Project Management

Project Objectives

Concisely list and prioritize the project objectives and constraints 

High Priority Objectives

Research and prototype:

• 1. ‘uncuttable wire hook’

  2. ‘Unbreakable outer shell by hammer or screwdriver’

  3. Ergonomic, scratch proof design of outer shell

Second Priority Objectives

• 1. Attractive industrial design and optimization by applying DFM principles

  2. Water-, sand- and dust-proofing lock box

  3. Researching locking mechanisms (number, other combinations, dial, button etc.)

Other Constraints and Issues

• 1. Price - lock box must come up to be manufactured at a cost sensitivity of $30 at 100 pcs to $15 at >1000 pcs to be retailing for a price of $40 per piece.

  2. Size - portability and usability is of importance

WOW Design Solution 

Ask what their dream design solution would be like. You may not achieve this, but it is good to know what it would be like.

Iconic design, intuitive usability, hammer-proof

Risk Reduction Objectives

First tasks (high risks aspects)

Since the device is a complex one, at least two weeks are required to set up a useful hardware test. Hence, the group plans to:

• 1. Develop a working model of the lock box on Autodesk Fusion or Solidworks using the specifications of the sponsor, use RFID proof materials for the models

  2. Conduct a FEA simulation of fracture and tensile stress on the lock box to improve strength and reduce breakability

  3. Based on FEA simulation, place purchase orders/sample requests to vendors for lock box materials

  4. Run generative design tests with constraints obtained from sponsor and insights from first FEA tests

Risk reduction tests

Preliminary hardware test: Not viable 

Analytical modeling: RFID, Using Autodesk Fusion or Solidworks

Software simulation: FEA test and subsequently, generative design

Intermediate Milestones

Intermediate milestones. (tentative)

W/ Week 8        Rapid CAD prototype of industrial design with optimal dimensions, contacting vendors for building materials. 

Milestone: Rapid CAD design ready

W/ Week 9        FEA tests of materials, compilation of results and presentation to sponsor

Milestone: FEA test results of hammering rapid prototype   

W/ Week 10        Receiving materials, consulting machine shop expert Tom on machining guidelines, planning

Milestone: Received materials for stress and tensile tests.

S/ Week 1        Prototype 3D print to present to sponsors, commence machining prototype

Milestone: 3D printed model ready.

S/ Week 2, 3, 4    Machining prototypes, refining design, reviewing locking mechanisms

Milestone: First machined prototype ready.

S/ Week 5, 6        Safety testing, performance testing, compiling results, cost analysis

Milestone: Machined prototype tested with hammer test.

S/ Week 7, 8        Building final iteration, compiling final cost data

Milestone: Final prototype ready.

S/ Week 9, 10        Further optimization, tweaks in design, addressing future iterations

Milestone: Future of Tebra presentation ready and presented to sponsor.

Individual Component Analysis Topics 

• 1. Design for manufacturing of complete design (Hrishikesh)

  2. Locking mechanism (Devang)

  3. Wire tensile and breaking tests (Bryan)

  4. Outer RFID-blocking shell breakability test (Prabdip)

Weekly Meeting Time with sponsor:

Every Monday at 5 PM at Rady Startup Accelerator Room