ACCESSIBLE COMPUTER INTERFACE FOR A CNC MACHINING CENTER

PROJECT REPORT TO

THE SEATTLE LIGHTHOUSE FOR THE BLIND, INC.

November 25th, 2003

Team ECE 04.7 Science and Engineering Project Center

School of Science and Engineering Seattle University

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ACCESSIBLE COMPUTER INTERFACE FOR A CNC MACHINING CENTER

Project Sponsor

The Lighthouse for the Blind, Inc.

Liaison Engineers

Norm Slader Ken Wolford

Doug Case Don Swaney

Engineering Design Team EE4.7

Seattle University project Engineers

Shriram Reddy Quyen Le

Rionald Soerjanto Diana Bonilla

Mr. Ward Silver Electrical Engineering Senior Design

Dr. Jeff Gilles, Director Science and Engineering project Center

November 25, 2003

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Table of Contents

Letter of Transmittal………………………………………………………………………….…4 Introduction……….………………………………………………………………………….…..5 A. Background B. Statement of the Problem Scope of Work………………………………………………………………………………….6-8 A. Overview B. Literature Review C. Alternative Solutions and Evaluation D. Decision Plan of Implementation………………………………………………………………………9-10 A. Research B. Design C. Prototype Construction D. Testing E. Documentation References……………………………………………………………………………………….11 Facilities…………………………………………………………………………………………12 Personnel and Organization Chart……………………………………………………………13 Schedule………………………………………………………………………………………....14 Budget…………………………………………………………………………………………...15 List of Figures…………………………………………………………………………………..16 Appendix A - Original Statement of Work………………………………………………….17 Appendix B - Student Resumes………………………………………………………………19

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Design Team EE 4.7 Seattle, WA 98122 November 25th, 2003 Mr. Ken Wolford Mr. Doug Case Mr. Don Swaney Mr. Norm Slader The Lighthouse for the Blind, Inc 2501 South Plum Street Seattle, WA 98144 RE: Accessible CNC Machining Center Dear Mr. Ken Wolford, Mr. Doug Case, Mr. Don Swaney, and Mr. Norm Slader: We are pleased to present to you our proposal for the Accessible Computer Interface for a CNC Machining Center. We strongly believe that we have found an appropriate solution for the project sponsored by The Seattle Lighthouse for the Blind. This report includes a detailed process for the design of the interface as well as costs for the development of the project.

We are looking forward to working with all of you at the Seattle Lighthouse for the Blind on this challenging project. Sincerely,

Seattle University Design Team EE 04.7: Shriram Reddy Diana Bonilla Quyen Le Rionald Soerjanto Mr. Ward Silver, Faculty Advisor

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I. INTRODUCTION A. Background The ability to make any system accessible by a disabled individual has become a necessity in today’s world. Providing such access to computer systems is especially important as they allow the user to access limitless amounts of information and control from a single console. An application developed by Freedom Scientific called JAWS (Job Access with Speech) provides speech technology that works with Windows 95/98/XP operating systems to provide access to software applications and the Internet. JAWS uses an integrated voice synthesizer and the computer's sound card to output the content of the computer screen to speakers. CNC (Computer Numerically Controlled) milling machines are intended to be used with limited interaction with the user which makes them accessible to a disabled individual with some minor modifications and software applications such as JAWS. The CNC machines often use proprietary software which is not included with accessibility features. B. Statement of the Problem The Seattle Lighthouse for the Blind (SLB) requires a user interface to operate one of its milling CNC machines. At the moment, the machine requires a software interface, not accessible by the disabled people, and an alarm system. This user interface will be operated mainly by the blind, deaf or deaf/blind people. This software interface would make a CNC machine (milling) accessible for them to set-up and operate. Since the SLB provides jobs for disabled people and also an increasing demand in the industry, they need their CNC machine to be able to be operated by disabled individuals as well. II. SCOPE OF WORK A. Overview

Before the initial design stage, the group has to acquire a fundamental knowledge of Job Access with Speech (JAWS), DOS, Microsoft Windows 98, mechanical sensors, and data acquisition cards. The SLB engineers suggested that the group should do some detailed research on mechanical sensors and data acquisition cards to make the decision on a particular brand and model adequate for the project. After the research stage, we will develop the graphical user interface (GUI) using Visual Basic software to accept inputs for part dimensions, which would feed directly to the Bridgeport system for the CNC machine. This GUI will have to be compatible with JAWS, which will be easily tested by using the free demo version via the Internet. The second half of the software stage is to have the machining parameters, which will be in Windows 98 format, saved in a permanent file and then transferred to the Bridgeport, which will be operating as a DOS platform.

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Finally, we have to decide which mechanical sensors and data acquisition card are reliable and cost efficient for the project while keeping in mind that this hardware will possibly be upgraded in the future.

B. Literature Review

One of the most important components of this project is the software JAWS (Job Access with Speech). This program allows someone who is visually impaired to access a computer using Windows by reading the on-screen text.1 The advantage to a program such as this is that it can be used to understand almost anything text-based which is on the screen.1,2 This allows one to design a custom interface which displays detailed alerts and confirmations as text on the screen and have JAWS read it to the user.6 Another advantage JAWS has as a screen reading tool in a corporate environment is its price. A professional license typically being priced at around $1000, the software is fare less expensive than Braille displays.7 Braille displays are hardware devices that use rounded retractable pins to translate on-screen text into Braille symbols which a blind user can read by touch. Although typically Braille can be read much faster than having to actually listen to the computer speak through JAWS, the price difference and the fact that a user has to be touching the Braille display at all times to be kept informed at all times makes the latter a better choice.7 CNC machines are one of the most common types of automated systems used in manufacturing. Evidence of this can be seen at such operations such as Boeing’s fabrication facilities and in vehicle manufacturing plants. CNC milling machines use a computer controller to guide a motor controlled armature or stand for the purpose of manufacturing specific parts.4 The system is designed to be fully automated requiring numerical input from the user which increases precision and speed of manufacturing. Typically, in addition to coordinate information, the computer controller uses a script written in a language called G-Code. These custom scripts can be used to guide the CNC milling machine to perform an almost limitless combination of tasks.4 C. Alternative Solutions and Evaluation The GUI will be programmed in Visual Basic as it is the best solution for the software part of the project. This is because Visual Basic provides an effective solution to the software interface problem without all the complexities that go with other languages such as C++. Since all of the group members have general knowledge of Visual Basic (VB), and this software language has a powerful system that handles the GUI well, VB will be the platform to execute this task. The sensors to be used are Honeywell silicon pressure sensors. These sensors have features such as small size, low cost, excellent repeatability, high accuracy and reliability under different environmental conditions. All these features are important in an environment like a machining center where the sensors will have to endure a great deal of vibration from the machine and where device failure could result in damage to machinery or personal injury.

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Since we have selected a specific kind of sensors and programming language, the only item that can be varied is the data acquisition card. This component will be key to combining the hardware alert system to the accessible software interface. Solution 1: Omega has a large variety of data acquisition cards such as the OME-PCI-1002 series, which is a family of PCI bus A/D boards. They feature a 110 kHz data acquisition rate under DOS and Windows. The boards provide 32 single-ended or 16 differential inputs, 16 digital input and 16 digital output channels. All boards are supplied with a standard software development kit for Windows 98/NT/2000/XP. The software development kit includes DLL files for programming in C, C++ or other high level languages such as Visual Basic. Solution 2: Another solution is to use Adlink Technology’s cPCI-7300 High Speed Digital I/O data acquisition card. The 7300A performs high-speed data transfers using bus mastering DMA and scatter/gather via 32-bit PCI bus architecture. The 7300A is configured as two ports, PORTA and PORTB, each port controls 16 digital I/O lines. The I/O can be configured as either input or output, and 8-bit or 16-bit. Users can configure the 7300A to meet high speed digital I/O data transfer according to the outside device environment. Evaluation of Solutions: Solution 1 provides the best PCI data acquisition card for this project as it allows one to use the inputs as 32 single-ended or 16 differential. This provides us with the greatest compatibility with sensors of varying types and also allows room for expansion. Since one may wish to add to the system in the future, providing more inputs would be a prudent thing to do.

D. Decision With the equipment currently available (Windows 98 PC, sensors, etc.) the decision is to use any one of the Omega data acquisition cards and use sensors that are compatible with it. The best choice is the OME-PCI-1002 series which provides a large number of single input or differential inputs. We will have to make sure that the sensors already available from the Seattle Lighthouse for the Blind are compatible with the card or perhaps modify them so that they are. This would reduce cost and also allow us to use sensors that have already been tested and approved by the Lighthouse engineers. Since we will only have to outfit a single machine, it might be prudent to simply purchase the entire array of desired sensors from a single manufacturer and connect them to the DAQ which could very well decrease compatibility problems for a minimal extra cost. The software portion of the project will definitely be designed in Visual Basic and tested on a Windows 98 platform. This will allow the interface to perhaps be used on other CNC milling machines without having to spend a great deal on licensing since Windows 98 is a now an inexpensive operating system. The finished product including the hardware and software deliverables is outlined in figure 1 below.

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Figure 1 - Outline of the finished CNC milling machine with accessibility features added.

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III. Plan of Implementation The following task listed below is an overview for Design Team EE 04.7 to fulfill the request to make a CNC milling machine fully accessible to a blind or deaf operator. A. Research

For this particular project, we divided the deliverables into two parts, the software and hardware components. First, we came to a decision to use Visual Basic to design the GUI (Graphical User Interface) with. Then we thoroughly researched the different types of data acquisition cards (DAQs), which would be most appropriate for the project. Currently, the CNC milling machine has only one sensor, the door position detector that is operating with the Bridgeport computer. During the initial phase of the research, we have found many compatible DAQs that would be ideal for this project at a particular company called Omega (www.omega.com). And it has been suggested that the sensors should also be ordered from the same company that the DAQ will be purchased from to eliminate compatibility problems. A list of remaining research topics is as follows:

• Approve choice of an adequate DAQ for project • Select sensors that are compatible • Bridgeport operating under DOS and MS Windows 98 operation of PC • Consider alternatives method of approach

B. Design Once the team has decided on the DAQ to implement, the design process can proceed. The group needs to be aware of all possible scenarios that can arise during an operation of the CNC milling machine. Since the team is responsible for the alert system, we need special precaution during the system design because the SLB’s main concern is safety. As a team, we will have to consistently meet with our facility advisor (Prof. Silver) and our liaisons (Ken Wolford, Doug Case, and Don Swaney) to double check the safety system for dependability. We intend on using the layout in Figure 1 to begin the design and then create diagrams that show the details of each component and how it should work. Once that is complete, we may begin coding and building the new accessibility features piece by piece as well as test them individually and together to make sure that each part will work together. C. Prototype Construction The software section is straightforward; we will design the GUI using VB.NET. However, the most important requirement of the program is having JAWS fully operational with our software interface.

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The hardware section will have more flexibility, since the requirements state that the DAQ would handle more than 8 digital or analog inputs and that the sensors are completely compatible with the chosen DAQ. Ken Wolford and Doug Case from the SLB will assist us in the assembly and simulation of the alert system. D. Testing After the initial design and build process is complete, the team will test and debug the entire prototype. First, the software component of the project is tested by running the program in Microsoft Windows 98; in addition, the program will also have JAWS (Job Access With Speech) operating simultaneously with our software. The difficult part of this testing assignment is that the tester will be blindfolded, to represent a blind operator, to prove that the software is user friendly to visually impaired individuals. We will use a number of different volunteers not involved with the project to validate that the software design is acceptable. The second half of the testing procedure is the alert system testing, which will be more challenging than the software testing. This test includes a complete assembly of the DAQ with all of the sensors connected to the DAQ. We will create manual switches to simulate the on/off sensors that are detecting. The pressure sensors are more challenging than the other switches to simulate during the testing. However, Ken Wolford and Doug Case from the Seattle Lighthouse for the Blind suggested using sensors already on site at the SLB which need to be simulated for the testing phase. E. Documentation Every aspect of the research process, design, and testing of both software and hardware deliverables will be documented. Each person from the team will have their own notes recorded in their individual notebooks. The project completion report, notebooks, and both deliverables will be available by Project Day on June 4, 2004.

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IV. References:

1) Minnesota WorkForce Center. ASSISTIVE TECHNOLOGY TOOLS. < http://www.mnwfc.org/eo/atmanual/atm1h.htm>. Accessed 2003 October 11.

2) Kathy Plett, 2003. College of New Caledonia Library Facilities and Services for Learners with Disabilities. < http://www.cnc.bc.ca/library/disabilities.html>. Accessed 2003 October 11.

3) Bridgeport Corporation, 2003. < http://www.bpt.com/products.html >. Accessed 2003 October 11.

4) Efunda Engineering Reference, 2003. <http://www.efunda.com/processes/machining/mill_cnc.cfm>. Accessed 2003 October 11.

5) Techno-Vision Systems Ltd, 2003. JAWS Screen Reader. <http://www.techno-vision.co.uk/JAWS.htm >. Accessed 2003 October 12. 6) The Canadian National Institute for the Blind, 2002. Screen Reading Software. <http://www.cnib.ca/tech_aids/screenreaders/>. Accessed 2003 October 12. 7) Freedom Scientific, 2003. JAWS for Windows.

<http://www.freedomscientific.com/fresci/showdetl.cfm?&DID=9&Product_ID=262&CATID=40>. Accessed 2003 October 12.

8) Freedom Scientific, 2003. Braille Displays.

<http://www.freedomscientific.com/fresci/showdetl.cfm?&DID=9&Product_ID=399&CATID=42>. Accessed 2003 October 13.

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V. FACILITIES:

The facilities to be used for the Accessible Computer Interface for a CNC Machining Center project will be mainly the Lighthouse for the blind, the Computer laboratory (room 210) and room 216 located in the Bannan building at Seattle University. The equipment that will be mainly used to develop this project will be the M6 CNC machine, which is located at the Seattle Lighthouse for the Blind. In addition, the use of software such as Visual basic, JAWS and Windows 98 will need to be accessible for Team 4.7 in the room 210 located in the Bannan building at Seattle University. Although, the Bridgeport controlling system and Vocal-eyes are also needed to develop this project, they could be used in the testing process at the Seattle Lighthouse for the Blind.

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VI. PERSONNEL/ORGANIZATION CHART

Figure 2 - Project organization chart

Shriram Reddy Shriram is an Electrical Engineering student who is currently the team leader and point-of-contact for group ECE 04.7. He has a great deal of software and computer hardware experience and will working on the design and implementation of the software interface. Quyen Le Quyen is a Computer Engineering student and is involved with implementation planning and will assist Shriram Reddy with the design of the custom software interface. His experience with getting software and hardware systems to communicate with one another will be extremely important for this project. Diana Bonilla Diana is an Electrical Engineering student who will primarily be working on the sensor alert system that will connected to the software interface. Her experience with logic circuits and other hardware based design will be invaluable for this part of the project. Rionald Soerjanto Rionald is a Computer Engineering student who will be assisting Diana in with the hardware alert system. His interest in software/hardware interfacing will be very useful when it becomes time to test the hardware alert system with the software interface.

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VII. SCHEDULE ID

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VII. BUDGET

BUDGET FOR GROUP ECE 04.7 References materials $150 Visual Basic reference manuals JAWS reference manuals Sensor Documentation Administrative supplies $320 Travel, # trips to sponsor office/quarter or # miles @ $0.36/mile $50 Parking permits for client on-campus visits, # times $50 Long distance telephone / Fax $40 Postage & Shipping $75 Photocopying # @ $0.05 $20 Printing supplies $20 # zip disks, # CDs $10 Office supplies (notebooks, paper, pens, etc.) $55 Expendable supplies $100 Solder, Wire, Plastic enclosures, comparators Capital equipment $2,000 Visual Basic .NET or 98 (development software) $290 Windows 98 (software upgrade) $10 JAWS (software upgrade) $100 Bridgeport (software upgrade) $100 Data Acquisition Card (hardware) $500 Sensors (pressure, temperature, touch, etc.) (hardware) $1000 Team building $200 Maximum is # of team members @ $50/team member Staffing Sponsor liaison $0 Students $0 Faculty advisor $0 TOTAL: $2770

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VIII. List of Figures 1. Outline of the finished CNC milling machine with accessibility features added (p. 8) 2. Project organization chart (p. 13)

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Appendix A

Request for Proposal

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First Priority Development of a custom computer control for a CNC Machining Center – Develop a custom software application that would make a CNC machining center accessible for a blind person to set-up and operate. Software would also facilitate the set-up and operation of the machining center that has been modified to produce a specific family of machined parts. Development of additional software/hardware systems to make machines accessible to people who are blind or Deaf Blind could be included in the project. Development and Implementation of the following Databases and Reporting Systems: • Fixture Tracking Database & Reporting System • Interpreting Services Database & Reporting System • Machine Proficiency Training Database & Reporting System

Second Priority Assembly Process Improvement – Opportunities to improve assembly processes for mops and other products. Consideration and evaluation of usual factors, plus additional consideration of need for flexible production systems that accommodate a work force with a wide range of skills. Material Handling Improvement – Opportunity to focus on material handling improvement. Typically would be considered in conjunction with “Assembly Process Improvement,” but possible opportunities to focus on this. Product Development and Improvement – Possible opportunities for design using Solidworks (3D CAD), production of prototype and evaluation of prototypes. No good candidate items at present. Packaging and packing improvement – Opportunity for analysis of current product packaging and packing with goal of the development of alternative approaches for packaging and packing that offer greater value for the lighthouse.

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Appendix B

Student Resumes

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Quyen Van Le 30028 128th Ct SE, Auburn, WA 98092

Leq1@seattleu.edu (206) 850-8293

SKILLS

Computer Skills: * Visual Basic * C/C++ *Scheme *PSpice *MS Office and Project *All of MS Operating Systems *MATLAB

EDUCATION

June 2004 SEATTLE UNIVERSITY Seattle, WA Degree: Bachelor of Science in Electrical Engineering Major: Electrical Engineering with Specialization in Computer Engineering

• Vietnamese Student Association: Web Master

Dec 2000 GREEN RIVER COMMUNITY COLLEGE Auburn, WA Associate of Science Cumulative GPA: 3.33/4.0

EXPERIENCE

2000-Present SEATTLE LIGHTHOUSE FOR THE BLIND Seattle, WA Project Title: Accessible Computer Interface for a CNC Machining Center with visual and audio alert system.

Description: Designing a software interface for the visually impaired individual that allows him/her to transfer instructions to a CNC machine.

Personal

• Music, football, baseball, bowling, US citizen, fluent in Vietnamese

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Shriram Reddy 8037 NE 112th St, Kirkland, WA 98034

reddys1@seattleu.edu (425) 891-9939

SKILLS

Windows 9x/NT/2000, UNIX, Mathematica, MATLAB, Cadence Orcad, PSPICE, MS Office, C++, gCC, C#, SQL, Visual Basic, Macromedia Flash, Dreamweaver, Fireworks, and Coldfusion. Tektronix and Hewlett-Packard Oscilloscopes, Agilent Arbitrary Waveform Generators, and Spectrum Analyzers.

EDUCATION (List in chronological order starting with the last one)

June 2004 SEATTLE UNIVERSITY Seattle, WA Batchelor of Science in Electrical Engineering

• Dean’s List • Member of IEEE • Currently Researching for CNC Interface Project

EXPERIENCE (List in chronological order starting with the last one)

Summer 2003 BAE Systems Keyport, WA

Engineering Intern • Built and maintained inventory databases using SQL and Access to aid Navy logistics

department. • Repaired damaged training devices such as laptops and projectors for the Air Combat

Training Systems (ACTS) help desk. • Edited technical documents for the Raytheon documentation team.

Fall 2000 VOLT Everett, WA Technician (as a contractor working for Boeing)

• Set up networks in classrooms and upgraded existing computers. • Assisted in Windows 2000 deployment and upgrade, as well as assisting employees in

adjusting to the current Windows 2000 upgrade.

HONORS AND ACTIVITIES

• Web designer for IEEE club

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Diana Bonilla 14351 6th St. S Apartment O-102, Bellevue, WA, 98007

bonilld@seattleu.edu (206) 649-7364

SKILLS

• Assembly language, C, Matlab, Mathematica, Multislim, Pspice, Minitab, MS. • Fluent Spanish. • Oscilloscope, Function Generator, HP Spectrum Analyzer, Multimeter.

EDUCATION

June 2004 SEATTLE UNIVERSITY Seattle, WA Batchelor of Science in Electrical Engineering Minor in mathematics

• Vice President, Society of Women Engineers. • Member, IEEE.

June 2001 ARMY POLYTECNIC SCHOOL (ESPE) Quito, Ecuador Associate of Science

• Social Activities Coordinator, ESPE Student Council .

EXPERIENCE (List in chronological order starting with the last one)

2003-Present The Lighthouse for the Blind, Inc Seattle, WA Senior Design Project: Accessible Computer Interface for a CNC Machining Center

• Develop a custom software application that would make a CNC machining center accessible for a blind person to set-up and operate.

• Project must include conditional input/output monitoring with alarm indicators. 1999-2000 ESPE (Polytechnic School in Ecuador) Quito, Ecuador Real Application of C Language

• Develop different programs that could be used in fire stations, bus routes, parking lots, and other.

• Graphics must be included. • Teamwork and presentation skills developed.

Summer 03 Occidental Exploration and production Company. Quito, Ecuador Volunteer Business Intern

• Assist Electrical Engineer Manager. • Perform financial and environmental damage presentations.

2001-2002 Seattle University Learning Center Seattle, WA

HONORS AND ACTIVITIES

• Third place in Guayasamin Art Competition. • Second place in the Art Competition of the Ecuadorian House of Art.

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Rionald Anggara Soerjanto

10337 Midvale Avenue N Suite 203, Seattle, WA 98133 soerjantor@seattleu.edu

(206) 778-8808

SKILLS

• A self-motivated, fast learner and highly energetic person with excellent management skills • Consistently provide leadership, commitment, integrity, and innovative problem solving in a fast-

paced environment • Responsible, detail oriented, and ability to manage multiple task with on the timely manner • Computer: C/C++, Visual Basic, Java, MATLAB, Multisim Pspice, Assembly language (MC

68000), Unix, Windows, MS Word, Excel, Access, Power Point. • Equipment: Oscilloscope, DMM, and Function Generator. • Languages: Written and oral fluency in English and Indonesian

EDUCATION

June 2004 SEATTLE UNIVERSITY Seattle, WA Batchelor of Science in Electrical Engineering with Specialization in Computer Engineering

June 2002 NORTH SEATTLE COMMUNITY COLLEGE Associate of Science Degree

• Dean’s Academic List, 2001

EXPERIENCE

1998-2000 HARINDO PRIMA KREASI Cirebon, Indonesia

Foreign Representative • Examined products trend that could be marketed in Indonesia • Made first contact to potential suppliers and mediated company for decision making • Provided assurance about products ordered from the ordering process to shipping

HONORS AND ACTIVITIES

IFGF, Seattle, Washington

Group Leader (2002-Present) • Organized a group of 15 people to achieve group’s vision and mission • Coordinated and planned group events • Learned to identify member’s needs and accommodated to it