Analyzing and Formulizing the Manufacturing Processes for the POOPSTA - Case Study Example

Introduction; POOPSTA is a simple, effective and ingenious device that can transform a plastic bag and a rubber band into the world’s first one-push pooper scooper. POOPSTA has the following features and benefits (poopsta.com/index.html); 1- Poopsta can pick up the dog poo more efficiently than any hand bag. 2- Poopsta can easily enclose the bag-packed poop behind an odor-minimizing lid. 3- It also has a free adjustable easy-clip shoulder strap, which makes it easy to carry. 4- Poopsta is a stool, which has a multi-poop capacity. 5- Due to the capacity there is no need to empty between scoops. 6- Poopsta is completely hygienic as the poop never touches the poopsta when it is used as instructed. 7- Poopsta always works with standard-sized shopping bags or nappy bags. 8- There is no need to stoop for picking up the dog poo as it already has a free shoulder strap. 9- It is tested that poopsta can pick up the sloppy poop even in long, marshy grass, even better than the hand bags. This assignment aims at; 1- Selecting the appropriate and suitable materials for POOPSTA or components of this product. 2- Analyzing and formulizing the manufacturing processes for the POOPSTA (component of the product). 3- Identifying the machines, the tooling and the manufacturing parameters for each of the manufacturing processes. 4- Suggesting a better design for the product by using any CAD package in order to improve the package. 6- Analyzing the performance of the product by using any CFD package or any FEA package, for the improvement of the product. Manufacturing of POOPSTA includes; Manufacturing of POOPSTA has different stages. On these various stages different techniques are employed. These techniques include, product design, machinery and tooling, materials, process planning, purchasing of the materials, manufacturing processes, manufacturing process requires production control, support service, sales, marketing, shipping, customer service (Serape Kalpak Ian, Steven R. Schmidt). Product design; While designing this product concurrent engineering is applied. Concurrent engineering includes analysis of design, production of production, product distribution, manual supplied with the product to give instructions for product’s use, recycling or disposal. Product design also includes lifecycle engineering which means that the product can be reconditioned, remanufactured or it can be recycled. A design for manufacturing is first made then it is assembled and the required materials are selected. Materials; Material is selected while keeping in view its cost and properties of the materials I-e physical, mechanical, chemical and manufacturing properties. Mechanical behavior of the material is also checked by testing it by different methods. While selecting the metal alloys, their structure and strength is checked by heat treatment. Manufacturing process Manufacturing process involves manufacturing technology along with the metal casting process (a process in which different car parts are fixed in a typical passenger car). While selecting the manufacturing processes, over engineering should be avoided, manufacturing should be net shape, manufacturing must be sustainable, global competitiveness should also be considered. Manufacturing process is of three types, a) Plug Manufacture, b) Mould Manufacture, c) Component Manufacture. A plug; is a representative model of the component from which a mould can be taken. Plugs can be made from wood, metal, plastic, foams; any none porous materials. Types of Plug; There are two principle types of plug, male and female. Male plugs make female moulds and vice-versa. Mould Features; Features can include return edges, wide flanges, sharp corners, fillets, bolt fixings and other areas requiring special attention. It is important when working with composites that the mould is made from the same material as the final component. This reduces the possible size variations due to thermal expansion. The stiffness of the mould is directly related to its thickness, the stiffness can also be inherent in the shape of the mould. It is an important consideration in large flat shaped moulds. Component Manufacture; Component manufacture involves basics of a composite which are to be made from multiple materials with different properties that are combined to make a new material that takes advantages of these properties. These are normally a fibrous material suspended in a resin. Glass is the most common fiber; it is available in woven, chopped strands and layers of unidirectional strands. The most readily available resin is polyester resin, dissolved in styrene monomer; this represents a good value option for composite components. Principles for the economic production; The main principles which should be followed by manufacturing POOPSTA are; 1- The quality of the product must be assured. 2- Total quality should be managed. 3- General trends in manufacturing should also be given due importance. Metal casting process; The metal casting process involves fundamental principals of metal casting; a design for metal casting is also prepared. Metal casting process involves pouring down of molten metal into a molded pattern, after the manufacturing of the part of the POOPSTA. Then, this molten metal is allowed to cool down and solidify, after that, the part is removed from the mould. Advantages of casting for the POOPSTA; The process of casting metals has some important advantages, mentioned below; 1- It is a versatile process that explores complex geometry, hollow sections and internal cavities of the metals. 2- By utilizing this process different and versatile parts of metals can be cast like the small part of ~10 grams and large part of ~1000 Kg. 3- This very economical process, the metal is not wasted in a large amount; the wastage of metal is very little. The extra metal is re-used in this process. 4- The process of casting metals is an isotropic process; all the casted parts of metals have same properties along all the directions. Important features of casting process; The important clauses in casting process are the flow of the molten metal into the mould cavity; the mould design and the fluid flow. The cooling down and solidification of the metal responds to the ambient temperature. The shape, size, uniformity and the chemical composition of the metal grained formed throughout the casting process. Types of the metals are also paid due heed. The thermal properties of the metal and shape of the mould, the volume vs. the total surface area of the casting process can be counted as following. Temperature works as a function of time for the solidification of pure metals in the casting process. By using the nucleating agents three cast structures of metals can be obtained. These three cast structures are a) pure metals, b) solid-solution alloys, c) structure. The capability of the molten metal of filling the mould cavities is called “fluidity”; there are two basic factors of fluidity; 1- The characteristics of the molten metal. 2- The casting parameters; a) surface tension, b) solidification pattern of the alloy, c) viscosity and inclusions, d) mould deign, e) pouring temperature, d) mould material and its surface characteristics and rate of pouring. Defects of casting process; There are also certain defects of this casting process; 1- The projections of the metals into different directions. 2- Cavities of various metals. 3- Discontinuities during the entire process at different stages. 4-Due to the discontinuities the casting process sometimes remains incomplete for long durations. 5- Incorrect dimensions or shapes of the metals. 6- Inclusions, during the casting process. Different types of casting process; Different kinds of casting process used in the manufacturing of POOPSTA are as follows; 1- Sand casting process. This process includes dried or baked sand moulds prior to pouring the metal. 2- Shell mould casting process. It is lost foam, evaporative-pattern process. The metal is dipped in refractory slurry which is dried. Sand is also added in order to provide support. When liquid metal is poured the foam evaporates and the metal fills the shell. The shall part is then broken, polystyrene pattern is applied and sand is provided as support. Molten metal is then separated the polystyrene burns and gas escapes. 3- Plaster mould casting process. In this process wax pattern is used in which molding id injected. A shell is built; it is then immersed into ceramic slurry. After immersing into ceramic slurry it is immersed into fine sand. The wax is then melted. The molten metal is poured, cooled and solidified. 4- Ceramic mould casting process. The suitable materials for this process are Aluminum, Zinc, copper-based alloys and magnesium. These alloys are of low temperature. Impellers and cutters for machining operations. 5- Evaporative pattern casting process. 6- Investment casting process. It is a low pressure and vacuum casting. Materials which are used and suitable for this process is ferrous and non-ferrous metals and alloys. Some of the typical products are valves, cams and gears etc. 7- Permanent mould casting process. Die mould casting process; It is the permanent mold and rotated about its axis at 300 ~ 3000 rpm the molten metal is poured, then the Surface finish is done in a much better manner along outer diameter than inner, the Impurities are automatically removed by inclusions of other metals. This has to be taken care of those Defects and associated problems like avoid sharp corners, use fillets to blend section changes smoothly avoid rapid changes in cross-section areas. The other process involved in manufacturing POOPSTA is fusion welding process. Principles of Fusion welding process; A general term used to describe any welding process, which uses a fuel gas combining with oxygen to produce a flame. This flame is the continuous source of heat, which is used to melt the metals at the joint. The most common gas-welding process uses acetylene, and this process is known as oxyacetylene-gas welding (OAW) and is used typically for structural sheet-metal fabrication, automotive bodies, and different repair works. The flame temperature sometimes reaches 3300 C. Filler rod (Consumable) is used as an additional supply of metal to weld when it is required. The Shielding flux may be used as protection of weld pool when necessary. Welding quality and defects of fusion process; It has different types namely; a) Forge Welding (FOW), b) Cold Welding (CW), c) Friction Welding(FRW), d) Resistance Welding (Spot Welding), e) Explosive Welding (EXW), f) Diffusion Welding (DFW) and Ultrasonic Welding (USW) process respectively. Brazing and soldering processes; Brazing is a joining process in which a filler metal is placed between the faying surfaces which have to be joined and the temperature is raised sufficiently to melt the filler metal (but not the components). Thus Brazing is a liquid-solid-state bonding process. Soldering is the process of making a sound electrical and Mechanical joint between certain metals by joining them with a soft solder. This is a low temperature melting point alloy of tin and lead (Weman, Klas, 2003). The joint is heated to the accurate temperature by using soldering iron. Given below are the various chassis; 1- The Material and its various forms. 2- Manufacturing processes, required machines and tools or dies. 3- Quality and/or productivity improvement. Manufacturing technology also involves powder metallurgy; Powder metallurgy; Processing of the metal powders includes; 1- The Production of metal powders. 2- Compaction of the metal powders. 3- Sintering of the metal powders. 4- Additional operations and finishing operations. 5- Design considerations for the processing of the metal powders. Atomization; Atomization of the metal powders involves; 1- Chemical reduction, the reduction of metal oxides from the metal powders. 2- Metal carbonyls are injected by allowing the iron and nickel react with carbon monoxide. 3- The mechanical comminuting that includes crushing, milling of powder in a ball mill or the grinding of the brittle metals into small particles. 4- Mechanical alloying of the metal, powers of two or more [pure metals are mixed very finely in a ball mill. The atomization of powder metals have different stages in the manufacturing of POOPSTA, are mentioned below; 1- Net shape manufacturing of the component of the product (POOPSTA). 2- Minimum wastage of material while operating the entire process. 3- Production of porous parts of the product, typically for self-lubricating applications. 4- To produce parts from material difficult to process for the production of components of POOPSTA. 5- To produce parts with special alloying contents. 6- Good dimensional control over the materials during the manufacturing process and welding process in which the metal is melted. 7- This entire process can be automated for economic production. The classification of ceramics produced during the manufacturing process is as follows; a) Traditional or natural ceramics such as white ware, tiles, bricks, sewer pipe and pottery. B) Industrial ceramics or engineering ceramics for turbine, automotive, and aerospace components as well as seals and cutting tools. The ceramics are composed of at least two elements, i.e. metallic element and non-metallic element. NaCl, Si3N4, AL2O3, SiC respectively. Ceramics are based on ionic bonding or covalent bonding in crystal structures. The Crystal structure is strongly influenced by bonding. This influences mechanical & physical properties in the ceramics. E.g. most ceramics are not electrical conductors; little ductility at room temperature. Some natural materials are also used while making ceramics such as clay, Flint: a rock composed of very fine-grained silica, SiO2, Feldspar and Porcelain. Properties of ceramics; 1- The ceramics are brittle in structure. 2- Ceramics have High strength and hardness at elevated temperatures. 3- Ceramics have High elastic modulus. 4- Ceramics normally have Low toughness, ductility, density and thermal expansion. 5- Ceramics lack impact toughness and thermal-shock resistance. 6- Ceramics have Low thermal and electrical conductivity. There are also different types of plastics used in the production of POOPSTA; These types include; Thermo-plastics i.e. Thermosets. For thermosets, the temperature is slowly raised and the curing reaction is takes place. This curing reaction, unlike that of thermoplastics, is also irreversible. Examples are baking cakes and boiling eggs. The polymerization process for thermosets generally takes place in two stages. The first stage occurs at the chemical plant. The second stage occurs at the parts-producing plant, where it is called plastics processing. General properties of thermoplastics: 1- These are more durable, harder, tough, and light. Typical uses of thermoplastics: Thermoplastics are used in automobile parts and construction materials. And very good for use in the manufacturing of a good poopsta. Properties of Thermosets; 1- These are Unsaturated Polyesters: lacquers, varnishes, boat, hulls, and furniture. 2- These thermosets plastics are used in Epoxies and Resins as glues, coating of electrical and circuits. 3- Thermosets are applied as Composites, fiberglass in helicopter blades ad boats etc. 4- Thermosets have rubber-like properties. 5- Thermosets are used in medical masks, gloves and rubber-substitutes. Plastics Processing: Extrusion Open cross-sections (channels) are closed cross-sections (tubes, pipes) pellets. Plastics processing has different kind like Blow Molding, Compression and Transfer Molding and glass and plastics processing (Lincoln Electric, 1994). In blow molding Sheet of plastic is Heated (soft) Molded using a shaped die. Compression and transfer molding process is used; 1- Mostly for thermosetting polymers. 2- The mold is heated and closed using pressure. 3-plastic always flows to fill the cavity. 4- The flash is trimmed by finishing. 5- Dishes, handles for cooking pots, skis, housing for high-voltage switches some rubber parts like shoe soles and even composites such as fiber-reinforced parts are molded by using the compression and transfer molding process. Turning: 1- Turning is a method used for removing the surface from the circular part by bringing the cutting edge of a tool against it while the part is revolving. 2) Turning is the machining operation that produces cylindrical parts or rotating parts. Machine tool used for turning: The basic machine tool for turning is lathe.. It is usually considered as the "father" of all other machine tools because many of its fundamental mechanical elements are incorporated into the design of other machine tools. Specific calculus for machining parameters in Turning; If: N = 530 [rev/min] f = 0.1 [mm/rev] Fr = 53 [mm/min] Feed rate; Fr [mm/min] If initial (raw material) diameter: Di = 120 [mm], and final (required), Diameter DF = 110 [mm], Then d = 5 [mm] Depth of cutting; d [mm] If cutting speed V = 100 [m/min], Work piece diameter D0 = 60 [mm], Then N = 530 [rev/min] Rotational Speed; N [rev/min]. After turning, drilling is done in manufacturing the components of POOPSTA. Definition of Drilling: Drilling is a machining process in which a multi-point cutting tool is used to penetrate the surface of a work-part and makes a cylindrical hole (Cary, Howard B; Scott C. Helzer 2005). The most common tools are twist drills that generally perform both cutting motion (rotation) and the feed motion (translation). Characteristics of Drilling; There are some characteristics of drilling that sets it apart from other metal cutting operations. Among these are: 1- The chips must exit out of the hole created by the cutting and the exit of chips can cause problems when these are large and/or continuous. 2- The drill can wander upon entrance and for deep holes. 3- Drilling operation does not need very highly skilled operators. Drilling parameters; 1- Depth of cut: it is the depth of the hole generated by the drilling process. 2- Feed rate: The rate that the drill advances into the material; it is generally measured in distance per flute. 4- Thrust: The axial force needed while drilling. 5- Torque: The twisting moment required to drill. 6-Surface Finish: The roughness of the walls of the drilled hole; it is the measurement of the hole quality. Machining process; Machining is a family of shaping operations in which excessive material is removed from a starting work part (raw material) so that what remain is the desired geometry in accordance with needed shape, dimensions and roughness. Machining is a manufacturing process in which a sharp cutting tool is used to cut away material to obtain the desired part shape. Machining process involves various hardware, a) relays, b) magnetic contractor, c) motor starter, d) solenoid, e) solenoid valves. a) Relays; Relays are electromechanical devices that operate through an electromagnet formed by passing current through a coil of wire. They can be considered as switches activated by the movement of a soft iron plate through magnetism. b) Solenoid; A solenoid is a device used to convert an electrical signal or electrical current into linear mechanical motion. A solenoid valve is a combination of two basic, functional units: 1) A solenoid. 2) To control hydraulics (oil fluid), pneumatics (air), or water flow. c) Solenoid valves; Directional solenoid valve (are commonly called spool valves) start, stop and control the direction of the flow path (http://www.canlii.org/qc/laws/sta/i-9/20050616/whole.html.) 1- Any machining process assumes a relative motion, between the cutting tool and work piece. 2- For all these motions, belong either to tool or work piece, a geometrical axis can be allocated. 3- A CNC controller is responsible for these motions: * Direction * Speed * Length of time each motor runs (distance, angle), Acceleration & deceleration 4- A programmed path is loaded into the machine's computer and then executed. 5- The program consists of numeric point data in conjunction with specialized machine control, commands and function codes. 6- Numerical control (NC) is the original term given to this technology and is still often used interchangeably with CNC. Machining process is required to; 1- Obtain the final shape for a PARTY. 2- Get the needed and final accuracy of dimensions. 3- Acquire the required quality of the surface. There are four types of chips used in machining for the manufacturing of POOPSTA, Types of chips; these types include A) Discontinuous chips. B) and Continuous chips. These are narrow, straight and primary shear zone chips and have secondary shear zone at chip-tool interface (Hicks, John, 1999). c) Build-up edge (BUE) chips. These have build-up deposit on the tool’s edge. d) Segmented chips: non-homogeneous chips. Milling; Milling is a machining process where a work part is shaped and sized by feeding material to a rotating; multiple tooth cutters that remove material during each pass (Blunt, Jane; Nigel C. Belching, 2002).Material may be feed vertically or horizontally. Things to be kept in mind while milling; 1. Machining setup assembly of the equipment. 2. Work setting & measurement. 3. Program zero point. 4. Tool setting and measurement. 5. Safety height. 6. Machining process planning. 7. Selection of tools (or cutters). 8. Machining parameters calculation, cutting speed, spindle speed. NC Machine Tool; 1- It is operated manually by Operator and Automated by Industrial Robot. If operated manually by Operator; 1- The cutting parameters are adjusted. 2- The cutting fluid is started. 3- The cutting motion is started. 4- The cutting depth is corrected and adjusted. 5- Start the feed motion. 6- Finally the whole machining process is started. All machine controllers perform the same, basic functions; 1- Machine controllers Receive data for input. 2- They Process the received data. 3- Output the processed data. 4- Interface with other equipment. Conclusion. Poopsta is a wonderful invention with many benefits. It has a simple but intricate manufacturing process. The manufacturing concepts are detailed like any other product. The technology employed contains all the processes that are needed in the manufacturing of a high tech car or a computer. Manufacturing of POOPSTA has different stages. On these various stages different techniques are employed. These techniques would include, product design, proper machinery and tooling, proper selection of materials, process of planning, purchasing of the materials, detailed manufacturing processes, the manufacturing process requires proper production control, support service, sales, marketing, shipping, customer service. The design concepts must be clear for the beginners of the manufacturing of poopsta. The designs are many but only those should be selected that are more efficient, economical, handy and easy to pick by the customers (Ambrose Krishna, 1999). The casting, molding, drilling, plastic alloying and welding processes are very detailed and must be taken care of. This wonderful product is very much liked in Japan, China (Needham, Joseph 1986)., Hong Kong, Singapore and Koreas. However, recently the European countries and North America (Cato Institute) have also shown a lot of interest in this product for its benefits. Therefore, this report answers the entire questions abbot the manufacturing of a good quality poopsta (André Shalom, 2007). However it is suggested that during the manufacturing process of poopsta all the environmental concerns like air, water and soil pollution (Joseph, Keith , 1976). This should be kept in mind and all the social corporate responsibility towards education (Friedman, David 2006). And literacy, poverty alleviation, gender equality and government levies and taxes must be fulfilled at all costs (http://onlineethics.org/codes/.). In this way the production, manufacturing and sales of poopsta can be spread throughout the world. References 1- poopsta.com/index.html – 2- Cato Institute article: Thriving in a Global Economy: The Truth about U.S. Manufacturing and Trade 3- Kalpakjian, Serope; Steven Schmid (2005). Manufacturing, Engineering & Technology. Prentice Hall. pp. 22–36, 951–988. ISBN 0-1314-8965-8.  4- Friedman, David (2006). "No Light at the End of the Tunnel". Los Angeles Times. New America Foundation. http://www.newamerica.net/publications/articles/2002/no_light_at_the_end_of_the_tunnel. Retrieved on 2007-05-12.  5- Joseph, Keith (1976). "Monetarism Is Not Enough". Center for Policy Studies. Margaret Thatcher Foundation. http://www.margaretthatcher.org/commentary/displaydocument.asp?docid=110796. Retrieved on 2007-05-12.  6- Burstall, Aubrey F. (1965). A History of Mechanical Engineering. The MIT Press. ISBN 0-262-52001-X. 7- Science and Civilization in China: Volume 4. Taipei: Caves Books, Ltd. 8- "Engineers Act". Quebec Statutes and Regulations (CanLII). ^ 9- "Codes of Ethics and Conduct". Online Ethics Center. http://onlineethics.org/codes/. Retrieved on July 10- .http://www.canlii.org/qc/laws/sta/i-9/20050616/whole.html. Retrieved on July 24 11- ASM International (2003). Trends in Welding Research. Materials Park, Ohio: ASM International. ISBN 0-87170-780-2.  12- Blunt, Jane; Nigel C. Balchin (2002). Health and Safety in Welding and Allied Processes. Cambridge: Woodhead. ISBN 1-85573-538-5.  13- Cary, Howard B; Scott C. Helzer (2005). Modern Welding Technology. Upper Saddle River, New Jersey: Pearson Education. ISBN 0-13-113029-3.  14- Hicks, John (1999). Welded Joint Design. New York: Industrial Press. ISBN 0-8311-3130-6.  15- Kalpakjian, Serope; Steven R. Schmid (2001). Manufacturing Engineering and Technology. Prentice Hall. ISBN 0-201-36131-0.  16- Lincoln Electric (1994). The Procedure Handbook of Arc Welding. Cleveland: Lincoln Electric. ISBN 99949-25-82-2.  17- Weman, Klas (2003). Welding processes handbook. New York, NY: CRC Press LLC. ISBN 0-8493-1773-8  18- André Shalom , 2007. , The small technologies for Greater Things. Cambridge ISBN 19- Ambrose Krishna, 1999, manufacturing concepts. 3rd edition New Delhi publishers. INDIA Read More