Final Project Management Plan

FINAL PROJECT PLAN
MHPSA STEM ELECTRODE REDRESSER MACHINE
MAN 4583 SUMMER 2016
STRATEGICSAMURAIS
ARCHI ADVANI
SHANNON COCHRAN
ZACKARY JONES
JASON RAULERSON
SPENCER STOLFO

2
Table of Contents
Project Charter:..................................................................................................................................3
Project Scope .....................................................................................................................................4
Project Mission:..............................................................................................................................4
Deliverable:....................................................................................................................................4
Requirements:................................................................................................................................4
Limits and Exclusions:......................................................................................................................4
Project Priorities:............................................................................................................................4
Project Change Request Form:.........................................................................................................5
KeyAssumptions:............................................................................................................................6
Stakeholder Analysis:..........................................................................................................................7
Communication Plan:..........................................................................................................................8
Work Breakdown Structure.................................................................................................................9
Work Breakdown Structure Dictionary:..........................................................................................10
Time & Cost Estimates:.....................................................................................................................14
Time Estimates:............................................................................................................................14
Network Diagram:.........................................................................................................................18
Critical Path:.................................................................................................................................19
Direct Cost Estimates:...................................................................................................................19
Schedule & Budget:..........................................................................................................................23
Schedule & MS Project Gantt Chart:...............................................................................................23
Time Phased Budget: ....................................................................................................................24
Risk Management Plan:.....................................................................................................................25
Procurement Plan:............................................................................................................................26
Requestfor Quote: .......................................................................................................................27
RFQ Response Form:.....................................................................................................................28
Responsibility Matrix:.......................................................................................................................29
Quality Management Plan:................................................................................................................35
Raw Materials & Outsources Parts:................................................................................................35
Final Machine Operation:..............................................................................................................36
Quality Assurance Log #1...........................................................................................................37
Quality Assurance Log #2...........................................................................................................37

3
Project Charter:
Below is the official project charter for the MHPSA STEM Elecrode Redresser Machine. This Charter
signifiesthe start of the project.The signaturesrequiredare those of the sponsors,the leadengineerat
MHPSA, the academic advisor at the UCF’s College of Engineering, and as the signature of the project
managers(StategicSamurais).ThisCharterisanagreementof workthat details the scope of the project.
Changes to the scope will have to be done through a change request form (see page 5).

4
Project Scope
Project Mission:
The purpose of thisprojectistocreate amachine andestablishaprocesstoresurface titaniumelectrodes
whentheywearout duringelectrochemical machining(“ECM”).The machine will be usedbyMitsubishi-
Hitachi PowerSystemsAmericaattheirOrlandobranchfortheirShapedTube Electrochemical Machining
(“STEM”) Process. No alterations will be made outside of the intended use of the machine. The STEM
machine is being created to alleviate reliance on outsourcing the electrode resurfacing to vendors. Not
having to rely heavily on vendors will save time and money while increasing process confidence when
manufacturing gas turbine engine components.
Deliverable:
StrategicSamurai’shave beenhiredbythe EngineeringSeniorDesigngrouptohelpthemcreate aproject
plan and manage the delegation of tasks during the designing of the MHPSA STEMElectrode Redresser
Machine.
AlthoughMitsubishi-Hitachi PowerSystemsisaJapanese company,the projectplanwill be completedin
English.
Requirements:
The STEM machine will be able to redress titanium electrodes with a nonconductive coating with
diameters between 1.5mm-1.75mm at a 30-degree angle.
Limits and Exclusions:
The STEMmachine willnotbe abletofix brokenelectrodesandwillonlyredresstitaniumelectrodes.Also,
this machine will not be able to redress mass quantities.
Project Priorities:
The triple constraint that we will be prioritizing throughoutthe duration of thisproject are scope,time,
and cost in order to track the progress of the machine.
Costhasbeenacceptedsincecertainpartsthatare requiredtocreate thismachine willbe purchasedfrom
vendorswithsetprices.Also,whenreferringtocost,nostrictbudgethasbeensetbythe projectsponsor.
Whatever costs the machine retains, will be accepted. Since this machine is being designed to reduce
dependencyonexternalresources,the scope mustbe optimizedinorderforthe teamtocreate the most
efficientmachine.Time isconstrained(inflexible) because thisprojecthastobe completedbya deadline
that has beensetbythe College of Engineeringforgraduatingseniorsandisanon-negotiable factor. The
table below summarizes the project priorities.

5
Project Change Request Form:
The project change request form is included in case a stakeholder wishes to make any changes to the
project.Since thismachine hastowork flawlessly,scope will be enhancedandinorderto make changes,
there has to be a formal method of action in place to keep track of the changes and get approval from
necessary stakeholders.

6
Key Assumptions:
Beloware the assumptionsthatwere made tocomplete the projectplan.These assumptionsshapedthe
decisions made throughout the plan.
 All electrodes that will be redressed are in good enough condition to handle the process.
 Mitsubishi-Hitachi Power Systems has space on the manufacturing floor to accommodate the
machine.
 Once a process is implemented, a worker will be assigned, by MHPSA, to use the machine.
 All approvals can be made in one day.
 Engineering team members work four days a week and 30 hours a week per head.
 Engineering team members are employed by Mitsubishi, they have other tasks that have been
allocatedtothemdifferentfromthisproject.Hence,we knowthattheydonotcommitall of their
man hours to this project. Instead,we are assuming that three out of eight hours of a work day
are devoted to this project.
 None of the overhead costs such as existing machinery and operations will be included in the
budget for this project.

7
Stakeholder Analysis:
The table belowentailsall of the stakeholdersinthis project.A stakeholderisanyone whohasinfluence
or interestinthe productand/orcouldbe affectedbythe final product.
Stakeholder
Register
Power
High,
medium,
low
Interest
(High/Low)
Requirements
UCFCollege of
Engineering
Low Low
Accepted the projectfromMitsubishi Hitachi Power
SystemsAmerica(MHPSA) andisoverseeingthe
qualityandcompletionof the project.
UCFEngineering
SeniorDesign
Students
High High
UCF engineeringstudentsare giventhe opportunity
to designaprojectfor the client,inexchange for
experience,grade,orajobopportunity.
Mitsubishi
Power Systems
America
(Orlando)
High High
Sponsoringoverall projectthroughoutthe duration
of the projectandare the ultimate clientaccepting
the deliverable.
Lead Engineer High High
MHPSA employeewhoisoverseeingthe entire
projectand isthe directsupervisortothe UCF
engineeringstudents.
Operations
Manager
Medium High
MHPSA employeewhooverseesdailyoperationsof
EngineeringDepartment. Initial advocate convincing
UCF College of Engineertoaccept project.
Professor Low Low
Assignedprojectandproject
requirements. However,theydonothave anactive
role inthe project.
Advisor High High
UCF College of Engineeringemployeethatisassigned
to advise studentengineeringteamthroughthe
durationof the project. Advisorwill receive weekly
updatesfromstudentengineeringteam.
Operator
Low High
MHSPA employeethatisresponsible foroperating
the machine deliverable aftercompletionof the
project.

8
Vendors Low Low
Providescomponentsneededtocompletethe
product.
End Consumers
Low High
The end consumerwhowill be purchasingthe final
gas turbine engine thatthe project’s deliverable
helpscreate.
Communication Plan:
The communicationplanbelowdetailsthetype ofcommunicationneeded,whoitgoestoandthe method
of delivery.Thisplanallowsthe teammembersandprojectmanagers to easilyidentifywhoneedstobe
notified for each type of update.
Information
Type
Timing &
Frequency
Sender Receiver Methodof Communication
Status
Reports
Weekly SeniorDesign
Team Leader
Lead Engineerand
Operations
Manager
Face-to-face meetingsand
e-mail.
Milestone
Reports
Twice a
Semester
SeniorDesign
Team Leader
Lead Engineer,
Operations
Manager and UCF
Advisor
Face-to-face andE-mail
Team Status
Reports
Weekly SeniorDesign
Team Leader
UCF Advisor Face-to-face meetings
Deliverable
Issues
As Needed SeniorDesign
Team Leader
Lead Engineer Face-to-face meetings
Purchase
Requests
As Needed SeniorDesign
Team Leader
Lead Engineer Face-to-face meetings
Cost Updates Constantly SeniorDesign
Team Leader
Lead Engineer,
UCF Adviser,and
Team Members
Constantlyupdatedon
shareddrive thatsenders
and receivershave access
to.

9
Work Breakdown Structure.
This work breakdown structure categorizes the type of work needed to complete the project and
granulates the actual work packages that make up the project work. This structure will be the bases of
time and cost estimates.

10
Work Breakdown Structure Dictionary:
Takingthe work breakdownstructure one stepfurther,aWBSdictionarywascreated. Thisdictionary
detailseachworkpackage and givesabrief descriptionforeach.Thisisa useful tool toreferenceif there
are questionsaboutwhatawork package entails.
Outline
I.D.
Activity Name Description
1.0.0 DesignMachine Parts In thisphase,the teamwill identifythe bestoptionforeachpart of
the machine,draw it usingSolidworksCAD,andgetapproval from
theirLeadEngineer.
1.1.0 DesignFrame The team will completethe necessarystepstodesignthe frame
that will holdupthe entire machine.Thisalsoincludesmounting
the metallurgical polishingpadtothe frame,since the frame will be
builtaroundit.
1.1.1 Brainstorm/Research
Options
The firststepin the designprocessistobrainstormoptionsforthe
designandthenresearchwhatmaterialswill be besttomake itout
of.
1.1.2 SelectBestDesign The secondstepin the designprocessistoselectwhichdesignthey
wantto move forward with.
1.1.3 Draw Design UsingSolidworksCAD,the teamwill now draw eachpart that
makesup the frame to bringthe designtolife.
1.1.4 DrawingApproval The final drawingneedsapproval fromthe LeadEngineerwho
closelylooksoverthisproject.
1.2.0 DesignElectrode
HolderAssembly
The team will completethe necessarystepstodesignthe electrode
holderassemblythatwill firmlyholdthe electrode atthe intended
angle duringresurfacing.
Options
of.
wantto move forwardwith.
makesup the holderassemblytobringthe designtolife.

11
1.3.0 DesignZ-axis
Fasteningassembly
The team will completethe necessarystepstodesignthe Fastening
assembly.Thiswillbe the branchstemmingfromthe base of the
machine thatholdsthe electrode holderassemblyatthe proper
angle andsupportsit during redressing.
Options
of.
1.3.2 SelectBestDesign The secondstepin the designprocess istoselectwhichdesignthey
wantto move forwardwith
makesup the fasteningsystemtobringthe designtolife.
1.3.4 Get approval The final drawingneedsapproval from the LeadEngineerwho
1.4.0 DesignMotor
Assembly
The team will completethe necessarystepstodesignthe motor
and gear/pulleysystemthatwillmove the polishingpadagainstthe
electrode tipandmove the holderassemblyatthe properheight
for redressing.Thispartalsoincludesthe designof all wiringand
powercomponents.
Options
designandthenresearchwhatmaterials will be besttomake itout
of.
makesup the motorassemblytobringthe designtolife.
1.5.0 DesignMachine
Enclosure
The team will completethe necessarystepstodesignthe enclosure
of the machine.
Options
of.
1.5.2 SelectBestDesign The secondstepin the designprocess istoselectwhichdesignthey
makesup the frame to bringthe designtolife.

12
closelylooksoverthis project.
1.6.0 DesignLubrication
System
The team will completethe necessarystepstodesignthe
lubricationsystemthatwill pushwaterontothe metallurgical
polishingpad.Thiswill keepthe electrodetiplubricatedtoprevent
damage duringredressing.
Options
of.
wantto move forward with
makesup the lubricationsystemtobringthe designtolife.
closelylooksoverthis project.
1.7.0 Write Machine
ComputerCode
The team will completethe necessarystepstowrite the computer
code that will tell the machine whattodo.
Options
The firststepis to brainstormoptionsforthe designandthen
researchwhatthe code shouldlooklike andwhatfunctionsit
shouldhave.
1.7.2 Write Code The team will use MicrosoftExcel VBA Macro to developthe
computercode
1.7.3 Code Approval The final code needstobe reviewedbythe LeadEngineerandgiven
approval.Runon G Code Sensorusingchilipepperprogram.
2.0.0 OrderParts/Machine
Parts
Identifywhatpartscan be outsourcedandwhichonesneedtobe
machinedin-house.
2.1.0 OrderMaterialsto
Make MachinesParts
If materialsare not readilyavailable,place orderswithappropriate
vendors.
2.2.0 Purchase Outsourced
Parts
Thissteprequiresthe teamtoidentifyall of theiroutsourcedparts
and place orderswithappropriate vendors.
2.3.0 Machine parts The team will use materialsorderedto machine the partsthey
designed.
3.0.0 Assemble Machine Afterall parts are machinedor delivereditisnow time toassemble
the parts inphasesto complete the machine.

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3.1.0 Assemble Frame The frame is the firstto be built.Thiswill serve asthe structure for
the machine.
3.2.0 Assemble Z-Axis
FasteningSystem
The z-axisisthenconstructedontop of the frame at the correct
angle.
3.3.0 Assemble Electrode
HolderAssembly
The electrode holderisbuiltoff of the z-axisframe toallow vertical
movementof the electrodetothe polishingpadonthe frame.
3.4.0 Assemble Motor The motor and powersource will needtobe addedtothe frame
nextto give powertothe machine
3.5.0 Assemble Lubrication
System
The lubricationsystemwillbe addedtothe frame nexttothe
polishingpadandconnectedtoa watersource.
3.6.0 Assemble Enclosure Afterthe machine isassembled,the enclosure will needtobe built
aroundit.
4.0.0 TestMachine/Final
Report
Afterthe machine isbuilt,testingwill commence andafinal report
will be drafted.
4.1.0 Non-workingdryrun Initial testingof machine componentstoensure properfunction.
4.2.0 DOE TestingThrough
ComputerSimulation
Designof Experiment(“DOE”) willoccurandmachine will undergo
full testing.
4.3.0 Optical Microscopy
Analysis
Aftera testis done,the teamwill analyze the testelectrodeto
ensure properfunctionusingamicroscope.
4.4.0 Redesign Aftertesting,the teamhasallottedtime torevisitthe designof the
machine tomake changeswhere appropriate.
4.5.0 SecondaryDOE If a redesignhastakenplace,anew designof experimentwillbe
draftedandthe machine will be testedagain.
5.0.0 EstablishProcess In orderto implementthe machine ontothe manufacturingfloor,
an official processwill be developed.
5.1.0 DevelopSOPfor
CircularElectrode
In thisstep,the teamwill create astandard operatingprocedure
(“SOP”) detailinginstructionsonhow touse the STEM machine and
redressa circularelectrode.
5.2.0 ModifyCircularSOP
for “Racetrack”
Electrode
In thisstep,the teamwill create astandard operatingprocedure
(“SOP”) detailinginstructionsonhow touse the STEM machine and
redressa “racetrack” electrode.
5.3.0 TrainingProcedure
for Operators
The team will developatrainingprocedure fortrainingnew
employeesonthe machine.

14
5.4.0 Create HR Plan The team will helpdevelopaplanto helpHRtrain future workers.
6.6.0 ProductionRelease Install STEMmachine andbeginintegrationonmanufacturingfloor.
Time & Cost Estimates:
Time Estimates:
Each work package has been assignedatime durationindaysandeach predecessorhasbeenidentified
as below.
ID Work Package Duration Predecessors
1.1.1
Brainstorm/Researchoptions
(Frame)
5 Days None
1.1.2
Select Best Design
(Frame)
1 Days 1.1.1
1.1.3
Draw Design
(Frame)
3 Days 1.1.2
1.1.4
Drawing Approval
(Frame)
3 Days 1.1.3
1.2.1
Brainstorming/Research
options
(Electrode Holder)
5 Days None
1.2.2
Select Best Design
(Electrode Holder)
1 Days 1.2.1
1.2.3
Draw Design
(Electrode Holder)
3 Days 1.2.2
1.2.4
Drawing Approval
(Electrode Holder)
3 Days 1.2.3
1.3.1
Brainstorming/Research
Options
(Fastening System)
5 Days None
1.3.2 Select Best Design 1 Days 1.3.1

15
(Fastening System)
1.3.3
Draw Design
(Fastening System)
3 Days 1.3.2
1.3.4
Drawing Approval
(Fastening System)
3 Days 1.3.3
1.4.1
Brainstorming/research
options
(Design Motor Assembly)
5 Days None
1.4.2
Select Best Design
1 Days 1.4.1
1.4.3
Draw Design
3 Days 1.4.2
1.4.4
Drawing Approval
3 Days 1.4.3
1.5.1
options.
(Design Machine Enclosure)
3 Days None
1.5.2
Select Best Design
1 Days 1.5.1
1.5.3
Draw Design
3 Days 1.5.2
1.5.4
Drawing Approval
3 Days 1.5.3

16
1.6.1
options
(Lubrication System)
5 Days None
1.6.2
Select Best Design
1 Days 1.6.1
1.6.3
Draw Design
3 Days 1.6.2
1.6.4
Drawing Approval
3 Days 1.6.3
1.7.1
options
(Write Machine Code)
3 Days None
1.7.2
Write Code
7 Days 1.7.1
1.7.3
Code Approval
3 Days 1.7.2
2.1.0
Order Material to Make
Machine Part 7 Days
1.1.4, 1.2.4,
1.3.4, 1.4.4,
1.5.4, 1.6.4,
1.7.3
2.2.0 Purchase OutsourcedParts 7 Days
1.1.4, 1.2.4,
1.3.4, 1.4.4,
1.5.4, 1.6.4,
1.7.3
2.3.0 Machine Parts 7 Days 2.1.0
3.1.0 Assemble Frame 2 Day 2.2.0, 2.3.0

17
3.2.0 Assemble Fastening System 1 Day 2.2.0, 2.3.0
3.3.0 Assemble Electrode Holder 1 Day 2.2.0, 2.3.0
3.4.0 Assemble Motor 1 Day 2.2.0, 2.3.0
3.5.0 Assemble LubricationSystem 1 Day 2.2.0, 2.3.0
3.6.0 Assemble Enclosure 5 Day 2.2.0, 2.3.0
3.7.0 Assemble Entire Machine 3 Day
3.1.0, 3.2.0,
3.3.0, 3.4.0,
3.5.0, 3.6.0
4.1.0 Non-Working Dry Run 3 Days 3.7.0
4.2.0 DOE Testing 14 Days 4.1.0
4.3.0 Optical Microscopy Analysis 7 Day 4.2.0
4.4.0 Redesign 14 days 4.3.0
4.5.0 Secondary DOE 7 Days 4.4.0
5.1.0
Develop SOP for circular
electrode. 7 Days 4.5.0
5.2.0
Modify SOP for racetrack
electrode. 7 Days 5.1.0
5.3.0
Training Procedures for
Operations 4 Days 5.2.0
5.4.0 Create H.R ManagementPlan 4 Days 4.5.0
6.0.0 Production Release 7 Days 5.3.0, 5.4.0

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Network Diagram:
The networkdiagramisa visual representationof eachworkpackage inorderof completion.Thisisa
useful tool whenidentifyingpredecessorsandthe critical path.

19
Critical Path:
The critical path startsat activity 1.7.1 andtravels through activities 1.7.2, 1.7.3, 2.1.0, 2.3.0, 3.6.0, 3.7.0,
4.1.0, 4.2.0, 4.3.0, 4.4.0, 4.5.0, 5.1.0, 5.2.0, 5.3.0 andendsatactivity 6.0.0. Thisisthe critical pathbecause
it’sthe longestpath onthe networkdiagram;itcontainszeroslacktimeandtherefore cannotbe crashed.
The total time it will take to complete the entire project is 105 days. The activities on the critical path
consistof writingthe machine code,orderingmaterial andmachine parts,assemblingthe enclosureand
thenthe entire machine,conducting the experiment and finally, releasing the machine to production.
Direct Cost Estimates:
Each workpackage hasbeenanalyzedtoidentifytotal directcosts. Indirectcostshave notbeenaccounted
for because this is not the responsibility of the Engineering team to calculate and include. Most of the
costs incurred come from labor. The total cost for this project is about $22,000.00.
ID
Type of Skill
Required
Number
of
People
Needed
Cost
per
day
per
person
Duration
in Days
Labor
Cost of
Work
Package
Materials or
Other
Resources
Cost of
Material
Work
Package
Total
Direct Cost
1.1.1
Basic Engineering
Background
3 115 5 646.875 None 0 646.875
1.1.2
Basic Engineering
Background
3 115 1 129.375 None 0 129.375
1.1.3
Basic Engineering
Background
3 115 3 388.125
CAD
Solidworks
0 388.125
1.1.4
Advanced
Engineering
Background
1 350 3 393.75 None 0 393.75
1.2.1
Basic Engineering
Background
3 115 5 646.875 None 0 646.875
1.2.2
Basic Engineering
Background
3 115 1 129.375 None 0 129.375
1.2.3
Basic Engineering
Background
3 115 3 388.125
CAD
Solidworks
0 388.125
1.2.4
Advanced
Engineering
Background
1 350 3 393.75 None 0 393.75

20
1.3.1
Basic Engineering
Background
3 115 5 646.875 None 0 646.875
1.3.2
Basic Engineering
Background
3 115 1 129.375 None 0 129.375
1.3.3
Basic Engineering
Background
3 115 3 388.125
CAD
Solidworks
0 388.125
1.3.4
Advanced
Engineering
Background
1 350 3 393.75 None 0 393.75
1.4.1
Basic Engineering
Background
3 115 5 646.875 None 0 646.875
1.4.2
Basic Engineering
Background
3 115 1 129.375 None 0 129.375
1.4.3
Basic Engineering
Background
3 115 3 388.125
CAD
Solidworks
0 388.125
1.4.4
Advanced
Engineering
Background
1 350 3 393.75 None 0 393.75
1.5.1
Basic Engineering
Background
3 115 5 646.875 None 0 646.875
1.5.2
Basic Engineering
Background
3 115 1 129.375 None 0 129.375
1.5.3
Basic Engineering
Background
3 115 3 388.125
CAD
Solidworks
0 388.125
1.5.4
Advanced
Engineering
Background
1 350 3 393.75 None 0 393.75
1.6.1
Basic Engineering
Background
3 115 5 646.875 None 0 646.875
1.6.2
Basic Engineering
Background
3 115 1 129.375 None 0 129.375

21
1.6.3
Basic Engineering
Background
3 115 3 388.125
CAD
Solidworks
0 388.125
1.6.4
Advanced
Engineering
Background
1 350 3 393.75 None 0 393.75
1.7.1
Knowledge of
Software
Development
3 115 3 388.125 None 0 388.125
1.7.2
Knowledge of
Software
Development
3 115 7 905.625
Excel
‘Chilipeppr’
Macro
0 905.625
1.7.3
Advanced
Knowledge of
Software
Development
1 350 3 393.75 None 0 393.75
2.1.0
Knowledge of Part
Specifications
1 115 7 301.875
Multipurpose
Aluminum
(6061-T6)
200 501.875
2.2.0
Knowledge of Part
Specifications
1 115 7 301.875
Water pump,
polishing
pad, motor,
electrical
system, z-
axis, collett
holder,
Computer.
1000 1301.875
2.3.0
Ability to Machine
Parts
1 115 7 301.875 None 0 301.875
3.1.0
Knowledge of
Machine Schematics
1 115 2 86.25 None 0 86.25
3.2.0
Knowledge of
Machine Schematics
1 115 1 43.125 None 0 43.125
3.3.0
Knowledge of
Machine Schematics
1 115 1 43.125 None 0 43.125
3.4.0
Knowledge of
Machine Schematics
1 115 1 43.125 None 0 43.125

22
3.5.0
Knowledge of
Machine Schematics
1 115 1 43.125 None 0 43.125
3.6.0
Knowledge of
Machine Schematics
1 115 5 215.625 None 0 215.625
3.7.0
Knowledge of
Machine Schematics
1 115 3 129.375 None 0 129.375
4.1.0
Knowledge of
Machine Operation
3 115 3 388.125 None 0 388.125
4.2.0
Knowledge of
Experimental
Process
3 115 14 1811.25
MiniTab
Software
0 1811.25
4.3.0
Knowledge of
Experimental
Process
3 115 7 905.625 Microscope 0 905.625
4.4.0
Knowledge of
Machine Proper
Function
3 115 14 1811.25 None 0 1811.25
4.5.0
Knowledge of
Experimental
Process
3 115 7 905.625 None 0 905.625
5.1.0
Knowledge of
Machine Operation
and Knowledge of
Electrode
Redressing Process
1 115 7 301.875
Microsoft
Word
0 301.875
5.2.0
Knowledge of
Machine Operation
and Knowledge of
Electrode
Redressing Process
1 115 7 301.875 None 0 301.875
5.3.0
Knowledge of
Machine Operation
1 115 4 172.5 None 0 172.5

23
5.4.0
Knowledge of
Machine Operation
1 115 4 172.5 None 0 172.5
6.0.0
Knowledge of
ManufacturingFloor
Operations
1 115 7 301.875
All Stainless
Steel Table
700 1001.875
Schedule & Budget:
Schedule & MS Project Gantt Chart:
Below is a schedule and Gantt chart created using Microsoft Project. This was created based off of the
time estimatesforeachworkpackage (see page13).Thisshowsthe flow of tasksthroughoutthe project’s
life.

24
Time Phased Budget:
Below is an excerpt of the time-phased budget for this project. This spreadsheet shows the distribution
of cost throughout each day of the project with each work package. (See attached for full budget).
IDDur.TaskBudget123456789101112131415161718192021222324252627282930313233343536
1.1.15
(Frame)
646.875129.375129.375129.375129.375129.375
1.1.21SelectBestDesign(Frame)129.375129.375
1.1.33DrawDesign(Frame)388.125129.375129.375129.375
1.1.43DrawingApproval(Frame)393.75131.25131.25131.25
1.2.15
(ElectrodeHolder)
646.875129.375129.375129.375129.375129.375
1.2.21
SelectBestDesign(Electrode
Holder)
129.375129.375
1.2.33
DrawDesign(ElectrodeHolder)
388.125129.375129.375129.375
1.2.43
DrawingApproval(Electrode
Holder)
393.75131.25131.25131.25
1.3.13
Brainstorming/Researchoptions
(FasteningSystem)
646.875129.375129.375129.375129.375129.375
1.3.21
SelectBestDesign(Fastening
System)
129.375129.375
1.3.32DrawDesign(FasteningSystem)
388.125129.375129.375129.375
1.3.43
DrawingApproval(Fastening
System)
393.75131.25131.25131.25
1.4.13
(DesignMotor)
646.875129.375129.375129.375129.375129.375
1.4.21SelectBestDesign(DesignMotor)
129.375129.375
1.4.34DrawDesign(DesignMotor)388.125129.375129.375129.375
1.4.43DrawingApproval(DesignMotor)
393.75131.25131.25131.25
1.5.13
(DesignEnclosure)
646.875129.375129.375129.375129.375129.375
1.5.21
SelectBestDesign(Design
Enclosure)
129.375129.375
1.5.33DrawDesign(DesignEnclosure)388.125129.375129.375129.375
1.5.43
DrawingApproval(Design
Enclosure)
393.75131.25131.25131.25
1.6.13
(LubricationSystem)
646.875129.375129.375129.375129.375129.375
1.6.21
SelectBestDesign(Lubrication
System)
129.375129.375
1.6.33DrawDesign(LubricationSystem)
388.125
1.6.43
DrawingApproval(Lubrication
System)
393.75
1.7.13
(WriteCode)
388.125129.375129.375129.375
1.7.27WriteMachineCode905.625

25
Risk Management Plan:
This chart details all of the risks associated with this project. Probabilityand impact have been assigned
and a contingency plan has been created in an effort to deal with this risks if they arise. The impacts of
high,moderate,and lowhave beenassignedonthe basis of the amountof time that the projectwill be
pushed back if the risk occurs.
Risk
ID
Risk Title Risk Description Probability Impact
Response
Strategy
Contingency Plan
1
Operating
Errors
Risk involved with
any errors during
machining of raw
materials.
30% High Mitigate Re-machine parts.
2
Machine
Failure
Experimental
processes may have
to be revisited.
90% High Retain Secondary DOE
3 Design Errors
Initial designs could
be incorrect or not
viable
30% Moderate Mitigate
Lead Engineer approval
before each design is
accepted. Redesign will
occur if problem arises.
4 Outsourcing
Receivingwrong,late
or low quality parts
50% High Mitigate
Return parts to supplier
or receive a refund.
5
Increase in
Material Costs
Cost of raw materials
may increase
20% Low Retain Re-evaluate the budget
6
Increase in
Labor Costs
More labor hours
could lead to higher
labor costs
50% Low Retain
Addmore labor hours per
day to the forecasted
budget.
7
Time
Allotment of
Tasks
Certainaspectsof the
project could take
longer time.
30% High Mitigate Submit change request.

26
Procurement Plan:
The procurement needs for this project come from two work packages. In order to machine parts, raw
materials have to be ordered. Also, any off the shelf parts need to be ordered to be included in the
machine.
Work Package
(WBS)
Procurement
Needs
Time
Frame
Order
Date
Date
Received
Notes
2.1.0 Raw Materials:
Aluminum
7 days 4/25/16 5/4/16 Lead Time isbuiltintothe
schedule toallow forshipping
and receiving.
2.2.0 OutsourcedParts:
Motor
MetallurgicPolisher
CNCController
7 days 4/25/16 5/4/16 Lead Time isbuiltintothe
schedule toallow forshipping
and receiving.

27
Request for Quote:
The RFQ belowisa hypothetical letterthatcouldbe sentbythe Engineeringteamtorequestquotesfor
parts and materialsfromdifferentvendors.

28
RFQ Response Form:
Thisresponse formwasincludedtoallow possible supplierstosubmitaformal quote.Ideally,itwillbe
sentalongwiththe RFQ at the time of procurement.

29
Responsibility Matrix:
Thisresponsibilitymatrix wasincludedat the requestof the Engineeringteam.Issuesarose withthe
teammembersbecause workpackageswere notformallyassignedtoindividuals.The chartbelowis
similartothe work breakdownstructure dictionarywithacolumnaddedtoassignthe work to a team
member.
Outline
I. D
Activity Name Description Names Dates
1.0.0 DesignMachine Parts In thisphase,the teamwill identifythe best
optionforeach part of the machine,draw it
usingSolidworksCAD,andgetapproval from
theirLeadEngineer.
Team 4/21/2016
1.1.0 DesignFrame The team will completethe necessarysteps
to designthe frame thatwill holdupthe
entire machine.Thisalsoincludesmounting
the metallurgical polishingpadtothe frame,
since the frame will be builtaroundit.
Team 2/11/2016
Options
The firststepin the designprocessisto
brainstormoptionsforthe designandthen
researchwhatmaterialswill be besttomake
it outof.
Raef,
Aaron,
Andrew
2/1/2016
1.1.2 SelectBestDesign The secondstepin the designprocessisto
selectwhichdesigntheywanttomove
forwardwith.
Raef,
Aaron,
Andrew
2/2/2016
1.1.3 Draw Design UsingSolidworksCAD,the teamwill now
draw eachpart that makesup the frame to
bringthe designtolife.
Andrew 2/8/2016
1.1.4 DrawingApproval The final drawingneedsapproval fromthe
Lead Engineerwhocloselylooksoverthis
project.
Jared 2/11/2016
1.2.0 DesignElectrode
HolderAssembly
The team will completethe necessarysteps
to designthe electrode holderassemblythat
will firmlyholdthe electrodeatthe intended
angle duringresurfacing.
Team 2/23/2016
Options
it outof.
Raef,
Aaron,
Andrew
2/1/2016

30
selectwhich designtheywanttomove
forwardwith.
Raef,
Aaron,
Andrew
2/2/2016
draw eachpart that makesup the holder
assemblytobringthe designtolife.
Aaron 2/17/2016
project.
Jared 2/23/2016
1.3.0 DesignZ-axis
Fasteningassembly
to designthe Fasteningassembly.Thiswill
be the branchstemmingfromthe base of
the machine thatholdsthe electrode holder
assemblyatthe properangle andsupportsit
duringredressing.
Team 3/3/2016
Options
it outof.
Raef,
Aaron,
Andrew
2/1/2016
selectwhich designtheywanttomove
forwardwith
Raef,
Aaron,
Andrew
2/2/2016
draw eachpart that makesup the fastening
systemtobringthe designtolife.
Raef 2/29/2016
1.3.4 Get approval The final drawingneedsapproval fromthe
project.
Jared 3/3/2016
1.4.0 DesignMotor
Assembly
to designthe motorand gear/pulleysystem
that will move the polishingpadagainstthe
electrode tipandmove the holderassembly
at the properheightforredressing.Thispart
alsoincludesthe designof all wiringand
powercomponents.
Team 3/15/2016
Options
it outof.
Raef,
Aaron,
Andrew
2/1/2016

31
forwardwith
Raef,
Aaron,
Andrew
2/2/2016
draw eachpart that makesup the motor
assemblytobringthe designtolife.
Andrew 3/9/016
project.
Jared 3/15/2016
1.5.0 DesignMachine
Enclosure
to designthe enclosure of the machine.
Team 3/24/2016
Options
it outof.
Raef,
Aaron,
Andrew
2/1/2016
forwardwith
Raef,
Aaron,
Andrew
2/2/2016
draw eachpart that makesup the frame to
bringthe designtolife.
Aaron 3/21/2016
project.
Jared 3/24/2016
1.6.0 DesignLubrication
System
to designthe lubricationsystemthatwill
pushwateronto the metallurgical polishing
pad.This will keepthe electrodetip
lubricatedtopreventdamage during
redressing.
Team 4/5/2016
Options
it outof.
Raef,
Aaron,
Andrew
2/1/2016
forwardwith
Raef,
Aaron,
Andrew
2/2/2016

32
draw eachpart that makesup the lubrication
systemtobringthe designtolife.
Raef 3/30/2016
project.
Jared 4/5/2016
1.7.0 Write Machine
ComputerCode
to write the computercode that will tell the
machine whatto do.
Team 4/21/2016
Options
The firststepis to brainstormoptionsforthe
designandthenresearchwhatthe code
shouldlooklike andwhatfunctionsitshould
have.
Raef,
Aaron,
Andrew
1/27/2016
1.7.2 Write Code The team will use MicrosoftExcel VBA Macro
to developthe computercode
Raef,
Aaron,
Andrew
4/18/2016
1.7.3 Code Approval The final code needstobe reviewedbythe
Lead Engineerandgivenapproval.RunonG
Code Sensorusingchilipepperprogram.
Jared 4/21/2016
2.0.0 OrderParts/Machine
Parts
Identifywhatpartscan be outsourcedand
whichonesneedtobe machined in-house.
Team 5/17/2016
2.1.0 OrderMaterialsto
Make MachinesParts
If materialsare not readilyavailable,place
orderswithappropriate vendors.
Andrew 5/4/2016
2.2.0 Purchase Outsourced
Parts
Thissteprequiresthe teamtoidentifyall of
theiroutsourcedpartsand place orderswith
appropriate vendors.
Aaron 5/4/2016
2.3.0 Machine parts The team will use materialsorderedto
machine the partstheydesigned.
Raef 5/7/2016
3.0.0 Assemble Machine Afterall parts are machinedor delivereditis
now time to assemble the partsinphasesto
complete the machine.
Team 6/9/2016
3.1.0 Assemble Frame The frame is the firstto be built.Thiswill
serve asthe structure forthe machine.
Raef 5/19/2016
3.2.0 Assemble Z-Axis
FasteningSystem
The z-axisisthenconstructedontop of the
frame at the correct angle.
Raef 5/23/2016

33
3.3.0 Assemble Electrode
HolderAssembly
The electrode holderisbuiltoff of the z-axis
frame to allow vertical movementof the
electrode tothe polishingpadonthe frame.
Andrew 5/24/2016
3.4.0 Assemble Motor The motor and powersource will needtobe
addedto the frame nextto give powertothe
machine
Aaron 5/25/2016
3.5.0 Assemble Lubrication
System
The lubricationsystemwillbe addedtothe
frame nextto the polishingpad and
connectedtoa water source.
Andrew 5/26/2016
3.6.0 Assemble Enclosure Afterthe machine isassembled,the
enclosure willneedtobe builtaroundit.
Andrew 6/6/2016
4.0.0 TestMachine/Final
Report
Afterthe machine isbuilt,testingwill
commence anda final reportwill be drafted.
Team 8/29/2016
4.1.0 Non-workingdryrun Initial testingof machine componentsto
ensure properfunction.
Aaron 6/15/2016
4.2.0 DOE TestingThrough
ComputerSimulation
Designof Experiment(“DOE”) willoccurand
machine will undergofull testing.
Raef 7/11/2016
4.3.0 Optical Microscopy
Analysis
Aftera testis done,the teamwill analyzethe
testelectrode toensure properfunction
usinga microscope.
Aaron 7/21/2016
4.4.0 Redesign Aftertesting,the teamhasallottedtime to
revisitthe designof the machine tomake
changeswhere appropriate.
Raef,
Aaron,
Andrew
8/16/2016
4.5.0 SecondaryDOE If a redesignhastakenplace,anew designof
experimentwill be draftedandthe machine
will be testedagain.
Raef 8/29/2016
5.0.0 EstablishProcess In orderto implementthe machine ontothe
manufacturingfloor,anofficial processwill
be developed.
Team 9/28/2016
5.1.0 DevelopSOPfor
CircularElectrode
In thisstep,the teamwill create astandard
operatingprocedure (“SOP”) detailing
instructionsonhow to use the STEM
machine andredressa circularelectrode.
Andrew 9/8/2016
5.2.0 ModifyCircularSOP
for “Racetrack”
Electrode
In thisstep,the team will create astandard
operatingprocedure (“SOP”) detailing
instructionsonhow to use the STEM
Raef 9/21/2016

34
machine andredressa “racetrack”
electrode.
5.3.0 TrainingProcedure for
Operators
The team will developatrainingprocedure
for trainingnew employeesonthe machine.
Aaron 9/28/2016
5.4.0 Create HR
ManagementPlan
The team will helpdevelopaplanto helpHR
trainfuture workers.
Team 9/5/2016
6.6.0 ProductionRelease Install STEMmachine andbeginintegration
on manufacturingfloor.
Jared 10/11/2016

35
Quality Management Plan:
Qualityforthisprojectisdefinedby the EngineeringSeniorDesignteaminconjunctionwiththe standards
and specifications set by Mitsubishi Hitachi Power Systems America and engineering specification
drawingspublishedbythe vendorsof the parts.The purpose of thisqualitymanagementplanistodefine
the specifications needed for the components of the machine, as well as define overall qualityof the
completed machine’s ability to redress worn electrodes.
Raw Materials & Outsourced Parts:
The chart belowdetailsrawmaterialsandoutsourcedparts,the methodof testingtheywillundergo,and
the specificationsneededtopassthe qualitycheck.The qualitiesdetailedwill assistinassuringthe overall
quality of the completed MHPSA STEM Electrode Redresser Machine. If quality is not maintained with
these materials and parts, they will have to be exchanged and retested to ensure function.
Process Action Test Type
Acceptable Process
Standards
Interval
Quality Check of
Aluminum
Passive Test –
Measurements Taken
(80mm x 70mm x
63.5mm) +5mm.
Once
QualityCheck of Motor Active Test
Run motor on 12V
power,testconnection
to CNC Controller.
Once
Quality Check of
Metallurgic Polisher
Active Test
Connect to power to
ensure it will run, Pad
component needs to
be completelylevel +/-
0.0254mm
Once
Quality Check of CNC
Controller
Active Test
Connection to motor
and computer had to
be established and
functional.
Once

36
Final Machine Operation:
The next chart details the qualifications needed at the completion of the project. The specifications will
be for the final dimensions that will be accepted when an electrode is put through the machine. These
tests will be done on the final MHSPA STEM Machine and the results will be analyzed using optical
microscopy. If Quality is not reached in this testing, the machine will need to be analyzed and
specificationswill be changedatthe discretionof the SeniorDesign Team until ideal quality is reached.
Test Subject Process Phase Quality Specifications Assessment Interval
Circular Electrode Initial DOE Testing
Angle Tolerance: 30
degrees +/- 2 degrees
Visual: Identify
presence of “burs” or
uneven surfaces on
redressed electrode.
Diameter: Verify
diameters are
consistent on face of
electrode 2mm +/-
.005mm for larger
diameter; 1.75mm +/-
0.005mm for smaller
diameter.
100 Test Electrodes
“Racetrack” Electrode Initial DOE Testing
Angle Tolerance: 30
degrees +/- 2 degrees
Visual: Identify
presence of “burs” or
uneven surfaces on
redressed electrode.
Diameter: Verify
diameters are
consistent on face of
electrode 3mm +/-
0.005mm for larger
diameter; 1.5mm +/-
0.005mm
100 Test Electrodes

37
Quality Assurance Log #1
The log below can be used during the testing of each material and product. All quality testsneedto be
documented.
Item # Date
Item
measured
Required
Value
Actual
Measured
Acceptable
(Y/N)
Recommendation
Date
Resolved
Item 1
Item 2
Item 3
Quality Assurance Log #2
The logs below can be used during the testing of each type of electrode. All quality tests need to be
documented.
Circular
Electrode
Date
Process
Measured
Required
Value
Actual
Measured
Acceptable
(Y/N)
Recommendation
Date
Resolved
Test 1
Test 2
Test 3
‘Racetrack”
Electrode
Date
Process
Measured
Required
Value
Actual
Measured
Acceptable
(Y/N)
Recommendation
Date
Resolved
Test 1
Test 2
Test 3

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