingfeedbackandrevisionateachstep. Figure4providesanotherwayofenvisioningthisprocess.

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Figure4.Anotherviewoftheengineeringdesignprocess.Source:BostonMuseumofScience5.ProfessionalismandPolicies CollaborativeWork&AccountabilityEachteammemberisaccountableforthecontentandqualityofeachteamproduct.Anydrawing,spreadsheet,document,orpresentationisthesharedresponsibilityofall teammembers.Likewise,allmembersof the teamwillbeheldaccountable foranyplagiarizedmaterial in your reports. Some teamsmaywish to formalize thissharedresponsibilitybyaskingallteammemberstosignoffonallreports;evenifnot formalized, you should be cognizant of your role as amember of your seniordesignteam. SafetyThedepartmentsafetyrulesandproceduresareincludedinSection7andarealsoavailableonthedepartmentwebsite.Compliancewiththeserulesandproceduresismandatoryforyoursafetyandthesafetyofstaff,facultyandvisitorstothedepartment.WhenworkinginEngineeringLaboratory,Project,andShopAreas:

1. Ifyou’renotsurewhetheryoushouldbewearingsafetyglasses,wearsafetyglasses.

2. Rotating elements should surrounded by a protective shield to preventaccidentalusercontact,ortocontainpartsshouldtherotatingelement fail.Ifashieldisimpracticalthenappropriateproceduresarerequiredtoensuretheequipmentcanbeoperatedsafely.

3. Students should not bewiring equipment that is 110V. Contact the shoptechniciansoryourfacultyadvisorforsupport.

4. Before using hazardous materials, liquids or gases, refer to the MaterialSafety Data Sheets (MSDS) – available in each laboratory – for specialhandling, storage, and disposal methods. The appropriate personalprotectiveequipment(PPE)suchaseyeprotectionandspecialclothingmustbeusedinaccordancewiththeMSDS.

5. KEEPTHEWORKAREASORGANIZEDANDCLEAN. This is foryour safety,butitwillalsoimproveyoureffectiveness.

It is the responsibility of theproject teams and faculty advisor to ensure that thetesting and experiments performed under their direction meet the appropriatesafetystandards.

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Asspecifiedinthedepartmentsafetyrulesandprocedures,ariskassessmentmustbe performed prior to any experiments or testing. The risk assessment shouldincludeanidentificationofthehazardsandtheirrisks.Inthiscaseahazardisanactorconditionthatcancauseinjury,illnessorharmtotheenvironment.Theriskisthelikelihoodofthehazardcausingharmandtheimpactofthatharm.Figure5shows a suggested risk ranking matrix that can help identify the highest riskhazards.

Figure5.Riskrankingmatrixbasedonimpactandlikelihoodofanevent.Source:UnitedTechnologiesResearchCenter

Theriskmatrixandassessmentformsareavailableat:me.lafayette.edu/safety/Performance of unauthorized experiments is cause for dismissal from the courseandfurtherdisciplinaryaction.

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WorkingwiththeMachineShopStaffThe shop supervisor and technicians act as both consultants and contractors onyour senior design project. Clear, timely communication with the machine shopsupervisor is vital, and must be carried out in a professional manner. Theestablishedproceduresexistforefficiencyandfairness,andmustberespected.Thesupervisormaintains a detailed schedule for eachmember of the shop staff,whoworkinsupportofallMEseniordesignprojectsandotherMEprojects,aswellastheotherengineeringdepartments.Yourownpartsreceiveprioritybasedonwhenyousubmitcorrect,completedrawingstothestaff.It is important to recognize that themachine shop supports classes for the entireengineering division. Many of these classes, such as ME210, place significantdemandsontheshopresourcesneartheendofthesemester,soplanaccordingly.The most important form of communication with the technicians will be yourdetailedpartdrawings. Acompletedrawing thatmeets thestandardsset forth inME210isrequired.Quickchecklistforacompletedrawing● Ensurethedrawingisthemostcurrentpart/fixture ● Fullydimensioned(evenforpartstobemadeviaCNC). ● Materialisspecified ● Lafayetteorprojectspecificboarderisused ● Completetitleblockwithallinformationincludingpartnumberandrevision

Sometips:● For parts to be milled, please orient the datum to the top left corner, to

simulatethecornertouchingyour“dead”jawandastop,ifusingone. ● Forlatheparts,pleaseorientdatumtothefaceofthepart. ● Inventor/GibbsCAM filesMUSTbeoriented to absolute zero relative to the

drawingdatum,ANDmusthavetheproper“layer”selected.Thisalsoappliesto.dxfand.dwgfiles.

● Justasyouprepareanagenda for teammeetings inother locations,haveaplanofactionforyourmachineshoptime.Arriveontime,andstayontask.

The technicians are available to assist you from 8am-3:45pm. The time from3:45pm-4:00pm is reserved for clean-up and you will not request work becompletedbythetechniciansduringthistime.Ifyouareworkingonamachine,youwillbegincleanupnolaterthan3:45pmaswell.

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PurchasingAs a member of a design team, you may need to purchase equipment, software,parts,etc.Beforemakingapurchase,checkfirstwithyourfacultyadvisorandwiththe machine shop supervisor to ensure that the item you require is not alreadyavailable.If your itemmustbepurchasedor leased, you should complete aPurchaseOrderrequestform(seeAppendix).Pleaseshiptothefollowingaddress:LafayetteCollegeAttn:(NameandDesignProjectTeam)AECRoom130740HighSt.Easton,PA18042OrderswillbesubmittedtoyourfacultyadvisorbynoononeitherTuesdayorFriday.Apurchaseorderformwillbeprovidedtheprojectteams.Whenordersarrive,pleasechecktomakecertaineverythinghasarrivedandall isintact.Ifthereisadiscrepancywithyourorder,pleasenotifyyourfacultyadvisor.Alwaysprovideyourfacultyadvisorwithanyandallpackingslipsorinvoices.TravelYour teammay have the opportunity to travel to a competition or other off-sitefacility. The department secretary, Serena Ashmore, will make your travelarrangements for you; please inform her of your plans as early as possible, andcontactherwithanychangesinyourplanswhileawayfromLafayetteCollege.

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ReimbursementsIf you wish to purchase an item yourself and be reimbursed, please see SerenaAshmore. LafayetteCollegehasapolicy forreimbursementofexpenses for travelandotherprojectexpenses.TherearesomevendorswithwhomtheCollegealreadyhasabusinessrelationship; thereareothervendors fromwhichallexpensesmaynot be reimbursed. Please note thatwhen you are traveling, your transport andhousing,butnotyourmeals,willbereimbursedbytheCollege.TolearnabouttheCollegepolicyandtoobtainreimbursementforms,contactyouradvisorbeforethepurchaseismade.Ifastudentchoosestobuysomethingwiththeirownmoneyandischargedtax,theCollegewillnotreimbursethetax.

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6.ASMECodeofEthicsofEngineers

TheFundamentalPrinciples

Engineersuphold andadvance the integrity, honor anddignityof the engineeringprofessionby:

I. using their knowledge and skill for the enhancement of humanwelfare;

II. being honest and impartial, and serving with fidelity their clients(includingtheiremployers)andthepublic;and

III. striving to increase the competence and prestige of the engineeringprofession.

TheFundamentalCanons

1. Engineersshallholdparamountthesafety,healthandwelfareof the

publicintheperformanceoftheirprofessionalduties.2. Engineers shall perform services only in the areas of their

competence; they shall build their professional reputation on themeritoftheirservicesandshallnotcompeteunfairlywithothers.

3. Engineers shall continue their professional development throughouttheircareersandshallprovideopportunitiesfortheprofessionalandethicaldevelopmentofthoseengineersundertheirsupervision.

4. Engineersshallactinprofessionalmattersforeachemployerorclientas faithful agents or trustees, and shall avoid conflicts of interest ortheappearanceofconflictsofinterest.

5. Engineers shall respect the proprietary information and intellectualproperty rights of others, including charitable organizations andprofessionalsocietiesintheengineeringfield.

6. Engineers shall associate only with reputable persons ororganizations.

7. Engineers shall issue public statements only in an objective andtruthfulmanner and shall avoid any conductwhich brings discreditupontheprofession.

8. Engineers shall consider environmental impact and sustainabledevelopmentintheperformanceoftheirprofessionalduties.

9. Engineers shall not seek ethical sanction against another engineerunlessthereisgoodreasontodosoundertherelevantcodes,policiesandproceduresgoverningthatengineer’sethicalconduct.

10. EngineerswhoaremembersoftheSocietyshallendeavortoabidebytheConstitution,By-LawsandPoliciesoftheSociety,andtheyshalldiscloseknowledgeofanymatterinvolvinganothermember’sallegedviolationofthisCodeofEthicsortheSociety’sConflictsofInterest

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Policyinaprompt,completeandtruthfulmannertothechairoftheCommitteeonEthicalStandardsandReview.

7.DepartmentSafetyRulesandProcedures

AllstudentsworkingonThesis/Sr.Projectsarerequiredtoknowthesafetyrules,proceduresandpoliciesadoptedbytheDepartment.Themostrecentversionofthedepartmentrulescanbefoundat:

me.lafayette.edu/safety/

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AppendixSampleTeamMeetingReport(Minutes)TeamMeetingFeb.14,2004Present:Joe,Erika,Steve,Nikhil,Prof.RossmannAgenda:1. Reportofweek’sactivities(includingphotometerpurchase)2. Workassignments3. ProgressReportoralpresentation,March24. Effectofutilityratestructureonestimatedenergysavings5. BriefbiographiesforrevisedproposalMinutes: DONE: TODO:Joe ReceivedinfofromMainstemCoon

vehiclesystemforPaloAlto.FoundbookonIESlightstandardsatlibrary.

Joe Contactmfrsre:filtersforYAC.Recommendlightfiltertobuy.

Team MeasuredlightlevelsatYACbuilding.Problemsintransmissivityratios.

Erika MeetBrontzmanre:streetlights

Erika FoundlightmeterstorangefromGE$50(±15%)toWeston$170(±7%)

Joe GetvehicledatafromJ.Kennedy

Nikhil

Hasinfoonlampmfrs. Team GetlightmeasurementsatBaselinetoday,noon

Steve TriedtogetinfoonprojectionsofenergypricesfromDoE

Nikhil GetANSIstandardsandmarketdataonlights

Steve Talktofactoryre:theoryofheat-fluxmeter

Prof.R. CheckLWVonuseofnewHomeEnergyAuditforms

Team MeetingThurs4pmre:oralpresentation

Notes:

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SamplePurchaseOrderRequest

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