The document summarizes the development of a medication dispenser prototype called Medisense. It includes:
1) An introduction with the engineering team members.
2) The problem statement of creating an autonomous system to sort and dispense pills to save time and reduce errors for users.
3) Requirements for the prototype including specifications, functionality, and validation methods.
4) A schedule and labor loading chart for the project timeline.
5) Descriptions and images of the conceptual design, preliminary design, and final prototype which uses a screw conveyor, V-channel, lasers and other components to sort and dispense pills.
6) Examples of problem solving during development and validation
The document discusses measurement quality assurance and reducing risks from in-tolerance measurement errors. It explains the concepts of in-tolerance measurement risk and guard bands, using an example of temperature measurements on a heart-lung bypass machine. While an in-tolerance calibration result may not flag an issue, product measurements could still be incorrect if the instrument drifted within its tolerance range. The document recommends using an instrument with accuracy at least 4 times better than the process tolerance and establishing guard bands to reduce the need for costly non-conformance investigations when drift occurs.
The document describes an automatic pill dispenser designed by Group #7. It aims to help patients easily take the correct number of pills each day by automatically counting and dispensing medications. Key features include a programmable system to distribute the right number of pills per day, accurate dispensing to prevent overdosing, and a compact design for both home and facility use. The group's solution involves creating components like an Arduino circuit, assembling a full-scale model, and testing to ensure proper functioning.
The document summarizes work to automate leak testing of food storage containers. Key points:
- The project aims to develop a testing apparatus to improve on the current manual leak testing procedure and free up technician time.
- The proposed apparatus would rotate containers filled with water and use infrared sensors to detect and count any drips, standardizing the test.
- Testing showed the apparatus results correlated with manual tests and did not affect container seals. It was estimated to save over $6,000 annually in technician time.
- Future work may include automating lid attachment, more rigorous testing plans, and minimizing human error to increase confidence in results.
Statistical solutions to help you with 5 FDA medical devices stagesMinitab, LLC
This document provides a summary of a webinar about statistical solutions to help with the five stages of FDA medical device development. The webinar discusses each stage in detail, including goals and case studies applying Minitab tools. Stage 1 involves concept development and identifying user needs. Stage 2 includes design, prototyping, and testing. Stage 3 focuses on approval pathways and validation. Stage 4 is FDA review and deployment. Stage 5 is post-market monitoring, maintenance, and support. The webinar demonstrates how statistical analysis with Minitab can help optimize processes and ensure quality at each stage of medical device development and production.
Thermal Imaging in your Maintenance Program: Intermediate Infrared Concepts a...Transcat
Industrial Maintenance Professionals, please join us on August 2nd for the latest Thermal Imaging best practices webinar presented by Sat Sandhu, Thermography Services Support Manager Thermal / Infrared Thermography, Level III, Fluke. View our Fluke Thermal Imager Selection Guide: http://www.transcat.com/calibration-resources/selection-guides/fluke-thermal-imager/
Aplication of on line data analytics to a continuous process polybetene unitEmerson Exchange
This Emerson Exchange, 2013 presentation summarizes the 2013 field trail results achieved by applying on-line continuous data analytics to Lubrizol’s continuous polybutene process. Continuous data analytics may be used to provide an on-line prediction of quality parameters, and enable on-line detection of fault conditions. Information is provided on improvements made in the model used for quality parameter prediction, and how the field trail platform was integrated into the process unit. Presenters Qiwei Li, production engineer, Efren Hernandez and Robert Wojewodka, Lubrizol Corp., and Terry Blevins, principal technologist at Emerson, won best in conference in the process optimization track for this presentation.
This is my academic project. Our company had two problems 1) Battery charging issue 2) Customer Service. We solved both these problems by using DMAIC and PDSA methodologies.
Qualification of Tablet Compression Machine.pptxDhruvi50
Tablet Compression Machine
Principle of Tablet Compression Machine
Construction of Tablet Compression Machine
Working of Tablet Compression Machine
Qualification of Tablet Compression Machine
Installation Qualification
Operational Qualification
Performance Qualification
References
The document discusses measurement quality assurance and reducing risks from in-tolerance measurement errors. It explains the concepts of in-tolerance measurement risk and guard bands, using an example of temperature measurements on a heart-lung bypass machine. While an in-tolerance calibration result may not flag an issue, product measurements could still be incorrect if the instrument drifted within its tolerance range. The document recommends using an instrument with accuracy at least 4 times better than the process tolerance and establishing guard bands to reduce the need for costly non-conformance investigations when drift occurs.
The document describes an automatic pill dispenser designed by Group #7. It aims to help patients easily take the correct number of pills each day by automatically counting and dispensing medications. Key features include a programmable system to distribute the right number of pills per day, accurate dispensing to prevent overdosing, and a compact design for both home and facility use. The group's solution involves creating components like an Arduino circuit, assembling a full-scale model, and testing to ensure proper functioning.
The document summarizes work to automate leak testing of food storage containers. Key points:
- The project aims to develop a testing apparatus to improve on the current manual leak testing procedure and free up technician time.
- The proposed apparatus would rotate containers filled with water and use infrared sensors to detect and count any drips, standardizing the test.
- Testing showed the apparatus results correlated with manual tests and did not affect container seals. It was estimated to save over $6,000 annually in technician time.
- Future work may include automating lid attachment, more rigorous testing plans, and minimizing human error to increase confidence in results.
Statistical solutions to help you with 5 FDA medical devices stagesMinitab, LLC
This document provides a summary of a webinar about statistical solutions to help with the five stages of FDA medical device development. The webinar discusses each stage in detail, including goals and case studies applying Minitab tools. Stage 1 involves concept development and identifying user needs. Stage 2 includes design, prototyping, and testing. Stage 3 focuses on approval pathways and validation. Stage 4 is FDA review and deployment. Stage 5 is post-market monitoring, maintenance, and support. The webinar demonstrates how statistical analysis with Minitab can help optimize processes and ensure quality at each stage of medical device development and production.
Thermal Imaging in your Maintenance Program: Intermediate Infrared Concepts a...Transcat
Industrial Maintenance Professionals, please join us on August 2nd for the latest Thermal Imaging best practices webinar presented by Sat Sandhu, Thermography Services Support Manager Thermal / Infrared Thermography, Level III, Fluke. View our Fluke Thermal Imager Selection Guide: http://www.transcat.com/calibration-resources/selection-guides/fluke-thermal-imager/
Aplication of on line data analytics to a continuous process polybetene unitEmerson Exchange
This Emerson Exchange, 2013 presentation summarizes the 2013 field trail results achieved by applying on-line continuous data analytics to Lubrizol’s continuous polybutene process. Continuous data analytics may be used to provide an on-line prediction of quality parameters, and enable on-line detection of fault conditions. Information is provided on improvements made in the model used for quality parameter prediction, and how the field trail platform was integrated into the process unit. Presenters Qiwei Li, production engineer, Efren Hernandez and Robert Wojewodka, Lubrizol Corp., and Terry Blevins, principal technologist at Emerson, won best in conference in the process optimization track for this presentation.
This is my academic project. Our company had two problems 1) Battery charging issue 2) Customer Service. We solved both these problems by using DMAIC and PDSA methodologies.
Qualification of Tablet Compression Machine.pptxDhruvi50
Tablet Compression Machine
Principle of Tablet Compression Machine
Construction of Tablet Compression Machine
Working of Tablet Compression Machine
Qualification of Tablet Compression Machine
Installation Qualification
Operational Qualification
Performance Qualification
References
Transcat Webinar: :Suitability Of Instruments: Presented By: Howard ZionTranscat
Join us as Howard Zion, Transcat's Director of Service Application Engineering, discusses the process of selecting instruments that are suitable for the measurements on your products or in your manufacturing processes. This webinar, entitled “Suitability of Instruments”, will teach you the different aspects of determining suitability, including:
• Parameter, Range, Resolution, Accuracy?
• How Process Tolerances factor into the decision
• Some new terms: Process Accuracy Ratio (PAR) and Process Uncertainty Ratio (PUR)
• Other factors that can lead to false measurement results: Operator influence, Storage/Handling/Transportation influence, etc.
This document discusses nonconforming products and the process for handling them. It defines nonconforming products as those that do not meet specified requirements. The process for handling nonconforming products involves identification, documentation, evaluation, segregation, and disposition. Nonconforming products must be evaluated to determine if investigation is needed, documented, segregated from conforming products, and properly disposed of through methods like rework, downgrade, return or scrap. Minor nonconformances are typically handled under 21 CFR 820.90 while more serious or recurring issues should be referred to the Corrective and Preventive Action system under 21 CFR 820.100. Proper handling of nonconformances can help drive continuous improvement.
How to Size a Lab
Increase deal size AND provide the exact solution to the customer
Covered in this webinar:
- How to correctly size a lab to accomplish high quality and velocity
- The importance of gathering data from the customer
- Finding out what the customer is willing to NOT cover
By the end of this webinar, you will be able to more comfortably help your customers choose the best size lab for their needs, leading to bigger deal sizes.
This presentation shows how meter farms are a new tool for managing AMI meter populations and testing continuously evolving communication technology in a post deployment world.
The document describes four engineering exercises involving shipping a potato chip safely, sorting coins by size, using pulleys to reduce lifting force, and designing a load-bearing structure out of cards. The exercises are intended to teach engineering concepts like package design, sorting systems, mechanical advantage, structural efficiency. Students work in groups to complete tasks like designing a protective chip packaging, sorting washers by size using a mechanical sorter, using pulleys to lift a bottle with reduced force, and building a card structure to support a load.
PAT for packaging real time monitoring of pharmaceutical bottles’ induction s...PT Asia Limited
- The need for PAT Packaging
- Sealing integrity inspection methods
- What is thermal imaging?
- The induction sealing process
- Case studies
- Reliability test
- Summary
- About DIR Technologies
DIR Technologies | PAT for Packaging by Fabian SchapiroDIR Technologies
The need fpr PAT in packaging:
1) The primary package is an integral part of the drug.
2) The sealing process of the package must be validated and monitored.
3) In a PAT framework, 100% inspection of the seal integrity is the ideal approach.
Previously there was no process analytical technology for continuous process verification of the sealing process. Sampling was the best option available. Now there is a technological, 100% in-line, non-destructive, testing method.
Summary:
1) Sampling provides probabilistic monitoring and cannot provide a solid process analytical control.
2) Thermal imaging technology enables a PAT approach to the induction sealing process with 100% in-line testing and process monitoring => Continued Process Verification
3) Case studies from packaging lines reflect the potential impact of PAT for induction sealing.
4) Reliability of Induction Integrity Verification System tested and proved.
*presentation given at IFPAC 2015 session
The document summarizes a nasogastric intubation training simulator project. It describes the clinical need for a more affordable and realistic simulator to train medical professionals on nasogastric intubation procedures. The document analyzes current simulator solutions and identifies gaps. It then outlines the design of a new Nasogastric Intubation Dummy simulator consisting of a physical model, fluid tubing system, and electrical components to provide feedback. Testing showed positive feedback from nurses but also areas for improvement, such as adding sphincter action.
The document discusses validation of a fluidized bed dryer. It describes the purpose of equipment validation and the typical stages: installation qualification (IQ), operational qualification (OQ), and performance qualification (PQ). For a fluidized bed dryer, IQ involves installing the equipment according to specifications. OQ involves testing that the dryer operates as intended under normal conditions. PQ involves drying product batches and ensuring the dryer reduces moisture content as specified and maintains quality/quantity of output. The document provides details on procedures, acceptance criteria, and revalidation for each qualification stage of the fluidized bed dryer.
This document provides an overview of troubleshooting skills for process operations. It discusses the key elements of troubleshooting including defining the problem, investigating causes, planning solutions, implementing plans, evaluating results, and concluding. Common troubleshooting techniques are explained such as fishbone diagrams, fault tree analysis, 5 whys, and mind mapping. A case study example applies these techniques to troubleshoot a pump failure where the root cause was determined to be reverse motor rotation due to an operator error in verification. The presentation aims to improve troubleshooting skills for both experienced and new process engineers.
This document summarizes a student project that aimed to reduce the time required to diagnose faults in wind turbine slip rings. The team:
- Engineered a controlled failure on a slip ring simulator to test monitoring variables like voltage, amperage, and temperature using Fluke Connect tools.
- Found monitoring voltage provided the best resolution and thermal imaging helped isolate problems.
- Estimated the tools could reduce average repair time per failure by 3 hours, saving 17% of work hours annually on a 140 turbine wind farm.
- Recommends the Fluke Connect system for its user-friendliness and potential to improve safety, efficiency and documentation in the renewable energy industry.
Fluke Ways Test Tools Can Improve Safety Around Rotating MachineryTranscat
The document discusses ways that test tools can improve safety when working around rotating machinery. It recommends (1) being careful of moving parts, (2) working from a distance using wireless tools like vibration meters and infrared cameras, and (3) quickly identifying faults on machines before catastrophic failure using vibration analysis to reduce time spent near machinery. The tools can help technicians work more safely by monitoring machines remotely, reducing entry/exit times near moving parts, and taking faulty machines offline before hazardous conditions occur.
The problem is that the width of materials produced by the cutting-to-size (CTS) machine was found to be varying outside the allowed tolerance of ±0.5mm. This was discovered during a quality inspection and could lead to rejected materials. The root cause was determined to be uneven mill edges on the raw materials. To address this, the corrective action was to change the feeding method on the CTS machine to use a back stopper, which would shear off the mill edges. The preventative action would be to create standard operating procedures for the machine and implement a poka-yoke system to prevent similar issues in the future. The benefits would be no customer complaints due to improved quality and accuracy of materials,
Goodman Final Presentation_French_JeremyJeremy French
Jeremy French completed a controls engineering internship at Goodman Manufacturing where he worked on various projects including HMIs, control panels, and a heat exchange leak tester. Over the course of the internship, he learned how to troubleshoot machinery issues, input questions to problems, and saw improvements to the leak tester to make the testing process more efficient with fewer leaks. The leak tester uses pneumatics, a PLC, HMI, and control panel to automatically clamp units, conduct tests by measuring pressure and flow, and send results to a database. Potential future improvements include updating seals, adding automatic scanning, and sensors to check for insulation brackets.
Here are the definitions from the document:
Friction is the resistance against movement.
Friction problems can cause heat, wear, and cost industries over $1 billion per year.
Thresholds are the necessary determined data under actual operating conditions that can be safely applied on a device before it will break.
The functions of a lubricant are to:
- Reduce friction
- Reduce wear
- Prevent overheating (cool)
- Reduce mechanical shock
- Prevent corrosion
- Protect against dirt
This document provides guidance on designing a photovoltaic (PV) system through an 8-step process: 1) conducting an electricity audit; 2) assessing available sun resources; 3) surveying the installation site; 4) sizing the PV system; 5) selecting modules and inverters; 6) string sizing; 7) assessing finances; and 8) making a decision. The document outlines the key considerations and calculations at each step to appropriately size a grid-tied PV system to meet a home's electricity needs while working within physical and budget constraints. A sample string sizing example is also provided to demonstrate how to match modules and inverters based on technical specifications and location weather data.
This document discusses techniques for scaling up processes from a pilot plant to full production. It covers definitions of pilot plants, their significance in allowing examination of formulas and refinement of processes and equipment. General considerations for pilot plants include reporting structure, personnel requirements, space needs, and review of formulas and raw materials. Process evaluation and development of master manufacturing procedures are also covered. The document discusses various dosage forms including solids, liquids, parenterals, and semisolids, outlining equipment and parameters considered for scaling up each type of product. GMP considerations and advantages and disadvantages of pilot plants are also summarized.
Transcat Webinar: :Suitability Of Instruments: Presented By: Howard ZionTranscat
Join us as Howard Zion, Transcat's Director of Service Application Engineering, discusses the process of selecting instruments that are suitable for the measurements on your products or in your manufacturing processes. This webinar, entitled “Suitability of Instruments”, will teach you the different aspects of determining suitability, including:
• Parameter, Range, Resolution, Accuracy?
• How Process Tolerances factor into the decision
• Some new terms: Process Accuracy Ratio (PAR) and Process Uncertainty Ratio (PUR)
• Other factors that can lead to false measurement results: Operator influence, Storage/Handling/Transportation influence, etc.
This document discusses nonconforming products and the process for handling them. It defines nonconforming products as those that do not meet specified requirements. The process for handling nonconforming products involves identification, documentation, evaluation, segregation, and disposition. Nonconforming products must be evaluated to determine if investigation is needed, documented, segregated from conforming products, and properly disposed of through methods like rework, downgrade, return or scrap. Minor nonconformances are typically handled under 21 CFR 820.90 while more serious or recurring issues should be referred to the Corrective and Preventive Action system under 21 CFR 820.100. Proper handling of nonconformances can help drive continuous improvement.
How to Size a Lab
Increase deal size AND provide the exact solution to the customer
Covered in this webinar:
- How to correctly size a lab to accomplish high quality and velocity
- The importance of gathering data from the customer
- Finding out what the customer is willing to NOT cover
By the end of this webinar, you will be able to more comfortably help your customers choose the best size lab for their needs, leading to bigger deal sizes.
This presentation shows how meter farms are a new tool for managing AMI meter populations and testing continuously evolving communication technology in a post deployment world.
The document describes four engineering exercises involving shipping a potato chip safely, sorting coins by size, using pulleys to reduce lifting force, and designing a load-bearing structure out of cards. The exercises are intended to teach engineering concepts like package design, sorting systems, mechanical advantage, structural efficiency. Students work in groups to complete tasks like designing a protective chip packaging, sorting washers by size using a mechanical sorter, using pulleys to lift a bottle with reduced force, and building a card structure to support a load.
PAT for packaging real time monitoring of pharmaceutical bottles’ induction s...PT Asia Limited
- The need for PAT Packaging
- Sealing integrity inspection methods
- What is thermal imaging?
- The induction sealing process
- Case studies
- Reliability test
- Summary
- About DIR Technologies
DIR Technologies | PAT for Packaging by Fabian SchapiroDIR Technologies
The need fpr PAT in packaging:
1) The primary package is an integral part of the drug.
2) The sealing process of the package must be validated and monitored.
3) In a PAT framework, 100% inspection of the seal integrity is the ideal approach.
Previously there was no process analytical technology for continuous process verification of the sealing process. Sampling was the best option available. Now there is a technological, 100% in-line, non-destructive, testing method.
Summary:
1) Sampling provides probabilistic monitoring and cannot provide a solid process analytical control.
2) Thermal imaging technology enables a PAT approach to the induction sealing process with 100% in-line testing and process monitoring => Continued Process Verification
3) Case studies from packaging lines reflect the potential impact of PAT for induction sealing.
4) Reliability of Induction Integrity Verification System tested and proved.
*presentation given at IFPAC 2015 session
The document summarizes a nasogastric intubation training simulator project. It describes the clinical need for a more affordable and realistic simulator to train medical professionals on nasogastric intubation procedures. The document analyzes current simulator solutions and identifies gaps. It then outlines the design of a new Nasogastric Intubation Dummy simulator consisting of a physical model, fluid tubing system, and electrical components to provide feedback. Testing showed positive feedback from nurses but also areas for improvement, such as adding sphincter action.
The document discusses validation of a fluidized bed dryer. It describes the purpose of equipment validation and the typical stages: installation qualification (IQ), operational qualification (OQ), and performance qualification (PQ). For a fluidized bed dryer, IQ involves installing the equipment according to specifications. OQ involves testing that the dryer operates as intended under normal conditions. PQ involves drying product batches and ensuring the dryer reduces moisture content as specified and maintains quality/quantity of output. The document provides details on procedures, acceptance criteria, and revalidation for each qualification stage of the fluidized bed dryer.
This document provides an overview of troubleshooting skills for process operations. It discusses the key elements of troubleshooting including defining the problem, investigating causes, planning solutions, implementing plans, evaluating results, and concluding. Common troubleshooting techniques are explained such as fishbone diagrams, fault tree analysis, 5 whys, and mind mapping. A case study example applies these techniques to troubleshoot a pump failure where the root cause was determined to be reverse motor rotation due to an operator error in verification. The presentation aims to improve troubleshooting skills for both experienced and new process engineers.
This document summarizes a student project that aimed to reduce the time required to diagnose faults in wind turbine slip rings. The team:
- Engineered a controlled failure on a slip ring simulator to test monitoring variables like voltage, amperage, and temperature using Fluke Connect tools.
- Found monitoring voltage provided the best resolution and thermal imaging helped isolate problems.
- Estimated the tools could reduce average repair time per failure by 3 hours, saving 17% of work hours annually on a 140 turbine wind farm.
- Recommends the Fluke Connect system for its user-friendliness and potential to improve safety, efficiency and documentation in the renewable energy industry.
Fluke Ways Test Tools Can Improve Safety Around Rotating MachineryTranscat
The document discusses ways that test tools can improve safety when working around rotating machinery. It recommends (1) being careful of moving parts, (2) working from a distance using wireless tools like vibration meters and infrared cameras, and (3) quickly identifying faults on machines before catastrophic failure using vibration analysis to reduce time spent near machinery. The tools can help technicians work more safely by monitoring machines remotely, reducing entry/exit times near moving parts, and taking faulty machines offline before hazardous conditions occur.
The problem is that the width of materials produced by the cutting-to-size (CTS) machine was found to be varying outside the allowed tolerance of ±0.5mm. This was discovered during a quality inspection and could lead to rejected materials. The root cause was determined to be uneven mill edges on the raw materials. To address this, the corrective action was to change the feeding method on the CTS machine to use a back stopper, which would shear off the mill edges. The preventative action would be to create standard operating procedures for the machine and implement a poka-yoke system to prevent similar issues in the future. The benefits would be no customer complaints due to improved quality and accuracy of materials,
Goodman Final Presentation_French_JeremyJeremy French
Jeremy French completed a controls engineering internship at Goodman Manufacturing where he worked on various projects including HMIs, control panels, and a heat exchange leak tester. Over the course of the internship, he learned how to troubleshoot machinery issues, input questions to problems, and saw improvements to the leak tester to make the testing process more efficient with fewer leaks. The leak tester uses pneumatics, a PLC, HMI, and control panel to automatically clamp units, conduct tests by measuring pressure and flow, and send results to a database. Potential future improvements include updating seals, adding automatic scanning, and sensors to check for insulation brackets.
Here are the definitions from the document:
Friction is the resistance against movement.
Friction problems can cause heat, wear, and cost industries over $1 billion per year.
Thresholds are the necessary determined data under actual operating conditions that can be safely applied on a device before it will break.
The functions of a lubricant are to:
- Reduce friction
- Reduce wear
- Prevent overheating (cool)
- Reduce mechanical shock
- Prevent corrosion
- Protect against dirt
This document provides guidance on designing a photovoltaic (PV) system through an 8-step process: 1) conducting an electricity audit; 2) assessing available sun resources; 3) surveying the installation site; 4) sizing the PV system; 5) selecting modules and inverters; 6) string sizing; 7) assessing finances; and 8) making a decision. The document outlines the key considerations and calculations at each step to appropriately size a grid-tied PV system to meet a home's electricity needs while working within physical and budget constraints. A sample string sizing example is also provided to demonstrate how to match modules and inverters based on technical specifications and location weather data.
This document discusses techniques for scaling up processes from a pilot plant to full production. It covers definitions of pilot plants, their significance in allowing examination of formulas and refinement of processes and equipment. General considerations for pilot plants include reporting structure, personnel requirements, space needs, and review of formulas and raw materials. Process evaluation and development of master manufacturing procedures are also covered. The document discusses various dosage forms including solids, liquids, parenterals, and semisolids, outlining equipment and parameters considered for scaling up each type of product. GMP considerations and advantages and disadvantages of pilot plants are also summarized.
1. 1
Medisense Medication Dispenser
From Left:
Nicholas Kemme – Chief Engineer
Andrea Kemmerrer – Editor-in-Chief
Gregory Hutchins – Manufacturing Engineer
Thomas Wojtas – Team Leader
Ryan Campbell – Test Engineer
Jeremiah Dwight – Quality Control Manager
2. 2
Problem Statement
Sorting your medications into single
doses is a tedious and mistake-prone
process, especially for older, more
forgetful people. A fully autonomous
system that sorts and dispenses pills
and alerts the user would save time and
decrease this likelihood of user error,
leading to a safer means of taking
frequent, complex combinations of
medications.
3. 3
Requirements
Part 1 of 6
Prototype Requirement Method of Validation
1 Weigh less than 20 pounds Place final device on scale and record final weight
2
Be less than 24 in x 24 in x 18 in in
size
Measure final product with a tape measure or other measuring
device.
3
Machine must take less than 30
minutes to generate one pill
Using a stopwatch or other timing device the dispense device
will be timed on how long it takes to sort and dispense one pill
4
Back up battery must last more
than 2 days
Disconnect the machine from a power source and run it under
normal conditions, at end of 2 days machine must still be
functioning at full capacity.
4. 4
Requirements
Prototype Requirement Method of Validation
5
The noise of the machine while it
is sorting must be less than 70 dB
The machine will be placed on a stand and a decibel meter
will be placed next to it to as the machine is sorting to
determine its loudness.
6
Alert noise clearly audible from 20
feet
No notable decrease in volume from 20’ when compared to
immediately next to the device
7
System reliability must be greater
than 95%
95% dosage delivery rate over the 100 pills trial
Part 2 of 6
5. 5
Requirements
Prototype Requirement Method of Validation
8
The dosage must be be accurate
99% of the time
The correct dosage amount must be given 99 times out of 100
runs
9 Cost less than $150 (Production)
Production model overall cost will be valued at less than $150
10
Prove ability to handle up to 6 pill
containers
One pill container will work well and a system will be
introduced to prove the implementation of multiple containers
11
Must be able to program full
dosage in less than 10 minutes
An individual unfamiliar with the device or the technology used
within it will be timed while setting up the medication to
determine if the system is easy enough and fast enough and
that it takes them less than 10 minutes
Part 3 of 6
6. 6
Requirements
Prototype Requirement Method of Validation
12
Must be able to retrieve dosage in
less than 5 seconds
Once dosage has been sorted and dispended and the user has
been notified of its readiness it must take less than 5 seconds
for the user to retrieve their medication. This will be timed
using a stopwatch.
13
Must be able to sort any pill
between Zyrtec (small, pressed
pill) and Nyquil (large, gel
capsule)
A variety of pills will be placed in different hoppers and the
machine must sort all of them equally as well, with high
accuracy. In addition, mechanical analysis (kinematics,
dynamics, structural analysis, etc.) will be performed on key
components.
14
Must run on standard outlet
(120V) or standard batteries (AA)
The device will be configured to accept these power supplies,
and perform at the same level
Part 4 of 6
7. 7
Requirements
Prototype Requirement Method of Validation
15
Any font must be greater than
20pt size
When programming the user interface a font size greater than
20pt will be used
16
Inside must be accessible in less
than 30 seconds
Utilizing a stopwatch an individual unfamiliar with the product
will be timed as they attempt to open the device
17
Must require no tools to access
inside
The device will be designed so that no tools will be required to
open up the Medisense dispenser. A system of latches will be
implemented.
18
Time to clear a stuck pill must be
less than 1 minute
An individual unfamiliar with the Medisense device will be
timed as they attempt to clear an obstructing pill from the
device
Part 5 of 6
8. 8
Requirements
Prototype Requirement Method of Validation
19
Maintenance interval must be
greater than 6 months
The parts within the Medisense device must have a high
durability to ensure that they will not need regular care and
maintenance
20
Must survive a drop from 4 feet, 3
times
The machine will be dropped from a height of 4 feet 3 times
then checked to ensure it is still sorting and dispensing pills
properly.
21
Lid must withstand pulling force
of 100 lbs
Pull on lid with a force greater than 100 lbs while using a force
meter to verify
Part 6 of 6
9. 9
Schedule
Deliverable Completion Date
Pre Concept Design 9/22/15
Conceptual Design 10/16/15
Preliminary Design 12/6/16
Detailed Design 1/8/16
Fabrication, Assembly, and
Testing
4/6/16
Initial Delivery, Support and
Improvement
4/29/16
10. 10
Labor Loading Chart
• Approximately 10 hours
per week, per person
• Suggested time to
spend on project per
week
• Considerations made
for breaks
0
200
400
600
800
1000
1200
0 5 10 15 20 25 30 35 40
CUMULATIVELABOR(HOURS)
PROJECT TIMELINE (WEEKS)
Labor Budget Chart
MEE 488 MEE 489
14. 14
Preliminary Design
• Packaging determined
• Several screws printed and tested
to determine best pitch
• V-channel printed to confirm
surface roughness and angle
16. 16
Final Prototype: Screw Conveyor
1
2
3
4
1 Fans Cool Stepper Motors
2
Stepper
Motors
Move Conveyor Screws
3 Hoppers Holds pills
4
Conveyor
Screws
Moves pills out of the
hoppers and into the
system
17. 17
Final Prototype: V-Channel
5
6
7
8
9
10
11
5
Curved
V-channel
Moves pills into straight line
6 Lasers Detects pills passing through
7 Photoresistors
Sends signal indicating pill has
passed through
8 Light blocker
Allows photoresistors to work
more optimally
9 V-channel
Moves pills through system in
single file
10 Solenoids Moves doors
11 Doors Blocks unwanted pills
18. 18
Final Prototype: Sorting
12
1314
1516
12 Rotating
funnel
Moves pill to dispensing cup or reject tray
13 Load cell Measures to ensure only one pill has made it
through
14 Dispensing cup Holding chamber for dosage of medication
15 Reject tray Holding chamber for extra/wrong pills
16 Servo motors Moves the rotating funnel/reject tray
12 Rotating
funnel
Moves pill to dispensing cup or reject tray
19. 19
Final Prototype
Performance
• Testing has been done to validate functionality of prototype
Meets the Need
Machine must be able to quietly and accurately sort and dispense a wide variety of
medication
• Quiet: Operates at <40dB for majority of sorting
• Accurate: Reliability testing passed
• Dispense: Can differentiate between pills and dispense them correctly
• Variety: Prototype has been successfully been tested with materials ranging
from 0.2g to 2g
20. 20
FMEA
• Failure modes
• Motor imprecision
• Pill speed
• Bad device
• RPN reduction
• Change to steppers, servos
• Analysis
• Pill speed
• V-channel angle
• Test parts prior to installation
• Feedback loop
21. 21
Problem Solving Example 1
Problem:
Stepper motors heat up to 130°F if powered constantly
Steps to solve this Problem:
I. Step 1 - Identify solutions
a. Option 1: Have fans blowing on stepper motors
b. Option 2: Use relays to operate motors non-continuously
II. Step 2 - Evaluate options
a. Option 1 Pros: Minimal rewiring
Cons: Doubles power draw of motor system
b. Option 2 Pros: Solves root cause of problem; less power draw
Cons: Significant rewiring; additional Arduino pins
III. Step 3 - Choose and implement solution
a. Problem is significant safety issue, and neither option is high-cost, so implement BOTH
solutions
b. Fans and relays added to system; testing ensured functionality
22. 22
Problem Solving Example 2
Problem:
H-bridge short caused safety doors to not function properly
Steps to solve this Problem:
I. Step 1 - Identify solutions
a. Option 1: Have both doors open and close together
b. Option 2: Allow one door to be functional and always leave the second open
c. Option 3: Order new H-bridge
II. Step 2 - Evaluate options
a. Option 1 Pros: Can be done immediately
Cons: Doesn’t serve original design aspect
b. Option 2 Pros: Can be done quickly
Cons: Results in potential lower reliability
c. Option 3 Pros: Completely fixes problem
Cons: Costs more money and could cause delays
III. Step 3 - Choose and implement solution
a. Chose and successfully implemented Option 3
23. 23
Problem Solving Example 3
Problem:
Once servos added to system, photoresistors behaved strangely
Steps to solve this Problem:
I. Step 1 - Isolate problem
a. Used LED to determine where problem was local or global
b. Determined problem was global - nothing was working right
II. Step 2 - Determine root cause
a. Consulted EE student with more experience
b. Determined servos were starving system of power, causing irregular voltage across
photoresistors (and everywhere else)
III. Step 3 - Identify and implement solution
a. Separated servos from rest of circuit to give them their own power
b. Now everything behaves normally
31. 31
Validation
Prototype Requirement Method of Validation
Test for
Validation
Validation Status
1 Weigh less than 20 pounds
Place final device on scale and record final
weight
Specification
Test
Pass: 19.4
lbs.
2
Be less than 24 in x 24 in x
18 in in size
Measure final product with a tape measure
or other measuring device.
Specification
Test
Pass: 13in x 17.5 in x
14.75 in
3
Machine must take less
than 30 minutes to
generate one pill
Using a stopwatch or other timing device the
dispense device will be timed on how long it
takes to sort and dispense one pill
Dispense
Test
Pass: 12 min 02 sec
4
Back up battery must last
more than 2 days
Disconnect the machine from a power source
and run it under normal conditions, at end
of 2 days machine must still be functioning
at full capacity.
N/A for
Prototype
N/A for
Prototype
Part 1 of 6
32. 32
Validation
Prototype Requirement Method of Validation
Test for
Validation
Validation
Status
5
The noise of the machine
while it is sorting must be
less than 70 dB
The machine will be placed on a stand and a
decibel meter will be placed next to it to as the
machine is sorting to determine its loudness.
Noise Test
Conditional
Pass: See Test
6
Alert noise clearly audible
from 20 feet
No notable decrease in volume from 20’ when
compared to immediately next to the device Noise Test
Pass: Clearly
Audible from 25'
3"
7
System reliability must be
greater than 95%
95% dosage delivery rate over the 100 pills trial Dispense Test Conditional
Pass: See Test
Part 2 of 6
33. 33
Validation
Prototype Requirement Method of Validation
Test for
Validation
Validation
Status
8
The dosage must be be
accurate 99% of the time
The correct dosage amount must be given 99
times out of 100 runs
Dispense Test
Pass: 100%
accuracy
9
Cost less than $150
(Production)
Production model overall cost will be valued at
less than $150
Cost Analysis
Prototype Cost:
$583.24
10
Prove ability to handle up
to 6 pill containers
One pill container will work well and a system
will be introduced to prove the implementation
of multiple containers
Dispense Test Pass
11
Must be able to program
full dosage in less than 10
minutes
An individual unfamiliar with the device or the
technology used within it will be timed while
setting up the medication to determine if the
system is easy enough and fast enough and that
it takes them less than 10 minutes
Dispense Test
(prove ability to
receive user
input)
N/A for
Prototype
Part 3 of 6
34. 34
Validation
Prototype Requirement Method of Validation
Test for
Validation
Validation
Status
12
Must be able to retrieve
dosage in less than 5
seconds
Once dosage has been sorted and dispended and
the user has been notified of its readiness it
must take less than 5 seconds for the user to
retrieve their medication. This will be timed
using a stopwatch.
Dispense Test Pass: 4 seconds
13
Must be able to sort any
pill between Zyrtec
(small, pressed pill) and
Nyquil (large, gel
capsule)
A variety of pills will be placed in different
hoppers and the machine must sort all of them
equally as well, with high accuracy. In addition,
mechanical analysis (kinematics, dynamics,
structural analysis, etc.) will be performed on
key components.
Dispense Test
(proved
versatility)
Pass
14
Must run on standard
outlet (120V) or standard
batteries (AA)
The device will be configured to accept these
power supplies, and perform at the same level
Dispense Test Pass
Part 4 of 6
35. 35
Validation
Prototype Requirement Method of Validation
Test for
Validation
Validation
Status
15
Any font must be greater
than 20pt size
When programming the user interface a font size
greater than 20pt will be used
N/A for
Prototype
N/A for
Prototype
16
Inside must be accessible
in less than 30 seconds
Utilizing a stopwatch an individual unfamiliar
with the product will be timed as they attempt
to open the device
N/A N/A
17
Must require no tools to
access inside
The device will be designed so that no tools will
be required to open up the Medisense dispenser.
A system of latches will be implemented.
N/A N/A
18
Time to clear a stuck pill
must be less than 1
minute
An individual unfamiliar with the Medisense
device will be timed as they attempt to clear an
obstructing pill from the device
N/A N/A
Part 5 of 6
36. 36
Validation
Prototype Requirement Method of Validation
Test for
Validation
Validation
Status
19
Maintenance interval must
be greater than 6 months
The parts within the Medisense device must have
a high durability to ensure that they will not
need regular care and maintenance
N/A for
Prototype
N/A for
Prototype
20
Must survive a drop from 4
feet, 3 times
The machine will be dropped from a height of 4
feet 3 times then checked to ensure it is still
sorting and dispensing pills properly.
N/A N/A
21
Lid must withstand pulling
force of 100 lbs
Pull on lid with a force greater than 100 lbs
while using a force meter to verify
N/A for
Prototype
N/A for
Prototype
Part 6 of 6
38. 38
0
200
400
600
800
1000
1200
0 10 20 30 40
CUMULATIVELABOR(HOURS)
PROJECT TIMELINE (WEEKS)
Labor Budget Chart 489
Cumulative Semester Actual
Team Performance
0
100
200
300
400
500
600
700
0 5 10 15 20CUMULATIVELABOR(HOURS)
PROJECT TIMELINE (WEEKS)
Labor Budget Chart 488
Cumulative Year Actual
On schedule - Never missed a deadline
Under budget - $583.24 out of $600
Team - 10/10
39. 39
Lessons Learned
• Team must be easily compatible
• Other teams struggled which resulted in setbacks
• Importance of a clear set of deliverables being determined and
agreed upon by the team.
• Clear deliverables allow everyone to know what must be done
• Cohesion of the systems must be considered early on
• Most additional work was caused by considering electrical system later
40. 40
Summary
• Prototype functionally dispenses two different
medications
• Wide range of medications can be sorted and
dispensed
• Prototype never distributes an incorrect dose
• Team worked well together to finish the project
on time and under budget
• Prototype can be scaled to accommodate more
medication and produced at a lower cost