SIUE Industrial Engineering Senior Design Project 2012

1. Presented By: Erica Miller, Eray Ozturk, Paul Jansen, and Jared Schneider
SENIOR DESIGN 2012

2.  What is a dynamometer?
 Problem statement
 Cost prevents many shops
from investing in the tool
 ME conceptual design
 Objective:
 To convert a single prototype
design to a marketable
product and production
strategy suitable for large scale
manufacturing
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3. Team Leader:
Erica Miller
Enterprise:
Design: Production:
Eray Ozturk*
Paul Jansen* Jared Schneider*
Serra Akyol
Furkan Enderer Burcu Demir
Emre Ulugol
Ryan Alberter Miray Kaya
Selin Kanli
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4.  Market Research
 Forecasting
 Production Redesign
 Personnel Requirements
 Facility Design
 Quality
 Cost Analysis
 Conclusions
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5.  Market Research
 Existing Brands
▪ DynoJet
▪ Mustang
▪ Land and Sea
 Market Forecast
 Market Share
 Forecasting the Demand
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6.  Customer: Motorcycle Mechanics
 Surveys
 Influencing factors on number of mechanics
▪ Number of repair facilities
▪ Number of bike shops
▪ World Price of Crude Oil
▪ Per Capita Disposable Income
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7. Heuristic Approach – Non-Linear
Correlation analysis of influencing factors using
Pearson Product Method
Determination of weights by minimizing error
Used forecast values by professionals
Facilities which Employee Motorcycle Mechanics:
Potential Dynomometer Customers
8000
Number of Potential Dynomometer
7534 7700
7500 7061 7176 7373
7000 7158
Customers
6500 Actual Demand
6000 Forecasted Demand
5500 Connection
5000
2000 2005 2010 2015 2020
Year
7 8/22/2012 Source: IBIS World Industry Report SCHOOL OF ENGINEERING

8.  Market Share Indices for initial demand
Purchase
75%
Available
100%
Price OK Not Purchase
90% 25%
Attractive Not Available
55% 0%
Marketing
Sales and
Aware High Price
30% 10%
Not Attractive
45%
Not Aware
70%
Would You Purchase a Dynamometer?
Yes
13%
Possibly
No 27%
60%
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9. Preliminary Data Source Pessimistic Neutral Optimistic
Definitely will buy Customer Survey 13% 13% 13%
Probably will buy Customer Survey 13% 27% 27%
Likely buyers
Buyers form definites = Definitely buy * 80.00% 10.67% 10.67% 10.67%
Buyers form probables = Probably buy * 30.00% 4.00% 8.00% 8.00%
Trial Rate Total of likely Buyers 14.67% 18.67% 18.67%
Marketing Adjustments
Market Share Index Estimated from
Marketing Plan 7.50% 11.14% 13.16%
(MSI)
Adjusted Trial Rate = Trial Rate*MSI 1.10% 2.08% 2.46%
2012 Target Population Marketing Plan Data 7158 7158 7158
=Target Pop*Adjusted Trial
Trial Population Rate
79 149 176
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10.  Normal distribution and influencing factors
 Start-up / S-Curve
 Adjusted yearly
Production Level
450
400 390
350
286 330
Number of Dynos
300
250 210
242
200 176 180
150
177 175
149 153 128
100 94
79 81
50
0
2011 2012 2013 2014 2015 2016 2017
Optimistic Neutral Pessimistic
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11.  Inertia Dynamometer
 4 Major Components
 Drum Assembly
 Frame Assembly
 Front Wheel Plate
 Loading Ramp
 209 individual
parts, 1532 pounds
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12.  Reduce cost
 Maintain mass moment of inertia
 Lead vs Water
 A500 structural casing
 AISI 4340 mount shafts
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13.  Minimal vibration
 Worst case scenario calculation
 Steel pipe has bend in center
 Offset center of mass creates vibration
 Absolute worst case
 2500 RPM Drum Speed
 1,759 lbf due to normal acceleration
 ≈ 1,400 lbf dynamic load on each bearing
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14. Tire Speed (MPH) vs Drum RPM
Size Tire Speed Rating MPH Limit Tire OD (inch) Tire RPM at Limit
 Motorcycle tire 500S16 S 112 26.4 1426
MT90H16 H 130 25.3 1727
max speed ratings 130/90H16
130/90H16
H
H
130
130
25.4
25.6
1720
1707
 Converted to 140/90H16
140/90H16
H
H
130
130
25.6
25.8
1707
1694
drum RPM 160/80H16
160/80H16
H
H
130
130
26.1
26.1
1674
1674
 Sized bearing 120/90H16
120/80V16
H
V
130
150
26.3
23.8
1662
2118
140/80VB16 V 150 24.8 2033
above max RPM 130/90V16 V 150 25 2017
150/80V16 V 150 25.4 1985
 Life ≈100,000 hrs 130/70VB18 V 150 25.4 1985
140/70V18 V 150 25.7 1962
200/60VB16 V 150 25.9 1947
120/80V18 V 150 25.9 1947
170/60VB18 V 150 26 1939
150/70VB18 V 150 26.2 1924
130/80V18 V 150 26.3 1917
180/55VB18 V 150 26.3 1917
120/90V18 V 150 26.4 1910
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15.  Square steel tubing
 1x1x0.065 inch
 2x2x0.125 inch
 Optimized cutting layouts
 1D Cut Optimizer – Nikita Yurchenko
 Welded and annealed
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16.  Anti-vibration mounts
 Mount shaft press fit
 Bearing attachment
 SAE Grade 5 nuts/bolts
 Electronics mount
 Sandwiched between anti-vibe
and bottom of bearing
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17.  Electronics
 Programmable System on Chip (PSoC)
 Rotary Encoder
 Direct Serial connection to PC (RS232 protocol)
 Ramp Assembly
 Ease load/unload of motorcycles
 Basic construction
 D-Link strap points
 Secure motorcycle while running test
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18. Material/Component Units/dyno Units
1x1x0.0625 Square Steel Tube* 1680 INCH
MAKE 18x0.375 Steel Pipe* 1 FEET
Lead* 986 LB
1/2" x 72" X 144" HR Plate - ASTM A-36 Steel* 324 IN2
2x2x0.25 Square Steel Tube* 140.8 IN
Floor Plate - 1/8" x 48"X144“* 6384 IN2
2x2x0.125 Steel Angle Iron* 4 FT
AISI 4340 Steel - HR Q & T Rounds* 9.64 IN
Black HDPE Sheet* 1.67 SHEETS
Material/Component Units/dyno Units
7/16"-20 x 7/8" Black Oxide Alloy Steel Socket Cap Screw 12 PARTS
5/8"-11 x 5" Plain Finish SAE J429 Grade 8 Hex Cap Screw 4 PARTS
5/8"-11 Yellow Zinc Finish Grade 8 Finished Hex Nut 4 PARTS
Blind Rivets 1/8" Dia.—For Hole Size: 0.129"-0.133" 100 PARTS
US Digital E2 Rotary Encoder 1 PART
PSoC 1 PART
BUY
Vibration Isolation 4 PARTS
Hammerite 43180 Red Hammered Metal Finish Size Quart 1 PARTS
1" D-Ring Tie down with mounting bracket 6 PARTS
1/2"x1" Plain Finish Clevis Pin 4 PARTS
Zinc Hitch Pin Clip (for 1/2"-5/8" Shaft) 4 PARTS
Antivibration Foot Mounts (Part No. - V41C01M10012X075) 10 PARTS
Timken Type E Tapered Roller Bearing E-P2B-TRB-65MM 2 PARTS
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19. Drilling Chop Saw 1x1 Square Steel Tube
Frame Assembly
(Welding)
Chop Saw 1x1 Square Steel Tube
Chop Saw 2x2 Square Steel Tube
AISI 4340 Steel HR
Drilling Machining Bandsaw Q&T Rounds
1/2" x 72" HR Plate -
Tapping Drilling Plasma Cut ASTM A-36 Steel
Drum Assembly
(Welding)
Plasma Cut 18 x 0.375 Steel Pipe
Final Assembly
Casting Melting Lead
Chop Saw 1x1 Square Steel
Ramp Assembly
(Welding) Floor Plate - 1/8" x
Plasma Cut 48"X144"
Front Wheel Lock 2x2x0.125 Steel Angle
Assembly
Drilling Chop Saw Iron
Floor Plate - 1/8" x
Front Wheel Plate Plasma Cut 48"X144"
Assembly
(Welding) Chop Saw 1x1 Square Steel Tube
Side Walls Table Saw Black HDPE Sheet
Floor Plate - 1/8" x
Deck Surface Plasma Cut 48"X144"
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20.  Basic metal fabrication
 Chop saw
 Plasma cutter
 Welder
 Annealing torch
 Drill press
 NC machining
 High precision needed for drum mount shaft
▪ Press fit into bearings
 Machine size calculations
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21.  Office Workers
• Manufacturing Engineer
• Secretary
• Sales Representative
• Contract Programmer
 Laborers
 Material Handlers
 Skilled Workers
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22.  24.7 labor hours required per dyno
 One 8 hour shift – 250 days/year
 Optimal worker quantities for production
rate, wages, and hiring/firing costs
Number of Laborers
10
8
6
4 Material Handlers
2 Skilled Workers
0
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23. 
EOQ for Dyno Inventory
35
31
30
26
25 22
21 21
20
15
10
5
0
2012 2013 2014 2015 2016
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24. Material Handling Decisions
 Cherry Picker vs. Gantry Crane
 Roller Dolly
 Pallet Truck
Racking
 Three Main Types of Material
o Steel Pipe (Drum)
o Square Tubing
o Sheet Metal
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25. Systematic Layout Planning Approach (SLP)
I. From-To Matrix
Chop Plsma Drum Ramp Frame Final Qlty
Saw Drilling Melting Lathe Cut Bandsaw Casting Assy FWP Assy Assy Assy Assy Cntrl Paint
Chop Saw 6 0 0 0 0 0 0 0 7 44 0 0 0
Drilling 0 0 0 0 0 0 0 0 0 4 2 0 0
Melting 0 0 0 0 0 1 0 0 0 0 0 0 0
Lathe 0 2 0 0 0 0 0 0 0 0 0 0 0
Plsma Cut 0 0 0 0 0 0 1 1 1 0 1 0 0
Bandsaw 0 0 0 2 0 0 0 0 0 0 0 0 0
Casting 0 0 0 0 0 0 1 0 0 0 0 0 0
Drum Assy 0 0 0 0 0 0 0 0 0 0 1 0 0
FWP Assy 0 0 0 0 0 0 0 0 0 0 1 0 0
Ramp Assy 0 0 0 0 0 0 0 0 0 0 1 0 0
Frame Assy 0 0 0 0 0 0 0 0 0 0 1 0 0
Final Assy 0 0 0 0 0 0 0 0 0 0 0 1 1
Qlty Cntrl 0 0 0 0 0 0 0 0 0 0 0 0 0
Paint 0 0 0 0 0 0 0 0 0 0 0 0 1
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26. II. Weighted From-To Matrix
III. Relationship Diagram
IV. Activity Relationship Diagram
Symbol Definition Score
A Absolutely Necessary 46 to 60
E Especially Important 31 to 45
I Important 16 to 30
O Ordinary 1 to 15
U Unimportant 0
X Undesirable -
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27. V. Department Sizing
• Machine/Table Space and Workspace
 5,100 ft2
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28.  Geographic midpoint of customers
 6 possible counties in KS, MO, OK
 Hybrid approach to account for
Tax rate Unemployment rate
Right to Work Energy Prices
Minimum Wage Land Value
 1245 North Santa Fe, Wichita, Kansas
Wichita, KS
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29.  Drum and Lead Casting
• Clearance of 0.050 in
 Weight of Drum
 Straightness of Frame
 Straight edge and feeler gauge
 Horsepower and Torque Curves
• Use electric motor to run tests
• Calibrate
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30.  Packaging Material
• Extended Pallets
• Shrink Wrap
• Plastic Bands
 Shipping
Option Carrier Estimated Transit Cost
Longest Distance YRC Freight 4 business days $668
Shortest Distance Lakeville Motor Express 1 business days $177
Source: www.freightquote.com
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31. Start-Up Cost (Equipment)
Machinery $ 56,685.47  Malstrom’s Estimates
Supplemental Items
Material Handling
$
$
24,569.00
4,239.90  Selling Price
Warehousing $ 1,763.64
Total Start-Up Cost $ 87,258.01  Survey & Competitors
Fixed Cost ▪ $6,500
Building Rent $ 22,488.00
Management Salaries $ 171,150.00 ▪ 41% Markup
Total Fixed Cost $ 193,638.00
▪ $5,000 less expensive
Variable Cost
Materials $3,279.00 than closest competitor
Mechanical Labor $395.00
Material Handling Labor $110.00
Packaging $99.00
Shipping $375.00
Total Variable Cost/Dyno $4,258.00
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32.  Demand taken constant after 2016
 Optimistic: 482 Units – July 2014
 Neutral: 655 Units– August 2015
 Pessimistic: In year 2030
Break-Even Analysis for Neutral Scenario
$12,000,000.00
$10,000,000.00
$8,000,000.00 Cost
Dollars
$6,000,000.00 Income
$4,000,000.00
655
$2,000,000.00
$-
0 200 400 600 800 1000 1200 1400 1600
Quantity
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33. Cash Flow in Neutral Scenario
Adjusted by Inflation Rates
Income Cost
$2,403,283.75 $2,456,155.99 $2,510,191.43
$1,722,784.05
$990,775.50 $1,041,790.46 $1,231,723.16
2012 2013 2014
$(1,103,042.64) $(1,040,675.71) $(1,191,415.46) 2015 2016 2017 2018
$(1,573,243.86)
$(2,100,753.58) $(2,146,970.16) $(2,194,203.51)
Rate Of Return
(Depreciation MACRS & Inflation)
Scenario 2012 2013 2014 2015 2016 2017 2018
Neutral -73% -11% 40% 132% 288% 430% 578%
Optimistic -116% -59% -19% 54% 180% 292% 407%
Pessimistic -227% -185% -172% -148% -101% -67% -37%
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34.  Decision Analysis
 Net Present Values over next 6 years
Optimistic Neutral Pessimistic
$1,345,600 $875,600 -$346,500
 EMV = $687,600
 CougarDyno has potential to succeed
 Establish new market share
 Production redesign
 Efficient facility
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35.  Questions?
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36. 36 8/22/2012 SCHOOL OF ENGINEERING

37. What could be the most
Would you be willing Is portability
Why would like to important attributes for Why have not you How much would you like to
Store Location to invest in a Do you need a dyno? important feature for Other features to include
get one? a dynamometer bought one before? pay for the dynamometer?
dynomometer you?
needed?
Action cooling something expensive, not not sure, cheaper than whats
817 West Union Avenue, Litchfield, IL Possibly yes maybe yes, have a small shop cooling feature
Powersports rather? enough room on market
Chesterfield
expensive, not a
Valley Power 17501 N Outer 40, Chesterfield, MO possibly yes tuning good software,
demand
6-7 k yes atv/motorcycle
Sports
doesn't matter what
Southern Illinois type - inertia etc, ease
not really, wants to warranty, updates,
Choppers & Power 304 North Van Buren Street, New Athens, IL yes yes tuning of use, software can be price less than 10,000
just put it in his shop memberships
complicated, does it
Sports
come with software
oh yeah, definitely,
they would have to have g sensor can mount on
Lincoln Power fuel to air ratio,
100 Raceway Park Drive, Moscow Mills, MO yes sure
bragging rights
accuracy, cost not sure, build a room to house there, can hook up things to the
Sports it and an exhaust bike now
system
PMC Super Tuners portability would help,
174 Kings Drive, Florissant, MO no
especially racing
n/a n/a n/a n/a n/a n/a
Inc.
Knebel's
mainly do
Autobody Center 2702 Illinois 160, Highland, IL possibly if it was cheap enough n/a Portability not an issue
automotive repairs
doesn't know no n/a
& Towing
if it was not
Ritter Cycle Racing 11202 Ellis Road, St. Jacob, IL possibly possibly n/a portability not an issue electric and a n/a n/a n/a
water brake dyno
Donelson Cycles not into
9851 Saint Charles Rock Road, St Ann, MO no no n/a portability not an issue n/a n/a n/a
Inc performance
Royalty Racing 920 Dock Street, Saint Louis, MO no no n/a portability not an issue n/a n/a n/a
the demand is
Black Diamond Williamson County Pkwy, Marion, Illinois 62959 no no n/a portability not an issue declining, people n/a n/a n/a
are afraid
They don't have,
Bier Brothers 1921 East Terra Lane O'Fallon, MO 63366 no no n/a portability not an issue it's too expensive, n/a n/a n/a
they don't need
JMP Cycle 1490 E Edwardsville Rd, Wood River, IL no no n/a portability not an issue n/a n/a n/a n/a
AMT Fergonson 715 South Florissant Road, Ferguson, MO 63135-2949 no no n/a portability not an issue n/a n/a n/a n/a
Matt Johnson St.
3326 Woodson Road, Saint Louis, MO no no n/a portability not an issue n/a n/a n/a n/a
Johns
West County
956 S Highway Dr, Fenton, MO no no n/a portability not an issue n/a n/a n/a n/a
Power Sports
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38. Preliminary Data Source Pessimistic Neutral Optimistic
Definitely will buy Customer Survey 13% 13% 13%
Probably will buy Customer Survey 13% 27% 27%
Likely buyers
Buyers form definites = Definitely buy * 80.00% 10.67% 10.67% 10.67%
Buyers form probables = Probably buy * 30.00% 4.00% 8.00% 8.00%
Trial Rate Total of likely Buyers 14.67% 18.67% 18.67%
Marketing Adjustments
Market Share Index Estimated from
Marketing Plan 7.50% 11.14% 13.16%
(MSI)
Adjusted Trial Rate = Trial Rate*MSI 1.10% 2.08% 2.46%
2012 Target Population Marketing Plan Data 7158 7158 7158
Trial Population =Target Pop*Adjusted Trial 79 149 176
Rate
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39. Scenario Pessimistic Neutral Optimistic
Productio Productio Productio
Cum Market Cum Market Cum Market
Year n n n
Penetration Penetration Penetration
Level Level Level
2012 1.10% 79 2.08% 149 2.46% 176
2013 2.23% 81 4.19% 152 4.96% 180
2014 3.44% 94 6.49% 177 7.67% 210
2015 5.07% 128 9.56% 242 11.30% 286
2016 7.24% 175 13.64% 330 16.12% 390
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40. Units for Regular Workforce Units with OT
Worker Starting Ending Starting Ending
s Quantity Quantity Quantity Quantity
1 1 64 65 66
2 67 129 130 130
3 131 194 195 195
4 196 259 260 260
5 261 323 324 325
6 326 388 389 390
7 391 453 454 454
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