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Masimo Tray Stacker and De-stacker
Group members: Faakhir Ali, Ali Alazmi, Saud Almutairi, Ian Estacio, Steven Magayanes, Kevin Adrian Uy, Joel Osuna
Karim Omara, Alejandro Ortiz, Chaitanya Patel
Masimo’s manufacturing line is currently using a manual system of workers stacking trays and de-stacking trays, which can be time-consuming and leads to irregularities in the process. The task for the team is to design columns that can automatically index trays as the operator processes them, either stacking or de-stacking, to eliminate human error and increase productivity.
Solution
The project team will design either stacking or de-stacking columns that hold a total of 100 trays. Columns need to have the ability to index the trays in both motions and have a setting to switch to the customers desired intent. Once the column indexes the top of the tray to a manageable level for the operator, the operator may remove the product while the other column will index the empty trays to the bottom of the column for collection.
Technical and Logistical Plan
Given that the project is a joint ME/ECE project, the logistical plan would be to work closely with the ECE team on cementing the best possible solutions for the problem. These solutions would be proposed to the sponsor for approval, and further improved upon as questions and complications arise. Materials would be mainly sourced from consumer off the shelf (COTS) providers, and custom-ordered parts will hopefully be avoided to accelerate the research and development process and to allocate more time and resources on testing and prototyping.
Use Case
Step 1: With the system OFF, Column A has a stack of trays that contain a black circuit board and Column B has no trays
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Step 2: Column A will index the Trays with a black circuit board up, after the operator obtains the tray and transfers it to his work bench to then remove the black circuit board.
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Step 3: After the operator is finished, he will place the empty tray on Column B.
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Step 4: The process repeats itself where Column A will index up and Column B will be the location for the empty trays.
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Step 5: Operator A will bring more full trays to Column A where the operator will be notified when there are less than a variable amount of trays, which can be changed via a user interface. The trays will be removed by Operator B from Column B when there are more than 35 empty trays.
The storyboard is a basic schematic in order to demonstrate our understanding of the current system desired by Masimo. The use case diagram description was confirmed to be accurate by the sponsor and subsequently the storyboard was created. The sponsor, once approval is obtained, has agreed to provide further information on the current system in the form of video and images.
System Requirements and Engineering Specifications
There are many engineering requirements and specifications for this project, so for detailed information please refer to the Systems Description Document file at the bottom of the page.
Misc. Images and Information
The project is currently still in development so more information will be posted as the project progresses. Here are some images and animations of the CAD and system.
Systems Description Document
Project Management Plan
Preliminary Design Review
Project Poster
Final Report
