Problem

• Inherited a preliminary sample holder design from a previous co-op in which samples would be placed between larger spacers and sit on smaller spacers strung on threaded rods

• Refine the design to meet customer specifications and feedback from the EO lab team

• Develop a repeatable assembly process to mass produce the sample holders in-house

Actions for Design/Fabrication

• Redesigned the end-plates of the sample holders to allow for different sample sizes; I also added an ergonomic hand grip on both ends to easily transport the holders when they're full of parts

• Verified the raw materials required to build a single holder then organized a bill of materials for purchase to produce about 40 holders

• Used a laser cutter to manufacture the end-plates and cross beam supports from acrylic sheets; cut sections of threaded rod with a handsaw for the length of the holder

Actions for Assembly/Production

• Developed assembly instructions for the holder; an issue that arose was finding the best way to put the second end-plate on while making sure the spacers on the threaded rods didn't fall off, so I found the best approach to securing the first end-plate that easily allowed the second plate to just drop right onto the threaded rods

• Organized an assembly line utilizing the instructions I wrote to mass produce the holders with a number of other lab team members; a challenge was finding the best approach to counting out the correct number of each type of spacer, so I experimented with a scale and weighing dishes until I settled on zeroing the scale with the correct number of spacers required with benchmarks for each type so you can easily determine if you need more or less of either kind

Results

• Developed a simple, yet effective sample holder design that is easy to produce while maintaining the customer's desired specifications

• Organized a working assembly line complete with instructions to streamline the fabrication process

• Successfully manufactured around 40 holders for the lab; the assembly instructions and assembly line made it easy to quickly train people on how to properly assemble them; the repeatable, easy-to-follow process also means they can easily train new assemblers and mass produce more of them even after I left E Ink

Skills Developed

• Mechanical design for parts that will support moderate loads, be handled constantly by engineers, and be exposed to different thermal environments

• Laser cutting to maintain accuracy and uniformity of fabricated parts

• Assembly line organization to ensure quality while minimizing production time

• Leadership of a small assembly team to make sure everyone is working towards the same goal