ImprovingtheEfficiencyof

DoorswithAluminum
EngineeringDesign100009
Team#2:FluffyTurnUpSquad
Members:CharlesJonescyj5054@psu.edu
KyleSteinmetzkls5986@psu.edu
HassanRashidhyr5079@psu.edu
EdwardCabreraewc5239@psu.edu
Submittedto:Prof.WallaceCatanach
Date:December16,2013
TableofContents
ExecutiveSummary
Abstract
MissionStatement
CustomerNeedAnalysis
ExternalResearch
MetricsMatrix
ConceptGeneration
ConceptScoring
Cost
Model
Conclusion
ExecutiveSummary
TheAlcoaCompanyhasrequestedtheFluffyTurnUpSquadAgencytouse
aluminumtobettertheefficiencyinoneormoreaspectsonPennStateMainCampus.
Aluminumisastrong,lightweight,andversatilematerialthatishighlyrecyclableandhas
playedamajorroleinmanyothermarkets.Wehavedecidedtousealuminumtoreplace
theheavy,lessinsulateddoorsaroundcampus.Aluminumdoorswouldbelighterand
easiertoopenandclose.Itisalsoamuchbetterinsulatorthanforexamplesteelor
woodendoors.
Whendevelopingthedesign,weresearchedhowmanydoorsthereareonthe
mostheavilytraffickedareasoncampus.Wealsoresearchedwhatmaterialsthesedoors
aremadeofandhowmuchmoneyitwouldcosttoreplacethesewithaluminumdoors.We
conductedafewsurveysaskingstudentsoncampuswhichdoorsoncampuswere
heaviestandiftheyshouldbereplaced.
Somerisksinvolvedwiththisprojectisthataluminumdoorsarelessdurableand
moreeasilydamagedthanincomparisonwithsteelandwoodendoors.Thiscanbe
avoidedbecausethesedoorscanberecycledtoreplacenewdoors,sotheyareeasier
andcheapertobereplaced.ThefinalproductisscheduledtobedeliveredtoAlcoa
CompanyonDecember16,2013.
Abstract
OurcompanyTeamFluffyTurnUpSquadproposedplanistoreplaceallthedoors
ontheUniversityParkCampusofPennStatewithaluminumdoors.Thiswould,inthelong
runsavealotofmoneyandismoreenergyefficientthanconventionaldoors.Aluminumis
agoodthermalconductorsoitwillkeepheatin,anditisalsolightweightsostudentswill
beabletoopenandclosethedoorsmucheasier.Usingenergyefficientdoorswillbevery
beneficialtothecampus.
MissionStatement
OurmissionIstoimprovetheefficiencyandsustainabilityofthePennStatecampus
whilealsoimprovingandpayingattentiontorecyclability,reducedenergyconsumption,
andeconomicviability.
CustomerNeedAnalysis
ThecustomerneedspresentedtousspecificallybyAlcoacamedowntobasicallythree
needs:
Costeffective
Safeforeverydayusebystudents,faculty,etc.
Recyclability,environmentallyfriendly
# NEED Imp
1 Thedoorismadefromaluminum 5
2 Thedoorislightweight 5
3 Thedooriseasytoinstall 3
4 Thedooriseasytoreplace 3
5 Thedoorkeepspreservesheat 5
6 Thedoorisaestheticallypleasing 2
7 Thedooriseasytooperate 5
8 Thedooriscanbemaintainedwithreadilyavailable
tools
4
9 Thedoorisdurable 3
10 Thedoormustfitthestandarddoorframe 5
ExternalResearch
Herearesomebenchmarkswefoundfromalreadymadealuminumdoors:
Anderson3000series Anderson4000series
Height 80in 80in
Width 36in 36in
Thickness 1.5in 1.5in
Weight 60lbs 98lbs
Weconductedsomesurveysaroundcampusaskingstudentswhattheirthoughtswereon
thedoors,suchasweretheyheavy,whichonesweretheheaviest,andiftheywould
approveofachangetoaluminumdoors.Basedontheresultswegotback,moststudents
saidthatthemajorityofdoorswereheavyandtheywouldlikelighterdoors.Notmany
studentscaredwhetherwemadethemaluminumornothowever.
MetricsMatrix
ConceptGeneration,Scoring,and
Selection
Whendesigningthealuminumdoortouseasthereplacement,weneededtotakeinto
considerationwhatkindofaluminumwewantedtouse.Forexample,virgin,ornew
aluminumwouldbeinbetterconditionhoweveritwouldbemoreexpensive.Recycled
aluminumwouldbecheaperbutwithalittlelowerquality.Wealsoneededtochoosewhat
typeofinsulationwewantedtouseinthemiddleareaofthedoor.
Wealsomadesixdifferenttypesofaluminumdoordesignsforustochoosefrom.Some
withairvents,windows,both,ornoneatall.
Weusedaconceptscoringmatrixtothendecidewhichoneswewantedtouse.
Selection
Criteria
Door
with
big
windo
w
Door
with
small
windo
w
Door
withno
window
Door
with
vents
andno
windo
w
Door
with
vents
and
small
windo
w
Door
with
vents
andbig
window
Energy
Efficient
1 1 1 1 1 1
Affordable 0 1 1 1 1 1
Durable 1 0 0 1 1 1
Aesthetics 1 1 1 1 1 1
Amountof
Insulation
0 1 1 0 0 0
Recyclability 0 0 0 1 0 0
FinalScores 1 4 2 3 2 2
Basedoffoftheconceptscoringmatrixwedeterminedthatthetwobestchoicesfor
designswouldbethedoorwithasmallwindowandadoorwithanairventbutnowindow.
Cost
Thecosttoreplaceallthedoorsoncampuswasestimatedbyfirstcountingallthedoors
oncampus.Nownotalldoorswereaccessiblebyustocountfornumerousreasons,but
wewereabletocomeupwitharoughandfairlyaccuratecountofhowmanydoorsthere
are.
Weestimatedabout350doorsperbuilding:
~~~
Thereareabout114buildingsoncampus.Soafterafewcalculationswegotarough
estimationofabout80,000doorsoncampus.Andtherawmaterialstoconstructadoor
(insulationandaluminum)isabout160dollarsadoor.
Sotheoverallpriceofthewholeprojectwouldcostaround13milliondollars.
Model
Wealsomadeamodelofthedesignofthedoorsonsolidworkstobettervisualizethedoor
weplanonusing:
Conclusion
Usingtheengineeringdesignprocess,ourcompanydesignedaplanthat
wouldbenefitPennStateUniversitybothfinanciallyandenvironmentally.
Therearemanybenefitinreplacingthedoorswithaluminummadedoors.
Aluminumdoesnotrustorcorrode,andisveryrecyclablesoifitdoes
needtobereplaced,thesamematerialcanberecycledandusedover
again,reducingcosts.Thesedoorsarealsolessheavierthantheoneswe
havenow,makingiteasierforstudentsandfacultytouse.Althoughthis
projectwillcostalargeamountofmoneyatfirst,eventually,thesavingsin
energyandrepairswillofferpaybacktothemoneyspent.Wehereat
FluffyTurnUpSquadthinkthatourproposedplanwouldbenefitAlcoaand
PennStategreatly.