Senior Design I Final Report

ENGR 4463
Senior Design I
ASU College of Engineering
Display/Box Assembly Project
Final Report
Written By:
Taylor Barnhill
Robert Bise
Kevin Muñoz
Jed Schales
Submitted on: November 17, 2014

REK’M Engineering
State University, AR 72467
Tel: (870) 972-2088
November 17, 2014
Attention: Dr. Tanay Bhatt
Subject: Display/Box Assembly
To Dr. Bhatt:
On August 26, 2014, REK’M Engineering was assigned the task of designing a system
capable of increasing the production rate of cardboard displays created by American
Greetings Corp as well as improving the comfort and safety of all parties involved in the
process. This report covers the material the students have studied and created, the process
used to develop the final design, and figures illustrating the design alternatives.
Feel free to contact us if any questions should arise.
Sincerely,
Taylor Barnhill
Electrical Engineer
Banthi Muñoz
Mechanical Engineer
Robert Bise
Mechanical Engineer
Jed Schales
Mechanical Engineer

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TABLE OF CONTENTS
Section Title Page
TABLE OF CONTENTS ii
LIST OF TABLES iii
LIST OF FIGURES iv
I EXECUTIVE SUMMARY (JS) 1
II INTRODUCTION 2
Background (TB) 2
Constraints (BM) 3
Task Management (RB) 4
III ALTERNATIVE ANALYSIS 5
Brainstorming (TB RB BM JS) 5
Folding 5
Filling 14
Packaging 16
Selection Criteria (BM) 18
IV PRELIMINARY DESIGN (RB) 19
Folding
Manual Folding Flaps (BM-T2) (BM)
User Input and Mechanical Pump (JS-T3) (JS)
Robotic Linkage Folder (TB-T4) (TB)
Hollow Loaded Table (RB-T2) (RB)
Filling
Retractable Shelf (BM-F1) (BM)
Worker-Controlled Hopper (BM-F2) (TB)
Table Space for Product (JS-F2) (JS)
Product Located at Starting Point (JS-F3) (RB)
Packaging
Packaging Chute (BM-P1) (TB)
Break in Conveyor (BM-P2) (BM)
Automatic Taping Machine (JS-P1) (RB)
Weighted Box Holder (JS-P2) (JS)
19
21
24
26
28
30
32
34
35
36
38
39
V SELECTION OF FINAL ALTERNATIVE (RB) 42
Creation of Weighted Indices
Narrowing Alternatives to Final Designs
42
43

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VI FUTURE WORK (TB BM JS) 46
Materials
Fabrication
46
47
Testing and Future Plans 48
VII LIST OF REFERENCES (TB RB BM JS) 50
VIII APPENDICES
Man-Hour Table A-1
Gantt Chart B-1
Surveys C-1
Descriptive Diagrams of Final Designs D-1
Bill of Materials for Final Designs E-1
LIST OF TABLES
Table 1. BM-T2 Bill of Materials 20
Table 2. User Input and Mechanical Pump Bill of Materials 23
Table 3. TB-T4 Bill of Materials 25
Table 4. Cost Breakdown for RB-T2 28
Table 5. BM-F1 Bill of Materials 29
Table 6. BM-F2 Bill of Materials 32
Table 7. Table Space for Product Bill of Materials 33
Table 8. BM-P1 Bill of Materials 36
Table 9. Weighted Box Holder Bill of Materials 41
Table 10. Weighted Indices 42
Table 11. Weighted Property Index Analysis of Folding Preliminary Designs 43
Table 12. Weighted Property Index Analysis of Filling Preliminary Designs 44
Table 13. Weighted Property Index Analysis of Packaging Preliminary Designs 45

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LIST OF FIGURES
Figure 1. Cardboard Display 2
Figure 2. Manual Folding Flaps 20
Figure 3. User Input and Mechanical Pump 23
Figure 4. Robotic Linkage Folder 26
Figure 5. Hollow Loaded Table 27
Figure 6. Retractable Shelf 30
Figure 7. Table Space for Product 34
Figure 8. Packaging Chute 36
Figure 9. Specified Pallet Lift 37
Figure 10. Break in Conveyor 38
Figure 11. Weighted Box Holder 41

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I. EXECUTIVE SUMMARY
For factory workers and their employers, safety is of the utmost concern when
designing any manufacturing process that the worker must perform in their daily routine.
Recently brought into consideration is the manufacturing process associated with creating
a display unit for greeting cards and other seasonal goods that can be found at most
grocery stores during the holiday season. An example of the display making process can
be found at American Greetings in Osceola, AR where workers construct display units in
three basic steps. First, flat cardboard sheets are folded into an empty display unit on top
of a table. Next, workers slide the empty unit along a dummy conveyor to a filling
station where products are then placed into the unit. Finally, the unit is moved to the
packaging station where a box is built from a second flat cardboard sheet, fitted around
the display unit, and then sealed and sent on its way to the shipping department via an
automated conveyor. Due to the size of the cardboard displays, the number of
components associated with a filled and packaged unit, and the vastly different worker
profiles of employees, this process is not currently optimized for worker comfort.
The following report by REK’M Engineering offers a solution that not only increases
worker comfort, but also makes the process safer overall by removing some of the
physical strains imposed on a worker’s body due to the repetitive nature of the process.
While the design is based upon research conducted at American Greetings, the solutions
created by REK’M Engineering were designed to be applicable to any manufacturer that
uses a similar process.
To produce designs that optimized worker comfort and safety the most, the group
started by appropriately defining the problem at hand and listing constraints based on the
limitations imposed due to the Occupational Safety and Health Administration (OSHA),
the American National Standards Institute (ANSI), the Code of Federal Regulations, the
National Society of Professional Engineers’ (NSPE) code of ethics, and the physical
restrictions that arose from the layout of the factory floor and the nature of the
manufacturing process. Once this task was completed, the group individually created
thirty-three possible solutions related to the folding, filling, and packaging processes.
In order to narrow these alternatives down to one folding, filling, and packaging idea
per group member, thirteen selection criteria were developed and given weights based on
a survey conducted at American Greetings. From a narrowing method based solely on
the selection criteria in order to eliminate any member bias, four solutions for each
section of the manufacturing process were found to best fit the thirteen selection criteria,
and each group member then worked on each of their assigned solutions. After each
member had developed their respective alternatives, a second narrowing method based on
a weighted-property-index was employed to select the alternative that would provide the
best solution to the problem.
The proposed final solution consists of a table for folding that features an adjustable
height based on user inputs, a cart for product boxes featuring a slide-out platform that
will aid with the filling process, and a chute that holds packaging boxes in place that will
improve the packaging portion of the process. The group plans to manufacture and test
each of these components in order to further optimize worker safety and other important
criteria so that the final design of each of these components may be fully and properly
specified.

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II. INTRODUCTION
Background
Over the years, American Greetings (AG) has provided many different ways to
communicate with friends and family through the use of greeting cards. These cards
range from congratulating graduates or wishing someone a happy Mother’s Day. The
market for these cards has spread to many large businesses such as Wal-Mart and Target,
along with various smaller businesses. In addition to the large quantities of cards that AG
manufactures, it has started to build cardboard displays and pre-pack the cards into the
displays’ pockets before sending them to stores. Figure 1 shows a typical cardboard card
display that AG builds to send to its buyers.
Figure 1. Cardboard Display
These cardboard displays are built completely by employees standing at a table. This
process requires repetitive movements and muscular endurance by each employee
working at the station. First, a stack of flat cardboard is loaded onto the table from a
separate pile. Then, one employee folds one piece of cardboard into the shape of the
display and pieces together smaller portions to create pockets for the different cards.
After the display has been created, it is passed off to another worker who then inserts the
various cards in their respective pockets. Finally, the completed display with all the cards

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inserted into it is slid into a shipping box and stacked on a pallet waiting to be stretch-
wrapped.
This process of building, filling, and prepping each single display for shipment is
very time consuming. The current setup has also been reported to cause back and
shoulder problems for employees that work on a table that is not at a comfortable height
for them. Workers also have to pick up multiple stacks of flat cardboard to place on the
workspace every shift which can fatigue the body.
The goal of the project is to redesign the process of collecting all the necessary pieces
of a display, building it, stocking it with cards, and finally packaging it. By designing a
whole new process with workplace ergonomics in mind, the group hopes to lessen the
fatigue employees experience by reducing the amount of physical work required. Another
outcome the group is looking for is the increase in the production rate of display units.
This project will be designed and completed in compliance with state and federal
regulations such as OSHA and other agencies and organizations that deal with worker
safety.
Constraints
The conditions that will limit the solution are called constraints. These constraints
need to be met for a successful solution to be developed. The constraints for this project
have been defined as follows:
1. The solution must not create fumes that are hazardous to employee health (OSHA
1910.14(a)(1)(vi)).
2. Moving parts must be concealed in order to prevent employees from experiencing
bodily harm (ANSI B11.19-2003).
3. The solution must be available for use with different employee physical profiles.

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4. The design must optimize the use of industrial floor spacing without exceeding
the floor space that the current process uses.
5. All electric motors must have average full load efficiency specified in the Code of
Federal Regulations (CFR 431.446).
6. The design must be able to compensate for multiple types of folding techniques
for various displays.
7. The solution must be able to work for an entire shift without breaking down or
needing maintenance.
8. The solution must have a minimal learning curve.
9. The design must be moveable by no more than three personnel for slight
relocations and be moveable by forklift for large distances such as during
installation and removal.
10. The production rate cannot fall below that of the current process with the
implementation of the solution.
11. The design must include space to carry all necessary equipment required in the
display making process.
12. There should be justification for return on investment.
13. The solution should not solely be limited to American Greeting’s specifications.
The design should be able to be marketed to any card distribution company so that
potential conflicts of interest are avoided and so that a quality solution is found.
(NSPE Rule #3.1)
14. The process must conform to pre-determined cardboard flat dimensions.
Task Management
Throughout the semester, each member of REK’M Engineering worked with one
another to accomplish the twelve project tasks. Each week, the design group met with the
project advisor, Dr. Tanay Bhatt. Each group member kept a log book to keep record of
the hours and also to record details of the individual work completed. A man hour table
showing the number of hours completed by each member for each task is located in
Appendix A, and a Gantt chart is shown in Appendix B.

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III. ALTERNATIVE ANALYSIS
Brainstorming
Folding –
The following designs were created to address problems associated with the folding
stage of the display making process.
Center Table Manual Press (TB-T1)
This design includes a table that has a hole cut out of the middle that is the size of a
cardboard display. The idea is to fill the hole with a piece of plywood or thin aluminum
that is spring loaded to be the exact height of the table top. The employee can place an
unfolded piece of cardboard over the hole, then press down on the cardboard thus
pushing all of the flaps of the display upwards. This cuts down on time by making four
individual folds turn into one motion of pushing down on the spring loaded area. The
table itself is height-adjustable by using the existing method of height variation: two car
jacks, one on either side of the table that work in unison.
Floor Scissor Lift (TB-T2)
This design consists of an automated scissor lift that is placed next to the folding
table. Its minimum height is around six inches, while its maximum height is up to 40
inches. The device is placed next to the table for the purpose of bringing the materials
such as the stack of flat cardboard closer to the worker and to make the height of the
stack at a more comfortable level for the worker at the station. The lift will move up as
the worker uses more and more cardboard. When a couple pieces of cardboard have been
removed, the worker can press a button to raise the platform up to a desired height, thus

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removing the process of walking over to a stack, bending down, and carrying a small
quantity of cardboard to the table to work on.
Automatic Center Table Press (TB-T3)
Pneumatic presses are used everywhere in industry to do many different tasks. In this
design, a press is used to push down on a piece of cardboard that is placed on a table that
has a spring loaded surface just like the previous design. All that a worker must do is
place a piece of cardboard in the desired area with the right orientation, step back to
avoid any kind of physical contact with the device, and press a button to initialize the
press. The press pushes a piston that has a wide head down onto the cardboard flat to
press it down into the hole to fold the four sides of the box at once. After this, the press
pulls back and allows the finished box to ascend to the top of the table to be worked on
further by the worker at the station. This design alleviates the need to fold all four sides
of a display manually, thus saving both time and minimizing the number of potential
injuries to the worker.
Automatic Arm Folding (TB-T4)
The main problem with workers folding flat cardboard into displays is the repetitive
motions that they follow to complete the box. Automatic arms can potentially reduce a
process that normally requires twenty separate manual folds into one that requires less
than eight. This design focuses on making the main important folds automated while
leaving the fine, smaller folds for the workers to finish. This reduces the amount of
physical work that the worker has to put forth to complete a display. It can work with a
programmable board that can control multiple motors connected to flaps that rotate to
fold the flat cardboard into the final shape of the display. By implementing this design, a

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large amount of wasted time can be saved that can instead be used to create more
displays.
Manual Height Adjustable Table (TB-T5)
Another problem with the folding aspect of production is the fact that employees have
to work on tables that are not suited for their height. Some workers that are 6’2” work on
a table that is 3’6”, where others that are as short as 5’2” work on a table that can be up to
4’ tall. This causes pain in the shoulders and back for many employees. A table that is
able to adjust its height based on the height of a worker will alleviate many physical
problems with the current process. By adding a car jack on each side of the table in
between the table top and a middle shelf, workers can manually adjust the height of the
table by turning a wheel on the side of the table. The table can then be locked in that
position by putting a pin in each of the four telescoping legs that are made out of
perforated steel square tubes. This allows a unique height to each unique individual
working on the floor.
Metal Mold (RB-T1)
This design is a simple mold that is the size of the displays that are to be built. The
mold goes on top of the current table that AG uses to fold their display units. The worker
first takes a cardboard cutout of the display, places it on top of the mold, and then simply
applies pressure to the cutout to push it down into the mold. The sides of the display
come up on each side, and the worker can then finish the folding process by hand. This
solution addressed the problem by reducing the amount of folds one worker has to do.

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Hollow Loaded Table (RB-T2)
This is a table design that delivers cardboard cutouts to the worker so that he or she
may make fewer trips back and forth to the pallet of cutouts during one shift. The table is
built from hollow metal tubing. In the middle of the table, a portion is cut out, and a
spring system is added so that the cardboard cutouts can be loaded in the middle. The
worker is then able to take a cardboard cutout off the top of the spring system and fold
the display on top of the other cutouts. The worker is also able to adjust the height of the
table by using two hydraulic lifts on each side.
Cardboard Cutout Press (RB-T3)
This design consists of a hydraulic press that is positioned over a table with the metal
mold (RB-T1) design on top of it. During operation, the worker places a cardboard cutout
on top of the model and uses a button control to make the press come down and push the
cutout into the mold. The worker then pulls the cutout from the press and finishes the
folding process. By using this design, up to three cutouts are able to be pressed at once.
Folding Sides on Conveyor Belt (RB-T4)
To reduce the time it takes to fold the display, the flat cardboard cutouts can be
placed at one end of a conveyor belt. As the cardboard cutout travels down the belt, the
sides of the conveyor slowly come in and get shallower. This slowly brings the sides of
the cardboard up. Once the cardboard gets to the end of the conveyor, the two large sides
are folded up, and a worker can finish the process of folding the display manually.
Pneumatic Arm Table (RB-T5)
This design is an automated table that folds each size of the display units used at AG.
This table has two programmable pneumatic arms attached to each side of the device.

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The worker first places a cardboard cutout on top of the table, and the pneumatic arms
then go to each side of the display and fold them. The worker finally takes the partially
folded cardboard and finishes the display building process.
Punch Press (BM-T1)
Another alternative solution is a punch press system used to create the displays. This
possible solution focuses solely on improving the assembly of the displays. Essentially,
the mechanism is a chest- to head-level, lightweight material box-shaped die. The die is
connected to a camshaft system to keep the die parallel to the table. The camshaft is then
attached to a pivot point located at the extreme side of the table, opposite of the operator.
The pivot point is elevated off the surface of the table by an extension that attaches to the
table. This punch press system is also equipped with a counterweight and spring
mechanism that makes this ergonomically safe for the operator.
Manual Folding Flaps (BM-T2)
The manual folding flaps alternative, BM-T2, is another alternative that focused on
improving the assembly portion of the folding process. Initially, there are plates of
lightweight material that are assembled with pins. These plates distribute the force from
the operator along the entire folding edge of the box displays. This design can be fixed to
the table top if needed or if preferred by the operator.
Pallet Lift (BM-T3)
The pallet lift idea, BM-T3, focuses on moving the working material (un-assembled
box displays) closer to the work station. This alternate solution consists of having pallet-
sized portions cut out of the table and attaching a pallet jack in the cutout’s place. The
pallet jack has a controller to raise the material to a comfortable height. This eliminates

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the worker having to bend over to reach the materials they need to create the display
units. This design also prevents the associates from carrying oversized loads of material.
Roller Assembly (BM-T4)
One process used widely in manufacturing is metal rolling. This process takes thin
gauge metal sheets and rolls them into a finished shape. Under this process, square
tubing, metal door frames, and many other parts can be fabricated. The roller assembly
system design, BM-T4, consists of three, bent to specification, metal sheets that gradually
roll the flat display box into its assembled form. Motors would strategically attach to the
inside of the bent metal sheets where the wheels make contact with the display boxes at
the bending point. At the beginning, the operator simply feeds the flat display boxes into
the motors. After the display boxes endure this process, the operator assembles the
bottom side of the display and inserts shelves. This process becomes highly optimized
with two associates on the same line.
Die-Punch Press (BM-T6)
BM-T6 is a customizable die for the punch press, BM-T1. This die incorporates an
additional step in the punching process - inserting the shelves on the customized die and
pressing an additional time. Unfortunately, this idea is not possible due to the dimensions
of the cutout holes in the flat boxes. Also, this design creates a highly unsafe environment
for the operator because of moving parts located at head level and the operator having to
place their hands inside a punching mechanism.
Foot Pump (JS-T1)
In order to accommodate for workers of varying heights, a mechanical foot pump
system can be used that adjusts the level of the working surface on which displays are

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folded. This foot pump system consists of a pump that raises the level of the folding
table by compressing air with each step on the pump and a release pump that lowers the
level of the table by letting air out of the system when the second foot pump is
compressed. In order to keep the surface level, all four of the table legs must be
connected through the same tubing such that the same air pressure exists within each leg.
This design specifically focuses on the comfort and safety of the worker during the
display folding process by producing a comfortable raised surface on which to perform
folding operations and removing strains on the body due to a taller worker having to bend
down constantly while at the folding station.
One Flip and Storage (JS-T2)
In order to aid workers when faced with lightly perforated cardboard that is difficult
to fold, a table that features a folding section to ease this struggle can be incorporated into
the assembly line. This device also provides some storage space for personal goods to
increase worker comfort. The folding section of this table has a handle at the edge of the
table for the user to operate the device and has some higher mass density than the rest of
the table so that it can easily fold the cardboard under its own weight. The storage space
for personal goods consists of a metal bracket attached to the underside of the table that
fits a “C-box”, or cardboard box, which are easily found all throughout the American
Greetings facility. This design focuses on the comfort of the worker by lessening the
difficulty of one of the tasks associated with the folding process and by providing a more
personal environment in which they will work.

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Waist Camera and Mechanical Pump (JS-T3)
In order to accommodate several different worker profiles, a table can be
implemented that contains an integrated camera that senses where the worker’s waist is
and adjusts the table accordingly by the use of a mechanical pump. This camera is
directly connected to the mechanical pump’s internal controls so that vertical adjustments
can be made based on where the user’s waist is in relation to the table surface. The
mechanical pump works similarly to the foot pump of JS-T3 in that the mechanical pump
sends air of the same pressure to all four table legs simultaneously in order to raise the
table and has a release mechanism to lower the table. This design focuses on easing the
strains on a worker’s body due to repetitive movements and also providing a surface at a
comfortable height for the worker to use during the creation of display units.
Half Table/Half Pallet (JS-T4)
To minimize the floor space taken up by the display making process, a table that is
half of the standard table length can be used alongside a lifted pallet that forms the
second half of the folding workspace. This design focuses mainly on conserving floor
space as well as delivering the cardboard flats directly to the vertical level of the folding
station in order to improve productivity and eliminate some bodily strains.
Vertical Table (JS-T5)
As an innovative solution to orient the entire folding process vertically, a standing
table can be used that features a swivel joint that allows for vertical construction of the
display unit at worker chest level and horizontally oriented filling and packaging
operations later on down the line. This design is aesthetically pleasing and provides the
worker with a more comfortable environment in which to make displays.

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Mechanical Robot Arm (JS-T6)
To completely remove the human element from the folding process and improve the
efficiency of the folding process, a fully automated mechanical robot arm can be
incorporated into the assembly line which performs each of the folding, filling, and
packaging processes in one central location. This design removes the worry of worker
safety entirely and allows for much more standardized displays. This solution optimizes
productivity and product quality on the line, but also gets rid of some worker’s jobs and
is very high in cost.
Two Flip with Guide Bars (JS-T7)
This solution is very similar to that of JS-T2, except that this table features two
folding sections to ease the struggle associated with difficult folds and two guide bars to
align the display units so that accurate folds may be performed. One of the flipping
sections is oriented along the table’s lateral axis, and another flipping section is oriented
along the table’s longitudinal axis. The benefit of having two flipping sections as well as
two guide bars is that the worker is able to quickly and accurately make difficult folds
more easily than they are able to make with the current setup.
Collapsible Box and Box Incasing (BM-T5 and BM-T7)
Two other alternatives were designed that focused on changing the dimensions of the
unassembled display boxes. These two alternatives were not considered due to the
designs not meeting the constraints that were set by the group. The two possibilities were
a collapsible box, BM-T5, and a box incasing device, BM-T7.

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Filling –
The following designs were created to address problems associated with the filling
stage of the display making process.
Swivel Table (BM-F1)
The swivel table alternative focuses on bringing the merchandise closer to the
working area so that the level of strain placed on the operator’s back is reduced from that
of the current process. This table features a retractable table top that is extended each
time that the operator needs to fill a display box. With the extendable table top, the
operator does not need to twist their trunk in order to get merchandise, and the amount of
bending down to lift something from the floor is also reduced. This solution is composed
of three pivot points and four major parts. The four parts are the table top, two extension
arms, and the base of the table. The pivot points link the base to one extension, one
extension to the other, and the opposite end of the extension to the table top.
Worker-Controlled Fill (BM-F2)
The worker controlled filling alternative, BM-F2, is a hopper idea that is operator
controlled. There are no limitations on this idea, meaning that this can be a programmable
hopper with operator input or it can be a mechanical operator input such as a lever used
to dispense the merchandise.
Swivel Hopper (JS-F1)
The swivel hopper design is one in which a hopper can be moved directly over pallets
of display product and then moved above the conveyor and dumped into the appropriate
display section on the unit so that the worker does not have to carry goods any horizontal
distance across the work floor. The hopper is mounted to the ceiling of the factory and

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has a vertical axis directly aligned with where a worker would normally stand along the
assembly line in a manner such that the pallet and conveyor are spaced equally from the
worker on both sides. The hopper’s mouth has a hinge joint so that product does not spill
out of the back end of the unit and so that the hopper allows for easy pouring of product
into the appropriate display section. This design specifically focuses on lessening the
amount of work that the user must perform and on making the filling process more
efficient by decreasing the time it takes to perform the filling process.
Table Space for Product (JS-F2)
By allotting table space for product goods to sit on beside the conveyor so that the
worker does not have to bend down to the floor each time they must fill a display, much
of the strain put on a worker’s body during the filling process is alleviated. This design
simply consists of a table that hangs over the dummy conveyor so that product goods can
be placed directly above the display unit during the filling process. This not only speeds
up the filling process, but also gives the worker a more comfortable environment in
which to perform their duties.
Product Location at Start (JS-F3)
To improve productivity on the display assembly line, a spot for product goods to sit
can be allotted at the beginning of the line near the folding table in order to optimize the
amount of floor space used and to reduce the physical movement required by the worker.
This alternative does not really consist of the design of a product, but rather a design of
the layout of the assembly line. It takes the existing parts of the display assembly line
and arranges them in a more efficient manner.

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Automated Hoppers (JS-F4)
To improve the productivity of the filling portion of the process and to eliminate
some strains imposed on the worker’s body during the filling task, automated hoppers can
be employed which dump products into the empty display units once they reach a certain
spot on the conveyor. The display’s location is sensed by sensors located on the hoppers,
and the products are then placed into the display with only minor touchups required by
the worker. This solution does not require the workers to lift any goods back and forth
from the pallet to the conveyor, and therefore removes some of the strains imposed on the
worker’s body.
Bladed Hoppers (JS-F5)
To improve the productivity of the filling portion of the process and to provide a
convenient source of product goods at the worker’s chest level, bladed hoppers can be
used that cut open the product boxes as they slide down chutes so that the worker may
simply grab product from the chutes and place the product into the empty display. This
design is manually loaded after several displays, but overall, the worker is required to
perform fewer physical movements that exhibit large strains on the body.
Packaging –
The following designs were created to address problems associated with the
packaging stage of the display making process.
Packaging Chute (BM-P1)
A packaging chute, BM-P1, can be used to more easily direct the display box into the
packaging box. This alternative takes a simple and effective concept and puts it into
application. During a facility tour, an associate was observed while performing the

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assembly process and small issues were seen with handling the packaging box before
successfully inserting the filled display box. A chute attached to the conveyor can instead
be used to keep the packaging box fixed to the conveyor while the operator places the
display box inside. This alternative aids the user by eliminating fumbling with multiple
boxes at once, but does not aid in the assembly or taping of the packaging box.
Break in Conveyor (BM-P2)
In this alternative solution, supplies are brought closer to the work station by taking
out a section of the conveyor and replacing it with a pallet of packaging boxes. This idea
also includes a pallet jack that brings the pallet of packaging boxes to a comfortable
height for the operator. Essentially, the operator receives a filled display box from the
filling station, places it on top of the pallet of packaging boxes, and forms the packaging
box around the filled display box. This method of completing the packaging process is
ideally safer for the operator and faster than the current process.
Automatic Conveyor Taping Station (JS-P1)
An automated conveyor taping station that seals packaging boxes and sends them
down the line to the shipping department can remove the taping process from the list of
the worker’s duties and increase the productivity of the line. Many automated taping
stations are currently in use at the American Greetings facility, but one is not currently in
use on the display making line. By adding an automatic taping unit at the end of the
display assembly line, the worker does not have to hassle with an extra task, and the
efficiency of the assembly line overall is improved.

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Weighted Box Holder (JS-P2)
The weighted box holder design aids workers by holding folded packaging boxes as
they are being filled with display units similar to the idea addressed by BM-P1. By
incorporating this device into the packaging portion of the display creation process, the
hassle a worker faces of holding a packaging box and filling it with a display unit at the
same time can be eliminated. The design consists of a spring and plunger system that
holds the empty packaging box on the conveyor due to friction with the conveyor rollers.
This assembly is held above the conveyor belt by a bracket assembly that can be easily
attached to and removed from the rails of the conveyor. This design focuses on
increasing the efficiency of the packaging process by making this process easier for the
worker to perform and therefore taking less time.
Selection Criteria
Selection criteria are qualitative pieces of information that are the most important
aspect of a fruitful design. It is important to have good selection criteria in order to
compare between alternatives and have a valid justification for the design chosen. A list
of all the selection criteria was written up, and the list was shown to several colleagues
for an outside opinion. This list was a safeguard that ensured that all the bases of the
project that needed to be addressed were covered. With the selection criteria chosen, the
team had a solid base for the narrowing process.

19
IV. PRELIMINARY DESIGN
The four designs for each part of the process that were chosen from the alternatives
solutions were then subjected to further scrutiny. This allowed each group member to
develop a design and weigh the pros and cons of each design against the criteria
developed for the project. Each design included drawings, a basic list of components, and
pros and cons for each design based on the selection criteria.
Folding
Manual Folding Flaps (BM-T2)
The folding flaps preliminary design is specified for a single style of box display.
This design needs to be replicated for other type of displays. In this case, the solution is
specified for a 51” x 17” x 7 ½” display box, not including the stand. To ensure the
proper use of this design, a list of steps is given as follows:
 The operator grabs a flat display box from the pallet.
 The operator places it on the folding flaps, ensuring that the edges match the pins
of the flaps.
 The operator folds up both sides of the display.
 The operator folds up the bottom side of the display.
 The operator inserts the shelves, divisions, and/or any other additional
components that are included in the particular design that is being assembled.
 The operator sends the assembled display box to the filling station via conveyor.
The materials specified need to be welded, machined, and assembled with an end
product such as the one shown in Figure 2. Table 1 on the following page contains the
materials needed to complete this design. Special equipment is needed for the completion
of this design. There are intricate cuts on the material that aid in making BM-T2
lightweight; these cuts need to be made with a plasma cutter or a milling machine. The

20
material for the folding flaps is aluminum. The top of the table needs to be drilled with
holes to fit the bolts that fix BM-T2 to the table. For the installation, only nuts, bolts, and
a socket wrench are required. Also, the supplying of the flat boxes is the same process as
currently used in AG, which is to grab them individually from a pallet at ground level.
Figure 2. Manual Folding Flaps
Table 1. BM-T2 Bill of Materials
Item Amount Description Stock #
Aluminum $20.34 (3) 1/8 X 1-1/2 6061 Aluminum Flat 6ft F418112
Pins $20.20 (6) Oil Hard Drill Rod, O1, #40,0.097 In 33J276
Tubing $56.81 Aluminum 3003 Seamless Round Tubing, 1/8" OD,
0.097" ID, 0.014" Wall, 12" Length (Pack of 3)
TTRA-03-
12-03

21
User Input and Mechanical Pump Table (JS-T3)
In order to begin the preliminary design for this idea to improve the folding portion of
the display making process, the idea was roughly conceptualized based on what functions
it needs to perform. The solution must be able to adjust its height based on simple user
inputs through an interface to an air compressor which simultaneously adjusts the height
of the four table legs equally. The table also needs to accommodate for workers storing
their personal goods such as purses or snacks on top of their workspaces by providing a
dedicated space for personal items. By performing these functions, the worker’s safety
and comfort are taken into consideration during the folding process. To lessen the
complexity of the design and to let the user have more control of the process, the camera
idea was scrapped and in its place, a display unit that the user may interact with was
incorporated.
The basic design features an aluminum surface that is eight feet long, four feet wide,
and two inches high. This sturdy surface acts as the main location where display folds
will take place. Bolted to the bottom corners of this table are four circular socket
brackets with holes cut out of the circular socket wall to allow for pneumatic tubing to be
inserted. Along with these four socket brackets, there are three additional sheet metal
brackets bolted to the bottom surface of the table which serve as attachments for the air
compressor, “C-box”, and height control mechanism. The height control mechanism
consists of an up button, a down button, and a kill switch that halts the operation of the
device when it leaves the user’s control. The mechanism is connected to the compressor
by electrical conduit, and the compressor’s tubes use three T-joints to split the tube into
four separate paths to then flow into each circular hole cut into the circular socket

22
brackets at the corners of the table. The “C-box” bracket supports a “C-box” which
workers of American Greetings commonly use to store their personal goods and are well
accustomed to already. Into the circular sockets, a one and a half foot hollow aluminum
tube with a quarter inch thickness is inserted. The other end of this hollow aluminum
tube feeds into an aluminum shell with a quarter inch thickness and inner diameter equal
to the outer diameter of the hollow aluminum tube. The end of the aluminum shell has a
threaded hole drilled into its circular face to allow for a caster wheel to be attached at its
end. The caster wheels allow for easy mobility when necessary and have a locking
feature that keeps the table stationary on the factory floor during the display making
process.
When the device must be moved, the legs may be completely removed from the
circular sockets, and the compressor and display unit may be dismounted from their
respective brackets. This allows the aluminum table to be stored more easily, since the
hassle of dealing with the extended table legs and the bulky weight of the compressor and
legs may be ignored.
Based on preliminary cost estimates, the table costs about $1,160 in materials, and is
made exclusively out of aluminum where metal components are concerned. This ensures
that the weight-to-strength ratio is optimized while keeping cost in mind as well.
Preliminary design models created in SolidWorks suggest that the table weighs around
200 lbs. Figure 3 and Table 2 below respectively show a SolidWorks model of the
design and a bill of materials for the unit.

23
Figure 3. User Input and Mechanical Pump
Table 2. User Input and Mechanical Pump Bill of Materials
Item No. Qty. Part Name Description Cost Source
1 4 Interior Leg 1.6in OD 24.25in length, aluminum $16.22/per Speedy Metals
2 4 Leg Shell 2.5in OD, 1.6in ID 30.5in length, aluminum $52.04/per Speedy Metals
3 4 Leg Stand Lock Casters w/ 0.5in stem $8.65/per Grainger
4 35 Standard Bolt 0.75in diameter head, 0.5in thread diameter, package of 50 $10.97 Grainger
5 4 Corner Bracket Cut from Compressor Bracket Sheet --- Speedy Metals
6 1 Table Top Cut from two 100in x 52in sheet aluminum w/ 0.1in thickness $378.00 Speedy Metals
7 1 Compressor Bracket Cut from 54in x 18in sheet aluminum w/ 0.1in thickness $166.14 Speedy Metals
8 1 Compressor 13.5in x 13.5in x 13in (LxWxH) 100PSI Compressor $80 Harbor Freight
9 1 Foam Block 5in x 3.5in x 2.25in Polyurethane Flexible Foam $2.89 Grainger
10 1 Display Casing 4.5in x 3in x 2in PMMA block $86.74 Grainger
11 3 Button 1in x 0.5in plastic buttons w/ electrical contacts $8.78/per Grainger
12 1 Display Screen 3.75in x 1.5in LCD Screen $15.00 Mouser Electronics
13 1 Tubing Bracket Cut from Compressor Bracket Sheet --- Speedy Metals
14 1 Cbox Bracket Cut from Compressor Bracket Sheet --- Speedy Metals
15 18ft Pneumatic Tubing 0.5ID $37.80 Grainger
16 1 Circuitboard w/ Simple Microprocessor Ebay
17 4ft Electrical Wiring Simple Copper Conduit Ebay
18 3 1Tube Tee Connector to connect one tube to 4others tubes $4/tee Grainger
19 1 Display Bracket Cut from Compressor Bracket Sheet --- Speedy Metals
Total $1,159.34
$35.82

24
Robotic Linkage Folder (TB-T4)
The main problem with the current folding process is that workers strain themselves
when they have to make multiple folds over and over again. To alleviate much of the
back and shoulder strain that many employees experience, a design that includes an
automatic display folding mechanism can be incorporated into the assembly line. This
design is intended to make the major folds in all of the different types of displays used by
any card company. In order to complete this design, research on controls and
programming is needed to know how to work the many different motors that are used to
make the folds automatic. The device is powered by a 120V AC outlet, and controlled by
an Arduino Mega 2560 R3 programmable board. The Arduino controls various servo
motors to actually move flaps that are located under a flat piece of cardboard to be
folded. The group members can create a program to govern when each motor should turn,
which direction it turns, and for how long. Also, for safety reasons, the program includes
a kill switch in case something happens to cause a defect in the process. In order to start
the folding process, the worker at the station must have both of his or her hands on safe
zones as to reduce the risk of injury. This design also cuts the amount of time required to
complete a cardboard display in half by converting most of the folds into one motion by
the machine.
Some disadvantages that this concept presents are safety, reliability, and how
complex the design is. With all of the moving parts, there are many chances to get a
finger, hand, or sleeve caught and pinched by the machine. All of the motors must also
work perfectly in unison, and always work exactly how they are supposed to. If there is
any deviation from the desired motion path or timing between folds, the entire operation

25
is at risk of malfunctioning. Also, wiring all the motors together to the Arduino board
while keeping the wires organized may prove to be a challenging task.
All that the employee must do to work with this machine after it is installed and
correctly programmed is:
1. Acquire a flat cardboard display sheet
2. Place the sheet over the device with correct placement and orientation
3. Place hands in the safe zone and press the start button
4. Wait for the machine to start folding and then return to starting position
5. Finish smaller folds and place shelves
6. Repeat
This process greatly reduces the amount of physical movement that the employee has to
put forth in order to complete the cardboard displays, as well as theoretically cutting the
production time in half. Table 3 below and Figure 4 on the following page show the
Inventor model and bill of materials for the design.
Table 3. TB-T4 Bill of Materials
Part Description Price Source
Arduino Mega Programmable board to control servos 45.95 sparkfun.com
HS-805BB Mega Servo Rotates the two largest flaps of folder 79.98 amain.com
HS-755HB Giant Servo Rotates the two medium folding flaps 55.98 amain.com
HS-485HB Deluxe Servo Makes minute folds with smallest flaps 118.93 amain.com
Total 300.84

26
Figure 4. Robotic Linkage Folder
Hollow Loaded Table (RB-T2)
The table depicted in Figure 5 on the following page is designed to assist the worker
while folding displays. The frame of the table is built from 14 gauge aluminum tubing,
and the shelves and table tops are built from sheet metal. The center of the table has a
spring system that can be loaded with cardboard cutouts. The spring system contains one
spring that is attached to a sheet of metal that holds flat pieces of cardboard to be folded.
There are four guide rails on each side of the spring system to assist the up and down
movement of the system. The guide rails also keep the spring from collapsing or shifting
to one particular side. Using the spring system, the worker is able to place several pieces
of cardboard on the sheet metal. The worker then pushes the sheet metal down, and two
latches keep the cardboard from coming back up. The worker is then able to take one
cardboard cutout at a time and fold it. This allows the worker to fold more displays in one

27
shift and minimizes the amount of walking back and forth to the pallet of cutouts. The
height of the table is also able to change to the worker’s comfort. The legs are designed
from perforated, telescoping tubing, and a hydraulic bottle jack is placed on each side of
the table. The worker can jack the hydraulic lifts up to bear the load of the table, take the
pins out of each leg, jack to the desired height, then place the pins back in each leg. This
design adds comfort for the worker and increases production. However, this design
contains several pinch points that cause safety hazards. Table 4 on the following page
shows the cost breakdown for the entire design.
Figure 5. Hollow Loaded Table

28
Table 4. Cost Breakdown for RB-T2
Filling
Retractable Shelf (BM-F1)
The concept behind the retractable shelf is to have a highly mobile table space that
can bring the filling merchandise closer to the work station. BM-F1 began as a table idea
that would be on swivel arms mounted on a single base; however, at the beginning stage
of the task seven, when developing the preliminary designs, it was realized that a swivel
table would not be very stable at all. In order to make a stable and durable design, the
focus shifted to having four locations to transfer the load to the floor as opposed to one. A
retractable shelf mounted on a cart serves the exact purpose intended from the beginning.
The following list of process steps put in place ensures the proper, safe use of the
retractable shelf.
 With one hand, the operator pulls the display box coming from the folding station.
 With the other hand, the shelf on the cart is pulled to its extended position.
Name of Material Quantity Vendor Total Cost
Torin Hydraulic Bottle Jack 2 Northern Tool $90.00
Perforated Telescoping Tubing 1-1/2"x48" 2 Midland Hardware $54.00
Perforated Telescoping Tubing 1-1/4"x48" 2 Midland Hardware $46.00
Canister Wheels 4 Midland Hardware $35.00
60" 6063-T52 Tubing 1 1/2"x1 1/2" 2 SpeedyMetal $44.00
60" 6063-T52 Channel 1"x1"x1/8" 1 SpeedyMetal $17.00
3003 Sheet 108"x72" 2 SpeedyMetal $400.00
3004 Sheet 67"x50" 1 SpeedyMetal $100.00
Spring 1 Century $35.00
Fasteners & Brackets N/A N/A $50.00
Total $1,035.00

29
 Without twisting at the trunk, the operator reaches from the hip area, grabs the
merchandise, and places it in the display box. This motion requires the arm, as
opposed to the torso, to move 10o
-90o
in the xy-plane (parallel to the floor).
 Once the display box is filled, it is then pushed to the packaging station.
When the retractable shelf is empty, which is estimated to be around every 20
displays, the operator returns the shelf to its retracted position and pushes the cart next to
the pallet of merchandise. The operator then opens a new box of merchandise and dumps
the content on the shelf. Then the operator returns to the filling station to continue the
process.
The cart includes caster lock wheels to prevent the movement of the cart while the
operator is working, and no installation is required with this filling idea other than the
assembling of the components. L-braces are needed to attach the rails to the cart and the
table top to the rails. All other components for this design are specified from existing
products. Table 5 below shows the list of parts required to build this design, and Figure 6
on the next page displays the SolidWorks model of the retractable shelf.
Table 5. BM-F1 Bill of Materials
Item Amount Description Stock #
Cart $225.95 Jamco Two Shelf All-Welded Heavy Duty Service Cart
SL236 36x24 1200 Lb. Capacity
WB502353
Drawer
Rails
$125.97 Drawer Slide, Full Extension, 36 in., Heavy Duty, 500
lb. Capacity, Zinc
3320
Tabletop $18.60 1/8 x 4 6061 Aluminum Flat F4184
L-braces $84.60 3 X 3 X 1/4 Steel Angle A-36 Steel Angle A23314
RIGID
wheels
$136 2 Swivel w/ Brake, 2 Rigid H-1495CASKIT

30
Figure 6. Retractable Shelf
Worker-Controlled Hopper (BM-F2)
Currently, employees have to walk over to a pallet that is ten feet from the assembly
line, grab what they need to fill the displays (napkins, cards, paper plates, etc.) and walk
back to the line in order to put the goods into their desired slots. This process takes time
because each item that the cardboard display needs is located ten feet from where it needs
to go, and the worker must take the time to walk all the way over to the pallet, acquire the
materials, walk all the way back, and then place the items into their respective areas. To
solve this problem, a device can be incorporated into the process that keeps all of the

31
filling items right above the assembly line for easy access during the filling phase. The
design consists of placing four hoppers on top of a stand that lets the bottom of each
hopper sit 1’6” above the top of the assembly line. Each hopper has a hole at the bottom
that a worker can reach into, grab one item at a time, and place them into the display that
is lying directly beneath the hopper system. In order to fill each hopper, all a worker must
do is cut open a box containing the items to be placed into a display box and then dump
the items into the hopper. Once this is accomplished, the worker can throw the empty box
onto the recycling line and start filling the display box with the items he or she just put
into the hopper.
This design greatly reduces the amount of time that it takes for a display box to be
filled since all of the necessary items that are needed are right above the box. There is no
need to walk back to the pallets every time a new box comes over to the filling station.
Also, it alleviates back problems by reducing the amount of times that each employee
must bend down to grab an item from the pallet when supplies dwindle down to the
bottom of the pile.
Some disadvantages that come with this design include extra movement of the arms
above the head and possible injury due to falling boxes. In order to load the hoppers, a
worker has to hoist a box of goods above his or her head and tilt the box to empty it. This
will put a great amount of strain on the shoulders of shorter employees. Also, there is
potential for an employee to drop a box of goods on themselves and cause a head injury.
Table 6 on the following page shows the cost of components that are required for this
design.

32
Table 6. BM-F2 Bill of Materials
Table Space for Product (JS-F2)
In order to begin the preliminary design for this idea to improve the filling portion of
the display making process, the idea was roughly conceptualized based on what functions
it needs to perform. The solution must be able to hold three to four boxes of different
product so that the worker can work solely from the table space in order to complete
display units. The table should not tip, deform, or break under the weight of these
product boxes, and the table should allow for six inches of clearance while the display
unit is on the dummy conveyor. With these qualifications, a worker’s safety,
convenience, and ergonomic capabilities are taken into consideration during the filling
process.
The basic design begins with a lipped surface that prevents boxes from sliding off the
sides of the table, and this surface perfectly fits one product box with half an inch of
clearance on all sides. The lipped surface is held up by a U-shaped bracket that is welded
to both this surface and the four foot standing arm which provides the necessary
clearance for easy filling operations. This standing arm fills a square socket bracket that
is then attached by screws to a 20” x 40” x 4” reservoir directly on top of the factory
floor. The reservoir may be filled with water or other suitable weighted material that
provides a stable base to support the table during loading and unloading of product boxes.
Gravity Hopper Hopper that worker dumps product into 270.00 5ssupply.com
Steel Bar Help make the skeleton to support structure Free American Greetings
Steel Plate Make base plate for stability Free American Greetings
Total 270.00

33
This reservoir has a central hole that is filled by a rubber plug after being filled with
weighted material so that spills are avoided if the unit accidentally tips over.
When the device must be moved, the standing arm may be removed from the
reservoir by unscrewing the screws, and the reservoir may be emptied and relocated
along with the standing arm to be refilled and set up again or put into storage. The tables
are designed such that multiple units may be placed beside each other to accommodate
for however many product boxes the assembly line may need for a particular display unit.
This unit stands behind the conveyor belt on the opposite side of the worker and hangs
the product boxes over the display unit as they pass along the conveyor belt. The
reservoir sits under the conveyor belt, but does not protrude enough for workers to stub
their toes or trip over when moving the display along the conveyor.
Based on preliminary cost estimates, one single table will cost almost $250 in
materials and will be made of folded sheet aluminum and 1” square aluminum tubing in
order to minimize weight and cost while maintaining structural strength. Based on
preliminary design models in SolidWorks, the device will weigh roughly 120 lbs when
filled with three inches of water and will weigh roughly 35 lbs when empty. Table 7
below shows a bill of materials for the design and Figure 7 on the following page shows a
SolidWorks model of the unit.
Table 7. Table Space for Product Bill of Materials
1 1 Lipped Table 24in x 34in sheet aluminum $55.38 Speedy Metals
2 3 Bracing Arm 12in length, 1in square aluminum tube $5.07/per Speedy Metals
3 1 Standing Arm 4ft length, 1in square aluminum tube $19.44 Speedy Metals
4 1 Base 50in x 40in sheet aluminum $148.50 Speedy Metals
5 1 Plug Rubber, 3in OD $8 Grainger
Total $246.53

34
Figure 7. Table Space for Product
Product Located at Starting Point (JS-F3)
This solution does not contain the design of a component but rather a design of the
layout depicting where to locate the merchandise to be placed within the display. This
design places the merchandise pallet next to the folding station to minimize the walking
between the folding station and the pallet. To retrieve the merchandise, the worker has to
take one or two steps towards the pallet, square up with it, and then pick up the
merchandise. This takes out the twisting of the trunk of the body, which according to the
ergonomics class taken by the design group, is worse than bending the trunk. With this
design, as soon as the display is built, it could be filled with merchandise. This design
does not cost anything since it is only a relocation of products used in the display

35
assembly process, and it increases the production rate which in turn increases the amount
of displays that can be filled within a shift.
Packaging
Packaging Chute (BM-P1)
This design includes an aluminum chute made out of two aluminum plates that line
the inside of the packaging box into which the filled display will fit. The distance
between the plates that fit into the packaging boxes is adjustable so that they can be used
in any box assembly line that requires a chute. This allows the display to slide easily into
the packaging box without much effort put forth by the employee. It can clamp onto the
existing assembly line so that anyone can take it off and move it whenever they want to.
Also, it comes with an optional footboard to place behind the packaging box to allow for
resistance when pushing a display into it.
When this design is implemented into the existing process, it is expected to reduce the
time required to fully complete a box so that it is ready for shipment. All the worker must
do is place the packaging box over the chute, adjust the aluminum plates, slide the
display into its box, and then push the completed box onto the line to go to the automatic
tape machine. This removes the need to continuously stuff the display into the packaging
box while trying to hold the box in place. Because of this, it saves the employee physical
pain due to juggling both the display and the packaging box at the same time.
Figure 8 and Table 8 on the following page respectively show the Inventor model and
bill of materials for the packaging chute design.

36
Figure 8. Packaging Chute
Table 8. BM-P1 Bill of Materials
Break in Conveyor (BM-P2)
The break in conveyor preliminary design concentrates around the concept of
bringing the working material closer to the working station. In this design, the idea is to
take the last 55” section of conveyor off the line and place a specified pallet and pallet
jack in its place. This pallet jack raises a pallet of packaging boxes beneath the display
boxes as the displays travel down the assembly line. This allows the packaging boxes to
be folded around the display units, which completely eliminates the need to fumble with
two objects at once. The pallet jack is specified to raise 3 ½’ and to hold 2500 lbs. A
12"x12"x.032" Al Sheet Cut to make funnel for displays 6.41 speedymetals.com
1.5"x1.25"IDx72" Square Tube Act as skeleton for entire product 25.93 speedymetals.com
2.5"x1.5"x18" Al Channel Clamps to attach to assembly line 7.91 speedymetals.com
Total 40.25

37
picture of the specified pallet jack is shown in Figure 9 on the following page. The only
item to be purchased is the pallet lift at $2549.99. The procedures that the worker must
follow in this stage are:
 Receive the display box from the filling station.
 Place it on the pallet of flat packaging boxes aligned with the creases.
 Place the stand on top of the display box.
 Lift the sides of the packaging box to form it around the display box and assemble
the packaging box around the display box.
 Tape the box by hand as is done in the current process.
 Push the packaged display onto the conveyor to send it to the labeling area for
shipping.
Figure 9. Specified Pallet Lift
After the operator packages two or three display boxes, the pallet lift can be raised
with the controller. This keeps the working area at a comfortable height for the operator.
Once the operator uses up the entire pallet of material, the pallet jack can be lowered to
ground level and wheeled off. The operator then drops off the empty pallet and wheels
another full pallet into place. The operator then continues with the process listed above.
Due to the pallet jack being incorporated, the operator at this station must learn to operate

38
a pallet jack. The 55” section of conveyor to be removed is for the width of the pallet as
well as for security posts that need to be put in place to eliminate the possibility of an
operator damaging the conveyor while placing the pallet jack into position. There is no
additional installation required other than the removal of the conveyor section. Figure 10
shows how the pallet lift is set up with the conveyor and pallet of boxes.
Figure 10. Break in Conveyor
Automatic Taping Machine (JS-P1)
In order to reduce injuries to the worker due to repetitions, this design takes the
packaging boxes and the filled displays and automatically packages and tapes the display
units by using two separate machines. This design is specified to have a box erector
connected to the automatic tape machine at the end of the conveyor belt. The worker first

39
builds the packaging box and places it inside the erector. The box erector assists the
worker by making it easier to place the filled display into the packaging box. The erector
then lifts the filled packaging box and sends it to the automatic tape machine. The
automatic tape machine senses the top of the box and tapes it shut. A BEL 505G3 Semi-
Automatic Case Former/Case Erector is specified for this design because of its size. The
3M 7000A Top/Bottom Belt Sealer is the automatic tape machine specified for this
design because it can be customized to fit the tall packaging boxes in which the displays
are shipped. With the two specified components of this design, the cost is estimated to be
near $8000. The cost of this design is very high, but it does improve the worker’s comfort
and safety and slightly improves the production rate.
Weighted Box Holder (JS-P2)
In order to begin the preliminary design for this idea to improve the packaging
portion of the display making process, the idea was roughly conceptualized based on
what functions it needs to perform. The solution should be able to hold a packaging box
in place as it is being filled with a display, the device should be attached directly to the
conveyor rails by a snap on joint or other easily removable attachment for easy
installation and removal, and the plunger should be weighted such that the worker can lift
the weight without much effort when the display unit is ready to be sent by automated
conveyor to the shipping department.
The basic design begins with a weighted plunger that holds down a display box after
it is constructed and placed on the dummy conveyor under the unit. This weighted
plunger compresses a spring while in contact with the packaging box that later aids the
worker in lifting the weighted plunger when the box is ready to be sent to the shipping

40
department. This spring and plunger system is suspended over the middle of the
conveyor by two L-shaped brackets that are attached directly to the conveyor through
several welded brackets and by two set screws.
The weighted box holder attaches to the railing opposite of the worker and locates the
weighted plunger at the middle of the conveyor’s width. This device may be easily
removed from the conveyor by unscrewing the set screws and lifting the device from the
rail. By removing the weighted plunger head, the spring and plunger system may be
separated from the L-shaped bracket system in order to conserve space in a storage room.
In its separated form, the device can fit all its components within three cubic feet of space
and weighs roughly 20 lbs according to the design model in SolidWorks.
From preliminary cost estimates, this packaging device costs about $120 in materials
and is made of folded sheet aluminum pieces that are welded together to form the bracket
assembly. Aluminum is chosen as the design material since it is cheaper than steel, yet it
can still withstand the loading conditions that this device experiences during its use.
Aluminum is also chosen in consideration that this design could be fabricated from the
same aluminum sheets as “Waist Camera and Mechanical Pump (JS-T3)” and “Table
Space for Product (JS-F2)” in order to save money by using the same material from
which to cut shapes for brackets. Figure 11 and Table 9 on the following page
respectively show the SolidWorks model of the weighted box holder and a bill of
materials for the device.

41
Figure 11. Weighted Box Holder
Table. 9 Weighted Box Holder Bill of Materials
1 2 Channel Bracket 54in x 10in sheet aluminum $43.15 Speedy Metals
2 1 Bracket Connector See Channel Bracket Note --- Speedy Metals
3 8 Knurled Thumb Screw 0.25in OD, Package of 25 $7.89 Grainger
4 8 Nut 0.5in OD, 0.25in ID, Package of 50 $14.71 Grainger
5 2 L Bracket See Channel Bracket Note --- Speedy Metals
6 1 Top Slat See Channel Bracket Note --- Speedy Metals
7 1 Rod 0.5in diameter, 12in length w/ 1in diameter, 0.5in head $7.25 Speedy Metals
8 1 Spring 0.6in helix diameter w/ 0.1in coil diameter, ~6in length $25 Grainger
9 1 Plunger Head 4in diameter, 0.5in ID spherical rubber head $8 Ebay
Total $106

42
V. SELECTION OF FINAL ALTERNATIVE
Creation of Weighted Indices
REK’M Engineering created a survey that can be seen in Appendix C in order to poll
employees on which selection criteria were most important for the preliminary designs.
The group received 34 completed surveys from American Greetings management and
factory employees. Based on the information received from the surveys, the design group
agreed on a method to assign weights to the criteria. The method consisted of first
summing the scores received from all of the surveys for every criterion together. The sum
for each individual criterion was then divided by the total sum calculated from the
previous step. This quotient resulted in the weighted value for each individual criterion.
Table 10 shows the list of weighted-property-indices based on the results of the survey
analysis.
Table 10. Weighted Indices
Criterion Weighted Value (%)
Worker Safety 8.853
Production Rate 8.824
Ease of Operation 8.767
Worker Comfort 8.278
Mobility 8.106
Job Positions Associated 7.933
Size 7.933
Physical Movement 7.933
Duration of Downtime 7.847
System (Manual/Automatic) 7.531
Environmental Issues 6.496
Aesthetically Pleasing 5.979
Cost 5.519

43
Narrowing Alternatives to Final Designs
After completing all of the preliminary designs and by using the weighted indices
found from the survey results, REK’M Engineering was able to analyze the alternatives
and select the final solution for each of the three parts of the process. For the folding,
filling, and packaging parts of the process, a preliminary design was chosen as the base to
analyze the other preliminary designs. JS-T3 was chosen as the base for the folding
design, JS-F3 was chosen as the base for the filling design, and BM-P2 was chosen as the
base for the packaging design. Tables 11, 12, and 13 show the analysis of the preliminary
designs based on the chosen bases. The three designs that were selected as the final
solutions are highlighted in green.
Table 11. Weighted Property Index Analysis of Folding Preliminary Designs
JS-T3 was selected as the best solution for the folding process. This design and RB-
T2, when analyzed, were very similar to each other. The table design of JS-T3, however,
is superior in this type of system because it allows the table height to be changed
Grade Weight Grade Weight Grade Weight Grade Weight
cost 5.519 0.05519 0 0 1 0.0552 0 0 3 0.1656
aesthetically pleasing 5.979 0.05979 0 0 -2 -0.1196 -1 -0.0598 -2 -0.1196
environmental issues 6.496 0.06496 0 0 0 0 1 0.065 2 0.1299
system(manual/automatic) 7.531 0.07531 0 0 2 0.1506 -1 -0.0753 -1 -0.0753
duration of downtime 7.847 0.07847 0 0 0 0 2 0.1569 2 0.1569
physical movement 7.933 0.07933 0 0 1 0.0793 2 0.1587 0 0
size 7.933 0.07933 0 0 1 0.0793 1 0.0793 1 0.0793
job position associated with the process 7.933 0.07933 0 0 0 0 0 0 0 0
mobility 8.106 0.08106 0 0 -1 -0.0811 0 0 0 0
worker comfort 8.278 0.08278 0 0 -1 -0.0828 0 0 -1 -0.0828
ease of operation 8.767 0.08767 0 0 -2 -0.1753 -1 -0.0877 -3 -0.263
production rate 8.824 0.08824 0 0 2 0.1765 0 0 1 0.0882
worker safety 8.853 0.08853 0 0 -3 -0.2656 -3 -0.2656 -2 -0.1771
sum 100 1
Folding Ideas
0 -0.18338603 -0.028456453 -0.097729233
BMRBTBJS (BASE)

44
automatically based on user input instead of having the user manually raise each leg. JS-
T3 is much better than RB-T2 based on worker safety. RB-T2 has many pinch points, and
manually changing the height of the table is severely hazardous to the worker’s fingers.
JS-T3 however has slightly higher downtime, and the amount of physical movement that
the worker must perform is greater, but these negatives aspects are outweighed by the
benefits when compared to RB-T2. Based on the folding design analysis, the best way to
have the displays constructed is to have the worker build them manually and have
assisting devices to increase production rate instead of making the folding process
completely automated.
Table 12. Weighted Property Index Analysis of Filling Preliminary Designs
BM-F1 was selected as the best solution for the filling process. When analyzed, this
design was found to be slightly better than the other designs. Based on the base JS-F3,
BM-F1 costs more than any other design, is larger than the other designs, and is slightly
less mobile than the base. However, BM-F1 increases worker comfort drastically and is
cost 5.519 0.05519 0 0 -1 -0.0552 -3 -0.1656 -1 -0.0552
aesthetically pleasing 5.979 0.05979 0 0 1 0.0598 2 0.1196 1 0.0598
environmental issues 6.496 0.06496 0 0 0 0 0 0 0 0
system(manual/automatic) 7.531 0.07531 0 0 0 0 0 0 0 0
duration of downtime 7.847 0.07847 0 0 0 0 0 0 0 0
physical movement 7.933 0.07933 0 0 2 0.1587 2 0.1587 2 0.1587
size 7.933 0.07933 0 0 0 0 -1 -0.0793 0 0
mobility 8.106 0.08106 0 0 -2 -0.1621 -1 -0.0811 -2 -0.1621
worker comfort 8.278 0.08278 0 0 1 0.0828 2 0.1656 1 0.0828
ease of operation 8.767 0.08767 0 0 0 0 0 0 0 0
production rate 8.824 0.08824 0 0 2 0.1765 1 0.0882 1 0.0882
worker safety 8.853 0.08853 0 0 0 0 1 0.0885 1 0.0885
sum 100 1
JS
0 0.260419661 0.294624892 0.2607071
RB (BASE) TB BM

45
safer than the other three filling preliminary designs. Based on the filling design analysis,
the best way to fill the display is to design an assisting device to help the worker fill the
displays instead of having the filling process be fully automated.
Table 13. Weighted Property Index Analysis of Packaging Preliminary Designs
BM-P1 was selected as the best solution for the packaging process. This design is
much better than the other three packaging preliminary designs. The design is manual,
large, has less worker comfort, and decreases production rate as compared to the base,
but it is cheap, has a low duration of downtime, is aesthetically pleasing, is very mobile,
and has high worker safety which make it the best alternative solution to the packaging
process. Based on the analysis of the packaging preliminary design, it was found that the
creation of devices that assist the worker in the packaging of display units was the best
design solution to improve this part of the display unit assembly.
cost 5.519 0.05519 0 0 3 0.1656 -3 -0.1656 3 0.1656
aesthetically pleasing 5.979 0.05979 0 0 1 0.0598 1 0.0598 -2 -0.1196
environmental issues 6.496 0.06496 0 0 2 0.1299 1 0.065 2 0.1299
system(manual/automatic) 7.531 0.07531 0 0 -1 -0.0753 1 0.0753 -1 -0.0753
duration of downtime 7.847 0.07847 0 0 3 0.2354 -1 -0.0785 3 0.2354
physical movement 7.933 0.07933 0 0 -1 -0.0793 0 0 -1 -0.0793
size 7.933 0.07933 0 0 -1 -0.0793 -1 -0.0793 -1 -0.0793
mobility 8.106 0.08106 0 0 3 0.2432 1 0.0811 3 0.2432
worker comfort 8.278 0.08278 0 0 -1 -0.0828 1 0.0828 -1 -0.0828
ease of operation 8.767 0.08767 0 0 1 0.0877 2 0.1753 1 0.0877
production rate 8.824 0.08824 0 0 -1 -0.0882 -1 -0.0882 -1 -0.0882
worker safety 8.853 0.08853 0 0 3 0.2656 3 0.2656 3 0.2656
sum 100 1
BM (BASE) TB RB JS
0 0.782121299 0.393216442 0.602759414

46
VI. FUTURE WORK
Materials
The folding design consists of nineteen individual components, but several of the
brackets can be manufactured from the same sheet of material. The required raw
materials for the folding design are as follows:
 24.25” of 1.6” OD Aluminum Tubing
 30.5” of 2.5” OD, 1.6” ID Aluminum Tubing
 4 Lock Casters with ½” Stem
 35 Bolts with ¾” diameter head and ½” diameter thread
 118” x 54” Sheet of Aluminum with 0.1” thickness
 1 1/3 Gallon 100psi Pancake Compressor
 5” x 3.5” x 2” Polyurethane Flexible Foam
 4.5” x 3” x 2” PMMA Block
 3 1” x ½” Plastic Buttons with Electrical Contacts
 3.75” x 1.5” LCD Screen
 18’ of ½” OD Pneumatic Tubing
 Circuit board with Microprocessor
 4’ of Copper Electrical Wire
 3 Pneumatic Tube Tee Connections
the materials that are required to successfully build the filling design are listed below:
 Jamco Two Shelf All-Welded Heavy Duty Service Cart SL236 36x24 1200
Lb. Capacity, WB502353 ($225.95)
 Drawer Slide, Full Extension, 36 in., Heavy Duty, 500 lb. Capacity, Zinc,
3320 ($125.97)
 1/8 x 4 6061 Aluminum Flat, F4184($18.60)
 3 X 3 X 1/4 Steel Angle A-36 Steel Angle, A23314 ($84.60)
 2 Swivel w/ Brake, 2 Rigid, H-1495CASKIT($136.00)

47
and in order to fabricate and test the functionality of the packaging design, the initial
materials deemed necessary for this portion of the design are:
 .032”x12”x24” 3003 – H14 Aluminum Sheet ($11.66)
 72”x1”x1” w/ 3/4” ID 6063 Aluminum Square Tube ($28.58)
 2.5”x1.5” 6063 Aluminum Channel ($5.32)
 72”x.75”x.75” w/ .5” ID 6063 Aluminum Square Tube ($11.78)
It should be noted that these lists are subject to change, as the budget for the project is
only $500 and details may change next semester during the actual fabrication/testing
phase.
Fabrication
The table surface will be constructed from two sheets of aluminum that fit together to
form a hollow box. There is no attachment to connect these two pieces. The brackets for
the “C-Box”, compressor and the display unit are bolted into the underside of the lower
aluminum sheet. The corner brackets will also be bolted into the underside of the lower
aluminum sheet, and the aluminum interior leg will have no direct attachment to the
corner bracket. The interior leg will slide into the aluminum shell with no direct
attachment. The caster wheels will be screwed into the bottom of the aluminum shell.
The PMMA block will be hollowed out to fit the circuit board, microprocessor, LCD
screen and the three buttons. This block will be encased in foam and then fit snugly into
the display bracket at the front of the table. Electrical wiring will connect the display unit
directly to the compressor, and pneumatic tubing will be used in conjunction with the T-
joints to distribute the compressed air to each leg of the table.
The fabrication of the filling device will be simple; all of the parts will be easily
assembled with screws and nuts. The only parts that will need to be machined are the

48
holes to fix the rails to the top of the cart and the table top. Also, the L-braces will need to
have the holes machined to match the ones on the cart top.
The entire packaging device should be easily made to specifications within a short
amount of time if worked on by the entire team. The dimensions of the existing assembly
line will have to be measured for the clamp to be sized correctly in order to wrap around
the sides and clamp onto them. Each clamp will be welded to a 1’ long 1” x 1” square
tube that will be connected to each other by a telescoping tube created by placing the
smaller square tube inside the larger square tube so that the length of the chute from head
to tail can be altered. Finally, a tube will be welded onto the front of the device
protruding out towards the worker to house the two aluminum plates acting as the chute.
These plates will be able to move to a desired location and lock into a comfortable
position for the worker.
Testing and Future Plans
The pressure inside the shell and hollow aluminum tube of the leg assembly need to
be analyzed to ensure that the threaded caster will not shoot from the end of the table leg
when the table is at maximum height and thus the compressed air pressure is at a
maximum. Loading conditions of casual worker behavior such as leaning against or
sitting on the table top need to be tested to ensure the worker’s safety even with improper
use of the device. The average working height of employees will need to be gathered to
determine the range of heights that the table should achieve. In order to perform these
tests, only one leg of the table and the table surface will need to be fabricated so that
pressure tests on the leg may be performed and several loading tests may be performed
on the table surface. Ergonomic tests need to be conducted as well by using the Rapid

49
Entire Body Assessment (REBA) and Rapid Upper Limb Assessment (RULA) tools on
people with heights at all points within the range of worker heights being considered.
Testing the filling design will consist of performing the filling process with the design
and without it. There will be several different people performing the task, including
employees that are currently performing this work and others that are not used to doing
the process. The reason for testing non-employees is to remove the bias of knowing how
to perform a job and disliking a new method that is being implemented simply because it
is new. The test results will display the change in production rate if any. Also, the test
will display how much of a learning curve exists for this product’s use and the effects it
will have on the current process. In terms of ergonomics, the team will again use the
REBA and RULA tools to test the comfort, physical movement, and safety of the
process. The team will also look for advice to ensure that the use of BM-F1 is safe in
every stage of the process.
After fabrication of the packaging device, the team will bring it to the American
Greetings Plant in Osceola, Arkansas to be placed on an assembly line and use multiple
different sized boxes to see if a worker can easily change the width of the plates and use
the device to effectively slide a display into the various packaging boxes. If the worker
can successfully place the displays into the packaging boxes with ease and confirm that
the process is easier to follow than the existing one, the team will consider that a success.

50
VII. LIST OF REFERENCES
[1] Ray, Justin, Matt Rowe, Stuart Etheridge, and Seth Parish. Washington Avenue
Extension Go-By. ASU College of Engineering. Print. 4 Sept. 2014.
[2] "Engineering Course Standards." Engineering Course Standards. Arkansas State
University College of Engineering, Fall 2013/2014. Web. 4 Sept. 2014.
[3] Walker, Chris. "Research Trip to Osceola #1." Personal interview. 19 Sept. 2014.
[4] "284 Greeting Card Manufacturers & Greeting Card Suppliers." Greeting Card
Manufacturers & Greeting Card Suppliers. Global Sources. Web. 24 Sept. 2014.
[5] "Hallmark History & Timeline." Hallmark Corporate Information. Hallmark. Web. 24
Sept. 2014.
[6] Nancy, Bryk EV. "How Products Are Made." How Greeting Card Is Made. Made
How. Web. 24 Sept. 2014.
[7] "As a Leading Manufacturers' Representative and Distributor. "Corrugated
Packaging & Boxes, Folding Cartons & Displays, and Shipping Supplies . Web.
25 Sept. 2014. <http://www.camdenpkg.com/>.
[8] "Code of Ethics." Code of Ethics. National Society of Professional Engineers. Web.
26 Sept. 2014.
[9] "Code of Ethics." Code of Ethics. American Society of Civil Engineers. Web. 26
Sept. 2014.
[10] Romero, Ivonne. Progress Report No. 1, January 21, 2011 through February 23,
2011; Slope Instability of Highway Overpasses. Arkansas State University
College of Engineering, 23 Feb. 2011. Print. 3 Oct. 2014.
[11] Walker, Chris. "Research Trip to Osceola #2." Personal interview. 3 Oct. 2014.
[12] Dethridge, David. "Ergonomics: REBA/RULA Assessments." Ergonomics Class.
American Greetings Plant, Osceola, AR. 10 Oct. 2014. Speech.
[13] "Torin Hydraulic Bottle Jack — 20 Ton, Model# T92003." Portable Generators,
Pressure Washers, Power Tools, Welders. Web. 26 Oct. 2014.
[14] "Boltmaster 11204 Perforated Tube 1-1/2 X 1-1/2 X 48 In." Midland Hardware.
Web. 26 Oct. 2014.
[15] "Boltmaster 11201 Perforated Tube 1-1/4 X 1-1/4 X 48 In." Midland Hardware.
Web. 26 Oct. 2014.

51
[16] "Speedy Metals 1-1/2" SQ X 1-1/4" ID X .125" Wall 6063 Aluminum Square
Tube.” Speedy Metals 1-1/2" SQ X 1-1/4" ID X .125" Wall 6063 Aluminum
Square Tube. Web. 26 Oct. 2014.
[17] "Speedy Metals 1-1/4" SQ X 1" ID X .125" Wall 6063 Aluminum Square Tube."
Speedy Metals 1-1/4" SQ X 1" ID X .125" Wall 6063 Aluminum Square Tube.
Web. 26 Oct. 2014.
[18] "Speedy Metals 1" X 1" X 1/8" 6063 Aluminum Channel." Speedy Metals 1" X 1" X
1/8" 6063 Aluminum Channel. Web. 26 Oct. 2014.
[19] "Speedy Metals .050" 3003 Aluminum Sheet." Speedy Metals .050" 3003
Aluminum Sheet. Web. 26 Oct. 2014.
[20] "Semi-Automatic Case Former / Case Erector - Box Erector / Box Former - BEL
505G3 - Wexxar / BEL." Wexxar. Web. 26 Oct. 2014.
[21] "3M 7000A Case Sealer | 3M Top/Bottom Belt Tape Machine | Carton Sealing Tape
Machine." BasicPackagingSupply.com. Web. 26 Oct. 2014.
[22] "3 Gal. 1/3 HP 100 PSI Oilless Pancake Air Compressor." Pancake Air Compressor.
Harbor Freight Tools. Web. 28 Oct. 2014.
[23] "Grainger Industrial Supply." Grainger Industrial Supply – MRO Products,
Equipment & Tools. Grainger Industrial Supply. Web. 29 Oct. 2014.
[24] "Mouser Electronics." Mouser Electronics – Electronic Components Distributor.
Mouser Electronics. Web. 29 Oct. 2014.
[25] "Drawer Slide, Full Extension, 36 In., Heavy Duty, 500 Lb. Capacity, Zinc." -
Cabinet And Furniture Drawer Slides. Web. 30 Oct. 2014.
[26] "0.097 Diameter Rod." Products. Web. 30 Oct. 2014.
[27] "Amazon Prime Free Trial." Aluminum 3003 Seamless Round Tubing, 1/8" OD,
0.097" ID, 0.014" Wall, 12" Length (Pack of 3): Industrial Metal Tubing:
Amazon.com: Industrial & Scientific. Web. 30 Oct. 2014.
[28] "U-Type Scissor Lift Table." Lift Tables Sitecraft Materials Handling Equipment
Brings You Quality Lifting Tables for a Great Price RSS. Web. 30 Oct. 2014.
[29] "Vestil Ground Lift Scissor Table — 2000-lb. Capacity, 70in.L X 55in.W Platform,
Raised Height: 48in., Model# EHLTG-5270-2-48."Portable Generators, Pressure
Washers, Power Tools, Welders. Web. 30 Oct. 2014.

52
[30] "Vestil High-Rise Lift Truck — 2,500-Lb. Lifting Capacity, Air/Oil Powered,
27in.W Forks, Model# HIPM-2748-AIR." Portable Generators, Pressure Washers,
Power Tools, Welders. Web. 30 Oct. 2014.
[31] "Heavy Duty Steel Table Carts." Trucks & Carts. Web. 30 Oct. 2014.
[32] Metals Depot. Web. 12 Nov. 2014.
[33] "AC Right Angle Gearmotors." AC Right Angle Gearmotors. Web. 12 Nov. 2014.
[34] "Arduino Mega 2560 R3." - DEV-11061. Web. 12 Nov. 2014.
[35] "Hitec HS-805BB Mega 1/4 Scale Ball Bearing Servo." [HRC31805S]. Web. 12
Nov. 2014.
[36] Clifft, Rick. Preliminary Plan for Senior Design II Work Go-By. ASU College of
Engineering. Print. 12 Nov. 2014.
[37] "Small Easy Flow Gravity Hopper - FIFO - Blue." Small Easy Flow Gravity Hopper
- FIFO - Blue. Web. 12 Nov. 2014.

A-2
Table A-1. Man-Hour Schedule for Project
Task
Estimated
Hours
Actual
Hours
Percent
Complete
Estimated
Hours Per
Person
Taylor
Barnhill
Robert
Bise
Banthi
Munoz
Jed
Schales
1. Develop Proposal 48 29 100 12 7.5 9 6 6.5
2. Research of Problem and Redefinition of Constraints 24 22.75 100 6 5.25 6 5 6.5
3. Creation of Alternative Solutions 24 28.5 100 6 5.5 7.5 11.5 4
4. Develop Selection Criteria 14 33.5 100 3.5 9 9.5 7 8
5. Selection of Four Designs 10 26 100 2.5 4 6 8 8
6. Progress Report 20 24 100 5 6 6 6 6
7. Preliminary Design 60 84.5 100 15 24.5 17.75 23 19.25
8. Judgment of Preliminary Designs and Final Design Selection 8 10 100 2 2.5 2.5 2.5 2.5
9. Future Fabrication/Design Specification 12 4 100 3 1 0 1 2
10. Final Report 40 23.25 100 10 3.5 7.5 5.25 7
11. Final Presentation 20 12.5 100 5 3 4 3 2.5
12. Record Keeping/Advising 40 35 100 10 8.75 8.75 8.75 8.75
Total Man-Hours 320 333 80 80.5 84.5 87 81
Individual Hourly BreakdownMan-Hour Schedule

B-2
Figure B-1. Gantt Chart Schedule

C-2
Display/Box Assembly
Students from the ASU College of Engineering are trying to redesign the
folding and package process of displays.
In a scale from 1 to 10, how important are the following aspects (1 being
least important and 10 being most important):
Overall Cost: Cost of the installation and maintenance
1 2 3 4 5 6 7 8 9 10
Production Rate: Speed of display making process
1 2 3 4 5 6 7 8 9 10
Ease of Operation: How quickly can one learn the process
1 2 3 4 5 6 7 8 9 10
Physical Movement: Amount of movement required to complete process
1 2 3 4 5 6 7 8 9 10
Worker Safety: To what extent is a worker’s health impaired
1 2 3 4 5 6 7 8 9 10
Frequency & Duration of Downtime: Importance of high
reliability/durability
1 2 3 4 5 6 7 8 9 10
Mobility: Ease of relocation and installation
1 2 3 4 5 6 7 8 9 10
Size: How well the process optimizes floor space
1 2 3 4 5 6 7 8 9 10
Aesthetically Pleasing: How it looks on the floor
1 2 3 4 5 6 7 8 9 10
System (Manual/Automatic): Amount of user interaction
1 2 3 4 5 6 7 8 9 10
Environmental Issues: Does the product raise any environmental concern
1 2 3 4 5 6 7 8 9 10
Worker Comfort: How taxing is the operation on a worker’s body
1 2 3 4 5 6 7 8 9 10
Job Positions Associated with Process: Number of jobs created or lost
1 2 3 4 5 6 7 8 9 10
Additional Comments:

C-3
Table C-1. Survey Tally
Survey# cost
production
rate
ease of
operation
physical
movement
worker
safety
durationof
downtime mobility size
aesthetically
pleasing
system(manual/
automatic)
environmental
issues
worker
comfort
jobposition
associated
1 4 10 10 8 10 2 8 10 5 10 2 1 8
2 10 10 10 8 10 8 8 9 5 7 5 9 7
3 1 10 10 5 10 5 1 1 0 0 10 10 10
4 4 10 10 0 10 10 7 10 10 0 3 10 10
5 1 10 10 10 10 10 8 10 1 5 1 10 7
6 6 0 10 10 10 10 10 10 10 10 7 0 10
7 6 10 6 7 10 5 9 10 7 10 7 3 1
8 10 10 10 8 10 10 10 10 10 10 10 10 10
9 8 9 7 3 10 8 9 6 6 8 9 9 7
10 6 10 10 10 10 10 10 9 5 10 10 10 10
11 7 10 10 9 10 10 10 7 8 10 8 10 8
12 1 7 10 10 10 6 8 8 5 6 5 10 7
13 9 10 10 10 10 9 7 8 8 10 9 10 10
14 8 10 10 0 10 0 7 10 10 10 10 10 10
15 5 10 10 7 10 7 10 4 10 10 10 10 10
16 1 8 8 8 8 8 10 5 5 5 5 10 5
17 5 10 10 10 6 10 10 10 5 7 5 10 7
18 5 10 10 7 10 10 7 10 4 10 10 10 10
19 10 10 10 10 10 8 10 10 9 10 0 10 9
20 5 8 10 10 10 5 10 10 5 8 10 10 10
21 5 9 10 9 10 9 9 9 4 9 0 8 9
22 2 10 10 10 10 7 10 10 1 7 2 10 6
23 10 10 5 10 10 10 10 6 10 10 9 10 8
24 4 9 9 9 7 10 5 8 4 10 9 9 9
25 3 9 9 10 0 9 9 8 8 9 9 8 10
26 5 10 10 10 10 10 10 10 9 8 7 7 7
27 10 10 8 10 10 10 7 6 8 10 9 10 8
28 10 10 10 10 10 10 10 10 10 10 10 10 10
29 5 9 9 9 9 9 8 6 1 4 5 5 5
30 10 10 5 10 10 10 10 10 10 5 10 10 10
31 1 10 10 10 8 10 7 7 1 9 6 10 10
32 7 9 10 10 10 8 9 10 10 8 9 10 10
33 8 10 9 9 10 10 9 9 4 7 5 9 8
Total 192 307 305 276 308 273 282 276 208 262 226 288 276
Weight 5.519 8.824 8.767 7.933 8.853 7.847 8.106 7.933 5.979 7.531 6.496 8.278 7.933

APPENDIX D
Descriptive Diagrams of Final Designs

D-2
Figure D-1. Folding Final Design

D-3
Figure D-2. Filling Final Design

D-4
Figure D-3. Packaging Final Design

APPENDIX E
Bill of Materials for Final Designs

E-2
1 4 Interior Leg 1.6in OD 24.25in length, aluminum $16.22/per Speedy Metals
2 4 Leg Shell 2.5in OD, 1.6in ID 30.5in length, aluminum $52.04/per Speedy Metals
3 4 Leg Stand Lock Casters w/ 0.5in stem $8.65/per Grainger
4 35 Standard Bolt 0.75 in diameter head, 0.5in thread diameter, package of 50 $10.97 Grainger
5 4 Corner Bracket Cut from Compressor Bracket Sheet --- Speedy Metals
6 1 Table Top Cut from two 100in x 52in sheet aluminum w/ 0.1in thickness$378.00 Speedy Metals
7 1 Compressor BracketCut from 54in x 18in sheet aluminum w/ 0.1in thickness $166.14 Speedy Metals
8 1 Compressor 13.5in x 13.5in x 13in (LxWxH) 100PSI Compressor $80 Harbor Freight
9 1 Foam Block 5in x 3.5in x 2.25in Polyurethane Flexible Foam $2.89 Grainger
10 1 Display Casing 4.5in x 3in x 2in PMMA block $86.74 Grainger
11 3 Button 1in x 0.5in plastic buttons w/ electrical contacts $8.78/per Grainger
12 1 Display Screen 3.75in x 1.5in LCD Screen $15.00 Mouser Electronics
13 1 Tubing Bracket Cut from Compressor Bracket Sheet --- Speedy Metals
14 1 Cbox Bracket Cut from Compressor Bracket Sheet --- Speedy Metals
15 18 ft Pneumatic Tubing 0.5 ID $37.80 Grainger
16 1 Circuitboard w/ Simple Microprocessor Ebay
17 4 ft Electrical Wiring Simple Copper Conduit Ebay
18 3 1 Tube Tee Connector to connect one tube to 4 others tubes $4/tee Grainger
19 1 Display Bracket Cut from Compressor Bracket Sheet --- Speedy Metals
Total $1,159.34
$35.82
Table E-1. User Input and Mechanical Pump
Item No. Qty. Part Description Price Source
1 1 Cart Jamco Two Shelf All-Welded Heavy Duty Service Cart SL236 36x24 1200 $225.95 Globalindustrial
2 1 Drawer Rails Drawer Slide, Full Extension, 36 in., Heavy Duty, 500 lb. Capacity, Zinc $125.97 Amazon
3 1 Tabletop 1/8 x 4 6061 Aluminum Flat $18.60 Metalsdepot
4 1 L-braces 3 X 3 X 1/4 Steel Angle A-36 Steel Angle $84.60 Metalsdepot
5 1 RIGID wheels 2 Swivel w/ Brake, 2 Rigid $136 Uline
Total $591
Table E-2. Retractable Shelf
Item No. Qty. Part Description Price Source
1 1 12"x12"x.032" Al Sheet Cut to make funnel for displays 6.41 speedymetals
2 1 1.5"x1.25"IDx72" Square Tube Act as skeleton for entire product 25.93 speedymetals
3 1 2.5"x1.5"x18" Al Channel Clamps to attach to assembly line 7.91 speedymetals
Total 40.25
Table E-3. Packaging Box Chute

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