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DSES 4270 Industrial and Management Engineering Design Spring 2001 DSES Coordinator: Professor William J. Foley, Department of Decision Sciences and Engineering Systems, CII 5211, 276-6837, [email protected], Office Hrs.: Open appointment calendar posted weekly on office door. Project Faculty Advisor: Faculty advisors in DSES and other Engineering departments will be assigned to projects. These advisors serve as content and conduct consultants to the student team. Frequent meetings and project status reports will be required with these advisors. Each advisor will establish the working relationship with each team. Faculty advisors will assign much of the project grade portion of the course. Sponsor Contact: Many projects have a listed sponsor contact. Other projects will have a sponsor identified later in the project time frame. The sponsor must be apprised of project status and progress on a frequent basis by the project team. The sponsor will be contacted by the course coordinator during the semester to evaluate team performance on the project. Course Description: This is a capstone design course for seniors in Industrial and Management Engineering (IME). The course seeks to develop problem formulation and analytical skills, organizational and teaming skills and general problem solving and design skills. Students work on real world problems as either a member of a multi-disciplinary design team or an industrial engineering consulting team. The course acquaints students with all phases of the design development process from requirements definition, concept development, engineering evaluation and operations management. All projects in the course are ‘sponsored’ and require students to draw upon their engineering background to successfully achieve goals. Required Text: None. Learning Objectives: To provide a meaningful capstone experience that educates students in the multidisciplinary aspects of design and project conduct and management. Students will develop an appreciation for the depth and breadth of knowledge and skills necessary for successful implementation of a design development effort. The integrative aspects of a capstone experience will be emphasized. Professional development in areas of leadership, team dynamics, interpersonal relationships, technical writing and communications and project management will be discussed and learned via active participation in design projects. Course Organization: During this semester, students are offered the option of: 1. Participating in one of several ongoing design projects under the initiative of the O.T. Swanson Multidisciplinary Design Laboratory (MDL). These projects are in the last stage and IME students will join a team of engineers from other engineering disciplines. 2. Initiating a new project in one of the MDL sponsored research areas. Working closely with a faculty advisor, the team would review the work done to date by previous teams and identify a new opportunity for project development. DSES 4270 Industrial and Management Engineering Design Spring 2001 Page 1 3. Developing designs and implementing solutions to meet project team needs related to use of the MDL for design projects in courses and MDL hosted and sponsored activities. 4. Conduct a problem stated project in a local firm. Several local firms have volunteered to host a team over the semester and have identified a named “problem”. Student teams are expected to fully complete these projects over the semester and provide a thoroughly developed solution to the client firm. 5. Design and develop a working and usable prototype to meet the needs of an identified disabled person or group of users under a National Science Foundation (NSF) funded program. NSF funds are available to purchases supplies and materials that become part of the prototype. Teams on these projects would work closely with the disabled person or persons who administer to the disabled. 6. Locate and identify a disabled person or group of users and design and develop a working and usable prototype to meet their needs. The teams first responsibility would be locate a need of the disabled and identify a person or persons with that need. NSF funds are available to purchases supplies and materials that become part of the prototype. Teams on these projects would work closely with the disabled person or persons who administer to the disabled. More description of these project options are presented at the end of this syllabus. Course Requirements Course requirements are those things that are graded. There are three classes of requirements. Individual Requirements. Individual requirements are those which stand apart from project and team requirements. Attendance and Availability. Each student is required to attend all scheduled class meetings and to be available for team meetings, faculty advisor meetings, team project work duties, and other class related activities on all Wednesdays between 10:00 AM and noon during the semester. Students should schedule no other activity during this time slot. Student Portfolios: Each student is required to develop and submit a portfolio of undergraduate work completed at Rensselaer. Portfolios are due on April 11, 2001. All students are urged to make their portfolios as complete and professional as possible. A small number of sample portfolios may be examined during regular office hours of the course teaching assistant. Portfolios should be organized into three major sections. The first section should include an updated, one-page statement of career objectives and plans following graduation. This section should also include an up-to-date resume and transcript. A draft of this first section of the student portfolio is due on January 31, 2001. The second section of the portfolio should include a summary of unique accomplishments. This section should be organized chronologically and include information and documentation on awards received, participation in undergraduate research programs, and CO-OP experiences. Students should also include copies of articles or papers written and descriptions and documentation of extracurricular activities. The third section of the portfolio is for course work. This section should be organized chronologically from the freshman year through the senior year. A separate section should be maintained for each semester that the student attended Rensselaer. Within each section (semester), materials should be organized by course. For each course, materials included in the portfolio should include sample copies of (graded) assignments such as major home-works and laboratory projects, exams and class projects. The Year 2001 Senior Survey is considered as a separate part of the portfolio package and should be included in the second section. Failure to submit the completed senior survey will reduce the portfolio grade by 15%, i.e., 3% of the course grade. Project Linked Individual Requirements. These requirements arise from the student’s work on a project as a member of a design team. DSES 4270 Industrial and Management Engineering Design Spring 2001 Page 2 Project Design Notebook. A project notebook is required of each student. This notebook should stand as proof of student involvement in the project and show the student’s contribution to the project activities and outcomes. This notebook can be loose leaf with section dividers, spiral bound, or edge bound. In the ideal case, the notebook would follow the guidelines for the notebook presented in Introduction to Engineering Design. At a minimum, the notebook should contain: 1. Time sheets showing daily time spent on the project and course with weekly and semester to date totals. The time recorded should be traceable back to the tasks of the project for project reporting purposes. The time should be recorded daily but no less frequent than weekly. 2. Research notes. 3. Design development notes and sketches. 4. Field observation notes and sketches. 5. Meeting notes. 6. Outlines of reports and other project communications. Entries should be date stamped Contribution and Teamwork. In order to receive credit for the work of the team on the project, the student must be a willing and active contributor to the work of the team on all phases of the project including design, research, communication, project management, data collection, data analysis, and fabrication. This contribution will be evaluated using the design notebook, meetings with faculty advisor, and peer evaluation. Project Team Requirements. The project team requirements involve frequent project reporting, meetings with the faculty advisor, project management, project quality, and progress of project work. Weekly Progress Memo. A weekly progress memo starting in week 3 is required to the faculty advisor and the course teaching assistant. This memo should be 1 to 2 pages in length and have 3 sections. The memo is due by noon Monday. Use short sentence or bullet form to report in each section. Progress last week. List what was completed, started, etc. For tasks in progress, state the percentage completed. Do not restate progress from previous weeks. Revisions to plans and activities. List the changes made to the project plan, scope of work, planned scope, etc. with reasons and justification for the changes. Defend your changes. This is the location to state problems encountered and the plans to address the problems. Hours worked by each team member on project. After week 4, a report from the project planning software should be attached. This report should be in Gantt chart form showing current date and status of completion of all project tasks. Biweekly Sponsor Progress Memo. Every 2 weeks, send via email a progress memo to the project sponsor and copy the course TA. This memo should be different from the weekly progress memo and focus on accomplishments, discoveries, conclusions, ideas, etc. You want the sponsor to feel confident in your work from this memo so don’t focus on how many hours you spent on the project but focus on progress to the conclusion and answer to their problem. Project Plan. A formal task based project plan using a work breakdown structure, estimate of time both person hours and time duration, precedence relationships, and assignment of project members (one member per task is ideal) must be done by week 5 in Microsoft Project 2000. A 60 day trial or evaluation version of the software is available from Microsoft for a small shipping cost charge. The team is responsible for getting a copy of the software. Visit Microsoft’s Web site to order. This plan must be updated at least weekly and reports submitted as part of weekly reporting. DSES 4270 Industrial and Management Engineering Design Spring 2001 Page 3 Advisor Meeting. Meet with the project advisor as appropriate and schedule meeting with the advisor as directed by the advisor. Sponsor Meeting. Meet with the sponsor periodically during the project to report significant findings and to discuss preliminary ideas or directions of problem solution. Avoid meetings for meeting sake. A meeting is an occasion for an exchange and dialogue. If a written report can communicate more efficiently then use a written report and avoid the scheduling problems that a meeting brings up. Project Description and Plan Presentation. A group presentation of the project and project plan is scheduled for week 5. This presentation will be made to your class peers. If there is insufficient time for all groups to present, this activity will carry over to week 6. Preliminary Project Final Report Presentation. A group presentation to your peers of the final report of your project is scheduled for week 12. This precedes submission of your final report to the sponsor and provides an opportunity for final review by your peers before presentation to the sponsor. Final Written Final Report. A final written report is required to your sponsor. Copies of the report must be provided in draft form to your advisor for review and comment 5 days prior to submittal to your sponsor. Copies of the final report are required by your faculty advisor and the DSES course coordinator. This report is due to the sponsor no later than April 19. Final Sponsor Presentation. A final project presentation to the sponsor is required no later than April 23. This presentation will involve handing over the solution or prototype if one was developed. Solution and/or Working Prototype. For projects involving a physical solution in the form of mechanical or structural prototype or software, the quality and functionality will be reviewed and become part of the final grade. Grading Contribution and Relative Weight The final grade for the course will be based on the student meeting the design and project requirements for a capstone design course such as this. The grade A is reserved for students showing excellence in all aspects of design project performance as stated in this syllabus. The relative weights of the elements will be: Individual Requirements Project Linked Individual Requirements 15% Project Team Requirements 60% 25% For some students in multidisciplinary design teams, some of the team requirements may be modified to improve compatibility with the requirements imposed by the faculty advisor from another department. Course Calendar Week Meeting Date 1 Jan 10 2 Jan 17 3 4 Jan 24 Jan 31 Activity Course Introduction, Project Selection Final Project Selection First Meeting with Client First Weekly Progress Memo due Monday, Jan 22. Continue weekly. Team Meetings Team Meetings Draft Portfolio First Section Due First Biweekly Sponsor Report due Monday, Feb 5. Continue biweekly. DSES 4270 Industrial and Management Engineering Design Spring 2001 Page 4 5 6 7 8 9 10 11 12 Feb 7 Feb 14 Feb 21 Feb 28 Mar 7 Mar 21 Mar 28 Apr 11 13 Apr 18 14 Apr 25 Project Introduction and Plan Presentations Project and Plan Presentations (con’t if needed) Team Meetings Team Meetings Team Meetings Team Meetings Team Meetings Preliminary Project Final Report Presentation Draft to Faculty Sponsor Portfolios Due Final Report to Sponsor by April 19 Team Meatings Final Sponsor Presentation by April 23 Individual Notebook due by April 23 No formal class meeting DSES 4270 Industrial and Management Engineering Design Spring 2001 Page 5 Spring 2001 Projects Participating in one of several ongoing design projects under the initiative of the O.T. Swanson Multidisciplinary Design Laboratory (MDL). These projects are in the last stage and IME students will join a team of engineers from other engineering disciplines. A1. Next Generation Vehicle Information System Test Station Construction Sponsor Organization: General Motors Faculty Advisor: Daniel Walczyk, Assistant Professor, Mechanical Engineering, JEC 4026, extension 2397. IME Opportunity: One student to join a multidisciplinary team. Provide expertise in ergonomics and project management and organization. Current Status: Previous teams have provided a framework and components of a system for testing driver attention when subjected to the demands of driving and external data and information. The goal of this project is to implement these in a hardware prototype. Project Background and Objectives: The ideal automotive information system allows for efficient and effective communications between the driver and vehicle, while facilitating focused attention to the primary task of safe driving. The scope of this project encompasses the traditional vehicle information systems related to vehicle control and service along with the auxiliary information systems related to navigation, entertainment and cellular communications. The project objective is to study vehicle workspace and human factors for design of a next generation automotive information system. The principle challenge associated with this project relates to balancing the appropriate information systems architecture with the human factors required for safe vehicle operation. The driver spatial and temporal areas of focused attention must be carefully studied to minimize distraction imposed upon the driver during information exchange. As a next generation automotive information system implies, there are relatively few technical constraints in as much that the ultimate design will make use of the most advanced information technology available. Sponsor Liaison Information: James H. Rillings Phone: (810) 986-2916 GM R&D Center Fax: (810) 986-3003 M/C 480-106-390 Email: [email protected] 305000 Mound Road Warren, MI 48090-9055 A2. Golf Cart Design Improvements for the Disabled Sponsor Organization: NSF Faculty Advisor: Daniel Walczyk, Assistant Professor, Mechanical Engineering, JEC 4026, extension 2397. IME Opportunity: One student to join a multidisciplinary team. Provide expertise in ergonomics and project management and organization. Current Status: Current designs are available but present many challenges for the disabled golfer. This project provides an opportunity to look fresh at the need and respond to it. The goal of this project is to implement a solution in a hardware prototype. Project Background and Objectives: Current golf carts used by the disabled are 4 wheel battery powered seats that swivel to provide the golfer a side ways approach to the ball once the cart has been maneuvered into position at the ball. These specialty carts are high in cost because of limited demand. One goal of this project is to design lower cost carts for greater access by the disabled. Initiating a new project in one of the MDL sponsored research areas. Working closely with a faculty advisor, the team would review the work done to date by previous teams and identify a new opportunity for project development. B1. Next Generation Vehicle Information System Sponsor Organization: General Motors DSES 4270 Industrial and Management Engineering Design Spring 2001 Page 6 Faculty Advisor: To be Named IME Opportunity: IME team or team formed on a nucleus of IME students. Current Status: Previous teams over two semesters have investigated this area from many perspectives. But new opportunities for new exploration still exist. This project would start with a review of past work and identify new opportunities for study, exploration, and design solutions. Project Background and Objectives: The ideal automotive information system allows for efficient and effective communications between the driver and vehicle, while facilitating focused attention to the primary task of safe driving. The scope of this project encompasses the traditional vehicle information systems related to vehicle control and service along with the auxiliary information systems related to navigation, entertainment and cellular communications. The project objective is to study vehicle workspace and human factors for design of a next generation automotive information system. The principle challenge associated with this project relates to balancing the appropriate information systems architecture with the human factors required for safe vehicle operation. The driver spatial and temporal areas of focused attention must be carefully studied to minimize distraction imposed upon the driver during information exchange. As a next generation automotive information system implies, there are relatively few technical constraints in as much that the ultimate design will make use of the most advanced information technology available. Sponsor Liaison Information: James H. Rillings Phone: (810) 986-2916 GM R&D Center Fax: (810) 986-3003 M/C 480-106-390 Email: [email protected] 305000 Mound Road Warren, MI 48090-9055 Developing designs and implementing solutions to meet project team needs related to use of the MDL for design projects in courses and MDL hosted and sponsored activities. C1. MDL Scheduling Website and Optimization Sponsor Organization: MDL Faculty Advisor: Mark Steiner, Clinical Associate Professor, Mechanical, JEC 4024 IME Opportunity: Two IME teams on separate tracks developing competing systems. The end product is a usable system. Current Status: Previous team over one semester just cracked the surface for this problem or opportunity. While the application is the MDL for the project, expansion to other reserved facilities on campus is likely such as conference rooms, meeting rooms, and study rooms in the library. The goal is a working scheduling system by project end. Project Background and Objectives: The MDL will provide students, faculty, and project sponsors a readily accessible and open environment in which to share ideas, stretch thinking, exercise creativity, and develop synergy. The objective of this project is to develop a web based scheduling system for the rooms of the MDL which can be used by faculty, staff, and students on a semester basis and on a short term basis including the next hour or next day. The use of the web makes the schedule readily accessible for reading in the event a dispute of who is scheduled. Two teams are requested so that two solutions are developed and provided for testing. C2. Meeting and Conferencing Software for the MDL Sponsor Organization: MDL Faculty Advisor: Mark Steiner, Clinical Associate Professor, Mechanical, JEC 4024 IME Opportunity: IME team working towards usable system. Current Status: No previous work has been done on this project. The marketplace shows several products available for such activities via computer and network connections including a Microsoft product packaged with Windows. DSES 4270 Industrial and Management Engineering Design Spring 2001 Page 7 Project Background and Objectives: The MDL will provide students, faculty, and project sponsors a readily accessible and open environment in which to share ideas, stretch thinking, exercise creativity, and develop synergy. The MDL is equipped with over 160 network connections installed to support the virtual project team meeting over the web. This meeting can be between the student on campus in one room, located across the campus at scattered sites, and/or with the project sponsor located in their workplace. The objective of this project is to investigate the state of the art of net based meeting software, to conduct experiments with different products and with different users, to recommend a product, to install and test the product, and to write user instructions for both students and faculty on use of the product for net based meetings among team members. The goal is to provide a turn key system for users on the RPI campus involved in team based project work especially MDL sponsored projects. Conduct a problem stated project in a local firm. Several local firms have volunteered to host a team over the semester and have identified a named “problem”. Student teams are expected to fully complete these projects over the semester and provide a thoroughly developed solution to the client firm. D1. Chart Scanning Analysis and Proposal Sponsor Organization: Northeast Orthopaedics, Albany, New York Contact is Alan Okun at 453-0596. Email at [email protected] Faculty Advisor: To be assigned. IME Opportunity: IME team working towards solution that satisfies customer or client need. Current Status:. New project proposed by sponsor. Sponsor has looked at some existing vendors. Project Background and Objectives: Purpose/Goal: To fully analyze the need for and make recommendations related to incorporating chart scanning into a busy medical practice. Outcomes would include: Flow chart of current charting process, Review of various scanning options and products (competitive analysis) including features, costs, benefits, results of reference checks, etc., Flow chart of new process incorporating scanning into it, Cost/benefit analysis, Recommendations including implementation plan. Skills/Tools Required: Flow chart analysis, Research skills/ techniques, Spread sheet development, Interviewing skills, Cost/benefit analysis, Report writing. Final Report: Complete written report incorporating outcome components listed above and presented to Senior Management Team of Northeast Orthopaedics upon conclusion. While the sponsor has specifically requested the assessment of scanning systems, the team should investigate other computer representations of medical charts and study their use in this practice as well. D2. Sponsor Organization: Faculty Advisor: IME Opportunity: IME team working towards solution that satisfies customer or client need. Current Status:. Project Background and Objectives: D3. Sponsor Organization: Faculty Advisor: IME Opportunity: IME team working towards solution that satisfies customer or client need. Current Status:. Project Background and Objectives: D4. DSES 4270 Industrial and Management Engineering Design Spring 2001 Page 8 Sponsor Organization: Faculty Advisor: IME Opportunity: IME team working towards solution that satisfies customer or client need. Current Status:. Project Background and Objectives: Design and develop a working and usable prototype to meet the needs of an identified disabled person or group of users under a National Science Foundation (NSF) funded program. NSF funds are available to purchases supplies and materials that become part of the prototype. Teams on these projects would work closely with the disabled person or persons who administer to the disabled. E1. Underwater Exercise Equipment Sponsor Organization: NSF Faculty Advisor: Mark Steiner, Clinical Associate Professor, Mechanical, JEC 4024 Others to be assigned at a later date IME Opportunity: IME team working towards solution that satisfies customer or client need. IME team may want to seek other engineering students for this project. There appears to be high possibility of new product development and new market development in this project. Current Status:. Client group has been identified and contacted. Project Background and Objectives: NSF funding is available for prototype construction. In water exercise has proven beneficial for many persons both the able and disabled. Water aerobics is a regular feature in many YMCAs. The therapeutic benefit of water exercise has long been recognized and water exercise rehabilitation is used on many persons including college athletes. But water exercises for those with many physical impairments is difficult and often requires a constant companion for stability and safety. The objective of this project is to design water exercise equipment that allows more persons to enjoy water based exercise especially persons who currently require one to one assistance when exercising in the water. E2. Easy Open/Close and Easy Passage Door for Retrofit into Existing Homes of Disabled Persons Sponsor Organization: NSF Faculty Advisor: Mark Steiner, Clinical Associate Professor, Mechanical, JEC 4024 Others to be assigned at a later date IME Opportunity:. IME team working towards solution that satisfies customer or client need. IME team may want to seek other engineering students for this project. There appears to be high possibility of new product development and new market development in this project. Current Status:. No client group has been identified for this project. Project Background and Objectives: One of the many obstacles facing a disabled person living in the community especially a person with a mobility disability that requires them to be in a wheelchair or other type of wheel conveyance is the passage between rooms. While furniture can be moved around in a room or removed from a room to create a more open path, moving between rooms always requires passage through a doorway. One of the most difficult passages is into and out of the bathroom. The standard door width for bathrooms was 24 inches nominal for over 50 years and it is still used in home construction. Further the standard door hinge configuration is to have the door open into the room. In the bathroom, this means we close the door behind us as we enter by pushing it. For persons in a wheelchair, pushing a door is easier but because doorway passage is in both directions, a push I one direction is a pull in another. The opportunity seems to present itself for a low cost door option that can easily be retrofitted into homes that makes it easier for the disabled to move between rooms. NSF funding may be available for prototype construction if an user client is located. Locate and identify a disabled person or group of users and design and develop a working and usable prototype to meet their needs. The teams first responsibility would be locate a need of the disabled and identify a person DSES 4270 Industrial and Management Engineering Design Spring 2001 Page 9 or persons with that need. NSF funds are available to purchases supplies and materials that become part of the prototype. Teams on these projects would work closely with the disabled person or persons who administer to the disabled. F1. Team Identified Disabled Client and Opportunity Sponsor Organization: NSF Funding Possible Faculty Advisor: Mark Steiner, Clinical Associate Professor, Mechanical, JEC 4024 Others to be assigned at a later date. IME Opportunity: IME team working towards solution that satisfies customer or client need. Team would have to find an opportunity and a client for the project. Current Status:. No client identified. Need has not been identified. Project Background and Objectives: The teams first responsibility would be locate a need of the disabled and identify a person or persons with that need. NSF funds are available to purchase supplies and materials that become part of the prototype. Teams on these projects would work closely with the disabled person or persons who administer to the disabled. DSES 4270 Industrial and Management Engineering Design Spring 2001 Page 10