Problem Set 2 V2 F23
pdf
keyboard_arrow_up
School
Cornell University *
*We aren’t endorsed by this school
Course
MISC
Subject
Industrial Engineering
Date
Jan 9, 2024
Type
Pages
2
Uploaded by hooooope
CHEME 5610: Product Design/Lean Operations Design
Problem Set #2 (50 Points): Assigned September 5, 2023
Due: September 19, 2023
1.
You are developing a new water treatment cartridge for
residential customers at your company.
The cartridge
contains three internal chambers that are separated from each
other by wire mesh screens.
Water flows in series from the
first chamber to the last.
Each chamber performs a specific
function:
the first chamber contains a ceramic filter and wire
mesh screen to remove particles from the water; the second
chamber contains a specially-formulated activated carbon
and wire mesh screen to adsorb any organic compounds in
the water; and the third chamber contains pellets made of a
new, zeolite-based water softener.
"Hard" water contains
relatively high concentrations of dissolved calcium and
magnesium, which tend to form hard-to-remove solid
deposits in many appliances. A water softener removes these
divalent cations from solution and replaces them with sodium
and potassium ions.
These monovalent ions have a lower
tendency to form solid deposits, making the water "soft".
The three chambers of the water treatment cartridge are
housed in a cylindrical metal vessel with threaded pipe
fittings at each end (see Figure 1).
Water flowing through
the outlet pipe will turn a small paddle wheel which is
mechanically connected to a totalizer and display window.
As the amount of water processed by the device increases,
the wheel will turn and slowly advance the totalizer display
from "0% used" to "100% used - replace cartridge" in 10%
increments.
There are no electrical components or wires
anywhere within the water softener cartridge.
The paddle
wheel and totalizer are calibrated at the factory to display
"100% used" after 150,000 gallons of water (the average
annual water consumption of a US-based household of 4
people) have passed through the device
Customers will be instructed to mail the spent cartridge back to your company when the display indicates "replace
cartridge”.
A replacement cartridge will then be shipped to the customer.
There are no user-serviceable
components within the water treatment cartridge.
Please use the product design and reliability concepts we discussed in class to answer the questions below.
a.
(15 points)
Complete an FMEA of your company’s water treatment cartridge using the template available on
Canvas.
b.
(5 point)
Identify the one failure mode (and ONLY one failure mode) that you think poses the biggest risk to
your company’s customers, and justify your answer using your FMEA analysis.
Do you have any ideas that could
mitigate this risk?
Please explain your ideas and how they might mitigate this risk.
c.
(5 point)
Critically assess one of your scores for severity, probability or detectability in the failure modes
listed in your FMEA.
Identify one failure mode (and ONLY one failure mode) that could be important to
Figure 1:
Sketch of the new water treatment
cartridge.
water flow in
water flow out
chamber #1
particle filtration
threaded
pipe fitting
chamber #2
organic adsorption
chamber #3
ion exchange
paddle wheel, flow
totalizer, and display
wire mesh screen
CHEME 5610: Product Design/Lean Operations Design
Problem Set #2 (50 Points): Assigned September 5, 2023
Due: September 19, 2023
understand the sensitivity of the overall risk to your assumptions, and explain why.
How would your overall risk
change for that failure mode in your sensitivity assessment? What would you need to do to mitigate this
sensitivity?
Again, please explain your reasoning.
2.
(
10 points)
A)
After listening to “Happy Family Organics”, what are the 3 most significant take-aways you get from
the podcast as it relates to start-ups.
Describe your thoughts in no more than a single page, single spaced.
B)
Following your completion of A) above, ask Google BARD the same question and describe, in no
more than ½ a page single spaced, two differences in your take-aways vs what BARD provided and
critique those two differences for validity.
3.
You have been developing this product for the last three years.
Over the course of that time, you have built
and tested numerous sets of prototypes.
Each set of prototypes contained changes and improvements based on the
observations from previous generations.
Reliability data from this test program is given in Table 1 below.
a.
(10 points)
Based on customer feedback, your company will not launch this new product until the
unscheduled service call rate (USCR) is less than 1.0 calls per year.
You have a gate review meeting for
the project next week, and one of the deliverables is to estimate when the product will be reliable enough
to start commercial sales.
Use the tabulated reliability data to project the
number of additional months
of prototype development that will be needed in order to have a product with the reliability required for
launch.
b.
(5 point)
You have heard that another company is developing a competing product based on reverse
osmosis technology.
The business unit for your company has told you that this competing product will be
available for sale worldwide in 12 months. Will you be able to beat your competitor to market?
Please
answer "yes" or "no" with supporting logic, and estimate the amount of time between the launch of your
product and the launch of your competitor’s product.
Test Number
Number of Units
in Test
Start Date of Testing
(mm/yyyy)
USCR
(calls/year)
1
15
Oct 2011
18.9
2
12
Jan 2012
12.1
3
17
June 2012
11.9
4
14
Oct 2012
9.4
5
16
Jan 2013
6
6
14
March 2013
6.5
7
16
May 2013
3.5
8
12
Aug 2013
4.2
Your preview ends here
Eager to read complete document? Join bartleby learn and gain access to the full version
- Access to all documents
- Unlimited textbook solutions
- 24/7 expert homework help