Individual Report (25%) Report Length: Approximately 1250 words equivalent (no more than 1500 words). Scenario: You are required to lodge a patent application for one of the inventions listed on the course webpage. Those inventions occurred in the past. Therefore, imagine if you were at that time and were asked to write a patent application. You must write a statement indicating how this invention is new, useful, and innovative. The application should include a title, abstract, description, up to five claims, and CAD drawings. The Task: 1) 2) Read the description of a selected invention that explains the effectiveness, novelty, elegance, and genesis of the product. You may have to do some background research as well, to identify why it is innovative and how it works (its functionality) Write a statement as a part of the patent application. Your statement should include a) b) c) e) Title Abstract (summary of your statement which enables the reader to quickly identify your invention) *Description of the product **Claims (at least 5) *** SolidWorks CAD Drawings * The description must • • • highlight the current issues; if the invention was made as a result of current problems and/or a specific problem that you are going to address with the proposed product describe the features you consider essential in the way that the invention works (i.e. efficiency, novelty, elegancy, and genesis) include specifications (details of each function of the product, e.g. what they consist of, and their positions, use figures/ drawings; use numbers when explaining different parts of the figures; materials to be used in the product/ preferred choice of materials) **Claims are important because they determine the scope of the monopoly given by a patent. The claims must, • be clear and concise • • • distinguish your invention from what is already known (because cannot get a patent for what already exists) set out all the essential technical features of your invention (features for which you wish to get a patent) be consistent with the description. Note: Statements about the advantages of your invention are not suitable as claims. ***The Drawings • • must be created using a SolidWorks model/drawing that you create to scale (or similar software such as AutoCAD, Revit, etc) with well-defined linework. All model and drawing files must be submitted. (Hand drawings are not permitted and Providing a model without a drawing is not sufficient for this assignment. the 3rd Angle orthographic views (front, side, and top) are recommended and isometric views can also be used to help show necessary details. You must provide sufficient views to fully display your design. TOP VIEW LEFT BACK END VIEW FRONT VIEW A. ORTHOGRAPHIC UP RIGHT LEFT FRONT DOWN UTBJ0007 B. THREE-VIEW ISOMETRIC • Do not include any descriptive wording or dimensions on the drawings. • You must label your views with terms such as front, side, or isometric perspective view. • • The drawings should be placed on an A4 page size with a title block stating the scale of the drawing, the author's name, and other necessary details. Landscape or portrait can be used. • All figures must be numbered starting at Figure 1. • • The items referred to in the text must be itemised in the figures starting at Item 1. Shading and cross-hatching can be used to help show a visual feature of your design. Dashed lines can be used to help highlight features on your drawings. What you will be assessed on: Format: Whether you can identify the innovative features of the chosen product Whether you can document the specifications of a product using the appropriate writing style Your engineering drawing skills, and Your general writing skills (i.e whether the writing is clear and concise, correct tense, etc) You should format your patent according to IP Australia guidelines A guide to applying for your patent (Australian Government, IP Australia) – page 17-18 contains an example Before you start have a look at some UniSA patent applications: • Weed seed devitalization arrangement • - Plastic automotive mirrors - (please note this is a US patent therefore the format is different) Additional resources: Australian and overseas patent databases- Patent Cooperation Treaty database - in this database, you can browse actual patent applications Marking Guide Criteria Format & general writing skills • • Well set out, easy to read. Correct paragraphing, spelling, tenses, etc.; concise writing, well expressed; The sections (e.g. description, claims, etc) are in the correct order. (2 points) Acceptable presentation but could be improved, Adequate paragraphing but some spelling or grammatical errors.; Some errors in the order (1 point) . The format is not correct; many spellings or grammatical errors ( 0-1 points) Description • Claims: Very good description provided; materials used are mentioned; functionality of the product is clear and supported by clearly labeled drawings/figures where appropriate. Novelty and efficiency of the product are highlighted (9-10 points) An adequate description is provided and supported by drawings/figures where appropriate. Could include more details of materials used/ novelty/ efficiency of the product (6-8) An average description is provided. Supporting materials used were not clearly labeled/ referred to within the main text. Need more details of functionality/materials used/ novelty/ efficiency of the product (4-5) Description poor; lacks detail and requires more supporting materials (figures/ drawings) (0-3) Marks Feedback /2 /10 /5 • • An appropriate number of claims are provided. Claims are clear and concise and consistent with the description; haven't left out any important features. (5) An appropriate number of claims are provided and consistent with the description, But some claims may be unclear/ too long/ be missing some important features. (3-4) Claims are not appropriate/ poorly stated. Missing important features. (0-2) Abstract: • The Abstract has an appropriate length. Readers can quickly identify the features of the invention by reading this abstract. (2) Abstract can be improved; abstract omits some important features/ information or is too long. (1) • Poor abstract; difficult to understand; lacks detail/too much detail. (0-1) Drawings: • • The drawings are to scale and without any descriptions or dimensions. Appropriate views are used to clearly show the invention. A title block is used to state relevant information. Each figure is numbered (starting at 1) and labeled with view type. All items described in the description are identified on the drawing with an item number and leader (starting at 1). (5-6) The drawings could be improved to help clarify the design, match the description and meet the requirements of the drawings. (3-4) The drawings lack detail to help explain the invention and do not meet the drawing requirements. Drawings may not have been created with CAD or the source model files are not included with the submission. (0-2) 12 /6

Question 2 ‘Smoothtools’ manufacturing company want to enter the ‘woodworking tools’ market and one of the first products it has decided to manufacture is a general purpose smoothing plane. (See Figure Q2- parts view). After ‘reverse engineering’ the wood plane, the planning department have arrived at a build sequence and timings for each task which is shown in Table Q2(a). Furthermore, the marketing department at ‘Smoothtools’ have produced a sales forecast for the new planes which is given in Table Q2(b). The plant is expected to have a work pattern of 40 hours week, 48 weeks per year. Assuming a Product layout (Long thin) arrangement, determine the following information for the 1st quarter of production: a) The required cycle time and the theoretical minimum number of people required to assemble the products (5 Marks) b) The ‘line design’. (5 Marks) c) The actual number of people required to manufacture/assemble the product based on your design and what would be the balance loss and estimated output for this arrangement? (6 Marks) d) If a ‘short fat’ layout is used in the 1st quarter, how many people would be required to assemble the products? What is the balance loss and potential output for this arrangement? (6 Marks) e) Considering the two options. Which layout is best suited to meet the demand in 4th quarter and why? (12 Marks) f) What are the advantages and disadvantages of both ‘long thin’ and ‘short fat’ layouts?

Part 2: Designing Lift Arm Assembly In Part 2 of this OEMP project you will be designing two aspects of the Lift Arm Assembly while ensuring functionality of your design. You will be selecting the length of parallel members CD and EB, as well as the height of chair assembly DEF. Throughout this project, all team's will be using US Customary units (pounds, slugs, feet, inches). E LOF do H d hu hg hc Figure 1: Side View (x-y plane) of Pool Lift with variable dimensions The lift arm assembly consists of a four-bar linkage, BCDE, where members CD and BE are the same length and remain parallel to one another at all times. The four-bar linkage ensures that the seat mount/chair DEF will maintain a vertical orientation throughout its motion. The goal of this OMEP is to develop your team's most competent Pool Lift Model allowing for a variety of users to comfortably enter and exit the pool safely. To limit the scope of this project, all teams will use the following dimensions: hc=56 inches and do = d = 2 inches, where he represents the height of pin C above the pool deck, hg represents the height of pin B above the pool deck, and de and d represent the length of hinges G and H, respectively, from the pin to the centerline of the member to which each hinge is attached. The lift arm assembly must be designed to successfully achieve your chair's selected vertical range of motion while limiting the necessary operating range of a angles (suggested less than 60°). Consider how the length of the parallel members and the height of the chair assembly affect the chair's vertical position. • Design the length of parallel members CD and BE (lcp in figure 1). Design the height of chair assembly DEF (DF in figure 1). Select the height of pin B above the pool deck (hg in figure 1). Based on your design, use geometry to find the a angles corresponding to your maximum and minimum chair positions. If your range of operating a angles is greater than 60° you need to consider redesigning lcD and lor as large ranges of angles may cause the hydraulic cylinder to overextend.

Problem 2 (10 marks) An I-beam is shown in the figure to the right. Given the following equations and constraints, develop a mathematical model and find the dimensions of a beam with a minimal cross sectional area. Cross sectional area: Section modulus: Bending moment: Axial force: Bending stress: Axial stress: Stress constraint: Buckling constraint: X₂ ↓ X4 TH A = x₁x₂ + 2x3x4 - 2x₂x4 S = X₁ (X3X4+*1X2) M = 350 P = 140 Og = Op -142* 1000M S OB + Op- 10P A 180 ≤0 (1+%² 1+171 SO And subject to the following constraints on plate thickness and width: x₁:38,40,41 x₂: 1.9, 2.2, 2.4 x3: 28,30,33 X4: 1.1, 1.3, 1.5 ·X₂ cm² cm³ kNm kN MPa MPa MPa

Question 2 'Smoothtools' manufacturing company want to enter the 'woodworking tools' market and one of the first products it has decided to manufacture is a general purpose smoothing plane. (See Figure Q2- parts view). After 'reverse engineering' the wood plane, the planning department have arrived at a build sequence and timings for each task which is shown in Table Q2(a). Furthermore, the marketing department at 'Smoothtools' have produced a sales forecast for the new planes which is given in Table Q2(b). The plant is expected to have a work pattern of 40 hours week, 48 weeks per year. Assuming a Product layout (Long thin) arrangement, determine the following information for the 1st quarter of production: a) The required cycle time and the theoretical minimum number of people required to assemble the products b) The 'line design'. c) The actual number of people required to manufacture/assemble the product based on your design and what would be the balance loss and estimated output for this arrangement? d) If a 'short fat' layout is used in the 1st quarter, how many people would be required to assemble the products? What is the balance loss and potential output for this arrangement? e) Considering the two options. Which layout is best suited to meet the demand in 4th quarter and why? f) What are the advantages and disadvantages of both 'long thin' and 'short fat' layouts?

Question 1 a) Define JIT and Lean Manufacturing and contrast the similarities and differences between the two. Discuss why the ‘Traditional approach’ is more intuitive and what approaches are needed to move toward a JIT scenario? b) Critically appraise five of the nine Just in Time (JIT) techniques e.g. reduction of set up time, TPM etc. highlighting what they are and how they would be implemented c) Describe a tool or technique which can be used to analyse and improve the performance of manufacturing systems e.g. Rank-order clustering, Ishikawa diagrams, Value Stream Mapping Root cause analysis, Pareto Analysis etc. Explain the basic principle behind the technique, how it would be applied and the potential benefits/inhibitors to implementation.

Assignment 2 - Reverse-Engineering: Functional Analysis, Design for Manufacture, and Environmental Impacts In this assignment, you are asked to undertake the reverse-engineering of a consumer durable (or similar product) in order to consider its overall design and that of its individual components. Central to the activities you undertake will be the analysis of its design for manufacture, the construction of a function hierarchy (Functional Analysis), and lifecycle analysis. There is a selection of very cheap toasters, irons, and hand-mixers available, and the disassembly is done in groups of four or so, (in order to economize on the number of products destroyed!). However, if you are able to find some other defunct product to use in this exercise, you are welcome to use that, (subject to checking suitability with me). Additionally, if you provide your own product, you can select your own disassembly group size and members. Health and safety are paramount in doing this exercise. It is important that the product you use for this disassembly is disposed of after this exercise. If the product you plan to disassemble uses mains electricity, it is a condition of using it for this exercise that before commencement you cut to electrical lead as close to the product as possible to prevent subsequent use. In conducting the reverse-engineering exercise, you should review the operation and performance of the product and consider how each of the components contributes functionally to the operation of the product. Use this to construct a functional hierarchy./nYou should then select two components from the product and produce a brief report on each discussing the design choices they embody. You should also use the software, Open CL, (to which you will be introduced), to estimate the environmental impacts of your two components. Ensure that the components you choose represent different manufacturing processes, and thus different DFM and potentially different environmental impact issues. (For example, do not select two injection molded components; for maximum marks you need to show an understanding of a wide range of DfM considerations, and even if different components, two components of similar manufacture will tend to embody the same points.) If you are sharing a product, ensure that you chose different components to discuss than those of your colleagues. Probable reasons for the choice of material and choice of manufacturing process should be briefly explained, but far and away more important is that you should highlight features of the component which have been designed to aid manufacture or assembly, (or perhaps compromises in this regard to satisfy other product characteristics). Nota Bene: The DfM/LCA submission should solely focus on those aspects of the components. You should not include a discussion of how you disassembled the product; it is not of interest here. Moreover, whilst you are expected to identify the manufacturing processes used, and the reasons for their selection, you may assume that the reader is familiar with the processes. Generic explanations of the processes are NOT required, and will not gain any marks.

Question 1 a) Define JIT and Lean Manufacturing and contrast the similarities and differences between the two. Discuss why the 'Traditional approach' is more intuitive and what approaches are needed to move toward a JIT scenario? b) Critically appraise five of the nine Just in Time (JIT) techniques e.g. reduction of set up time, TPM etc. highlighting what they are and how they would be implemented c) Describe a tool or technique which can be used to analyse and improve the performance of manufacturing systems e.g. Rank-order clustering, Ishikawa diagrams, Value Stream Mapping Root cause analysis, Pareto Analysis etc. Explain the basic principle behind the technique, how it would be applied and the potential benefits/inhibitors to implementation.

It is desired to design and manufacture continuous and aligned glass fiber- reinforced epoxy having a tensile strength of at least 1250 MPa in the longitudinal direction. The maximum possible specific gravity is 1.50. Using the following data, determine whether such a composite is possible. Justify your decision. Assume a value of 20 MPa for the stress on the matrix at fiber failure.S

4. There are many different gears in this tool. Find a gear model that is made using Powdered Metal. a. Briefly list the necessary functions and characteristics of the part. b. This part is made using the manufacturing process Powdered Metal Manufacturing. How does this manufacturing process fulfill each of the functions listed above? 5. c. How did you know this part was made using Powdered Metal? d. The engineers at DeWALT designed this part with Powdered Metal in mind. Look at the provided 2D and 3D models. Where can you see evidence that Design for Manufacturing guidelines were followed? Specifically look for: i. ii. 111. iv. Material selection (including the base material, and any additional material impregnation) PM Chamfer N530050 Detent Washer a. Briefly list the necessary functions and characteristics of the part. b. This part is made using the manufacturing process Sheet Metal Stamping/Bending. How does this manufacturing process fulfill each of the functions listed above? i. ii. Uniform cross section for even compaction Draft angles (are the draft angle requirements different for PM, and why is that important for this particular part?) c. The engineers at DeWALT designed this part with Sheet Metal in mind. Look at the provided 2D and 3D models. Where can you see evidence that Design for Manufacturing guidelines were followed? Specifically look for: 111. Material thickness Hole location and sizing (look up specific requirements for holes in relation to material thickness) Bend radii (look up specific requirements for bends in relation to material thickness)

Problem 1 (10 marks) Minimise: Subject to: f = 2x₁ - 6x₂ + 3x3 + 4x4 + 7x5 + 3x6 + 2x7 91 = x2 + 5x3 + 3x4 x5 + 2x6 + 3x7 ≥ 65 92 = -6x₁3x₂ − 2x3 + x4 + 2x5 - 2x6 ≥ -73 93-7x₁4x2 + 3x3 X₁, X₂ € (2,5,7,8), X3, X4 € {3,4,6} X5, X6 ≥ 0, X7 ER 4x4 + 3x5 - 2x6 x7 ≤-66