Upon arrival, my team was just starting the first round of testing on the next wave of prototypes. To ensure parts would work in the new design, they needed to be measured for accuracy against the CAD model. They were then tested to record if the inaccuracies would create issues while brewing. What I did was:

• Measured, recorded, and analyzed 50+ parts to understand variances from CAD designs

• Wrote assembly and re-work instructions to be used by overseas manufacturers

• Wrote, executed, and analyzed a design of experiment (DOE) (100+ brews) on 5+ PMs

• Researched and integrated changes for the next prototype based on findings of testing

The results of this were, based on the assembly guide I had created the first confirmed prototype (CP) build was able to move forward, and 60+ brewers were able to built in a streamlined manor. Furthermore the rework guide was used to fix most if not all of the brewers initially built in the CP builds. Next the finished DOE was used in the next steps to understand what pieces needed a redesign, and were implemented in later builds.  

Some of the skills I honed were:

• DOE creation and execution

• Design build guides for manufacturing/lab technicians

• Reliability methods and testing systems

• Experience with excel for statistical calculations

As the Alta Project moved towards tooling and manufacturing, drawings and tolerance stack analysis (TSA) were completed. During this time, I assisted in creating drawings for O-rings and springs as well as sliming the bill of materials (BOM) to the parts we decided to use based on testing. More specifically, what I did was: 

• Researched O-ring and Spring material and dimensional tolerance standards

• Wrote and modified, based on manufacture recommendations, 14+ drawings that were used in manufacturing for confirmed prototypes and beta units 

• Created an O-ring gland calculator to compute fit and effectiveness of O-rings based on location tolerances and espresso pressures

• Worked with product life management software to clarify the BOM and prepare a drawing package for manufacturing 

The results of this were I was able to create a calculator that was used by my team to quickly change and implement future sealing surfaces with out the need of indepth research or wasted testing time. Furthermore I was able to create drawings for these springs and o-rings such that the beta tests were able to continue and 100+ brewers were able to be built. Finally with this I was able to update the BOM and be able to streamline the model in Teamcenter 

Some skills that I honed in the process of this project were:

• Drawing best practices

• Communication with manufacturers

• Solid works Drawing creator and integration with Teamcenter

• Standards for O-ring and Spring manufacturing and communication

As the Alta project moved towards tooling and manufacturing, drawings and tolerance stack analysis were completed. During this time, I created a TSA of a switch used to determine if a pod is in the machine. More specifically, what I did was: 

• Wrote, executed, and analyzed a DOE to discover actual trigger distance of switch 

• Researched and reviewed current drawings to validate GD&T terminology and call outs

• Built and assembled 25+ part 2D model in Enventive to calculate the trigger distance tolerance using Six Sigma principles

• Identified largest contributors to the variability and modified drawings accordingly

Result of this were that I was able to create a model and apply the experimental knowledge that I had gained from the DOE to a theoretical model. With this understanding of GD&T terminology the theoretical model I built could be used to quickly and easily test new changes made to the drawings to ensure the switches will behave correctly.

Some skills I honed during this project were:

• GD&T terminology and standards

• Eneventive modeling

• DOE creation and execution