Post on 19-Dec-2015
Lucky Charms Marbit SeparationCritical Design Review
May 16, 2003
Gregory Dickman
Roy Mitchell
Karen Palumbo
George Simmonds
Scott Walker
Andy Wang
© 2002 Lucky Charms Senior Design Team 2
Agenda
• Background• Objective• Intricacies and Constraints• Deliverables• Concept Development• Preliminary Testing• Concept Selection• Fabrication• Final Testing• Proposed Design
© 2002 Lucky Charms Senior Design Team 3
Background
• Lucky Charms Cereal Consists of 2 main components, Marbits and Base Cereal.
• Currently General Mills employs an offline check to ensure the marbit percentage per box.
• The process is performed by separating marbits by hand.
• The marbits are discarded after this process, and the base cereal is utilized for further testing.
© 2002 Lucky Charms Senior Design Team 4
Objective
• General Mills requested that we develop a device, method and procedure to replace the current separation method.
• The process must…– Be statistically repeatable– Be Accurate within 1% of the current method– Be robust and straightforward– Be completed in 5 minutes or less by 1 lab technician– End with sample of base cereal that can be crushed and
used for further testing
© 2002 Lucky Charms Senior Design Team 5
Intricacies and Constraints
• Marbits and base cereal are approximately the same size, weight and density.
• Special promotional marbits are often added to the cereal.
• A budget of $1500 was allotted to the group for research, testing and prototype.
© 2002 Lucky Charms Senior Design Team 6
Concept Development
• A series of concepts ideas were developed, a few were chosen for further analysis.
Concept Development
© 2002 Lucky Charms Senior Design Team 7
Preliminary Testing
• Tests were performed in the chemistry lab.
• Simple prototypes were assembled in order to assess the feasibility of ideas.
• Ideas were analyzed and synthesized to find optimal design.
• Two most feasible designs were chosen to be fabricated as prototypes.
© 2002 Lucky Charms Senior Design Team 8
Concept Selection
Heat Tray design Pin Press design
Common components were utilized to enable both designs to be fabricated under the allotted budget.
© 2002 Lucky Charms Senior Design Team 9
Fabrication
100% Team Fabricated (Except Heating Element)
Similar Designs
Identical Sub-Frames
Modifications Made to Press Plates
© 2002 Lucky Charms Senior Design Team 10
Pin Press Testing
© 2002 Lucky Charms Senior Design Team 11
Heat Tray Testing
© 2002 Lucky Charms Senior Design Team 12
Heat Tray Testing (Destruction)
198 g separated by hand198 g separated with heat tray prototype
Base cereal was tested for Vitamin C and Moisture
Hypothesis tests were conducted and showed no
significant difference
5 boxes of cereal tested
Base cereal was tested for Vitamin C and Moisture
© 2002 Lucky Charms Senior Design Team 13
Heat Tray Testing (Temperature)
• Various studies performed to determine optimal temperature of hot plate and pressure time.
• Plate surface varies within +/- 10 degrees Celsius due to crude dial and nature of heating element.
© 2002 Lucky Charms Senior Design Team 14
Heat Tray Testing (Repeatability)
• A gage study was performed to determine differences between operators, within operators and between batches.
• Difficulties resulted due to the non-uniform distribution and randomness of the hot plate.
© 2002 Lucky Charms Senior Design Team 15
Heat Tray Testing (Time)
• Based on time study analysis, it is estimated that separation would take 6.54 min with a hot plate of the same effectiveness.
• Based on 100% accuracy (error times included in study)
• With incorporation of a higher caliber hot plate, it estimated error rates can be reduced by approximately 50% yielding a total process time of 4.80 minutes.
© 2002 Lucky Charms Senior Design Team 16
Proposed Design
• Based on a 12 by 24 inch proportional controlled hot plate
© 2002 Lucky Charms Senior Design Team 17
Budget
Part Description Supplier Part Number Qty Price SubtotalHeat Element Aluminum Hot Plate McMaster- Carr 3271K14 1 $216.11 $216.11Springs Precision Compression Springs McMaster- Carr 94340K142 1 $9.40 $9.40Plate Insert Perforated Sheet McMaster- Carr 9232T181 1 $36.36 $36.36Bearings Linear Ball Bearing McMaster- Carr 6483K13 8 $25.26 $202.08Shafts Precision Ground Shafts Metal Supermarkets n/a 1 $28.62 $28.62Base and Top Aluminum Plate (12"x12") Metal Supermarkets n/a 3 $95.00 $285.00Tray Aluminum Plate (8"x8") Metal Supermarkets n/a 1 $21.00 $21.00Foam Foam McMaster-Carr 8882K1 1 $1.70 $1.70Pins Spring Pins Donated n/a 900 $0.00 $0.00Assembly Misc Nuts and Bolts (estimate) Shop / Local Retailer n/a 1 $25.00 $25.00
TOTAL $825.27
Budget (Heat Tray and Pin Press Design Prototypes)
Part Description Supplier Part Number Qty Price SubtotalHeat Element Aluminum Hot Plate Wenesco HP 1224 D 1 $1,450.00 $1,450.00Bearings Linear Ball Bearing McMaster- Carr 6483K16 4 $53.30 $213.20Shafts Precision Ground Shafts Metal Supermarkets 60345K45 1 $145.54 $145.54Raw Material Aluminum Plate MSC 2255800 1 $224.84 $224.84Raw Material Aluminum Plate MSC 9425455 1 $17.52 $17.52Foam Foam McMaster-Carr 8882K1 2 $1.70 $3.40Assembly Misc Nuts and Bolts (estimate) Shop / Local Retailer n/a 1 $10.00 $10.00
TOTAL $2,064.50
Estimated Budget for Proposed Full Scale Model
© 2002 Lucky Charms Senior Design Team 18
Questions