Team ABILITY1
Southern Illinois University
College of Engineering – Mailcode 6603
Carbondale, Il 62901-6604
November 17, 2009
Mrs. Kay Purcell
Southern Illinois University
College of Engineering – Mailcode 6603
Carbondale, Il 62901-6604
Dear Mrs. Purcell,
On September 16, 2009, the ABILITY1 team received a request for proposal. The team members of ABILITY1 would like to thank you for the opportunity to bid on this project.
Attached is a comprehensive proposal delineation of engineering design and deliverables that will result in a successful project.
The National Industries for the Severely Handicapped sponsored AbilityOne Challenge has provided the opportunity for members of this university to participate in a rewarding competition. In conjunction with Specialized Training for Adult Rehabilitation of Murphysboro,
SEC will design and build a novel calendar-stapling device. Upon completion, the design will be tested through the host nonprofit organization to ensure it complies with the preset criterion.
The subsystems to be included in the proposal include ergonomics, stapler, mechanisms, jig positioning, economic analysis, and training aids. Design considerations from each subsystem will aid in the integration and development of the overall device.
The cost associated with this project is estimated to be $213.00. This minute expenditure accompanying our bid will allow Team ABILITY1 to improve the lives of numerous disabled persons in terms of quality of life and accessibility at the workplace.
Once again, I would like to thank you for the opportunity to bid on this Saluki
Engineering Company project. If you have any questions, please feel free to contact me at the information provided below.
Sincerely,
Eric W. Hoffmann
Southern Illinois University
ABILITY1 Project Manager erichoff@siu.edu
(847) 334-2426
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The AbilityOne Challenge is an initiative, sponsored by National Industries for the
Severely Handicapped (NISH), in which engineering students design a system or device that will aid people with disabilities in the work field. The goal of this particular project is to create a machine that will assemble promotional calendars with more precision, accuracy, and efficiency than the current system used at the sponsoring Nonprofit Organization (NPO). The NPO for this project is Specialized Training for Adult Rehabilitation (START) located in Murphysboro, IL.
Currently, START is employing a method that involves a worker aligning the calendar pad on the vinyl backing sheet manually, and then stapling them together freehanded. The new device will involve someone placing both the calendar pad and vinyl backing sheet into an alignment jig, which will automatically center the pad in the correct position every time. The worker will then pull the handle enabling the stapling mechanism to staple the pad and vinyl sheet together in a set location. This project will also involve studies of ergonomics causing the device to be easily and comfortably used by the clients, mechanical analysis to allow the proper input force to translate through all of the linkages and give the required output forces, sustainability so that the device can be easily and quickly repaired to limit the amount of downtime, and training to allow all users can quickly and easily learn to use and repair the device.
This project’s expected completion date is by the 16 of April 2010, in order to meet the requirements for the AbilityOne Challenge competition. While this device is being designed specifically for implementation at START, it can be used in several work environments that require an apparatus to accomplish similar tasks.
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The information provided in or for this proposal is the confidential, proprietary property of the
Saluki Engineering Company of Carbondale, Illinois, USA. Such information may be used solely by the party to whom this proposal has been submitted by Saluki Engineering Company and solely for the purpose of evaluating this proposal. The submittal of this proposal confers no right in, or license to use, or right to disclose to others for any purpose, the subject matter, or such information and data, nor confers the right to reproduce, or offer such information for sale. All drawings, specifications, and other writings supplied with this proposal are to be returned to Saluki Engineering Company promptly upon request. The use of this information, other than for the purpose of evaluating this proposal, is subject to the terms of an agreement under which services are to be performed pursuant to this proposal.
This proposal is valid for a period of 30 days from the date of the proposal. After this time,
Saluki Engineering Company reserves the right to review it and determine if any modification is needed.
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Cover Page (LF)………………………………………………………………………………………………………………………….1
Transmittal Letter (EH)…………………………………………………………………………………………………….…………2
Executive Summary (WB) ................................................................................................................ 4
Statement of Non-Disclosure (EH) .................................................................................................. 5
Validity Statement (EH) ................................................................................................................... 5
List of Tables & Figures (LF) ............................................................................................................ 8
Introduction (LF) ............................................................................................................................. 9
Literature Survey ........................................................................................................................... 10
Introduction (LF) ....................................................................................................................... 10
Ergonomics (RM) ....................................................................................................................... 12
Stapling Mechanism (WB) ......................................................................................................... 15
Mechanical Advantage (SS) ....................................................................................................... 18
Jigs and Fixtures (EH) ................................................................................................................ 21
Training Aids (LF) ....................................................................................................................... 23
Project Description (EH) ................................................................................................................ 26
Subsystem Description.................................................................................................................. 28
Ergonomics (RM) ....................................................................................................................... 28
Stapling Mechanism (WB) ......................................................................................................... 29
Mechanical Advantage Analysis (SS) ......................................................................................... 30
Jig Positioning (EH) .................................................................................................................... 31
Training Aids (LF) ....................................................................................................................... 33
Economic Analysis (LF) .............................................................................................................. 34
Design Basis (SS) ............................................................................................................................ 36
Project Organization Chart (WB) .................................................................................................. 36
Action Item List (WB) .................................................................................................................... 37
Team Timeline (SS) ........................................................................................................................ 38
List of Resources (WB) .................................................................................................................. 39
List of Data Analyses, Experiments, and Simulations to be Performed (LF) ................................. 40
List of Deliverables ........................................................................................................................ 41
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Appendix A: References (LF) ............................................................................................................ I
Appendix B: Communications (RM) ............................................................................................... IV
Appendix C: Request for Proposal ............................................................................................... VIII
Appendix D: Title Block (WB) ........................................................................................................ XV
Appendix E: 8th Annual AbilityOne Network Design Challenge (EH) .......................................... XVI
Appendix F: Financial Assistance (EH) ....................................................................................... XXIV
Appendix G: Resumes (EH) ......................................................................................................... XXV
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F IGURE 1: S TANDARD S TAPLER DIAGRAM [17] ....................................................................................................................... 15
F IGURE 2: S TANDARD C HISEL S TAPLE D IAGRAM [17] .............................................................................................................. 16
F IGURE 3: M ECHANICAL ADVANTAGE , LEVER ARM [24] ........................................................................................................... 19
F IGURE 4: F OUR B AR L INKAGE [26] ..................................................................................................................................... 20
F IGURE 5: W OODEN STAPLER JIG , A SSISTIVE T ECHNOLOGY S OLUTIONS [29] ................................................................................ 23
F IGURE 6: P ROJECT F LOW C HART ........................................................................................................................................ 27
F
IGURE
7: V
INYL AND CALENDAR USED IN MANUFACTURING PROCESS
......................................................................................... 33
T ABLE 1: D ESIGN B ASIS ..................................................................................................................................................... 36
F IGURE 8: P ROJECT O RGANIZATION C HART ........................................................................................................................... 36
T
ABLE
2: A
CTION
I
TEM
L
IST FOR
S
PRING
S
EMESTER
................................................................................................................ 37
T ABLE 3: T EAM T IMELINE ................................................................................................................................................... 38
T ABLE 4: L IST OF R ESOURCES .............................................................................................................................................. 39
F IGURE 9: T ITLE B LOCK ..................................................................................................................................................... XV
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One of the largest challenges facing over 35 million American citizens with severe disabilities is the ability to find and perform a job. Despite legislation enacted to protect those with disabilities from discrimination when applying for a job, a large percent are unable to find employment, or perform the tasks which are required for employment they may find.
NISH is a national NPO, which works with NPOs across the country to create jobs, or find ways for disabled individuals to improve their job performance. They sponsor a competition, The AbilityOne Network Design Challenge. This gives teams an opportunity to work with local NPOs, and more specifically a disabled individual, to develop a device which will solve a workplace problem.
START is a local NPO, which facilitates employment for individuals with severe disabilities. START provides several jobs, which are often outsourced by local companies. One project, the creation of a vinyl calendar, currently involves an inefficient process. Modifying this process would allow for increased productivity and quality, while allowing START to employ additional people.
By improving the calendar production system, the quality of the product would be more consistent and calendars would be assembled at a faster rate, which allows more orders to be completed. This allows more individuals to be hired and ultimately meets the goal of creating and improving jobs for those with severe disabilities.
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In the United States, over 18% of the population, more than 54.4 million people, have some level of disability. Of those who have a disability, roughly 35 million, or 12%, of the national population are considered to have a severe disability. Individuals who suffer from disabilities have reported difficulties in securing jobs and performing job duties. A census performed in
2005 reports that 22.7 million disabled individuals reported being limited in types of jobs they were able to perform, and 13.3 million of those individuals report their disabilities prevent them from working. Unemployment and compensation continue to be a problem for those who are disabled. Of those between the ages of 21 and 64, less than 50% of disabled individuals are employed. The rate of unemployment for those who are disabled is roughly 70%, as compared to the 16.5% unemployment rates for those who do not have a disability. More than 25% of severely disabled individuals are impoverished [1].
Other issues facing those with disabilities include the transition from the school system, and the wait lists for government funded services. Every year, more than 90,000 disabled young adults graduate from schools once they have reached the maximum amount of time a state permits them to stay in school. Once these young adults graduate, they often have nowhere to go, except a waitlist for adult programs. Without these programs, there are very limited opportunities for interaction with others, employment, or self sufficiency [2].
In studies on the quality of life of disabled individuals, the subjects responded that there were negative impacts on their dignity due to dependence on others for personal care, lack of
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employment, loss of power at their employment, and exclusion from activities. Every subject in the study responded that employment and their economic security were extremely important to each of them. Of those who had some level of economic security, most had achieved their economic security prior to the onset of their disability. The subjects of the study felt they were under-employed, underappreciated and wanted increased pay and opportunities for job advancement. The subjects felt they could increase their pay, but did not know how to, and often adaptive equipment and technology were not implemented to enhance their employment capabilities. Many with disabilities said that with appropriate support services they were able to be more self-dependent and active in their communities allowing them to feel better about themselves. The study found that disability impacted every aspect of the people’s life, and many subjects associated their disability with a perceived decrease in their quality of life [3].
The AbilityOne Challenge is a competition in which engineering students work with a person with disabilities, in order to design and build a device which will assist them in their employment. The competition is sponsored by NISH. NISH is a NPO, which focuses on increasing employment opportunities for those who are disabled. The objectives of NISH are; to create, design, and re-engineer jobs for people with disabilities, increase wages and benefits for those workers, enhance advancement opportunities, and increase the number of personally satisfying employment opportunities. The AbilityOne Program, part of NISH, currently provides employment opportunities for more than 40,000 disabled people and it is the largest single source of employment for people with severe disabilities. As part of the AbilityOne Program, over 600 NPOs are employing disabled individuals [4].
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As part of the design process, the team will work closely with START. START provides sheltered employment as well as supported employment, but the clients are part of the sheltered employment program. Sheltered employment programs are designed to assist individuals who are not capable of working in a competitive employment environment [5]. At
START, several disabled individuals can work on different types of jobs, such as cutting cardboard boxes and assembling calendars. Many of the jobs which the clients perform are jobs that are outsourced by local companies.
NISH and other NPOs, such as START, focus on increasing the number of jobs that are available to those who have disabilities, and they also attempt to increase wages and advancement opportunities. These are factors which directly impact the quality of life of those with disabilities. The AbilityOne Challenge program looks to assist in creating more jobs to allow individuals to perform their current job better.
Ergonomics, also known as human engineering, is “an applied science that coordinates the design of devices, systems, and physical working conditions with the capacities and requirements of the worker” [6]. One of many objectives of this project is to design a stapling device to ease the calendar stapling process for workers. In order to accomplish this particular goal, a device must be designed to suit the capacities and requirements of disabled workers [7].
This makes ergonomics very important to this design.
As ergonomics is the essential foundation of this project, there must be an understanding of both cognitive and physical ergonomic branches. The physical ergonomic
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branch involves reshaping tools to reduce awkward postures, positions, movements, and any unnecessary tasks. Physical ergonomics utilizes these reductions to amplify production and reduce errors, which is an objective of this project [8]. While cognitive ergonomics also include focusing on the environment and tasks, it pays particular attention to human abilities, limitations, and the device [9]. Informative decision making and careful considerations to all variables must be used in selecting a design to fit the needs of the worker [9].
In particular, this project will revolve mainly around developmentally disabled workers.
Some types of developmental disabilities include [10]:
 Spina Bifida

Autism

Cerebral Palsy (CP)

Mental Retardation

Prader-Willi Syndrome
Among these disabilities are motor disabilities, which arise from injury [10]. The capacities and requirements of developmentally disabled employees are often determined through vocational evaluation [11]. This assessment generally involves a field of medicine known as occupational therapy [12]. Occupational therapy is similar to physical therapy, but has a focus on helping individuals participate in everyday life or modifying an environment to allow them to participate [13].
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One important goal for this device will be to modify the environment in order to allow workers to use this device. A list of important environmental modifications to various components of this project include:
 The stapler
 Mechanical advantage
 Placement jig
Overall, this device will be a modification of the employees’ environment and will allow the employees to staple the calendars to the vinyl back more efficiently and accurately [13].
However, the stapler will not be automated but will involve the employee in the process of creating a product [14]. The staple must be able to pierce the paper and vinyl thickness with a relatively small input force. An exact value of force will be developed by an analysis of the average force a worker can exert on a stapler. An occupational therapist is used when evaluating hand and arm strength factors to determine a patient’s ability to achieve tasks. On account of the below average outcomes of these evaluations, it is important to design a device which suits the above circumstances.
Along with occupational therapy, additional assistance from a physical therapist will aid in determining the typical range of motion exercises for therapeutic purposes. Incorporation of these exercises into the stapling device can assist the worker’s therapeutic needs. Handle shape design will play a major design role due to worker’s grasp issues. Consideration of this project’s natural consequence of arising repetitive motion must be carefully considered due to its ergonomic concern. A physical therapist will assist in providing ways to prevent injury from
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repetitive motion. Also, design methods of coping with the repetitive motions involved with this device will be incorporated. Another consideration within this area will be the placement jig. It must be easily usable for those with dexterity and range of motion issues.
This project does not include evaluating the individuals that will be using this device but t will incorporate the evaluations of the NISH sponsor, START [15]. Their advice and feedback will be the input into the various iterations of the ergonomics for this product.
A stapler is a simplistic mechanism consisting mostly of a hammer, staple, and anvil as shown in Figure 1 [16].
Figure 1: Standard Stapler diagram [17]
The hammer pushes down on the top of the staple, which presses it into the grooves in the anvil causing the staple legs to buckle which in turn locks the papers into the staple [18]. As can be observed from Figure 1, the operator pushes directly on top of where the hammer presses against the staple. Most common staplers have a mechanical advantage of one.
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Industrial grade staplers, however, incorporate a lever which will increase the mechanical advantage, requiring the operator to input less force [17].
There is a variety of staplers ranging from more simplistic ones, such as Figure 1, to complex electrical and pneumatic powered staplers [16].
The most common brands of staplers are Swingline, Stanley Bostitch, and the Staples brand. There are also staple-free staplers on the market, but these can only fasten four pages at a time, which is unsuitable for this design [19].
Staple
The other important part of the stapling mechanism is the staple. There is a wide range of commercially-used staples.
Figure 2: Standard Chisel Staple Diagram [17]
Staples vary in the gauge of the metal used, type of metal used, length of the legs, and the shape of the teeth. Figure 2 shows a staple with chisel point teeth. This type of staple has been found, on average, to go through more paper, jam less, and require less effort than the ordinary flat tooth staple. The sharp pointed teeth of a chisel staple allow it to puncture paper
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with less resistance. The manufacturing of a chisel staple is more involved than a flat staple, making it more expensive, but the increase in efficiency of a chisel staple often counters the extra cost [20].
Stapling Assembly
A great deal of research goes into improving the stapler and staples. Companies are continually researching ways to make the stapler more ergonomic. Research is also being done to reduce staple jamming, and to increase the efficiency of operating and maintaining the assembly. Larger companies even go as far as having a stapler maintenance program where technicians ensure that the stapler is in proper working order [19].
Staplers tend to deteriorate faster than other office equipment as they undergo more
“wear and tear”. Therefore, for this project’s design, one goal is to incorporate a stapler that can be purchased over the counter in case one of the staplers becomes faulty and needs to be either repaired or replaced. For this reason, it is important to consider that the stapler assembly can easily be accessed or removed to make downtime and repair time as quick as possible.
Other factors that need to be considered when choosing what stapler to utilize involve how the stapler will be used and what material it will be used on. Since the intended machine design will only be used to create calendars, we will need to staple fourteen pages, including the vinyl backing. Most regular staplers are rated to staple about twenty pages, so this will not present a problem. The stapler will be used quite frequently, so it may be more cost effective to purchase a heavier duty stapler that will last longer.
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The concept of mechanical advantage has been around for several years. With today’s evolving technologies, there is always continuing demand for the use of mechanical advantage.
The idea of mechanical advantage involves effectively amplifying input force to your desired output of a simple machine [21]. Some common mechanical advantage devices include:
 Gears (Bicycles/Car Transmissions)

Levers

Pulleys

Inclined Plane
The above devices are not gaining something from nothing. In general there is a tradeoff between two changeable variables in a system to keep power (P) and work (W) constant [23].
More specifically in the case of mechanical advantage, you must decrease a factor to increase another. The engineering explanation of mechanical advantage is the ratio of F output
to I nputs
(i.e.
F output
F input
). In a rotational example such as a gear system, torque (  ) and angular velocity (  ) are the factors which are often manipulated. Keeping power (P) constant gives the equation P
 q

.
Increasing one factor will decrease the other improving the performance of the system for a given situation [22]. However, for this design the primary focus will be on the linear concept of displacement (
 x ) and force ( F ) as well as their uses. For a lever, when keeping work constant, in the equation W

F
 x displacement (
 x ) and force ( F ) are the varying factors. Figure 3 below shows the mechanical advantage of a lever system for a certain situation.
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Figure 3: Mechanical advantage, lever arm [24]
Here an increased displacement (  x) and decreased force (F) are observed on the input side
(right) which causes a decreased displacement (  x) and increased force (F) on the output side
(left) allowing for the heavy load to be lifted while doing the same amount of work [21].
The project design will utilize a stapler mechanism which typically does not use much mechanical advantage. This means that the input force applied to the stapler is the same output force required to inject the staple into a medium. The force required to staple increases depending on the hardness and thickness of the medium the staple must travel through.
For the purpose of the design, the medium consists of a small calendar and a vinyl sheet with an overall thickness of 1.58mm
.
Due to the operating circumstances and the thickness of the medium, having mechanical advantage here is favorable. However, implementing a lever type system to amplify output force for the staple will be inefficient due to its ratio of size to mechanical advantage. Instead, utilizing a more compact mechanism would be more beneficial.
Compact mechanisms have huge potential for gaining infinite mechanical advantage and are typically easier to design. A general type of compact mechanism is the 4-bar linkage system.
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The concept of a 4-bar mechanism is similar to that of the lever [25]. In today’s market there are many tools which utilize a 4-bar type linkage mechanism to increase mechanical advantage.
Two common types of 4-bars are lever or toggle clamps and vice grips.
The above are defined as mechanisms because they have two or more moveable links [23].
The vice grip consists of a lever where the input force is applied. This lever is an extension of a
4-bar mechanism on the vice grip. The nature of the mechanism allows a significantly amplified output force by increasing lever displacement and decreasing jaw displacement. A typical 4-bar mechanism includes four fundamental parts [26]:
 Crank (Input F)

Coupler

Lever

Frame
Figure 4: Four Bar Linkage [26]
In Figure 4, links p, l, s, and q are the crank (input), coupler, lever (output), and frame respectively [26]. The system has mechanical advantage depending on the mechanism’s configuration. When designing a mechanism to suit this project’s goal involving stapling, a
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consideration of speed and force must be accounted for. Typical stapler effectiveness is a function of both speed and force applied.
A jig can be defined as a work piece locating and holding device that will guide and control the position of a desired tool. The difference between a jig and a fixture is that fixtures do not control the actual working tool. In the case of the proposed project a stapler would be implemented as the tool, and based on the aforementioned definition the holding device would be classified as a jig because the tool would be integrated into the holding device, thus the device controls the tool. There are many factors that should be taken into consideration when designing a jig. The device must be strong enough to prevent deflection and therefore desires machining tolerances. This is done to ensure quality product productions. Permanent sections of the jig should be welded together where as replaceable/disposable portions should be bolted on. A key design feature of a jig that is especially critical to our project is that a work piece in a jig should only be able to be positioned in the correct manner. This design must allow the work piece to be inserted or removed easily. Clamps should operate rapidly and use springs to reduce user effort and to secure properly the work piece. Consideration should take into account chip removal; this would relate to the project if a staple were to get lodged in the jig and have to be removed for operation to continue [27].
Another important design consideration is the material the jig is made out of. There are three major material categories that need to be considered for the design of the jig;
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
Metal
 Wood
 Plastics
They all provide pros and cons and bring forth new design considerations. By far the most durable material that can be used is metal. It is suggested that steels with low carbon content not be used because such steels are not as easily machined to provide a smooth work surface
[28]. Wood is easy to work with and is readily available however it will not provide the durability need to support the forces of repetitive stapling without additional support from alternate material. Plastics also fall into the same category as wood with durability issues.
However, the use of plastic for the jig may be considered as to reduce device weight and manufacturing costs.
The tolerance of the jig will need to be within designed specifications so the design objective of a consistent quality product can be achieved. There are many different types of tolerances; straightness, length, position, diameter, flatness, and gap tolerance. A few that may be critical to the project include length, position and gap tolerances. The position is especially important because a staple anvil is needed for proper operation and it must be placed in a precise location to work properly.
Current Jig Technologies
A company in Tulsa, Oklahoma that resembles the START organization (providing job to people with severe disabilities), has currently implemented a stapling jig in their workforce operations. The jig is manufactured from wood and has a cut out for an automatic stapler. The
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worker can place the papers in the jig and it is automatically stapled in the correct locations
[29]. The jig is pictured below in Figure 5.
Figure 5: Wooden stapler jig, Assistive Technology Solutions [29]
The plans for this particular jig were purchased from Assistive Technology Solutions. This company has set forth to provide useful assistive devices that enrich the quality of life for people with disabilities. The company takes the engineering plans of assisted technology devices and publishes fabrication and assembly plans that are purchased by needing facilities.
Their website also provides a list of companies and website that produce and market disability assistive devices [30].
Training is “developing required human capabilities through the learning of skills that are needed for performing technical duties in military or industrial jobs” [31]. When companies are training employees, they will use training aids in order to facilitate the employees’ learning.
Training aids are ‘’ devices used to help present a subject matter” [31], and may include charts, manuals, and videos. Training material is developed using an instructional design model. A
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common instruction design model, the Gagne-Briggs model, has nine steps in order to effectively train the employee. The steps include; gaining the attention of the trainee(employee), informing the trainee of the goal (objective), stimulate recall of prior knowledge, present the material, provide guidance for learning, elicit performance(practice), provide informative feedback, assess performance, and enhance retention and transfer [32].
When developing training aids, it is important that the material is presented in a “logical and understandable format” [32]. It is important to consider not what the trainer thinks is logical and understandable, but whether the trainee thinks the material is logical and understandable. Important points should be emphasized by raising ones voice or slowing down the presentation. Video can be used to show examples of problems and procedure and should be stopped at each step in order to emphasize the step. Allowing the trainee to practice, and then providing feedback is essential in effective training. Trainees need to be made aware of what they are doing right and wrong, and any corrections necessary need to be made before the end of the training session [32].
After the training session is completed and the trainees (employees) begin to perform their job, job aids such as posters can be used in the work area to assist the employees. A job aid is “an external resource designed to support a performer in a specific task by providing information or compensating for lapses in worker memory” [33]. There are several types of job aids, such as pictures, checklists, to-do lists, buzzers and alarms [33]. These job aids serve as quick reminders to employees on how to perform various parts of their task at hand.
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A training program and training aids designed for individuals with disabilities require additional considerations. Current issues with sheltered employment include; not identifying the abilities of disabled employees, not implementing vocational training, and not using a developmental-orientated education approach [34]. Studies recommend that to fix the current issues with sheltered employment and training; trainers must inform their employees sufficiently about the training measures, the training measures must be carried out regularly, training must be integrated into employees daily life, the number of participants must be limited to three, and that the training is a teaching conversation as opposed to a lecture [34].
Implementing a training program and training aids allows the employee to correctly learn how to perform a job, and job aids allow for a quick reminder to the employee so they can continue to perform their job correctly. An employee learning to do a job correctly helps to ensure product consistency and prevents waste due to employee error.
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The AbilityOne Network Design Challenge was set forward to promote the development of creative technological solutions to aid people with severe disabilities in attaining and advancing their career goals. Team 27 Ability1 of Saluki Engineering Company will compete in the NISH AbilityOne design challenge in conjunction with the Southern Illinois University
Carbondale College of Engineering senior design course 495A & B. In compliance with the competition, the team will work with a NISH approved NPO. START in Murphysboro, Illinois has agreed to facilitate the project. The project concept includes designing a device that will staple a calendar to screen printed vinyl. The calendars with dimensions 7.6 mm X 5.7 mm will be stapled to a vinyl sheet of dimensions 80 mm X 122 mm with a standard 6.35mm staples. The subsystems included in the technical description include ergonomics, stapler, mechanisms, jig positioning, economic analysis, and training aids. Upon completion of the project, a working prototype to be used by START will be built. A final design report including an oral presentation and poster will be provided to Saluki Engineering Company.
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Figure 6: Project Flow Chart
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Ergonomics is required for this project to ensure that START’s employees are able to staple the calendars accurately and efficiently. Currently, a hand stapler is used that is often inconsistent and requires the use of undesired crimped staples. At this time, only one START employee is capable of performing this job. The new system must combine the use of the stapler, jig and mechanical system in a way that allows a larger portion of the client’s employees to assemble calendars. The primary ergonomic concerns will be the placement jig and the mechanical system. The placement jig must be usable by employees with limited dexterity and fine motor control to allow the accurate placement of the calendar at least 95% of the time. The mechanical analysis must provide enough mechanical advantage to allow an employee with below average arm and hand strength to operate the stapler efficiently. These attributes will be tested with START employees at their facility. Training material and economic calculations will also be provided to START. This will allow them to effectively train their employees and use this device to its fullest potential.
List of Activities:
 Assemble prototype with ergonomic concerns in mind
 Test mechanism with START employees
 Test force required for stapling
 Test force capability of START workers
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Deliverables:
 Functioning prototype
 START employee production 95% accuracy
The stapling mechanism is required to affix the calendar pad to the vinyl baking sheet.
The current system that is in use requires the worker to use a hand-held stapler to staple the two materials together using special crimp staples. This system is extremely inefficient and results in a high amount of rejected products and rework. The new system will consist of two staplers in a fixed position and will result in the staples being placed in a consistent position on each calendar stapled. The staplers will also use a plain chisel staple. This system will be designed in conjunction with the alignment jig to allow the two mechanisms to accomplish the stapling task together. The stapling mechanism will also be closely associated with the mechanical analysis system because of certain input forces being transmitted through the linkages, which will result in a specific output force on the stapler mechanism. The training aids section will also be very important in regards to the stapling mechanism because the aids will train the workers on how to repair the mechanism. Below is a list of activities and deliverables:
List of Activities:

Create CAD model of stapler

Stapler reliability testing
 Staple performance testing
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
Force analysis of stapler - computational
Deliverables:
 CAD model of stapler assembly
 Comparison of the reliability of different staplers
 Comparison of the performance of different staples
 Force required to operate stapler - computational
Mechanical advantage is required for this device due to design constraints and limitations of the worker. For the purpose of the design, the constraints involve having an appropriate application force for a staple to pass through the vinyl and calendar combination thickness of 1.58 mm. For environmental considerations, the constraints involve the worker’s potential for below average arm strength. Mechanical advantage will be used to effectively have the staple pass through the medium while allowing for minimum needed application force. This allows for a below average arm strength requirement to complete the task of stapling. Special consideration must be taken when applying mechanical advantage to the system due to the increased stress concentrations and force factors created, thus, this subsystem will be dependent on material properties. Below is a list of deliverables that will allow implementation of the mechanical advantage subsystem.
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List of Activities:
 Computer generated geometry analysis - Matlab
 Stress analysis at joints - Computational
Deliverables:
 CAD measurement design
 Calculated force increase required

Ratio of speed and range of motion to M.A.
A jig is required to position the calendar on the vinyl sheet ensuring an accurate and quality manufacturing process. Per the request of START, the positioning subsystem must align the calendar on the vinyl with a 2 mm border around the sides and bottom. The jig design must also take into consideration the stapler subsystem in aligning the staple to the calendar. This will require proper placement of the stapler anvil. Material selection for this subsystem plays an important role; it must provide uninterrupted long-term use. In order to accommodate the ergonomic considerations of the jig, the material chosen may depend on the amount of machining required and its intricateness. Working with the integrated subsystems, stress tests and analysis will be performed on the overall device to ensure longevity. The tolerance of the jig will be tight so that the design objective of a consistent quality product can be achieved.
There are many different types of tolerances; straightness, length, position, diameter, flatness, and gap tolerance. A few that may be critical to the project include length, position and gap tolerances. The position is especially important because a staple anvil is required for proper
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operation and must be placed carefully to work properly. Below is a list of deliverables that will constitute the completion of the jig positioning subsystem. Figure 7 is a photo example of the calendar and vinyl sheet to be used. Appendix D shows a CAD drawing of both pieces with detailed dimensions of object, boarder, and staple placement.
List of Activities:
 Integrated system stress analysis
 Ergonomic testing with START workers
 Develop test to measure accuracy
 Tolerance analysis for quality and ergonomic considerations
Deliverables:
 CAD prototype design
 Report tolerance quality vs. ergonomic analysis
 Functional prototype with positioning considerations
 95 % product placement accuracy
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Figure 7: Vinyl and calendar used in manufacturing process
In order to increase the productivity of the workers and the quality of the product, it will be necessary to train the employees how to use the prototype and how to perform repairs on the prototype. Possible repairs include fixing jammed staplers or adding additional staples.
Training aids, such as training manuals and training videos, can be used to educate the client on placing the calendar and vinyl in the jig to ensure that the position is correct, as well as how to make various repairs. Additional considerations due to the disabilities of the client will be necessary in order to ensure that the training aids effectively assist the client. In addition to training aids, which would be used to teach the clients how to use the prototype, job aids closely placed near the work area, such as posters, will be created to serve as a reminder to the client on how to use the prototype. The training aids and job aids will be developed with the assistance from individuals within Curriculum and Instruction and Workforce Education
Development at SIUC. The development of the aids will include considerations on effective
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learning styles for those with developmental disabilities. These training aids and job aids will allow the client to perform their job more efficiently while producing a high quality product.
List of Activities:
 Analyze considerations of learning styles vs. disabilities of the clients
 Step by step use of prototype to ensure thorough training manual and video
Deliverables:
 Training Video

Training Manual

Poster(Job Aid)
Increasing the number of employees and the wages of current START employees is the ultimate goal of this project, and of the AbilityOne Challenge sponsor NISH. In designing this prototype, it is extremely important for START to have the capability of making more promotional calendars, either by increasing the number of calendars that the worker can produce per hour, lowering the number of product mistakes, or both. The prototype must be designed so that a wide variety of workers with different types of disabilities from START will be able to complete the job. This would allow START to take more orders and thus hire more workers and ultimately meet the goal of increasing wages and/or jobs for those with disabilities.
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List of Activities:
 Determine the current cost per piece
 Determine production rates per hour
 Determine product production accuracy
Deliverables:
 Full economics analysis showing projected profit difference
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Table 1: Design Basis
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Figure 8: Project Organization Chart
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Table 2: Action Item List for Spring Semester
#
1
2
4
3
5
Activity
Info for Training Guides
Create Poster/DVD
Force Required to Staple
Stapler Selection
Force Analysis
6
7
8
9
Bearing Selection
Alignment Jig
CAD Drawing
Ergonomics Info
10 Handle Design
Person Assigned Due
LF 10-Nov-09 29-Jan-10
LF
WB
WB
SS
10-Nov-09
10-Nov-09
10-Nov-09
10-Nov-09
12-Feb-10
29-Jan-10
5-Feb-10
29-Jan-10
SS
EH
EH
RM
10-Nov-09 5-Feb-10
10-Nov-09 29-Jan-10
10-Nov-09 5-Feb-10
10-Nov-09 29-Jan-10
RM 10-Nov-09 5-Feb-10
Team Members:
Eric Hoffmann (PM) - EH
Lisa Furby - LF
Samir Shah - SS
Whitney Belt - WB
Ronnie Mays - RM
Status Comments
0% Collect info for the training guides
0% Create the Training Posters and DVD's
0% Find out how much force needs to be input in order to staple
0% Perform tests and choose stapler for design
0% Do a force analysis of all the links in the device
Select bearings for the machine based on the above
0% calculations
0% Come up with the final design for the alignment jig
0% Have a CAD drawing for the alignment jig
0% Collect info on ergonomic factors needed by client
0% Design handle based on limitations found from previous task
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Table 3: Team Timeline
Winter
Jan-09
Break Week 1
▲
Week2
Team 27 Draft Schedule 2010
Week 3
Feb-09
Week 4 Week 5 Week 6
Mar-09
Week 7 Spring Brk Week 9 Week 10 Week 11 Week 12
Apr-09
Week 13 Week 14 Week 15
May-09
Week 16
Task
Phase 1: Design / Specifcations
Stapler/Selection
Material/Selection
Jig Arrangement
Mechanism
Ergonomic Consideration
Training Aids
Integration of subsystems
Phase 2: Prototype
Training Aids
Prototype build
Testing Prototype 1
Redesign
Testing prototype 2
Phase 3: Design Reports
ABILITY1 Competition Report
Final Poster
Final Presentation
SEC Final Design Report
Subsystems
-Training Aids
-Economic Analysis
-Jig
-Mechanism
-Ergonomic
-Stapler
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Legend
Activity
Milestone
As-Bid
▲
▲
As-Worked
☼
Revised
▲
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Table 4: List of Resources
Subsystem Item Description
Stapling
Alignment Jig
1 Stapler
2 Box Staples
1 Steel Stock
2 Nuts/Bolts
3 Grease
4 Paint
5 Labor
Mechanical Analysis
1
2
Roller for lever
Bushings
Ergonomics
Training Aids
Misc. Materials
1 Lever
1 Video Camera
2 DVD
3 Misc. Poster Materials
1 Computer
2
3
4
MatLab
AutoDesk Inventor
Corel Draw
Quantity Cost Each ($) Sub Total ($)
1
1
1
1
1
1
1
1
1
1
4
1
1
1
1
5
1
$20.00
On Hand
$10.00
$25.00
On Hand
On Hand
On Hand
On Hand
$18.00
$5.00
On Hand
$15.00
$10.00
$6.00
On Hand
$12.00
$5.00
$20.00
$0.00
$10.00
$25.00
$0.00
$0.00
$0.00
$0.00
$90.00
$5.00
$0.00
$15.00
$10.00
$6.00
$0.00
$12.00
$20.00
$213.00
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1.
Assemble prototype with ergonomic concerns in mind
2.
Test mechanism with START employees
3.
Test force required for stapling
4.
Test force capability of START workers
5.
Create CAD model of stapler
6.
Stapler reliability testing
7.
Staple performance testing
8.
Force analysis of stapler - computational
9.
Computer generated geometry analysis - Matlab
10.
Stress analysis at joints - computational
11.
Integrated system stress analysis
12.
Ergonomic testing with START workers
13.
Develop test to measure accuracy
14.
Tolerance analysis for quality and ergonomic considerations
15.
Analyze considerations of learning styles vs. disabilities of the clients
16.
Step by step use of prototype to ensure thorough training manual and video
17.
Determine the current cost per piece
18.
Determine production rates per hour
19.
Determine product production accuracy
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1.
Functioning prototype
2.
START employee production 95% accuracy
3.
CAD model of stapler assembly
4.
Comparison of the reliability of different staplers
5.
Comparison of the performance of different staples
6.
Force required to operate stapler - computational
7.
CAD measurement design
8.
Calculated force increase required
9.
Ratio of speed and range of motion to M.A.
10.
CAD prototype design
11.
Report tolerance quality vs. ergonomic analysis
12.
Functional prototype with positioning considerations
13.
95 % product placement accuracy
14.
Training Video
15.
Training Manual
16.
Poster(Job Aid)
17.
Full economics analysis showing projected profit difference
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[1]U.S. Department of Commerce. Americans With Disabilities: 2005 Household Economic
Studies. U.S. CENSUS BUREAU, Dec. 2008. Web. 08 Oct. 2009.
<http://www.census.gov/prod/2008pubs/p70-117.pdf>.
[2]Zaslow, Jeffrey. "Moving On: The Graduates: What Happens After Young Disabled Adults
Leave School." Wall Street Journal [New York City] 29 Dec. 2005: D1. ProQuest. Web. 08 Oct.
2009.
[3]Fresher-Samways, Kathleen, Susan E. Roush, Kathy Choi, Yvette Desrosiers, and George
Steel. "Perceived Quality of Life of Adults with Developmental and Other Significant
Disabilities." Disability and Rehabilitation 25.19 (2003): 1097-105. Ebscohost. Web. 7 Oct.
2009.
[4]NISH. Web. 08 Oct. 2009. <http://www.nish.org>.
[5]Rosen, Marvin, Albert Bussone, Peter Dakunchak, and John Cramp, Jr. "Sheltered
Employment and the Second Generation Workshop." Journal of Rehabilitation
January/February/March (1993): 30-34. Ebscohost. Web. 08 Oct. 2009.
[6]"Ergonomics." Random House Webster’s College Dictionary. New York, 2005. Print.
[7]Specialized Training for Adult Rehabilitation. Web. 17 Oct. 2009.
<http://startinc.org/developmental_training.php>.
[8] Karwowski, Waldemar. International encyclopedia of ergonomics and human factors. Vol. 3.
Boca Raton: CRC, 2006. 2948-950. Print.
[9] Hollnagel, Erik. "Cognitive Ergonomics: It's all in the mind." Ergonomics. 10th ed. Vol. 40.
1170-182. Print.
[10] NSU. "NSU: Vulnerable and Hard-to-Reach Population: The Developmentally Disabled."
NSU: Vulnerable and Hard-to-Reach Population: The Developmentally Disabled. NSU. Web.
11 Nov. 2009. <http://www.nova.edu/allhazards/forms/dev_disabled.pdf>.
[11]Specialized Training for Adult Rehabilitation. Web. 17 Oct. 2009.
<http://startinc.org/vocational_rehabilitation.php>.
[12]"WFOT | World Federation of Occupational Therapists | Occupational Therapy." WFOT |
World Federation Of Occupational Therapists | Occupational Therapy. Web. 17 Oct. 2009.
<http://www.wfot.org/information.asp>.
[13]Hacker, B. "Single Subject Research Strategies in Occupational Therapy." The American
Journal of Occupational Therapy. Feb (1980). Print.
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[14] K. Bauman et al. (private conversation), 23 Sept. 2009
[15]Specialized Training for Adult Rehabilitation. Web. 17 Oct. 2009.
<http://startinc.org/developmental_training.php>.
[18]"Stapler: Facts, Discussion Forum, and Encyclopedia Article." Web. 07 Oct. 2009.
<http://www.absoluteastronomy.com/topics/Stapler>.
[16]"Stapler Guide - Staplers - ABC Office." Office Equipment - Paper Shredders & More. Web.
08 Oct. 2009. <http://www.abcoffice.com/stapler-guide.htm>.
[17]"The role of key characteristics in the design of mechanical assemblies." Web. 07 Oct. 2009.
<http://www.emeraldinsight.com/Insight/ViewContentServlet?Filename=Published/Emera ldFullTextArticle/Articles/0330260409.html>.
[19]"Best Staplers - Stapler Reviews - Electric Stapler - Swingline vs Bostitch." Galt Technology:
Technology Reviews, Internet Guides, Product Reviews, Travel Guides. Web. 07 Oct. 2009.
<http://www.galttech.com/research/home-office/best-staplers.php>.
[20]"Swingline Premium Staples -- Comparing them with Standard Staples - Swingline Premium
Standard Staples 25 Sheet Capacity 210 Strip Count 5000/Box - Epinions.com." Reviews
from Epinions. Web. 07 Oct. 2009.
<http://www.epinions.com/review/Swingline_Premium_Standard_Staples_25_Sheet_Cap acity_210_Strip_Count_5000_Box/content_173394988676>.
[21] Bautista, Emilio. Theory of Machines and Mechanisms. Pune, India 2006.[p282-300]
[22] Larry L. Howell. Compliant mechanisms, pp112-6. Wiley 2001., New York, NY.
[23] Sclater, Neil. Mechanisms and Mechanical Devices, pp14-22, Bookmart Press., USA 2007.
[24] Shah, Samir. Mechanical Advantage, lever arm. Four Bar Linkage. Digital graphic. 08 Oct.
2009. Personal.
[25] Google Patents,” Self-adjusting Toggle Clamps,” Raymond A. Okolischan. [Online].
Available: http://www.google.com/patents?vid=USPAT4407493 [Accessed Oct 15, 2009]
[26] Roymech, “Simple Linkages,” Roymech. [Online]. Available: http://www.roymech.co.uk/Useful_Tables/Mechanics/Linkages.html [Accessed Oct. 15,
2009]
[27]Pollack, Herman W. Tool design. 2nd ed. Englewood Cliffs, N.J: Prentice-Hall, 1988. Print.
[28]Henriksen, Erik Karl. Jig and fixture design manual. New York: Industrial, 1973. Print.
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[29]"Ashley's Mom - Exploring and designing technology solutions for today's educational needs." Ashley's Mom, Inc. - Exploring and designing technology solutions for today’s
educational needs. Web. 16 Oct. 2009. <http://www.ashleysmom.com/pages/newemployee.html>.
[30]Assistive Technology Solutions. Web. 16 Oct. 2009.
<http://www.atsolutions.org/folders/goals.htm>.
[31] Lumsdaine, Arthur. Design of Training Aids and Devices. Rep. no. AIR-290-60-FR-225. ERIC document reproduction service no. ED129337. Ovid. Web.
[32] Blanchard, Nick P., and James Thacker. Effective Training Systems, Strategies and Practices
(3rd Edition). Upper Saddle River: Prentice Hall, 2006. Print.
[33] Willmore, Joe. Job Aids Basics (ASTD Training Basics Series). New York: ASTD, 2006. Print.
[34] Eicker, Alexandra, and Stefanie Schnedier. "Production-Orientated Education and Training of the Mentally Disabled in Sheltered Employment." Disability and Rehabilitation 22.4
(2000): 206-10. Print.
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Tuesday, 9/15/09
Phone Conversation with Kathy Bauman from START
 START would like to be our NPC sponsor for AbilityOne
 Set up appointment to meet in person
Re: AbilityOne Engineering Design Team
From: START (startinc@verizon.net)
Sent: Mon 9/21/09 2:03 PM
To: Ron Mays Jr.
(ronmaysjr@hotmail.com)
We can meet Weds or Friday anytime this week or Weds, Thursday or Friday next week.
Let me know what works best for you.
Kathy Baumann
From: Ron Mays Jr.
To: startinc@verizon.net
Sent: Monday, September 21, 2009 9:25 AM
Subject: AbilityOne Engineering Design Team
Dear Kathy Bauman,
How was the Apple Festival? I hope it went well for you. It was such a pleasure to speak with you on Friday. I spoke with my team and we would like to set up an appointment to talk with you and your staff as you suggested. When would be a good time for this? We will look forward to meeting you in person.
Sincerely,
Ronnie Mays Jr.
SIU AbilityOne Design Team
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Monday, 9/23/09
Meeting with Kathy Bauman and staff at START
Employee Needs
 Limited mobility
 Limited range of motion
 Limited strength
 Limited fine motor skills
 Mechanism should not be automatic but should require the employee to do something
Project Ideas
 Help employee in motorized wheel chair sweep floors
 Help same employee use computer mouse
 Modify jigs to allow employee to cut squares
 Modify can crusher to use less strength
 Modify paper shredder for employees with shaky hands
 Create paper shredder table
 Create a safer and easier way to cut metal bands
 Create a jig to staple calendars
From: Kathy Baumann (kathybaumannstart@gmail.com)
Sent Wed 11/04/09 4:58 PM
To: ronmaysjr@hotmail.com
We are excited about your project and as an organization will do what ever is needed for you. I am forwarding you email to Carl Hartman who will be your contact person for this project. He is the supervisor of the production facility and can help you with the information you are seeking. He is at the same number as I, 687- 2378. I will ask him to make contact with you or you may try and call him. He should get your email in his box on
Thursday morning.
Kathy
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Stapling Operation at START
From: Carl Hartmann (carlhartmann1@gmail.com)
Sent: Thu 11/05/09 12:28 PM
To: ronmaysjr@hotmail.com
Ronnie,
Kathy Baumann asked me to follow up with you regarding the calendar stapling project you are working on. I would be glad to answer any questions. Regarding the accuracy, I would like to see a success rate of at least 95%. As far as the strength of the participant, I would like to use any of my clients, which would put the strength of some of them fairly low. I do not know exactly how to measure the strength for you.
I believe we would be able to designate a client to be the "designated" stapler, but I would like to talk with you further about the requirements of that person.
Thanks again for your help! Please feel free to contact me at any time.
Carl Hartmann
Production Supervisor
Re: Stapling Operation at START
From: Carl Hartmann (carlhartmann1@gmail.com)
Sent: Fri 11/06/09 10:59 AM
To: Ron Mays Jr. (ronmaysjr@hotmail.com)
Good Morning:
I am here from 7:30 - 3:30 on most days. Next week, we have a holiday on Wed (11/11) and I have an appointment on Tuesday (AM). Thursday or Friday would be great if it fits your schedule or we could wait until the following week. Let me know.
Carl (Not Mr. Hartmann)!!!
On Thu, Nov 5, 2009 at 9:23 PM, Ron Mays Jr. < ronmaysjr@hotmail.com
> wrote:
Mr. Hartmann,
How are you today? I am excited about working with you on this project. 95% is definitely reasonable for accuracy. I wasn't sure if there would be any way to empirically measure the strength of the participants. I was taking a shot in the dark on that one. We want any of your participants to be able to use this device as well. For the sake of the AbilityOne
Challenge, we have a "designated" participant like you said. We are out of our area of expertise when gauging the abilities of participants. So we will be very open to your input on the requirements for that person. I would like to come to your facility and talk with you more about these things. Would there be a good time for that? Thank you again for help.
Ronnie Mays Jr.
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Re: Stapling Operation at START
From: Carl Hartmann (carlhartmann1@gmail.com)
Sent:
To:
Thu 11/12/09 8:17 AM
Ron Mays Jr. (ronmaysjr@hotmail.com)
Ronnie - Friday would be fine. I will see you then.
Carl
On Wed, Nov 11, 2009 at 8:23 PM, Ron Mays Jr. < ronmaysjr@hotmail.com
> wrote:
Carl,
Good morning. How was your Veterans' Day holiday? Would it be possible to meet sometime around 1PM on Friday? I have a break between class and my team meeting. I would like to talk about the "designated" client and a test that might give us a starting point for the strength needed to staple. Thank you.
Ronnie
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Figure 9: Title Block
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3125 Boyd Road
Anna, IL 62906
Phone (618) 697-3434
E-mail ronmaysjr@hotmail.com
Objective To research performance and race automobiles due to their ingenuity and scalability that is useful throughout the automotive industry.
Work experience
Education
References
10/08 – Present Center for Advanced Friction Studies Carbondale, IL
Supervisor's Name: Dr. Peter Filip, (618) 453-7932
Student Researcher
 Create and test friction materials
11/98 - Present Barnes & Noble Booksellers Carbondale, IL
Supervisor's Name: Jean Modglin, (618) 351-0404
Café Manager, Café Lead, Barista, Bookseller
 Managing employees, retail and foodservice work
05/96 – 08/99
(Summers) Ironworkers Local #782 Paducah, KY
Supervisor's Name: Grover Mays, Jr, (618) 827-4756
Permit Ironworker
 Construction, metal buildings, concrete rebar, fence
‘98 – ’00, ’07-Present Southern Illinois University
Graduate 05/09
 Majoring in Mechanical Engineering
 Majored in Mathematics, Film & Physics
Carbondale, IL
’96-‘98 Olivet Nazarene University Bourbonnais, IL
College Credit
 Majored in Christian Ministries & Engineering
Professor: Gary J. Butson, (618) 453-7808
Professor: James Mathias, (618) 453-7016
Business Manager: Ken Murphy, (573) 270-6688
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1101 E. Grand Ave. #M6
Carbondale, IL 62901
(847) 921-7424 samir.sshah@yahoo.com
O BJECTIVE : To obtain a full-time Mechanical Engineering position that challenges my creativity, teamwork, and problem solving skills while allowing me to provide a meaningful contribution to an employer.
E
DUCATION
: Bachelor of Science in Mechanical Engineering: Graduating May 2010
Minor in Mathematics
Southern Illinois University Carbondale; Carbondale IL
Engineering GPA: 3.7/4.0
Study Abroad Spring Semester 2009; University of Newcastle, NSW; Australia
E XPERIENCE : Cherry Electrical Products, Intern; Pleasant Prairie, WI Summer 2007

Designed products and prototypes using AutoCAD/Hands-on analysis

Analyzed systems and tested apparatuses (Rogowski Coils/Harley Davis Switches)

Product Line assembling and organization of parts (Pitney Bowes)

Problem solving and troubleshooting equipment pertaining to magnetic field study
Takeda Abbott Pharmaceuticals Inc. (TAP) Intern; Lake Forest, IL Summer 2006

Assessed the development of training programs

Helped implement and devise methods for new employee training processes

Worked and tested training programs for new employees

Evaluated multiple functions in programs
Hospira, Inc. Intern; North Chicago Plant, Lake Forest, IL

Supported the Information Technologies (IT) infra-structure
Summer 2005
 Assisted and addressed employees with technical support issues/problems

Utilized teamwork to set up PC/Networks/Hardware/Software configurations
A
CTIVITIES
: Participation in numerous 5K Runs and Triathlons for Charity Organizations
Teaching Assistant:
-- Mathematics Teaching Assistant/Tutor Spring 2008 for Calculus II students
-- Mathematics Teaching Assistant/Tutor Fall 2008 for Pre-Calculus/Calculus I and II
Sports:
-- Saluki Masters Swim Club
-- Australia University of Newcastle Ultimate Frisbee Club
-- Australia University of Newcastle Mountaineering Club
--
SIUC Men’s Soccer Club Fall 2005
-- Intramural Football SIUC
Obtained international travel experience while visiting many countries on many continents, resulting in valuable global exposure to people and culture.
A
CCOMPLISHMENTS
/H
ONORS
:
 Dean’s List Spring 2006, 2007-Present

Pilot License/Aviation Experience; 300 hours of total flight time:
-- Private Pilot Certificate (May 2006)
-- Pilot Instrument Rating (May 2008)
Aeroflite/Stick & Rudder Flight School, IL
Stick & Rudder Flight School, IL
-- Commercial Pilot Certificate (Jan. 2009) Stick & Rudder Flight School, IL
-- Multi-Engine Pilot License (Dec. 2009) St. Charles, MO
References are available upon request
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212 S Canterbury Drive Carbondale, IL 62901**618-534-4325** llfurby@siu.edu
Education
Experience
Extracurricular
Activities
Achievements
SEC F09-27-ABILITY1
Southern Illinois University-Carbondale
Mechanical Engineering Major /Honors Degree
Senior Status
Expected Graduation: May 2010
2006- Present SIU College of Engineering Autonomous Systems Lab
Undergraduate Research Assistant
 Project Leader for synthetic gill project
 Lead Student on Artificial Kidney project

Presented/ Served as Session Chair at BIBE 2007 at Harvard Medical School
 Selected as a 2008 REACH Award Recipient, received research assistantship
 Selected as a 2009 SSRO Recipient, received research assistantship
 Presented at 2009 Southern Biomedical Engineering Conference
2006- 2008 SIU College of Engineering
Supplemental Instructor

Provided instruction in calculus and pre-calculus mathematics classes
2007- 2008 SIU College of Engineering
Peer Mentor
 Planned and lead study sessions
 Planned and lead college survival information sessions
 Organized group social activities
 Society of Women Engineers(President 2008- Secretary 2007-2008)
 Student Representative for the Honors Advisory Committee( 2008-2009)

Mentor for the University Honors Program(2008-2009)

Tau Beta Pi( Vice President 2009-)
 American Society of Mechanical Engineers (Secretary 2007-2008)
 Women in Engineering Summer Program Counselor (2007)
 Summer Bridge Program Supplemental Instructor(2006,2007)
 USA Today All-Academic Team (Second Team) 2009
 Barry M. Goldwater Scholarship Honorable Mention 2009
 Illinois Technology Foundation “50 For The Future” Winner

Glamour Top Ten College Women Nominee
 Chancellor Scholarship Recipient
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Home
730 Sweeney Ave.
beltbd@siu.edu
School
388 Warren Rd. Lot 32
Mt. Carmel, IL 62863
(618) 263-4135
Carbondale, IL 62901
(618) 262-6413
Education:
Southern Illinois University Carbondale

Bachelors of Science; Science and Arts

Majors: Automotive Technology, Mechanical Engineering

Minor: Mathematics

GPA: 4.0/ 4.0
Spring 2010
Wabash Valley College

Associate of Art; Associate of Science

GPA: 3.85 / 4.0
Spring 2006
Certifications:
ASE Certified In:

Manual Drivetrains, Automotive Electronics, Engine Repair, Suspension and
Steering, and Heating and Air Conditioning
EPA Certified for A/C Systems
Honors:
Dean’s List
American Honda Motors Scholarship
Edward Wright Scholarship
Fall 2006 – Spring 2008
Fall 2008
Fall 2007
Presidential Honors List
American Legion Award
Bethards Scholarship
Fall 2004 – Spring 2006
Spring 2006
Spring 2006
Experience:
Student Research Worker Fall 2009 – Present
Southern Illinois University – Carbondale, IL

Helping design and assemble various components for a waste oil burner as well as a new engine with a different style head; obtaining measurements such as exhaust composition, heat transfer, efficiency, and composition of residue
Co-op Student Engineer Spring 2009 - Present
Naval Surface Warfare Center– Crane, IN

Reverse engineered several special tools/mounts that are in use and created models and drawings for technical use

Headed design projects which created new models and technical drawings, and managed in the assembling and testing of new models
Service Technician Apprentice Summer 2008
Planet Mazda – Ferguson, Mo

Performed routine maintenance on vehicles, and assisted in the diagnosis and repair of electrical, drivability, and other complaints

Gained a better understanding of corporate etiquette, communication, cooperation, and logic/reasoning skills
Organizations:
Tau Beta Pi
American Society of Mechanical Engineers
SIUC Robotics
Member since: Spring 2009
Member since: Spring 2007
Officer since: Fall 2007
Member since: Spring 2009
Officer since: Fall 2009
Society of Automotive Engineers
Other Skills:
Member since: Spring 2008

Extensive knowledge of Microsoft Office

Proficient in 3D editing with Inventor, Pro-Engineer, and Solid Edge

Ability to command math programs such as Octave and MatLab
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SEC F09-27-ABILITY1

erichoff@siu.edu
847-334-2426
519 Lowestoft Lane
Elk Grove Village, Il 60007
OBJECTIVE Obtain an entry level mechanical engineering position in the field of energy processes with a focus on turbomachinery and combustion.
EDUCATION
Southern Illinois University Carbondale (SIUC)
Undergraduate Mechanical Engineering major
GPA: 3.96/4.0
Standing: Senior
Projected Graduation: May 2010
Future Education: Attend graduate school for Masters Degree
HONORS/AWARDS
 Dean’s List Fall 2006 - Present
 College of Engineering General Scholarship - 2007-08, 2008-09, 2009-10

College of Engineering Freshman Scholarship – 2006-07
RELAVANT COURSEWORK / SKILLS
Energy Management, AutoCAD, Auto Inventor, MATLAB, Motivated leader and worker
EXPERIENCE
Undergraduate Research Assistant, SIUC IMEL (08/09 – Present)
Illinois Clean Coal Institute research project, digital image correlation nondestructive evaluation design, write and edit papers and proposals. Collect and analyze data.
Platform Engineer Co-op, Caterpillar Inc. Global Engine Development. (01/09 – 04/09)
Coordinate engine validation tests, maintain cell operations and analysis data, give presentations on test findings and suggest improvements.
Production Engineer Co-op, Toyota Motor Engineering & Manufacturing, Inc. (06/08 – 8/08)
Design modifications for plant machinery and processes, developed cataloged system for auxiliary parts, collected and analyzed data for contractor estimates.
Peer Mentor, SIUC College of Engineering (08/07 – 06/08)
Plan and lead study sessions, plan and lead college survival information sessions, organize group social activities.
Automotive Technician, Accurate Auto Clinic, Des Planes, IL (05/06 – 07/06)
Diagnosed and repaired all makes models and heavy machinery, answered customer calls and processed service requests.
ACTIVITIES
 Tau Beta Pi – President - 2009
 American Society of Mechanical Engineers – President - 2007

Society of Automotive Engineers – International member
 Engineering Supplemental Instructor, and Engineering Tutor
 Society of Women Engineers - Social Coordinator 2007 - Public Relations 2008
REFERENCES
Available Upon Request
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SEC F09-27-ABILITY1