PDD

Executive Summary
Two-thirds of the employees at Goodwill of Central and Southern Indiana are people with either
physical or cognitive disabilities or have a criminal history. Goodwill is a contract manufacturing
company who is contracted by EHOB, a medical device manufacturing company. EHOB produces
the air inflated waffle mattress, used on hospital beds to reduce ulcers and bedsores.The mattresses
have perforated plugs that must be removed before use, as well as straps on the corners to secure
it to the hospital bed. Removing particular plugs leaves holes in the air mattress that help to reduce
pressure on the patient while they are in the hospital bed. The current plug-removal process,
performed by Goodwill, involves two employees on opposite sides of a manufacturing table, using
an uncomfortable poking tool to separate the plugs from the mattress. Once the appropriate plugs
have been removed, the mattress is then folded by a third employee.
Goodwill has requested the development of a more efficient plug-removal process that requires
fewer employees to perform this task without compromising efficiency. The client expressed a
particular need to accommodate a wide variety of employees, minimize damage to the mattress as
the plugs are being removed, and an effective way to collect the plugs after removal to be recycled.
Additionally, it would be advantageous if the new process improved the ergonomics, was intuitive
to perform, and enabled one employee to complete the process in less than 100 seconds for each
mattress.
The team narrowed down multiple design concepts including various tables and hand tools, to the
Lock ‘N Load Plug Remover table and the Two-Way Punch hand tool. The Lock ‘N Load Plug
Remover table features a customized tabletop with holes located where the plugs on the air
mattress need to be removed. The tabletop also includes pegs in the corners of the table to secure
the mattress throughout the plug-removal process. The dimensions of the table are such that the
corners line up with the perforated edges of the bed straps for easy separation. A funnel attached
under the tabletop guides the removed plugs into a collecting bin below the table. The legs of the
Lock ‘N Load Plug Remover are adjustable to accommodate employees of different heights. The
Two-Way Punch is used to punch the plugs through their respective holes in the tabletop. The
design includes a separate template for each of the two plug shapes, dog bone and circular, as well
as a comfortable spherical handle with adjustable sizes to further accommodate Goodwill’s
employees.
The Lock ‘N Load Plug Remover and Two-Way Punch are designed to meet the needs of the
client, and is estimated to cost $775, primarily due to the height adjustability mechanism. The
design includes a durable table developed from multiple parts and materials, and a strong and
unique hand tool. This solution not only improves the plug-removal process, but also enables
people with different abilities to perform the task. For these reasons, the team is requesting funding
for prototype development and testing.
Table of Contents
I. Design Scope ............................................................................... 2
II. Evaluation Criteria ...................................................................... 14
III. Design Concepts ........................................................................ 19
IV. Design Concept Evaluation .......................................................... 26

Summary of the Feasibility & Merit Analysis ................................... 33
V. Design Overview ......................................................................... 34
VI. Design Project Specifications ....................................................... 40

Two-Way Punch ...................................................................... 40
Tabletop ............................................................................... 43
Funnel .................................................................................. 49
Adjustable Table Legs .............................................................. 54
VII. Budget/Projected Costs ............................................................... 61
VIII. Conclusions & Recommendations ................................................. 66
IX. References ................................................................................ 67
X. Appendices ................................................................................. 69
Appendix A – Calculations .......................................................... 69
Appendix B – Dimensioned Drawings ................................................ 78
Appendix C – Failure Modes & Effects Analysis Worksheets .................. 82
Appendix D – System Interaction Diagrams ....................................... 84
XI. Personnel and Responsibilities ..................................................... 86

I. Design Scope & Background Information
Background
As of 2016, 10.5 percent of people with a disability were unemployed, two times that of people
with no disability (U.S. Bureau of Labor Statistics). Goodwill of Central and Southern Indiana is
striving to lower this percentage, as more than 80 percent of their employees have either a disability
or a criminal background.
Accommodating the risk associated with people with a disability working in manufacturing is an
important aspect to consider for this project. Being aware the variety of disabilities that employees
may have will be important for developing multiple solutions that provide a safe and efficient
mattress manufacturing process.
It is important to know the details of the current mattress manufacturing process at Goodwill and
the client’s desired outcome for this project. Our goal will be to improve the time, cost, and number
of workers it requires to complete each step. Improved efficiency will lead to employee satisfaction
and overall company success.
Market Analysis/Benchmarking
Market Analysis is performed at the start of the design process in order to get an idea of the kinds
of products on the market that are similar to the current project. It is helpful to find ideas that could
be used, identify their strengths and weaknesses, and figure out how they could be tailored to fit
the needs of the client. Specific parts of the products or whole products could be used in the final
design for the client.
Compass Circle Cutter
Figure 1. The compass circle cutter helps cut perfect circles and could improve consistency in the
removal of the plugs in the air mattress.
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The Olfa Compass Circle Cutter is capable of cutting through paper, films, acetates, cardboard and
light wood. As shown in Figure 1, the design of the cutter makes it easy to extract uniform circles
from a material. This is advantageous because it will result in more consistent cuts leading to a
higher quality product. The compass cutter features an adjustable slide which enables it to cut a
variety of circle sizes ranging from one centimeter to six inches in diameter to adapt to the needs
of the user accurate to the nearest quarter of an inch. One disadvantage of this product is that the
handle on the cutter does not seem very comfortable because it is small and would be hard to grip
for users with low dexterity. The product could be improved with a larger, more ergonomic handle
design making it easier to grip and maneuver for people with disabilities (Olfa).
Laundry Folding Board
Figure 2. The Laundry Folding Board folds t-shirts. This method could be incorporated into
Goodwill’s manufacturing process to fold the polyvinyl chloride sheets
The Laundry Folding Board (Alibaba group) depicted in Figure 2 allows users to fold shirts and
other garments in three quick and easy steps by folding the hinged panels. A larger folding board
similar to this could be used to fold the polyvinyl chloride sheets at Goodwill on the manufacturing
line. The use of a board similar to this would only require one operator to fold the sheets on the
line, decrease the amount of work required by the operator to fold the sheets, and reduce strain on
the operators. A challenge of trying to implement a folding board such as this one at Goodwill
Indy would be to scale the board up to the necessary size of the PVC sheets without drastically
increasing the weight of the board. Another challenge associated with this design would be
ensuring the board has the correct foldable compartments to fold such a long and thin sheet.
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Circle Lever Punch
Figure 3. Fiskars Brand Circle Lever Punch cuts circles out of paper. This design could be used
to remove the plugs from the PVC sheets.
The Fiskars Brand Circle Lever Punch is a device that punches a perfect circle into paper that is
placed in the slot on the bottom of the punch. To cut a circle into the paper, the orange lever on
top of the device, as shown in Figure 3, is pressed down and a blade is used to cut through the
paper. Once the circle is punched out, it is caught in the bottom compartment for easy clean up.
This idea could be used to easily and accurately remove the plugs from the PVC sheets during the
waffle mattress plug removal process. For this project, the punch would not be used to cut through
the sheet, rather just to press up or down on the plug for an easy removal. Three different punch
shapes could be made to accommodate the circular, dog bone, and teardrop plugs. The punch could
also be manufactured with a clear material so the user could see where they are pressing down on
to be sure the device does not tear the weld. Once the hole is punched, the scrap material would be
held in the compartment of the punch so it could be properly disposed of. One disadvantage of this
device is that the material it is cutting through has to slide into the slot at the bottom therefore, it
would be difficult to get to the plugs that are not around the edges of the sheet.
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C-Frame Inverter
Figure 4. The C-Frame Inverter uses a gear motor to rotate a load between hydraulic clamps.
Aspects of this device would be useful for rotating the air mattresses.
Figure 4 shows is the Bushman Equipment, Inc. C-frame inverter, which is equipped with a
hydraulic clamp to invert long and wide loads. The hydraulic clamping mechanism helps to secure
the load and allows for quick inversion. Once inverted, the ball rollers on the plates allow the load
to move in multiple directions out of the inverter. The design of the C-frame inverter allows for
high capacity cycle operations. An industrial caliber gear motor powers the inverters rotation over
wheels that roll on lubricated bearings. These features allow the C-frame inverters to be easily
integrated into automated manufacturing processes. The rotational aspects of this device may be
useful for this project, as it currently requires two people to flip over the polyvinyl sheets. One
disadvantage of this device is that it is very large and may not fit in the available manufacturing
space. Due to its size and complexity, the cost of designing and manufacturing this device is likely
to exceed the client’s budget. This device is large so it may not fit in the manufacturing space that
is available at Goodwill Indy. The complex parts involved with this product may also negatively
impact production, rather than improving it (Bushman Equipment, Inc.).
After meeting with the client, it has been made clear that inverting the polyvinyl material will not
be necessary for this project.
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Crochet Hook
Figure 5. A crochet hook could be used to punch the plugs out of the weld and then allow for the
operator to easily grab the plugs and remove them from the weld.
Figure 5 (Stenli) depicts a crochet hook that could be used to remove the plugs from the welds in
the waffle mattress. The head of the crochet hook could push the seal down to create the initial rip
between the plug and the weld. The edge part of the head of the crochet could then be used to grab
the edge of the plug and pull it towards the operator. This allows for the operator to grab the plug
and remove it from the weld by pulling on the plug. This is easier than the current process that is
used, which is to push down on the weld using the poker and pull up on the rest of the waffle
mattress, then pick up the removed plugs later. The tool would be more ergonomic than the poker
that is currently used, but remain approximately the same price.
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Hydraulic Work Bench
Figure 6. An adjustable height workbench allows workers to change the height of their workspace
to be the most ergonomic to reduce back pain.
Figure 6 shows a hydraulic workbench with height-adjustable legs. The hydraulic lift is operated
with an easy to turn handle allowing workers to effortlessly change the table to the desired height.
This feature reduces fatigue and pains associated with improper table height. The tables currently
used at Goodwill are a fixed height, but the employees have varying heights. If the process is
improved to require only one operator to complete the waffle mattress plug removal process, this
product would allow the operator to adjust the table to the most comfortable height for them.
Reducing back pain, would increase productivity because it would be easier and more comfortable
for the workers to perform their tasks (Global Industrial).
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Patent Search
Reviewing patents is also an important step in the design process in order to see the specific
mechanisms used in the products that are on the market. The following mechanisms could be
helpful for the final design and knowing exactly how they work will simplify the process.
Paper Punch
Figure 7. The paper punch patent design which cuts holes in paper with spring loaded punches
and collects the cut paper in the bottom compartment.
The patented paper punch, as shown in Figure 7, is a device that creates holes in paper by pressing
down on the handle and the spring loaded male elements punch through the paper. The force
needed to punch through a material will depend on the thickness of the material or the number of
sheets being punched through. A compartment at the bottom of the base catches the cut paper and
has a removable lid for disposal of the paper. The two main mechanisms of this patent could be
used for removing the plugs from the waffle mattresses. Punches made with different shapes for
each plug could be made in order to make it easier for the workers at Goodwill Indy to get the
exact shape of the plug. Another issue is that the workers must place the plugs into a bucket and
sometimes they fall on the ground, preventing reuse. Therefore, a compartment for the scrap PVC
could be developed in order to ensure that all excess material is getting reused (Hymmen).
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Strip Inverter
Figure 8. The strip inverter patent design inverts lugged strips in a semi-circular tube equipped
with a conveyor for easy transport.
The strip inverter, shown if Figure 8, is capable of inverting a lugged strip in a semi-circular tube
without manhandling the load and risking damaging the strip. The strip is inserted into a semi-
circular tube with the help of a conveyer to move the load. Once the strip makes contact with the
far wall of the tube, the tube can rotate, forcing the strip to follow its semi-circular path. This patent
is related to improving the mattress production table design because of the device’s ability to invert
a load. Currently, flipping or inverting the polyvinyl requires two or more people and can be
difficult for people with various disabilities. With a design such as the strip inverter, the mattress
flipping could become an automated process to increase efficiency of production and decrease
discomfort for the workers (Wellman, R.).
After meeting with the client, it has been made clear that inverting the polyvinyl material will not
be necessary for this project.
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The Garment Folding Apparatus
Figure 9. The garment folding apparatus folds clothing or fabric that is placed on it in simple, easy
to follow steps.
The garment folding apparatus shown in Figure 9 consists of three hinged panels connected to the
central panel. The side and bottom panels fold for simple and consist folding of garments less than
half an inch thick. This patent design is related to improving the process for the mattress sheets
folding that is done during production. Currently, folding the mattress requires two or more people,
and the labor required to move such larger pieces of PVC is intensive and difficult for people with
various disabilities. With a design like that of the garment folding apparatus, folding the mattress
PVC sheets would become a one person job while decreasing the physically demanding labor
required by the worker (Barker, D.).
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Compass Circle Cutter Patent
Figure 10. The Compass Cutter features a ratchet mechanism in the manipulate portion reducing
the need to re-grip the handle while cutting a circle.
The compass cutter produces smooth cuts on materials due to the ratchet mechanism in the handle
which eliminates the need to release and re-grip the handle during use. Figure 10 shows the various
parts of the Compass Cutter that makes cutting uniform circles easier. The needle (61) is positioned
at the center of the circle. The user pinches the handle (30) to move the blade (81) in a circular
motion. The internal ratchet mechanism in the handle transmits a rotational driving force in only
one direction. When the handle is rotated in direction A as noted in Figure 10, the teeth on the first
and second cylindrical members are engaged, rotating the blade in the same direction as the handle.
Rotating the handle in the B direction does not engage the teeth and the blade remains stationary.
The ratcheted handle is an advantageous design for users with reduced hand dexterity, grip
strength, and range of motion because it does not require excessive force or significant finger
repositioning. The easy ratchet turning mechanism would allow the employees of Goodwill Indy
to consistently cut uniform circle plugs in the PVC sheets while exerting minimal force (Okada,
S.).
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Literature Review
A literature review was performed to learn more about the project, our client, and general
manufacturing processes. This will give a better idea of what the design constraints will be and
what should be expected when working with Goodwill Indy.
Cutting Plastic Film by Thorsten Brandt discusses the different methods currently available to cut
plastic films such as PVC sheets. Goodwill Indy currently has their operators cut the plugs out of
the PVC sheets with knives, which is a long and tedious process. The use of knives causes every
cut to be different, and Brandt lists other downfalls such as the knives’ subjectivity to rapid wear,
while the consistency and quality of every cut varies. Brandt compares the punching method to cut
PVC sheets to the use of knives, because they are both cost effective when the batch sizes are
smaller; however, punching creates the same size hole with every punch. For larger scale
production lines, Brandt recommends the use of either water jet or laser cutting because of their
accurate and quick cutting. However, water jet and laser cutting would remove the job for the
operator to perform and be very expensive, which is unwanted in this project. The benefits and
disadvantages of each technique described above will be considered for potential changes in the
production of the mattresses at Goodwill Indy. After meeting with the client, it is now understood
that the plugs are already perforated and do not need to be hand cut using any of the techniques
described above (Brandt).
In the article, Accommodating Employees in Manufacturing Settings, the Job Accommodation

Network discusses the need to accommodate workers, especially those with disabilities in the
manufacturing setting. The goal of the Job Accommodation Network is to increase employment
for people with various disabilities. One of the primary ways they strive to make this happen is by
providing unique worksite accommodations for employees. The article describes a few specific
instances where workers were assisted to make them more comfortable and productive at work.
This article is relevant to improving the mattress production table design for Goodwill because
currently, the production process is uncomfortable and potentially harmful for many of the workers
with disabilities (U.S. Bureau of Labor Statistics).
Research and case study findings in the area of workplace accommodations by Butterfield and
Ramseur discusses the improvements that have been made in many employment settings with the
implementation of accommodation and assistive technologies. Some of the devices and services
offered are complex such as computer technologies, where most of them are simple and
inexpensive like typing sticks or gripping devices. It was found that small adjustments led to major
improvements in performance and decreases in pain. Accommodations were made to improve
posture including seating adjustments and desk height. This could be implemented at Goodwill for
workers who are experiencing posture related pains by designing more ergonomic seating and a
table workspace that is appropriately sized to support the worker’s operations. The implementation
of more ergonomic workspaces and tools will lead to more productivity and employee satisfaction
(Butterfield, Ramseur).
The article Quality bottleneck transitions in flexible manufacturing systems with batch
productions, by J. Wang et al., discusses how flexibility can affect the quality of a manufacturing
system. The flexibility of each line in the system will impact the quality of the final product. One
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way to improve the flexibility of a process is to improve the bottleneck transitions of the
manufacturing process. Bottleneck transitions are parts of a line where products get accumulated
or depleted quickly. It is important to identify the bottleneck transition indicators such as blockages
and starvations in order to create a smooth flow. Bottleneck transition indicators could be identified
at Goodwill Indy during their mattress manufacturing to ensure that the process is efficient and
that all the scrap material is placed in the correct place for disposal or reuse. One way to decrease
the blockage at this area would be to decrease the number of people around the table while
removing the plugs (Wang).
Problem Statement:
The current waffle mattress plug removal process at the Goodwill of Central and Southern Indiana
manufacturing facility is tedious and inefficient due to the equipment and workstation ergonomics.
The goal is to design and implement necessary equipment to improve the plug removal and
collection processes and reduce the dependence on a partner at a single work station.
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II. Evaluation Criteria
Feasibility Criteria
Feasibility criteria are the strict constraints that a design must satisfy. They are the minimum
features that the design must have in order to meet the client’s needs. If a design does not meet
one of the criteria, it must be modified or eliminated from consideration. Developing feasibility
criteria is an important step in the design process because it establishes what the developing design
must be able to accomplish in order to meet the needs of the client.
Collect removed plugs

It is important that the scrap material from the plug removal process is collected to be reused. The
excess material can be sent back to the mattress manufacturer to be melted and used to produce
future mattresses. The current process of recycling the plugs risks dropping them on the floor. It
may be difficult for some workers and time-consuming to pick the plug scraps up off of the floor.
Including a mechanism to catch the plugs will increase the amount of waste material collected for
reuse. The ability to reuse material reduces the amount of money and resources that have to be
used for each product. The client expressed the importance of being able to easily recycle the
material. This criterion will be satisfied if the table is able to collect the plug scraps without any
falling on the floor.
Adjustable height
The design must accommodate workers of different heights. Shorter workers currently may have
difficulties completing the mattress plug-removal and folding processes due to the height of the
manufacturing table. Therefore, the new design must enable the workers to complete this process
efficiently, regardless of their height. For this criterion to be achieved, there must be a mechanism
that allows workers of various heights to work comfortably and efficiently.
Ability to remove the plugs without tearing the welds

Removing the plugs is a vital step in the waffle mattress manufacturing process; however, if any
of the welds are damaged during this step, the mattress must be scrapped. The current hand tool
often has difficulty separating stiff weld areas, which sometimes causes damage to the welds.
When used correctly, the new hand tool and table designs must not cause any damage to these
welds. If either of the table or hand tool design risks tearing the welds in any way, then this criterion
will not be met.
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Merit Criteria
Merit criteria include the desirable functions that a user would prefer for a design to have. These
criteria are not required for the design, but rather are features that would add to the user experience.
These include special features or target performance goals. These are necessary to determine the
importance of each performance criterion. Merit criteria are also important to determine the least
desirable and optimal performance for each criterion.
Estimated time to complete one mattress (35%)

Description: A faster mattress plug removal process allows for more mattresses to be completed
within a given period of time. It is important that the process is quick to increase productivity and
profit for the company.
Weight: The time taken to complete each mattress is weighted highest at 35% because it directly
impacts the profit of the company. This merit criterion determines the productivity of each
employee as it relates to the number of mattresses that will be produced each day.
Metric: The estimated time taken to complete one mattress will be measured from the unfolding
of the mattress to the folding of the completed mattress. In order to make a profit, the client needs
the process to be 60 seconds or less. A lower time will receive a higher merit score and a higher
time will be given a lower merit score because it is desirable to reduce this time to increase profit.
Scale:
Suggested Merit Score Time (seconds) to complete one mattress
100 < 60
75 61-75
50 76-90
25 91-105
0 106+
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Ergonomics (25%)
Description: The ergonomics of the new hand tool is important for making the workers
comfortable while they are working. Currently, the workers are using a hand tool that requires a
lot of motion in the wrist, as well as a grip on a small object for long periods of time. Small,
intricate hand tools can be harmful to the workers’ joints and muscles. Research has shown that
for every 15 degrees of motion in the wrist, unnecessary pressure is placed on the median nerve
that passes through the carpal tunnel, which can lead to the development of carpal tunnel conditions
and arthritis (Ergonomics in the News). The new hand tools need to be comfortable for the workers
to hold throughout the duration of their shift while still being able to complete the plug-removal
process.
Weight: This merit criterion will be weighted at 25%. The ability for the worker to use the hand
tool without being uncomfortable and putting themselves at risk for developing joint and muscle
pain in their wrists is important to consider. Joint pain could also result in a decreased mattress
production rate, which is critical for Goodwill Indy’s success as a company.
Metric: The ergonomics of the hand tool design will be measured based on the motion required
by the worker’s wrist while using the device. This will be measured as degrees of flexion or
extension in the wrist, where a lower degree of required movement will receive a higher merit
score than a design that requires a large degree of movement in the wrist.
Scale:
Suggested Merit Score Degrees of Required Motion in Wrist
100 < 14
75 15-29
50 30-44
25 45-59
0 60+
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Ease of use of hand tool (25%)
Description: The current hand tool used at Goodwill Indy to remove the plugs from the waffle
mattresses is considered difficult to use by some people. Goodwill Indy desires a new tool that
allows the workers to individualize the plug removal process and use the tool in the most efficient
and comfortable way for them.
Weight: The ease of use of the hand tool criterion is weighted at 25%. This is an important
criterion because it addresses the client’s requests to have multiple ways that the workers can grip
their tool. This criterion is also important for the workers to be able to individualize the way they
use the tool to achieve maximum comfort and efficiency.
Metric: The ease of use of the hand tool will be measured based on how many different ways the
hand tool can be used during the plug removal process. The more options that are available to the
worker, the higher score the hand tool design will receive.
Scale:
Suggested Merit Score Number of Possible Ways to Hold the Hand Tool
100 4+
60 3
30 2
0 1
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Ease of use of table (15%)
Description: Designing a table that is easy to use is important for the workers to be able to set up
their workstation without difficulty. The need for many people to be present in order to set up a
table for a specific worker and/or mattress part number is inefficient. The amount of time and effort
needed to adjust the table is reflected by the number of people needed to set up the table. If the
table is heavier and the mechanism used to set it up is difficult, more people will be needed to
assist. Therefore, making a lightweight table with an easy to use raising and lowering mechanism
is important.
Weight: The ease of use of the table is weighted at 15%. This is the lowest merit criterion
considered because although it is important to start up quickly each day, the table will only need
to be set up at the beginning of each day if the same workers are at the same tables throughout the
day. Therefore, a decrease in efficiency of setting up the table will not significantly decrease
production for that station at Goodwill Indy.
Metric: The ease of use of the table will be measured by the number of people needed to set up
the table for a specific worker and/or mattress. The more people that are needed will result in a
lower merit score and when only one person is needed, the merit score will be higher.
Scale:
Suggested Merit Score Number of People Needed to Set Up Table
100 1
75 2
50 3
25 4
0 5+
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III. Design Concepts
The following design concepts address several areas where improvements can be made in the
waffle mattress plug removal process. These solutions include table and hand tool designs that will
improve the efficiency and ergonomics of the manufacturing process. Although they can be used
together, the hand tools and table designs are split into two sections below.
Hand Tool Designs

Design Concept #1 - Two-Way Punch
The Two-Way Punch, depicted in Figure 11, features two functional sides, each used to remove a
specific plug shape on the waffle mattress. The rounded side (Figure 11C) removes the circles
from the inside of the mattress, while the opposite end is used to remove the dog bone shaped
plugs (Figure 11B). This tool will be fabricated from one piece of material, making it less likely
to fail where two different materials meet and making it easier to manufacture. The handle features
an ergonomic grip (Figure 11A), which allows the user to grip the punch easily and comfortably.
The handle will be able to fit the width of the user’s hand comfortably, as well. To use the punch,
the employee positions the appropriate shape to match the mattress plug and applies a downward
force similar to the force required to break the perforated welds with the current hand tool used by
the workers. This device should be paired with a table with holes located under each plug so that
when the punch is used, the plugs will separate from the mattress and will fall down through the
table.
This tool will allow the workers to remove plugs faster because the tool is all inclusive. This is an
advantage because the tool is specific to the shape of the plugs on the waffle mattress. The Two-
Way Punch combines two hand tools into one, which is an advantage over having separate tools
for each plug shape. Currently, the hand tools being used are small and hard to grip for long periods
of time. The ergonomic handle on the Two-Way Punch will increase the comfort level of the
workers, enabling them to work longer without needing to take breaks because of discomfort.
Increased comfort will also lead to less work related injuries such as carpal tunnel.
A disadvantage of this design is that it must be pair with a table with holes. The Two-Way Punch
only features components that can push the plugs, not lift them up. An additional disadvantage is
that the employees have to flip the tool often causing excess hand motion.
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Design Concept #2 - The Captain Hook
The Captain Hook, shown in Figure 12, is a tool that is used to remove the plugs using the current
table design without holes. To use this tool, the hooked end (A), is poked into the perforation of
the edge of the plug. The other end (B), is used to hold down the mattress while the hook is slid
under and around the plug to remove it. This tool has an ergonomic handle (C) that would make it
easy for the workers to grasp and use throughout the day.
The Hooker could be manufactured in several ways, for example, by being 3-D printed, or by being
made in a mold. Because the Hooker would be one piece, it would be durable and easy to maintain.
The Hooker will also reduce the amount of tears to the weld in the mattress because the mattress
will be held down and controlled, rather than the plug being torn out.
A disadvantage of this design is that it is similar to the current poker that is used and therefore, the
hooker may not improve efficiency of the process. The workers would also still have to collect the
removed plugs in their hands while they are removing them which does not improve the efficiency
of the plug removal process.
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Design Concept #3 - Plug Sucker Punch
The Plug Sucker Punch depicted in Figure 13 is two separate tools that match the shapes of the
two different plugs: circular and dog bone-shaped. This design is easy to use and ergonomic by
allowing the worker to punch out the entire plug in one motion, rather than perforating the
polyvinyl material with a poking tool and pulling the plug out by hand. Additionally, the Plug
Sucker Punch includes a button (A) that activates the internal apparatus (B) that essentially scoops
up the plug scraps after they have been removed, and holds them within the tool until it is emptied
by the worker.
A disadvantage of this design is the frequency that the worker would have to empty the scrap
material from the tools. In order to make the Plug Sucker Punch a handheld tool, it would be
difficult to design it to be able to hold a significant amount of scrap material to prevent the workers
from having to empty it so often. There are also lots of moving parts, which could cause a plug to
get stuck up inside the Plug Sucker Punch and cause a jam. This would halt the plug removal
process until the stuck plug is removed from the hand tool. This could also cause the tool to be
difficult to maintain.
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Table Designs
Design Concept #4 - Lock ‘n Load Plug Remover
The Lock ‘n Load Plug Remover is a table design with holes at the location of the plugs to be
removed (Shown by B and C in Figure 14). It also features four dog bone shaped pegs at each
corner of the table to put the bone shaped plugs in to hold the mattress in place while removing
the plugs, as shown by D in Figure 14. To use this table, the user will lay out the mattress and
punch the dog bone shaped plugs out with the pegs so the mattress is flat on the table. Then, the
necessary plugs will be pushed out through the holes of the table. The table is also designed with
the appropriate dimensions so that when the mattress is lying flat on the table, the edge of the table
lies on the tear line for the straps, enabling the worker to pull the strap down on the corner of the
table in one easy motion. This is a more efficient process than the current technique that requires
the workers to use a poking tool to start the tear, and then pull up to separate the strap. This design
also includes a drawer underneath the top of the table which functions to hold the removed plugs
off the ground in a convenient location. The plugs would fall directly into the drawer after being
pushed through the mattress and at the end of each day, the drawer can be emptied and the plugs
can be recycled. Lastly, to make this table accommodating to workers of different heights, the legs
are designed with a push pin to adjust the height. To raise or lower the table, the push pins on the
two legs will be pushed in and the table will be raised or lowered until the pin comes out at the
hole at the desired height, shown in section A of Figure 14.
An advantage of this table is that it will identify which plugs need to be removed and prevent the
wrong plugs from being removed since the table only has holes where the plugs need to be
removed. Having the drawer under the table will make the plug recycling process easier and more
ergonomic because the plugs have a non-existent or much smaller chance of falling on the ground,
and wasting the workers time bending down and putting them in the bucket.
A disadvantage of this design is that since there are multiple mattress designs, there would have to
be multiple tables for each item number which could be a problem for storage, cost, and
manufacturability. One disadvantage of this design is that the corners of the table would have to
be relatively sharp in order to serve the same purpose as a poking tool. This could be a potential
danger to workers if they accidentally bump into the sharp corner when there was no mattress on
the table. Also, the drawer might fill up quickly and therefore, it would have to be large enough to
accommodate the plugs for a whole day. It might also be difficult to remove all the plugs from the
drawer because it will be so large and the plugs could be dispersed.
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Design Concept #5 - Tilted Table
The Tilted Table, shown in Figure 15, is a table design that prevents the worker from
uncomfortably reaching over the table to remove plugs. The Tilted Table features a table top that
rotates a maximum of 45 degrees towards the worker, which positions the far side of the mattress
closer to the worker. This table makes the plug removal process easier and more ergonomic for
the workers.
One of the primary advantages of the Tilted Table is that it eliminates the need for two workers
for each mattress, which would lead to a large cost savings. The table also features a drawer to
conveniently hold all the removed plugs in an easy to reach location. The legs of the table meet
the Adjustable Height Table feasibility criterion because they incorporate the push pin mechanism
so the workers can change the height of the table to their preference. The table will be made of on
the market products which will allow it to be easily manufactured and easy to maintain.
A disadvantage of the table is that keeping the mattress upright without folding over on itself or
sliding down the table may be difficult. Unfolding and folding the mattress before and after the
plugs are removed would also be more difficult on the Tilted Table. This table also does not have
holes in it so, it requires the workers to hold and collect all their removed plugs in their hands until
they can put them in the drawer.
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IV. Design Concept Evaluation
Analyzing the feasibility criteria is important when looking at multiple design concepts to be sure
that each design being considered meets the client’s requirements for the plug removal process.
Table 1 shows that all five designs meet each applicable feasibility criterion.
Two-Way Punch
The Two-Way Punch does not directly collect the plugs once they are removed from the mattress.
However, this hand tool can be paired with a table design that will collect the plug scraps after
they are removed. If the Two-Way Punch were to be used with the manufacturing tables currently
in use at Goodwill Indy, there would not be a way to easily collect the plugs that is different from
the current process that involves the workers holding onto the plugs and then placing them in a bin
to be recycled.
Adjustable height
The adjustable height feasibility criterion does not apply to the hand-tool design concepts because
the manufacturing table is the part of the plug-removal process that needs to be able to
accommodate employees of different heights. The hand-tools are not related to the height of the
employees.
Ability to remove plugs without tearing the welds

The Two-Way Punch will be able to remove the plugs from the waffle mattress without tearing
the welds, provided the appropriate material is used to manufacture this hand tool. The Two-Way
Punch is able to remove the plugs by pressing down on the perforated edges of the plug cutouts,
which will pop the plugs out through the bottom of the mattress. As long as the material that the
Two-Way Punch is made out of will not damage the polyvinyl material, and it can be ensured that
the workers can easily place the hand tool on the perforated edge of both the circular and dog bone-
shaped plugs, and that the Two-Way Punch will be able to remove the plugs without tearing the
welds on the waffle mattress.
The Captain Hook

While this tool does not have a direct collection system for the plugs, it will be paired with a table
design that would allow for an easy way to collect them. After being removed, the plug scraps will
be pushed to the edge of the table into a small drawer.
Adjustable height
employees.
Ability to remove plugs without tearing the welds

The goal of the Captain Hook is to provide the workers with a tool that will not be able to be used
incorrectly. The flatter end of the Captain Hook will be used to guide the tool around the edge of
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the weld, without pulling it and tearing the weld. The handle of this tool is also designed so the
workers will use it properly by holding it with a fist. Also, the material that would be used to make
this tool would be a soft plastic that would not be strong or sharp enough to tear through a weld.
Plug Sucker Punch

The Plug Sucker Punch will collect the removed plugs in the device each time a plug is removed.
When the worker pushes down on a plug, the tool will move the plug to a compartment in the top
of the tool. With this tool, the worker will not have to directly touch the removed plugs, making
the process much smoother than if they had to collect them in their hands.
Adjustable height
employees.
Ability to remove plugs without tearing welds

This tool prevents the worker from working near the welds with an uncontrolled hand tool. When
the Plug Sucker Punch is pushed down, the right amount of force will be applied to the edges of
the plug in order to remove it without damaging the weld. Therefore, because the tool is controlled,
there is no way the tool could be used incorrectly to damage the weld.
Lock ‘N Load Plug Remover

The Lock ‘N Load Plug Remover has a tray beneath the tabletop to collect the plugs after they
have been punched through the holes in the table. This will effectively collect all of the plug scraps
once they have been removed from the waffle mattress to ensure that no plugs land on the floor or
are unable to be recycled. At the end of the day or an employee’s shift, the worker will simply
transfer all of the collected plugs from the tray beneath the tabletop into the corresponding bin so
the plug scraps can be recycled appropriately.
Adjustable height
The Lock ‘N Load Plug Remover features a push-pin mechanism in each of the two table legs that
allow the employees to adjust the height of the table to accommodate workers of various heights.
The push-pin mechanism is low friction in order to make the height adjustment process easy and
efficient for all workers. At the beginning of their shift, each employee can set the height of the
table to a height that is most appropriate for them, and the Lock ‘N Load Plug Remover will remain
at that height for the entirety of that employee’s shift.

The Lock ‘N Load Plug Remover serves to hold the waffle mattress in place and collect the plugs
as they are removed from each mattress by hand tools. The four dog bone-shaped pegs on the
tabletop will be a measured distance apart that allows them to hold the mattress in place and taut
while the remaining plugs are removed, but will not hold the mattress so tight as to risk tearing the
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welds of the already removed dog bone-shaped welds, or any other welds that will be removed.
The hand tools are responsible for being able to remove the plugs without tearing the welds.
Tilted Table
The Tilted Table has a tray at the end of the table closest to the worker to collect all the removed
plugs. The tray is in a convenient location for the workers, reducing the motion required by the
workers to place the plugs into the recycling bin. The tray will also ensure all the plugs are
effectively collected, that they don’t fall on the floor, and that they don’t lose their ability to be
recycled. The employee can remove the plugs from the tray at the end of the day or their shift into
the plug recycling bin.
Adjustable height
The Tilted Table features a push-pin mechanism in each of the two table legs that allow the
employees to adjust the height of the table to accommodate workers of various heights. The push-
pin mechanism is low friction in order to make the height adjustment process easy and efficient
for all workers. At the beginning of their shift, each employee can set the height of the table to a
height that is most appropriate for them, and the Tilted Table will remain at that height for the
entirety of that employee’s shift.

The Tilted Table uses strips of silicone at the top and bottom to hold the waffle mattress in place
at a 45 degree angle. This table allows the worker to easily reach and remove the plugs using a
hand tool. The table itself will not be used to remove any of the plugs. The hand tools are
responsible for being able to remove the plugs without tearing the welds.
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Design Concept Merit Analysis
A detailed merit analysis for each design concept helps to determine which design most effectively
meets the needs of the clients and the design team. Each design was evaluated based on the
established definitions and scales for each merit criterion. An extensive explanation is provided
for each design, with a summary of the merit analysis shown in Table 1.
Two-Way Punch
Estimated time to complete one mattress
Provided that the employees are properly trained to use the Two-Way Punch coupled with a new
table design, the workers should be able to complete each mattress in under 60 seconds, similar to
their speed using the current plug-removal procedures. For this reason, the Two-Way Punch was
given a merit rating of 100 for the estimated time it would take an employee to complete the plug-
removal process on one mattress.
Ergonomics
The Two-Way Punch could be used by pressing straight down on the perforated edges of the
circular and bone-shaped holes, or it could be brought in at an angle to ensure proper placement of
the hand tool on the perforated edge. If the Two-Way Punch made contact with the waffle mattress
from an angle, it would likely require the employee to rotate their wrist more than 15 degrees.
Therefore, the Two-Way Punch was given a merit rating of 75 for ergonomics.
Ease of use of hand tool

An employee could hold the Two-Way Punch in multiple ways. They could grip the handle
between the two hole-punch templates with their whole hand, grip the hole template on the
opposite end of the hand tool like holding a stamp or cookie cutter, or position their hand around
either the handle or the opposite end in a different way. Due to the variety of ways that each
employee would be able to grip the Two-Way Punch, it was given a merit rating of 100 based on
our established definition of how easy the hand tool would be to use.
Ease of use of table

This merit criterion is only applicable for the table design concepts, not the hand tools.
The Captain Hook

The Captain Hook is very similar to the tool that is currently being used at Goodwill Indy with an
added feature to help guide the tool along the perforation. Currently, it takes two workers less than
60 seconds to complete one mattress, but with the new process, there will only be one worker per
table. This will slightly slow down the process by about 10 seconds. Therefore, this tool received
a merit rating of 75.
Ergonomics
This tool must be rocked back and forth to remove the plug from the mattress and also to first
puncture through the perforation. It is estimated that the worker will have to rotate their wrist 30-
44 degrees, giving this tool a merit rating of 50.
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Although there will be grips on the handle of the Captain Hook make it easier for the worker to
hold the tool in their palm, there are also other ways that the worker could hold it. Instead of
grabbing the tool with a fist, they could hold it more like a pencil, how they hold their current tool.
They could also grab onto the top of the handle. Since there are three different ways this tool can
be held, it received a merit rating of 60.

Plug Sucker Punch

The Plug Sucker Punch only requires one motion to punch out the plugs, making it a quick and
effective tool. This will allow the workers to punch out all required plugs in a short amount of
time. After proper training and an adjustment period for the employees to get used to the new
process, one mattress should be completed in under 60 seconds. This gives the Plug Sucker Punch
a score of 100 for the merit criterion of the estimated time to complete one mattress.
Ergonomics
The intended use of the Plug Sucker Punch is to press straight down on the tool once it is aligned
with the plug. The tool may have to be placed at a slight angle when lining it up with the mattress
which may require wrist flection between 15 to 29 degrees. For this reason, the Plug Sucker Punch
scored 75 for the ergonomics merit criterion.

The Plug Sucker Punch must have a downward force applied to remove the plug from the mattress.
This force can be initiated by pressing the button on top of the tool with the palm of the hand or
using the fingers. The two different ways to use the Plug Sucker Punch give it a score of 30 for the
ease of use of hand tool criterion.

Lock ‘N Load Plug Remover

The Lock ‘n Load Plug Remover Table requires the workers to remove four dog bone plugs by
pressing them on the pegs at the top of the table, and then remove the remaining plugs using a
hand tool. It may take longer for the worker to align the waffle mattress with the pegs on the table
which could add additional time to the plug removal process. It is estimated that the whole plug
removal process using the Lock ‘n Load table will take between 61-75 seconds, giving the table
design a score of 75 in this category.
Ergonomics
The Lock ‘n Load Plug Remover requires the worker to remove four plugs using pegs on the table
top. The estimated amount of wrist motion required by the workers to align the waffle mattress’
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plugs with these pegs is between 15-20 degrees. This range gives the table a score of 75 in this
merit criterion.

This merit criterion is only applicable for the hand tool concepts, not the tables.

The Lock ‘n Load Plug Remover Table only requires one person to remove all plugs from the
waffle mattress, however, it may require two people to change the height of the table using the
push pin mechanism. Since an additional employee would be needed to adjust the height of the
table, the Lock ‘n Load Plug Remover Table was given a merit rating of 75 based on the
established definition of how easy it is for employees to use the table.
Tilted Table
The Tilted Table could potentially extend the preferred amount of time that each employee spend
completing one mattress. Once the worker unfolds a waffle mattress, they will need to properly
position it on the Tilted Table so the silicon strips will hold it in place as the table’s tilt is adjusted.
If the silicon strips were fail in preventing the mattress from slipping on the table top once it is
titled, the employee would have to spend extra time securing the mattress again. For this reason,
the Tilted Table was given a merit rating of 50 for the estimated time it would take each employee
to complete the plug-removal process on one mattress.
Ergonomics
As the table tilts, it could provide relief for some workers so they would not have to bend over the
table in order to remove the plugs. However, once the table is tilted, the employee’s wrists may be
required to move in a different way than when the table was flat, increasing the unnecessary
amount of force placed on the wrist joint. This variability in the required wrist motion led to a
merit rating of 75 for the Titled Table’s ergonomics.

This merit criterion is only applicable for the hand tool concepts, not the tables.

While the angle of the table would be able to be adjusted by a single employee, it is likely that the
push-pin mechanism in the legs of the table would require at least two employees to change the
table’s height. Since an additional employee would be needed to adjust the height of the table, the
Titled Table was given a merit rating of 75 based on the established definition of how easy it is for
employees to use the table.
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Summary of Design Concept Evaluation
Based on the feasibility and merit analysis, the Two-Way Punch and the Lock ‘N Load Plug
Remover were selected as the best hand tool and table designs, respectively. All five designs met
the relevant feasibility criteria, therefore the final designs were determined based on the weighted
merit scores shown in Table 1. For the hand tool designs, the Two-Way Punch was set apart due
to its ergonomics and ability to be held in a variety of ways by the employees. The other hand tool
designs were comparable to the Two-Way Punch for the other merit criteria, but the Two-Way
Punch was determined to be easier and more comfortable for the employees to use. The Lock ‘N
Load Plug Remover was rated higher than the Tilted Table because its design allows the workers
to complete the plug-removal process for each mattress in a more time efficient manner. The Tilted
Table received the same weighted score for the other merit criteria, but since being able to
complete each mattress in less time is the most heavily weighted merit criterion, the Lock ‘N Load
Plug Remover was determined to be the best table design.
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V. Design Overview
The merit and feasibility analysis narrowed down the preliminary design concepts to the final
design: The Lock ‘N Load Plug Remover and the Two-Way Punch. This section will summarize
the function of each part of the design, and how it successfully meets the needs of the client.
The Two-Way Punch, shown in Figure 1, and the Lock ‘N Load Plug Remover, shown in Figure
2, work together to allow users employed at Goodwill Indy to efficiently remove the plugs from
the 1025 waffle mattress. The table is custom designed with holes at the locations of the plugs that
need to be removed and the Two-Way Punch is used to push the plugs through the holes to remove
them. The plugs are directed into a collecting bin below the table using a funnel system.
Additionally, the table can be adjusted to accommodate different heights of the workers.
Two-Way Punch
The Two-Way Punch shown in Figure 16 features two functional sides, each used to remove a
specific plug shape on the 1025 waffle mattress. The rounded side (Figure 16C) removes the circles
from the inside of the mattress, while the opposite end is used to remove the dog bone shaped
plugs (Figure 16B). A spherical handle (Figure 16A) with adjustable sizes, provides comfort to the
user and reduces the risk of carpal tunnel development due to work related tendon stress. The
punches are placed 90 degrees apart from each other to limit the amount of wrist movement
required to switch the punch orientation. The Two-Way Punch was preferred over other design
options because it allows the employees to be efficient with their movements. The punch only
requires one downward force to remove the plug as opposed to a push down, pull up method that
other tools required. Additionally, the Two-Way Punch is a dual purpose tool because of its two
attached punches. The Two-Way Punch is important to the overall design because it is the
mechanism that actually removes the plugs from the mattress which is the ultimate goal of
Goodwill's production process. To use the punch, the employee positions the appropriate shape to
match the mattress plug and applies a downward force on the mattress. This device will be paired
with the Lock N’ Load Plug remover table which holds the mattress in place while being punched
and has holes located under each plug so that when the punch is used, the plugs will separate from
the mattress and will fall down through the table.
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Figure 16. Isometric view of the Two-Way Punch featuring a spherical handle (A), circle shaped
punch (B), and dog bone shaped punch (C) used to remove both plug shapes from the waffle
mattress.
The clients expressed a need for a tool that is more comfortable and ergonomic for the workers to
use, and that the workers cannot misuse. The Two-Way Punch meets these needs with its
ergonomic handle that is spherical and has three different size options for the user to adjust to fit
their hand size. The handle can also be used by both left-handed and right-handed people. The
customized punch shapes prevent the worker from misusing the tool. The shapes line up with the
shapes of the hole so that the use in intuitive. The Two-Way punch will also be designed to
eliminate the potential of breaking the welds during the removal process. The hand tool will be
constructed as one part from a strong plastic material to ensure durability and decrease the amount
of hand tools needed.
This tool will allow the workers to remove plugs faster because the tool is all inclusive. This is an
advantage because the tool is specific to the shape of the plugs on the waffle mattress. The Two-
Way Punch combines two hand tools into one, which is an advantage over having separate tools
for each plug shape. Currently, the hand tools being used are small and hard to grip for long periods
of time. The ergonomic and interchangeable sizes of the handle on the Two-Way Punch will
increase the comfort level of the workers, enabling them to work longer without needing to take
breaks because of discomfort. Increased comfort will also lead to less work related injuries such
as carpal tunnel.
The Two-Way punch is a separate system from the table that it will be paired with. There are no
subsystems within the two-way punch. It will be treated as one entity. The entire Two-Way Punch
is shown in green in Figure 16.
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Lock ‘n Load Plug Remover
The Lock ‘n Load Plug Remover, shown in Figure 17, is a table design with holes at the location
of the plugs to be removed for the 1025 model waffle mattress. It also features four groups of
cylindrical pegs, shown in Figure 17 at each corner of the table to put the bone shaped plugs in to
hold the mattress in place while removing the plugs. A set of two cylindrical pegs were chosen
rather than a dog bone shaped peg for increased manufacturability. To use this table, the user will
position the mattress and punch the dog bone shaped plugs out with the pegs so the mattress is flat
on the table. Then, the necessary plugs will be pushed out through the holes of the table. The table
is also designed with the appropriate dimensions so that when the mattress is lying flat on the table,
the edge of the table lies on the tear line for the straps, shown in Figure 17, enabling the worker to
pull the strap down on the corner of the table in one easy motion. The width of the table at both
ends are shorter to align with the tear line for the bed straps, but thicker in the middle so the sides
of the waffle mattress are not hanging off the edges of the tabletop. This is a more efficient process
than the current technique that requires the workers to use a poking tool to start the tear, and then
pull up to separate the strap.
This design also includes a funnel that functions to direct the removed plugs into the recycle bin
underneath the table. The plugs would fall directly into the collecting bin through the funnel after
being pushed through the mattress. At the end of each day, the collecting bin can be removed from
under the table and funnel and then the plugs would be emptied and recycled. The funnel removes
the employee burden of holding all the removed plugs in their hands until all the plugs are removed,
and then putting them in the collecting bin. Lastly, to make this table accommodating to workers
of different heights, the legs are designed with a push pin to adjust the height. To raise or lower
the table, the push pins on the two legs will be pushed in and the table will be raised or lowered
until the pin comes out at the hole at the desired height.
An advantage of this table is that it will identify which plugs need to be removed and prevent the
wrong plugs from being removed since the table only has holes where the plugs need to be
removed. Having the funnel under the table will make the plug recycling process easier and more
ergonomic because the plugs have a non-existent or much smaller chance of falling on the ground,
and wasting the workers time bending down and putting them in the recycling bin.
This table design will meet the client’s needs because it will provide Goodwill Indy with a more
efficient and ergonomic plug removal process. The table is easily manufactured with minimal
movable parts, decreasing the amount of maintenance needed. The tabletop is specific to one
waffle mattress type, which decreases the chances of workers removing the wrong plugs.
Additionally, the use of a funnel to collect the removed plugs reduces the wasted time previously
used to collect the plugs. The width of the tabletop design allows for one person to easily remove
the plugs on a whole mattress, increasing productivity. The height adjustable aspect affects the
ergonomics of the process allowing each worker to set the table height to what is most comfortable.
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37
Subsystems
The design was divided into four subsystems: the Two-Way Punch, the Tabletop, the Funnel and
the Adjustable Table Legs. These subsystems are all functionally independent, but they work
together to achieve the goal of the process.
Two-Way Punch Subsystem

The Two-Way Punch shown in Figure 1 is a double sided hand tool that allows the workers to
punch out both the circle shaped and dog bone shaped plugs with one tool. An ergonomic handle
will provide a comfortable grip to the user and reduce pains associated with holding small tools
for an extended period of time. The Two-Way Punch uses a simple downward motion to extract
the perforated plugs from the mattress.
It will be a challenge to make a one-size fits all tool for the employees at Goodwill Indy. The staff
includes men and women of varying sizes. Each worker has a different sized hand, making it
difficult to determine the precise dimensions that will be best for a universal tool. Another
challenge associated with the Two-Way punch is ensuring that the tool does not put too much
shear on the welds and damage the mattress. Calculations will determine where failure is most
likely to occur and strategies developed to combat these modes of failure. Ensuring the durability
of the Two-Way Punch will be challenging because of its repeated force application. It will be
important to make sure that the joints between the punches and the handle are strong.
Tabletop Subsystem
The Tabletop subsystem functions to increase efficiency of the plug removal process at Goodwill
Indy. The Tabletop, shown in red in Figure 17, holds the waffle mattress in place during the plug
removal process. The holes in the table allow the removed plugs to fall through the funnel below
into the recycling the bin. The four groups of cylindrical pegs function to hold the mattress in place
so that the plugs that need to be removed perfectly align with their respective holes in the table.
One challenge that the tabletop subsystem will face is ensuring that the holes are not too sharp to
damage the welds in the waffle mattress when the plugs are being removed using the two-way
punch. If the welds or surrounding material is damaged using the table, the mattress must be
scrapped. Another challenge will be ensuring that the cylindrical pegs stay in place in the table
without falling off. It will be important to ensure that the team chooses the correct adhesive,
because if they fall off it would be much harder to keep the mattress in the correct location. Another
challenge with this subsystem is ensuring that all holes and pegs are in the correct spot on the table.
If one is slightly off-center with the others, the table makes the plug removal more difficult than it
currently is.
Funnel Subsystem
The Funnel subsystem functions as a way to easily collect the removed plugs and guide them into
the collecting bin below. The funnel, shown in purple in Figure 17, will be attached by snap buttons
to the bottom side of the tabletop subsystem and will only cover where the holes are so that the
funnel and legs do not interfere. Any size collecting bin can be used, as long as it is larger than the
bottom of the funnel. This subsystem is important because it is necessary that the design allows
the removed plugs to be collected efficiently. It was decided to make the funnel a separate
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subsystem from the tabletop because it will be a different material and serves a different function
for the overall design.
One challenge with this subsystem will be determining the material for the funnel. The material
must allow the plugs to slide down the sides and fall into the collecting bin below therefore, it must
have low friction. If the plugs do get caught on the side, there must be a way for them to get them
out to collect. Another challenge will be connecting the funnel to the tabletop without damaging
the table. The snap button screws must be short enough so they do not extend through the top of
the table, and cause damage to the mattress or user. Another challenge will be to determine the
height of the funnel. Since the table can be raised and lowered, the funnel will be further or closer
to the ground, respectively. Therefore, the funnel must be short enough so it does not drag on the
collecting bin when the table is short and tall enough so that the plugs will fall into the collecting
bin once removed.
Adjustable Table Legs Subsystem

The Adjustable Table Legs subsystem, shown in blue in Figure 17, allows the employees to adjust
the height of the table to be compatible with their individual height. Being able to adjust the height
of the table will allow the plug-removal process to be more efficient because the employees will
be at a workstation that is tailored to them specifically, which allows them to work more
comfortably and efficiently. A rack and pinion mechanism will allow the workers to easily adjust
the height of the table to any custom height by rotating a lever.
One challenge with this subsystem is making the mechanism as easy to use as possible. Ideally,
the client would like each employee to be able to adjust the height of the table by themselves,
without additional assistance. Since the lever on one side of the table will adjust the height of both
legs simultaneously, one person will be able to raise or lower the table alone. Another challenge
is determining a strong material to use for the legs so they can hold the weight of the tabletop.
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VI. Design Project Specifications
The final design was divided into four subsystems that each contributed to a different part of the
plug removal process. Each subsystem has a unique function that work together to accomplish the
goals established by Goodwill Indy and the design team.
Two-Way Punch
Two-Way Punch Purpose/Function
The Two-Way Punch shown in Figure 18 is a double sided hand tool that is used to remove the
perforated plugs from the waffle mattress. This tool is paired with the Lock N' Load Plug Remover
which is a table featuring plug specific holes in it. These two designs work together allowing the
worker to push through the mattress and table using the Two-Way Punch to remove the plugs from
the mattress. This design features two unique punches, one circular (B) and one dog bone shaped
(C), to match the shapes and sizes of the plugs on the 1025 waffle mattress. A spherical handle (A)
provides comfort to the user and reduces the risk of carpal tunnel development due to work related
tendon stress. There are three different handle sizes: small, medium, and large. The punches can
be screwed in and out of the different sized handles, so the user can choose a hand size that is most
comfortable for them. The punches are placed 90° apart from each other to limit the amount of
wrist movement required to switch the punch orientation. A survey was conducted using 22 peers
and professors as subjects to determine the most comfortable handle shape and punch placement.
The results indicated that a spherical handle is easiest to hold, that there should be different sized
handle options, and that the punches should be separated by 90°. This reduces the risk of
developing work related wrist injuries. The surface of the punches are curved so that the edges of
the punch break through the plugs first. This reduces the force that is required to punch through
the material. The circular punch requires 95.1 pounds to be applied and the dogbone punch requires
179.9 pounds to break through the mattress and remove the plug. Calculations in Figure A-1 show
the relationship between the shear stress, cross sectional area, and applied force. The shear stress
in this equation is for flexible polyvinyl chloride, which is the mattress material. This calculation
has a factor of safety of 2 applied to it, so in reality it will require even less force to remove the
plugs. Additionally, the plugs that need to be removed on the mattress are perforated and intended
to be torn, requiring less force than calculated to remove. The Two-Way Punch was preferred over
other design options because it allows the employees to be efficient with their movements. The
punch only requires one downward force to remove the plug as opposed to a push down, pull up
method that other tools required. The Two-Way Punch is a dual purpose tool because of its two
attached punches. The Two-Way Punch is important to the overall design because it is the
mechanism that actually removes the plugs from the mattress which is the ultimate goal of
Goodwill's production process.
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Figure 18. Exploded view of the Two-Way Punch featuring a spherical handle (A), circle shaped
punch (B), and dog bone shaped punch (C) used to remove both plug shapes from the waffle
mattress. The threaded shafts (D) allow the punches to screw into any of the three handle sizes.
To use the Two-Way Punch, the user will select the handle size that is most appropriate for their
hand and screw the punches into the threaded holes in the spherical handle. Next the employee
will grip the handle in an orientation so that the desired punch shape is facing downward. The user
will line the punch up with the corresponding plug on the waffle mattress ensuring that the punch
is on the perforations and not the welds. Then the employee will apply a downward force punching
through the mattress and the hole in the table to remove the plug from the mattress. This process
is repeated until all necessary plugs have been removed. To change the punch shape being used,
the employee simply turns their wrist to align the second punch. The punch will experience high
volume use so it is important that the punch is durable. A strong material (material with a high
ultimate tensile strength) will need to be used to manufacture the tool to ensure its long-term use.
As shown in the system diagram in Figure D-1, the Two-Way Punch mainly interacts with the user
and the tabletop subsystem. The hand tool is meant to seamlessly fit through the holes in the table
to remove the plugs. It is important that this interaction is smooth to keep the process efficient.
Dimensions
The dimensions of the Two-Way Punch are dictated by the dimensions of the table and the plugs
in the 1025 waffle mattress. The punch should be slightly smaller than the holes in the table to
allow for the punch to easily pass through the holes. The thickness of each punch is 1.125 inches.
The tabletop is one inch think, so this punch thickness is enough to ensure that the plug is fully
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removed from the mattress and falls into the funnel underneath the table without getting caught in
the table top. The diameter of the circle punch is 1.75 inches. The plugs in the mattress and the
holes in the table top are 1.82 inches in diameter and this slight difference between the holes and
the punch will ensure the punch does not get stuck in the table. This addresses one of the potential
failure modes identified in the FMEA in Table C-1 which would be if the punch does not fit
through the table. The circular ends of the dog bone shaped punch have a radius of 0.60 inches.
This is 0.03 inches less than the radius of the mattress plugs and holes in the table to allow for
clearance of the punch through the table. The length of the dog bone punch is 2.9 inches. This is
slightly smaller than the actual plug length of 3 inches. The small spherical handle diameter is 2.40
inches, the medium size is 2.60 inches, and the large size 2.80 inches. In the study conducted with
peers, the size of a tennis ball was shown to be a comfortable size for the majority of users with
only a few people requesting a smaller shape. The average diameter of a tennis ball is 2.70 inches
(ITF Tennis), so the final handle designs will feature diameters that are based off of that size. The
handle will attach to each punch with a 0.50 inch diameter cylinder.
Material Choices
Acrylonitrile Butadiene Styrene (ABS) will be used to fabricate the Two-Way Punch because it
has good shock absorbing properties and is very durable. The Two-Way Punch needs to be durable
because it will experience a lot of use throughout the day as employees punch the plugs out of
hundreds of mattresses. ABS is strong and affordable making it the best material choice for the
Two-Way Punch (Material). White ABS will be used to print the hand tool because this eliminates
the possibility of colors from the tool bleeding onto the mattress. The spherical handles will be
lined with a 0.08 inch thick sheet of a clear silicone to make the ball easier to grip and prevent
slipping. As shown in Figure A-2 the total weight of the Two-Way punch will be 0.61 pounds
making it lightweight and easy to maneuver.
Feasibility/Merit Criteria
The Two-Way Punch addresses the “does not tear welds” feasibility criterion because it will be
designed to have a surface that minimizes the amount of shear stress imposed on the flexible
polyvinyl chloride material. The surface of each punch will be curved so that the outer parts of the
tool touch the mattress plugs first and begin to break the perforation before the punch is pressed
all the way through, removing the plug from the mattress. The other two feasibility criteria of
height adjustability and collecting plugs does not apply to the hand tool. The Two-Way Punch
scored a 100 for the merit criterion of estimated time to complete one mattress because this tool
requires one simple motion to remove the plugs. This allows workers to remove the plugs more
quickly and achieve the goal of completing one mattress in less than 60 seconds. Regarding
ergonomics, the Two-Way Punch also scored a 100 because of the spherical handle and the limited
wrist motion required to operate the hand tool. The workers will be able to more comfortably grip
the tool because they can choose the size they like best, and will only need to press down to remove
the plugs from the mattress. The Two-Way scored a 30 for ease of use of hand tool because it will
require some extra motion to switch between each punch shape. The worker will have to rotate the
tool 90 degrees to switch between the circular shape and the dog bone shaped punches. The ease
of use of table merit criterion does not apply to the Two-Way Punch.
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Strengths/Weaknesses
A strength of the Two-Way Punch is that there are no moving parts. This means that there will be
little to no maintenance of the device. The tool’s parts can be 3D printed which is an advantage
from the designer’s standpoint because the whole device will be made out of the same material.
The punches will be 3D printed joined to their shaft, which decreases the amount of parts the tool
has and decreases the chance of the punch breaking off the end of the shaft. This addresses one of
the potential failure modes identified in the FMEA in Table C-1 which was the punches breaking
off from the handle. From the user’s perspective, a strength of the Two-Way Punch is that it
combines both plug shapes in one tool. This allows the worker to use just one device to remove all
of the plugs in the mattress. The motion required for the Two-Way Punch is also a strength. It does
not require a lot of fine movements, only one downward motion to separate the perforated plug
from the mattress. Another strength from the user’s perspective is that they have a new sense of
autonomy by being able to choose the size of spherical handle that feels most comfortable for
them. This allows the user to feel less discomfort while performing the plug removal process. This
is critical to ensure workplace health and safety by reducing stress applied to the tendons in the
wrist. A weakness of this design is that the punches have to be closely aligned to the plugs on the
mattress to ensure that the mattress will not be damaged. If force is applied outside of the
perforations, the welds in the mattress may tear. This is critical because if the welds are torn, the
mattress must be discarded. The tabletop design will help to avoid this problem by aligning the
holes in the table with the plugs so that if the Two-Way Punch is applied outside of that area, it
will just hit the table instead of damaging the mattress.
Manufacturing Plan
The Two-Way Punch will be 3D printed as 5 individual pieces using ABS thermoplastic: three
handles, and two punches with their shafts. The mechanical engineering department at Rose-
Hulman Institute of Technology has a 3D printer capable of printing parts using ABS and will be
used for this project. SolidWorks 3D models of the two punches, and three handles will be used to
print the hand tool parts. After printing, the tool will be assembled, sanded, and ready for use.
The Tabletop Subsystem

Tabletop Purpose/Function
The Tabletop subsystem, seen below in Figure 19, functions to increase efficiency of the plug
removal process of the waffle mattress at Goodwill Indy. This subsystem is vital for the overall
design of the Lock ‘n Load Plug Remover table design, because it holds the waffle mattress in
place while the plugs are being removed. The specific tabletop design is perfectly aligned with the
holes in the waffle mattress for easy plug removal and collection. This design is optimal compared
to the other table design, the Tilted Table. Both table designs make the plug removal process more
ergonomic for the workers, reduce the amount of workers required to perform the process, and
increase the amount of mattresses completed in a day. However, the Tabletop subsystem offers a
secure way to always keep the waffle mattress in place on the table. This design also ensures that
all plugs are collected at the time of removal through the holes in the table. The round edges are
functional, but also increase safety of the table by reducing the chances of employees getting hurt
by hitting them. The tabletop design is also easy to use and intuitive for the line workers who will
be using it every day for eight hours a day.
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Figure 19. Tabletop subsystem calling out the two types of holes, pegs, and the corners where the
bed straps will be separated from the mattress, while showing the major dimensions of the 3/4 inch
thick tabletop.
How it Works
The Tabletop subsystem can be adjusted to different heights for individual workers by changing
the Adjustable Table Legs subsystem. The ability to change the height of the tabletop allows the
design to be more ergonomic and increase the ease of the plug removal process. The worker starts
the plug removal process by spreading out the folded waffle mattress onto the Tabletop. The
worker then pushes the four corner plugs into their respective pegs to pop the plugs out; the worker
holds on to those four removed dog bone plugs. With the four corner dog bone plugs placed
securely on the pegs, the waffle mattress is held into place on the Tabletop, and the remaining
plugs are aligned with their respective holes in the tabletop. The worker then takes the Two-Way
Punch and presses down on the plugs. The circular end of the Two -Way Punch must be used for
the circle plugs, while the dog bone shaped end of the two way punch must be used on the dog
bone plugs. The plugs are separated from the welds, and pressed through their individual holes in
the Tabletop. The removed plugs then slide down the funnel into the recycling bin. The worker
then uses the four round corners of the tabletop to separate the bed straps from the waffle mattress.
The worker pulls down along the entire length of the four bed straps, separating them from the
mattress using the round edge of the table. The worker collects the teardrop plugs in their hand,
and deposits all plugs they are holding down any of the holes in the tabletop to be recycled. The
Tabletop subsystem will be durable enough to not break when the downward force from the
workers is applied to remove the plugs. The Tabletop subsystem is also very safe since it has no
moving parts or sharp edges where a worker could hurt themselves.
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Dimensions
The Tabletop subsystem must be manufactured to the specific size of the 1025 waffle mattress.
All dimensions of the tabletop will match the dimensions measured on the 1025 waffle mattress,
and can be found below in Figure 20. All the Tabletop dimensions were determined by measuring
by hand the 1025 waffle mattress. Both widths and heights of the table will be equal to the height
and widths seen in the engineering drawing shown in Figure 20, and the hole diameters and
locations in the Tabletop subsystem will be equal to the plug dimensions and locations in the
engineering drawing. All dimensions have a tolerance of 0.01in. The 1025 waffle mattress is the
highest volume mattress at Goodwill of Central and Southern Indiana with about 2000 1025
mattress completed in a day. Creating a table made with the same specific dimensions as the
mattress allows the workers to easily align the edges of the mattress with the edges of table. This
also allows the workers to ergonomically reach every side of the mattress to reduce the amount of
workers required. The workers no longer have to perform extended reaches because the maximum
the worker will have to reach is the width of the tabletop which is 32.13 inches. The width at both
ends of the tabletop will align with the tear areas of the bed straps on the waffle mattress for easy
weld separation. The exact width and length dimensions will be made to match the specific size of
the waffle mattress to ensure the mattress does not hang off the edges, and that the worker can
easily reach the far side of the table without straining their back. The hole and peg locations will
also be specific to the locations of the plugs in the waffle mattress. This is to ensure that the
holes/pegs perfectly match up with their respective plugs when the waffle mattress is lying on top
of the tabletop. The circular holes in the table are the same size as the holes in the waffle mattress
to allow for the plugs to seamlessly fit through their holes.
Holes and Pegs

To ensure that the holes do not damage the welds, the insides and edges will be sanded to achieve
a smooth surface. Instead of having four dog bone pegs, the tabletop features four groups of two
cylinders, as seen in Figure 19. These cylinders serve the purpose of holding the waffle mattress
in place, while increasing manufacturability. If any of these cylinders break, they can easily be
replaced because they are not custom made pieces. The cylinders will be made out of the same
MDF as the tabletop, and glued onto the tabletop using wood glue. The tabletop has long oval
shaped holes, seen in Figure 19, to remove the dog bone plugs instead of specific dog bone holes.
This increases the manufacturability of the table because it simplifies the cutting process. The pegs
will be an inch tall with diameters of 1 inch. The diameter is smaller than the diameters of the
plugs to allow for the mattress to be stretched in any given way if it is necessary.
Materials and Manufacturing

The tabletop will be made out of MDF. MDF was chosen for its light weight and durability. The
board is also cheap, but can be bought with a finishing coat to look professional. One sheet of
MDF will be purchased with the dimensions of 8ft x 4ft x 3/4in. This size was chosen because it
is big enough to get the table from and the four cylindrical pegs. The cylindrical pegs will be cut
out of the same type of MDF board and glued on to the tabletop using wood glue. Glue was chosen
because it is strong enough to hold the wood together and if it breaks off it is easy to fix and
maintain for Goodwill. The MDF board will be taken to the Department of Mechanical
Engineering to be cut to the exact size, and remove all holes using their woodworking router table.
Once the holes have been cut into the tabletop and the pegs have been attached, the Adjustable
Table Leg subsystem will be attached to the bottom of the tabletop in the locations shown in Figure
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21. Then, the Funnel will be connected to the bottom of the tabletop. The locations of this
connection are also seen in Figure 21.
Connections
Figure 21 shows the location of the interactions of the Tabletop subsystem with the Adjustable
Table Legs subsystem in blue and the Funnel subsystem in purple on the engineering drawing. The
type of connections between the Tabletop subsystem to the Funnel and Adjustable Table Leg
subsystem are addressed in the Funnel and Adjustable Table Leg subsystems. An overestimated
weight calculation of the tabletop subsystem is shown in the appendix as Figure A-3. This weight
calculation has been given to the Adjustable Table Leg subsystem for their calculations of
determining if the table legs will be strong enough to hold the tabletop subsystem.
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Merit/Feasibility Criteria
The Tabletop subsystem has various features that are vital for the Lock ‘n Load Plug Remover
table design to meet all feasibility criteria. These features also increase the Lock ‘n Load Plug
Remover table’s score in many of the merit criteria as well. Detailed descriptions of the Tabletop
subsystems contributions are below.
The Tabletop subsystem assists the Lock ‘n Load Plug Remover table meet all feasibility criteria.
The Tabletop subsystem contributes to the Lock ‘n Load Plug Remover table design’s ability to
collect the removed plugs by the specific hole locations under the plugs that need removed. The
plugs fall through the holes in the tabletop into the funnel to be deposited into the recycling bin.
This simplifies the recycling process because it removes the need for the workers to hold the plugs
while completing the plug removal process. The Tabletop subsystem also helps the Lock ‘n Load
Plug Remover table design to meet the adjustable height criterion. The Adjustable Table Leg
subsystem change the tabletop height based on what the worker wants, giving the workers the
option to choose what height feels more comfortable for them. The Tabletop subsystem also meets
the requirement that it must be able to remove the plugs without tearing the welds. The tabletop’s
holes feature smooth edges that do not risk cutting into the weld or any part of the waffle mattress.
The pegs on top of the table do not have any sharp edges to eliminate the risk of damaging the
welds when they are used to remove four of the dog bone plugs.
There are two merit criteria that are directly related to the Tabletop subsystem: the estimated time
to complete one mattress, and ergonomics. Because the Lock ‘n Load Plug Remover table reduces
the number of people working on one table, it increases the estimated time to complete one
mattress than what is currently used. However, because the tabletop offers a more efficient and
productive way to remove the plugs, the estimated time to complete one mattress is only slightly
increased to the 61-75 second range. This gives the design a score of 75. It is also estimated that
the tabletop requires the worker to move their wrist between 15-29 degrees to use it to remove
plugs. This causes the tabletop to also score a 75 in the ergonomic criterion.
Strengths/Weakness of the Tabletop Subsystem

One of the strengths of the tabletop from all perspectives is that it is the same size as the waffle
mattress. From the design perspective, this eliminates the need to calculate the optimal dimensions
of the table because they are already known. From the user’s perspective, the small table size
allows one user to reach all sides of the mattress, eliminating the need for two people to complete
the process. This saves time and increases the profit for Goodwill Indy. Another strength of the
design from the user’s perspective is that they are no longer required to hold all the plugs until
they complete the entire mattress. The tabletop subsystem has eliminated the need to hold all the
plugs by incorporating the holes into the design that allow the plugs to fall straight into a recycling
bin through a funnel. One of the weaknesses of the tabletop from the design perspective is the
manufacturability of the table. The hole locations must be in the correct spot to ensure the plug
will be removed from the weld. If the holes are not in the right spot, the Two-Way Punch will not
be able to push the plugs through the table holes into the recycling bin. The pegs must also be
secured to the table to prevent them from falling off. Without the pegs, there is no way to ensure
that the mattress will stay in the correct location. These concerns and how they are being mitigated
are addressed in the FMEA analysis in Part III under Table C-1 of this document.
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System Diagram
The system diagram for the Tabletop Subsystem that outlines the relevant inputs to the system
related to the environment, users, and other subsystems, as well the outputs of this subsystem can
be found in the Appendix, Figure D-2.
The Tabletop subsystem requires the purchase of the MDF board. The manufacturing will be done
in the ME department on the laser cutter for no cost. The wood glue to secure the pegs onto the
tabletop will be donated from the BBE department. The lacquer will then be used to coat the table.
Below is the link to the MDF board that is described in Table 3:
https://www.cherokeewood.com/store/mdf/
Figure 21. Tabletop subsystem that depicts the locations of the interactions of the tabletop with
the Funnel subsystem in purple and with the Adjustable Table Legs subsystem in blue.
Funnel Subsystem
Funnel Purpose/Function
The Funnel subsystem functions as a way to guide the removed plugs into the collecting bin under
the table. The funnel, shown in purple in Figure 22 will be attached to the bottom side of the
tabletop subsystem and will only cover where the holes are so that the funnel and legs do not
interfere. Any size collecting bin can be used, as long as it is larger than the bottom of the funnel,
therefore, Goodwill Indy will be able to continue to use their current collecting bin. Once the plugs
are punched out of the mattress through the holes in the tabletop using the Two-Way Punch, they
will go into the funnel, slide down the sides and fall into the collecting bin below. This subsystem
is important because it is necessary that the design allows the removed plugs to be collected
efficiently.
Another design that was considered for this function was to put a drawer under the bottom of the
table to collect the plugs. One problem with this design that was discussed with the client would
be that collecting the plugs after the drawer filled up could be difficult and add to the production
time, reducing efficiency. A design that allows the removed plugs to fall directly into the collecting
49
bin would reduce the number of times the workers would have to interact with the plugs. Therefore,
a funnel was chosen to collect the plugs so that the collecting bin that Goodwill Indy currently
uses could still be used.
Funnel Subsystem Details

To accomplish the function of the funnel, the material, dimensions, and attachment to the tabletop
will need to be determined. The preliminary design of the Funnel subsystem is shown in Figure
23.
Material
Instead of using a hard plastic or metal, a 100% nylon sheet will be used due to its smooth texture,
reducing the likeliness that plugs will get stuck to the sides of the funnel. If the plugs do get stuck,
at the end of the day, the workers will be able to tap the sides of the funnel to let the plugs fall
through. Nylon is also lightweight and therefore will not require stronger legs to hold it up. A steel
dowel will be used for the bottom rim of the funnel to hold the material down. The steel will be
heavy enough so the nylon will not curl up.
Dimensions
The dimensions of the funnel depend on the distance between the holes for the plugs to be removed
on the tabletop and the dimensions of the collecting bin. The dimensions of the funnel were
determined by doing calculations shown in Figure A-4. The top of the funnel has dimensions 58
inches X 31.25 inches, the bottom has dimensions 24 inches X 12 inches and it is 30 inches tall.
Since the holes are only in the center of the tabletop, the funnel will not have to span the whole
length of the table and interfere with the legs. Though, it is important that the length of the funnel
is taken into account when determining where the legs will be attached to the table. The bar
attaching the two table legs will go across the bottom of the tabletop and therefore interfere with
the funnel. To overcome this, two holes shown in Figure 22 will have to be cut out. The funnel
height will also have to be optimized for the table legs design since the table can be raised and
lowered causing the funnel to be further or closer to the ground, respectively. Therefore, the funnel
must be short enough so it does not drag against the collecting bin when the table is short and tall
enough so that the plugs will fall into the collecting bin once removed. To be sure the plugs fall
into the collecting bin, colored tape will be placed on the floor in the optimal location of the
collecting bin. Also, if the funnel is too short, the slope of the sides of the funnel will be gradual,
making it more difficult for the removed plugs to slide down. The smallest angle between the
funnel and the bottom of the tabletop for the plugs to easily slide down is 35°. Once the
calculations, shown in Figure A-4, were performed, it was determined that the angles were all
greater or equal to 40°.
Attachment
Properly attaching the funnel to the tabletop will be important. Since the funnel will be in the
manufacturing floor, it has a potential to collect dust and need to be cleaned. Therefore, the funnel
will be attached to the bottom of the tabletop with snap buttons. Snap button screw in studs will
be screwed into the table top around the perimeter of where the funnel will be placed. Hammer-on
snap buttons will be used for easy attachment onto the fabric. The snap buttons will be attached
around the top of the funnel shown in Figure 22A. To assemble the funnel with the tabletop, the
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snap buttons from the funnel will be pressed into those on the tabletop. With a removable funnel,
it can be cleaned as well as replaced if it gets torn. To ensure that the funnel can be easily placed
back on the table, a color coding system will be implemented where the buttons on the long sides
of the funnel are a different color than those on the short sides. The snap buttons will also be strong
and make the funnel sturdy enough to hold in place if someone brushes against the funnel, but the
buttons will be easy and intuitive to remove.
Figure 22. Isometric view of a model of the Funnel Subsystem. The wider top of the funnel (A)
will be attached to the bottom of the tabletop and the smaller bottom (B) will be the exit for the
removed plugs to fall through. The two cutouts (C) are where the connecting rod for the table legs
will go through.
Meeting the Client’s Needs

It is important that each subsystem helps to meet some of the criteria that were established for the
overall design to ensure that no part of the final design is unnecessary. The funnel directly
addresses the feasibility criterion that the design is able to collect the removed plugs. It allows the
removed plugs to seamlessly fall from the mattress on top of the table to the collecting bin below
the table without the workers having to handle them. This will improve efficiently from the current
process because the workers will not have to hold the plugs in their hand while they remove the
rest of the plugs from that mattress. It also allows the workers to continue to use their collecting
bin and it will likely only have to be emptied once at the end of each day.
While the funnel itself does not contribute to the adjustable table height mechanism, the table leg
design creates design constraints for the funnel. The nylon funnel allows the rack and pinion
mechanism to be implemented without interfering with the funnel because holes will be cut out of
the funnel to create a space for the bar extending under the table. The material chosen for the funnel
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allows the table to be raised and lowered freely without the funnel hitting the ground or collecting
bin below. Although it is ideal that the fabric funnel does not drag on the collecting bin, it would
still be possible to lower the table lower than the height of the funnel.
The funnel also helps to meet the merit criteria. The funnel assists in decreasing the time to
complete one mattress because the workers do not have to worry about handling the plugs after
they are removed from the mattress. They will fall directly into the collecting bin which will be
emptied at the end of each day.
The connection of the funnel and the tabletop allows for one person to easily remove and replace
the funnel from the table. The snap buttons will be easy to remove and snap back into the correct
place. Although the funnel will not need to be removed every day, it can be done easily by one
person, making the table easier to use.
Manufacturing Methods
The main method of manufacturing the funnel will be sewing. Bulk material will be cut into four
pieces, two pieces in the shape shown in Figure 23A and two in the shape shown in Figure 23A.
Figure 23. Sketches for the dimensions of the cut material to be sewn together, two pieces of each
geometry will make up the front and back (A) and sides (B) of the funnel. The dimensions were
slightly increased to accommodate for the seams and dowel placement. Dimensions are in inches.
The stock metal dowels will be cut into two 24 inch long pieces and two 12 inch long pieces to fit
at the bottom of each piece of cut fabric. Once the nylon is cut, the metal dowel will be rolled into
one layer of the fabric and the end of the fabric will be sewn to the fabric on the other side of the
metal dowel. This will be completed for the short end of each of the cut pieces. The fabric at one
end of the dowel will not be sewn so that the dowel can be taken out for replacement or cleaning
of the funnel, but it will not slide out during use.
Next, the snap buttons will be placed into the bottom of the tabletop and along the longer end of
the cut out pieces of fabric. The distance between each button will be measured out and marked
on both the tabletop and fabric to be sure each snap will fit once they are all placed. One part of
the snap button will be screwed directly into the tabletop and the other part will be hammered in
with the tool included in the purchased kit.
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Finally, each piece of fabric will be sewn together along the slanted edges using the sewing
machine in the BBE department.
Design Strengths/Weaknesses
Since there are no movable parts within the funnel subsystem and no mechanisms that would need
to be maintained, there is a minimal chance for failure. The funnel also will not undergo a lot of
mechanical stresses since the removed plugs are the only things that are falling through the holes.
This design also provides a very simple way for the workers to collect the removed plugs without
having to handle them while using their current collecting bin design. This will greatly increase
efficiency of the plug removal process and, therefore, decrease the time to complete one mattress.
A challenge associated with this subsystem and the workers using the design is the placement of
the collecting bin, as laid out in the FMEA shown below in Table C-1. It could be difficult for the
workers to get the bin directly below the funnel, but as discussed in the Dimensions section above,
tape in an outline of the location of the bin could be placed on the floor for consistent placement
of the bin. The placement of the bin under the table could also prohibit workers in wheelchairs
from performing the plug removal process, if the bin is wide. Therefore, if this could be a problem,
it must be determined if collecting bin should be changed.
A design challenge for the funnel is determining a fabric that will allow the removed plugs to
easily slide down the sides, while also creating a flat surface for the plugs to glide down towards
the collecting bin also shown in the FMEA below in Table C-1. In order to overcome this
challenge, 100% nylon sheets will be used which is smooth and allow the plugs to slide down it.
Also, a metal rod will be attached to the bottom of the funnel to keep the funnel from curling up.
The nylon is also a strong material so it will not be susceptible to tearing if the workers brush up
against it while removing the plugs.
System Diagram
The system diagram, shown in Figure D-3 shows how the funnel subsystem interacts with and is
dependent on the outputs of other subsystems. It is important to look into the system diagram
before completing each subsystem to ensure that each part of the design will fit and work together
seamlessly. The diagram shows that there needs to be communication between the subsystems in
order for the final design to come together properly.
The main subsystems that the funnel will interact with and depend on are the adjustable legs and
tabletop. The minimum and maximum height of the table legs and the dimensions of the tabletop
and holes on it will need to be known to determine the dimensions of the funnel. Once the width
of the funnel is determined, that will need to be communicated with the legs subsystem to be sure
that the two do not interfere. Lastly, the means of attaching the funnel onto the tabletop will need
to be communicated to the tabletop subsystem to be sure that the attachment will be able to go
through the table material and that it will not ruin it.
Outside information that will be necessary to determine the dimensions of the funnel are the
dimensions of the collecting bin that will be used. This will require communication with the
Goodwill Commercial Services Team.
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Adjustable Table Legs Purpose/Function
The adjustable table legs subsystem allows each employee to adjust the height of the table to the
most appropriate level for their individual height. This is important to the overall design because
the client requested a design that will help to make the plug-removal process more efficient for a
variety of workers, including those of different heights, ages, and those with different disabilities.
Allowing an employee to adjust the table to a height that is more comfortable for them will increase
the plug-removal efficiency for each employee, which is desired by the client.
The two adjustable table legs are shown below in Figure 24A at their lowest height, and at their
highest height Figure 24B. A rotating lever-operated rack and pinion mechanism that is connected
in each of the two table legs by a connecting rod adjusts the height of the table by 12.6 inches
every full rotation of the lever, starting at the lowest height (approximately 2 feet 1 inch) and
working up to the highest height (approximately 3 feet 8 inches). The tabletop is one inch thick,
so the lowest height of the table will be 2 feet 2 inches, and the highest will be 3 feet 9 inches. The
heights of the table were determined based on the height of an average table, which is 2 feet 6
inches. The lowest height of the table is just over 2 feet to expand the variety of workers that would
be complete the plug removal process. For example, an approximately two foot tall table may
allow someone who uses a wheelchair, or someone with a different disability to remove the plugs.
The adjustable component allows the table to raise to one and half times its lowest height, again
contributing to a wider variety of workers that can comfortably complete this process. If a taller
employee has to work on a table that is too short for them, they could be subject to back pain
throughout the day from having to bend over the table too much. A higher table would minimize
this problem.
Figure 24A. The adjustable table legs that are raised and lowered by rotating a lever that activates
a rack and pinion mechanism within the legs, connected by a cylindrical rod that can adjust both
legs 12.6 inches after every full rotation of the lever to its lowest height of approximately 2 feet 1
inch.
54
Figure 24B. The adjustable table legs that are raised and lowered by rotating a lever that activates
a rack and pinion mechanism within the legs, connected by a cylindrical rod that can adjust both
legs 12.6 inches every full rotation of the lever to its highest height of approximately 3 feet 8
inches.
Rack and Pinion Mechanism

The rack and pinion mechanism, shown close up and transparent in Figure 25, raises and lowers
the table by rotating the lever. The pinion gear is 2 inches in diameter with 18 teeth, and has a three
quarter-inch hole in the center for the connecting rod to link the pinion gears from each leg. Each
time the lever is rotated 360 degrees, the table will be adjusted 6.3 inches up or down. The
calculation detailing the vertical movement of the pinion gear as the lever is rotated is shown in
the Appendix, Figure A-5. This calculation contributed to determining what size pinion gear would
be used and is relevant for the user, as it gives them an idea of much the table will move as they
rotate the lever. The lever used to initiate the motion of the pinion is on an 18-inch arm that attaches
at the center of the pinion gear. The long lever arm was chosen to lower the force required to rotate
the lever, and in turn, the gear. This force was calculated to be approximately 30 pounds, and the
calculation is shown in detail in the Appendix, Figure A-6. This calculation is overestimated based
on the factor of safety and conservative calculations that determined the weight of the tabletop.
Determining this force is important in order to determine which employees will be capable of
operating this mechanism. A 2-inch gear was chosen because it was not only cheaper than a larger
gear, but required less force to rotate. Though it will not adjust the height of the table as much after
one full rotation of the lever as a larger gear, the lower force required to rotate the gear is more
appropriate for meeting the needs of the client, which are to accommodate a larger variety of
workers.
55
When designing the components of the mechanism, the thickness of the tabletop (1 inch) had to
be taken into account, because both the lowest and highest heights of the table legs were one inch
shorter than the height of the overall table would be.
Figure 25. The rack and pinion mechanism of the adjustable table legs functions to raise and lower
the table using a pinion gear that moves up and down an appropriately threaded rack by rotating
the lever shown. As the height changes, the telescoping rods adjust accordingly. One full rotation
of the lever in either direction adjusts the tabletop by 6.3 inches.
The connecting rod shown in Figure 24 is glued into the center of the pinions gears on each leg,
allowing the height of both legs to be adjusted by a single lever at one end of the table. At the lever
end of the table, the lever is glued to the end of the connecting rod on the other side of the rack
and pinion housing unit to further secure the rod. On the opposite leg, a securing plate is screwed
in place on the outer side of the table leg to further secure the connecting rod.
A mechanical mechanism was chosen for the height adjustability of the table in order to minimize
the amount of the maintenance that the table would be susceptible to. If an electrical mechanism
were implemented, it would have a greater chance of breaking down more often, which would
negatively impact manufacturing productivity. A mechanical mechanism is easy and intuitive to
use, and will be more durable than an electrical mechanism provided the appropriate materials are
used. The leg frames of the Lock ‘N Load Plug Remover are made from aluminum metal, as it is
lightweight, but strong enough to support the weight of the table top. The adjustable cover is
welded to a 5 inch by 18 inch aluminum connection plate. This plate will then be secured to the
underside of the tabletop using four screws, one in each corner of the plate.
As shown in Figure 26, the height of the table is adjusted by rotating the lever to move the rack
along the pinion gear as it rotates. Looking at the lever straight on, as seen in Figure 26, clockwise
rotation will result in upwards movement of the rack, increasing the height of the table. Contrarily,
rotating the lever counter clockwise results in downwards movement of the rack, lowering the
56
height of the table. Once the table is at the appropriate height, a pin can be inserted through a small
hole in the rack and pinion housing component, that will sit below the gear and hold it in place,
therefore, preventing rotation of the lever. When the height of the table needs to be adjusted again,
the pin can be removed and the lever will rotate as normal. The pin is tied to a piece of string that
is attached to a small hook on the rack and pinion housing unit so it cannot be misplaced when it
is not in use.
Figure 26. Necessary motions required to adjust the height of the table: The locking pin is removed
to allow motion of the pinion gear, the lever is rotated in either direction depending on the desired
motion of the table, the rack passes along the pinion gear as it rotates, moving 6.3 inches every
full rotation of the lever. Once at the appropriate height, the pinion is secured in place by locking
pin until the table needs to be adjust again.
The rack is two feet long and is attached to the center of the metal connecting plate via a strong
weld. Additionally, two cylindrical telescoping rods made of 6061 aluminum are located within
the leg frame, centered between the rack and the internal edge of the leg frame on each side. They
are welded to both the metal place at the top of the adjustable cover, and to the table leg base at
the bottom of the leg frame. These rods will lengthen and shorten as necessary when the table is
adjusted up or down, respectively. The cylindrical rods will be the primary supports of the table
as it is adjusted up and down. The maximum force that the telescoping rods will need to support
is calculated in the Appendix, Figure A-7. This was an important calculation to determine how
strong the material that the telescoping rods were made out of needed to be in order to support the
weight of the table and other components of the table legs.
Table Leg Base

The base of the table legs, shown close up in Figure 27, is designed to match the width of the
widest part of the tabletop (35.5 inches) to ensure stability, and is 1 inch thick. The width of the
base was made as wide as the tabletop make sure that the edges of the tabletop were stable enough
to push down on without the table wobbling. The employees have to punch out various plugs along
the edge of the table, so ensuring that the secureness of the tabletop is maximized is critical.
57
Figure 27. The base of the table legs is 35.5 inches long, 4 inches wide, and 1 inch thick. The base
is connected to the leg frame by a strong weld.
The base is also made of 6061 aluminum like the rest of the adjustable table leg components, and
is attached to the leg frame by a strong weld. A strong weld between the leg frame and the base
minimizes the chance of failure at this point. All attachment points of the Lock ‘N Load Plug
Remover are also points where the design could potentially fail, so making these connections is as
strong as possible is important for the success of the product.
Construction
The leg frame and other components of the legs, such as the rack, pinion, telescoping rods, and the
connection and stopper plates, will be pre-ordered to minimize alterations once the parts are
received. The raw materials (dimensions outlined in the budget, Table 5) to make these parts will
be purchased and cut appropriately in the Branam Innovation Center (BIC). The rack and pinion
housing component will be 3D printed using PLA thermoplastic.
The table legs will be constructed by welding the base plate of metal to the leg frame. The
telescoping rods will then be positioned inside the leg frame and welded to the base at the bottom.
The rack will be secured to the center of the metal connecting plate by a weld, as well. The gear
and its housing component will be constructed by placing the pinion gear into the housing
compartment and keeping it in place by inserting the connecting rod through the holes in the
housing unit and the hole in the center of the pinion gear. This assembly can be seen in Figure 28.
The rack will then be slid into the housing compartment and fed along the pinion gear until the
housing component as reached the underside of the table. As shown in Figure 28, a lip at the top
of the housing unit allows it to be easily secured to the underside of the tabletop using four screws,
one in each corner. This construction will be completed for each of the two legs. The connecting
rod that promotes synchronized motion between the legs will be glued into the hole in the center
of the pinion to make sure the components rotate together. At one end of the table, a washer-shaped
plate that is two inches in diameter will be screwed into the end of the connecting rod on the outside
of the table leg to keep the rod in place. One other end of the table, the lever will lock into place
58
at the end of the rod to keep it in place and allow its motion to be controlled by the rotation of the
lever.
Figure 28. Exploded view of the components that will be connected around the Rack & Pinion
Housing Component during the construction of the Adjustable Table Legs.
Feasibility/Merit Criteria
The adjustable table legs contribute to the Lock ‘N Load Plug remover being height-adjustable in
order to accommodate employees of different heights. Adjustable height is one of the feasibility
criteria because it was made clear by the client that implementing a design that allows a diverse
population of employees to work comfortably and efficiently is one of the primary goals of the
project. The lever-operated rack and pinion mechanism allows the table to be adjust to a wide
variety of heights, therefore meeting the client’s requests.
The ease of use of table is considered a merit criterion. The lever associated with the rack and
pinion mechanism, coupled with the connecting rod attaching the mechanism in each leg allows
the table to be adjusted by one employee. Minimizing the number of workers required to perform
any part of the plug-removal process is preferred by the client. In addition, the rack and pinion
mechanism is dependable and intuitive, so it would require minimal training and maintenance to
implement.
Strengths/Weaknesses
The primary strength of the of the adjustable table legs is the intuitive nature of the lever-operated
rack and pinion mechanism that adjusts the height of the table. The majority of the employees have
likely seen a similar mechanism before, making the training required to be able to operate this
mechanism minimal. The use of two legs rather than four is another strength of adjustable table
legs because it minimizes the necessary connections between each leg that allows the table height
to be adjusted by one lever and one person.
59
A potential weakness of this design is that if an employee forgets to lock the lever in place after
adjusting the table, if enough force is applied to the tabletop, the table height will drop. If the
employee has to stop the plug-removal process in the middle of a mattress to return the table to the
desired height and lock the lever in place, it compromises productivity. Additionally, if the table
changes height unexpectedly, it could potentially damage the rack and pinion mechanism or injure
an employee.
An additional weakness of this mechanism may be the force required to rotate the lever in order to
adjust the height of the table. The calculated force given a one and half foot long lever was
calculated to be approximately 30 pounds, which is a significant force. If the force required to
adjust the table is this large it will certainly have an impact on the employees that will be able to
operate this mechanism. Given that a primary goal of the client is to better accommodate a wide
variety of employees, this is not ideal. However, this force calculation, shown in the Appendix,
Figure A-6 was based on a calculation of the weight of the tabletop that was overestimated and
had a factor of safety of two applied to it. Therefore, the force required to rotate the lever will not
actually be 30 pounds. These failure concerns are outlined within the FMEA in Table C-1 along
with possible modifications and adjustments that can be made to minimize the chance of these
failures occurring and their impact on the manufacturing process.
System Diagram
The system diagram for the Adjustable Table Legs Subsystem that outlines the relevant inputs to
the system related to the environment, users, and other subsystems, as well the outputs of this
subsystem can be found in the Appendix, Figure D-4.
Construction Plans
After each subsystem has been individually constructed, as detailed in each subsystem’s section,
the table legs and funnel will be attached to the tabletop. The tabletop must be completed for any
aspect of the overall design to be constructed. Each table leg will be secured to the underside of
the table via a 4 inch by 4 inch plate that will be welded to the top of the adjustable component,
and will be secured to the tabletop using four three-quarter inch screws, one in each corner of the
plate. Once the legs are attached, the funnel will be attached to the underside of the tabletop using
snap buttons positioned along the bottom of the tabletop and secured using screws and a hammer
in the purchased snap button kit. The snap buttons on the underside of the tabletop will match up
with the opposite side of the buttons attached to the top of the funnel. The buttons can be snapped
together to secure the funnel to the tabletop. The Two-Way Punch is not directly involved with the
construction of the Lock ‘N Load Plug Remover table.
60
VII. Budget/Projected Costs
The estimated budgets for each subsystem are shown below. The total cost for a prototype of the
Lock ‘N Load Plug Remover and the Two-Way Punch is approximately $775.
Table 2: A detailed budget for the Two-Way Punch Subsystem, including all parts used, individual
vendors and prices
Subsystem 1- Two-Way Punch
Part # Part Name Vendor Unit Cost/Unit Quantity Shipping/Handling Total
741000069- 3D Printer Filament 1.75 mm Hobby King 1 KG $12.90 2 $10.25 $36.05

0 ABS (White)
85241 Self-Adhesive Sheeting AAA Wholesale 1 Pkg (4” x $9.28 1 $10.51 $19.79
Company 6”)
Subsystem 1 – Two-Way Punch Subtotal $55.84
61
Table 3: A detailed budget for the Tabletop Subsystem, including all parts used, individual
vendors and prices
Subsystem 2 – Tabletop
127- MDF: Menards 1 $25.59 1 N/A $25.59

2028 8ft x 4ft x3/4in
N/A Wood Glue BBE 1 Donated 1 N/A N/A

Department
N/A 90x40in Paper BIC 1 $31.25 1 N/A $31.25
5558291 Minwax® One Coat Clear Gloss Polyurethane Menards 1 $10.94 1 N/A $10.94
- 1 qt
N/A 1/4in 4x8ft wood board Menards 1 $13.98 1 N/A $13.98
Subsystem 2 – Tabletop Subtotal $81.76
62
Table 4: A detailed budget for the Funnel Subsystem, including all parts used, individual vendors
and prices
Subsystem 3 - Funnel Subsystem
1528- 100% Nylon Joann Yard $7.99 5 N/A $39.95

3070 Fabric
N/A Stainless Steel Press Studs Screw Bases Snap Walmart 62 $11.95 1 $0.00 $11.95
Fasteners pcs
W1D146 Water hard drill rod Zoro 36” $3.73 2 $5.00 $12.46
N/A Sewing Thread BBE Donated 1 roll N/A $0.00
Subsystem 3- Funnel Subtotal $64.36
63
Table 5: A detailed budget for the Adjustable Table Subsystem, including all parts used, the
individual vendors, and prices
Subsystem 4 - Adjustable Table Legs
Part # Part Name Vendor Unit Cost/Unit Quantity Shipping/ Total

Handling
741000011- 3D Printer Filament 1.75 HobbyKing 1.75mm $12.03 3 $42.65 $78.74

0 mm PLA 1KG Spool
8975K242 6061 Aluminum McMaster- 1” Think x 4” Wide, 3’ Long $79.97 1 $16.00 $95.96
Carr
6295K17 Metal Gear Rack McMaster- 14-½ Degree Pressure $30.74 1 $6.15 $36.89
Carr Angle, 2’ Long, 10 Pitch, ⅝”
Height
6867K84 Metal Gear McMaster- 14-½ Degree Pressure $42.79 1 $8.56 $51.35
Carr Angle, 10 Pitch, 18 Teeth
97065K25 Round Grips, Smooth McMaster- 6 pcs - 1-¼’ OD, Black $14.80 1 $2.96 $17.76
Carr
6546K73 6061 Aluminum McMaster- 3/16” wall thick., 4” high x $67.66 3 $40.59 $243.57
Rectangular Tube Carr 6” wide, 2’ long
89015K237 6061 Aluminum Sheet McMaster- ⅛” Thick, 6” x 24” $26.69 1 $5.34 $32.03
Carr
8975K83 6061 Aluminum Sheet McMaster- ⅛” Thick, 3” Wide, 1’ Long $3.38 1 $0.68 $4.06
Carr
1610T15 6061 Aluminum Disc McMaster- 2” Diameter, ½” Long $4.03 1 $0.81 $4.84
Carr
9062K33 Tight- Tolerance 6061 McMaster- ¾” Diameter, 3’ Long $28.65 1 $5.73 $34.38
Aluminum Rod Carr
64
94975A174 18-8 Stainless Steel Ring- McMaster- w/ Lanyard, ¼” Diameter, 2” $4.44 1 $0.89 $5.33
Grip Quick-Release Pin Carr Usable Length
Screws BBE 0.5”-0.75” Donated 8 N/A $0
Subsystem 4 - Adjustable Table Legs Subtotal $572.88
65
VIII. Conclusions and Recommendations
There are a few aspects of the Lock ‘N Load Plug Remover and Two-Way Punch that could be
improved throughout prototype development and construction. Additionally, once the design is
assembled, various tests will be performed in order to validate and confirm the function and safety
of the table and hand tool.
Storage of Two-Way Punch

One recommendation is the development of a storage space for the Two-Way Punch. The client
noted that the current hand tool often gets lost or taken home at the end of the day. The Two-Way
Punch is bulkier than the old poker tool so it is less likely that employees would accidentally take
the tool home with them in their pocket. However, developing a storage place would establish a
system to encourage employees to keep the tool at the table.
Additional Part Production

There will be three different sized handles and only one set of punches printed, therefore, it is
recommended that Goodwill invest in printing more shafts and punches to have available in case
the set breaks.
Testing
Testing is recommended to determine the strength of the assembled table to ensure the table will
remain sturdy even under high loads. Force testing will also need to be done to validate the
calculations performed to quantify the force required to turn the lever and the force required to
remove the perforated plugs from the mattress. These tests will help to confirm that the design is
safe and effective for the client.
Cost
The current design of the Lock ‘N Load Plug Remover and the Two-Way Punch is expensive and
potentially difficult to manufacture. Considering different materials, manufacturing techniques, or
vendors could help to reduce this cost. The prototype cost is expected to be high, however, if
Goodwill decided to invest in additional table production, the aforementioned cost-reduction
strategies would need to be taken into account.
Moving Forward
We request permission to proceed with the Lock ‘N Load Plug Remover and Two-Way Punch
designs and to deliver these designs to the client as detailed in this Preliminary Design Document.
66
IX. References
Barker, D. (2002, March 26). US6360927 B1. Retrieved from http://www.google.com/patents

/US6360927
Brandt, T. (2016). Cutting Plastic Film. Laser Technik Journal, 13(5), 22–25. https://doi.org/10
.1002/latj.201600032
Bushman Equipment, Inc. (2017). “Load Inverters”. Retrieved September 7, 2017, from http://
www.bushman.com/index.php/content/floor_based/inverters.
Butterfield, T. M., & Ramseur, J. H. (2004). Research and case study findings in the area of
workplace accommodations including provisions for assistive technology: A literature
review. Technology & Disability, 16(4), 201-210.
Circle Lever Punch (XXXX-Large). (2017). Fiskars Brand, Inc. Retrieved 10 September 2017,
from http://www2.fiskars.com/Products/Crafting-and-Sewing/Punches/Circle-Lever-
Punch- XXXX-Large
Crochet Hooks. (n.d.). Retrieved September 15, 2017, from https://www.pleta.bg/en/edna-kuka-7-

15-nomer.hml
Hymmen, K. (2017). US4656907A - Paper punch. Patents.google.com. Retrieved 10 September

2017, from https://patents.google.com/patent/US4656907A/en?q=lever&q=punch
ITF Tennis - TECHNICAL. (n.d.). Retrieved October 20, 2017, from

http://www.itftennis.com/technical/balls/approval-tests.aspx
Job Accommodation Network (n.d.). “Accommodating Employees in Manufacturing Settings”.

Retrieved September 8, 2017, from https://askjan.org/media/occind.htm.
Materials | 3D Printing for Beginners. (n.d.). Retrieved October 16, 2017, from
http://3dprintingforbeginners.com/category/materials/
New Universal Clothes T Shirt Folder Fold Board High Quality Small board Neanting Tool
adjustable folding clothing plate-in Clothes Pegs from Home & Garden on Aliexpress.com
| Alibaba Group. (n.d.). Retrieved September 7, 2017, from
//www.aliexpress.com/item/New- Universal-Clothes-T-Shirt-Folder-Fold-Board-High-
Quality-Small-board-Neanting-Tool-
adjustable/32750474078.html?src=ibdm_d03p0558e02r02
Okada, S. (2005, May 10). US6889440 B2. Retrieved from http://www.google.com/patents/

US6889440.
67
Olfa Compass Circle Cutter - CMP-1. (n.d.). Retrieved September 7, 2017, from https://www.
draftingsuppliesdew.com/olfa-cmp-1-compass-circle-cutter.
U.S. Bureau of Labor Statistics (2017). Persons with a Disability: Labor Force Characteristics
Summary. Retrieved on September 10, 2017 from
https://www.bls.gov/news.release/disabl.nr0. htm.
Wang, J., Li, J., Arinez, J., & Biller, S. (2013). Quality bottleneck transitions in flexible
manufacturing systems with batch productions. IIE Transactions, 45(2), 190-205.
http://dx.doi .org/10.1080/0740817x.2012.677575.
Wellman, R., Stubbendieck K., Rago M. (2003). Strip Inverter US 20030042111 A1. Retrieved
from http://www.google.com.pg/patents/US20030042111.
Work Bench Systems | Adjustable Height | Hydraulic Ergonomic Work Benches -

GlobalIndustrial.com. (n.d.). Retrieved September 16, 2017, from
http://www.globalindustrial.com/g/work-benches/systems/adjustable-height/hydraulic-
ergonomic-work-benches
68
X. Appendices
Appendix A - Calculations
69
Figure A-1. Engineering calculations for the acceptable forces applied by the Two-Way Punch
70
Figure A-2. Engineering calculations for the weight of the Two-Way Punch
71
Figure A-3. Engineering calculation to determine the maximum possible weight of the tabletop
subsystem
72
73
Figure A-4. Engineering calculations to determine the optimal dimensions of the funnel in order
to allow for the desired angle between the funnel and the bottom of the tabletop of greater than
35°.
74
Figure A-5. Engineering calculation to determine the vertical movement of the table after one full
rotation of the lever based on the size of the pinion gear.
75
Figure A-6. Engineering calculation to determine the force that needs to be applied to the lever in
order to rotate the pinion gear to adjust the height of the table.
76
Figure A-7. Engineering calculation to determine the maximum force that the telescoping rods
will have to be able to support given the weight of the table and other components of the adjustable
table legs.
77
Appendix B – Dimensioned Drawings
Figure B-1: Engineering drawing of the Two-Way Punch that depicts all necessary dimensions
for manufacturing
78
Figure B-2: Engineering drawing of the Tabletop subsystem that depicts all necessary dimensions
for manufacturing
79
Figure B-3: Engineering drawing of the Funnel subsystem that depicts all necessary dimensions
for manufacturing
80
Figure B-4: Engineering drawing of the Adjustable Table Legs subsystem that depicts all
necessary dimensions for manufacturing
81
Appendix C – FMEA Tables
82
Table C-1: Failure Mode and Effects Analysis planning worksheet consisting of failure modes for
each subsystem with design controls and recommended actions
83
Appendix D – System Diagrams
Figure D-1. System diagram for the Two-Way Punch subsystem outlining the inputs and outputs
that affect this subsystem.
Figure D-2. System diagram for the Tabletop subsystem outlining the inputs and outputs that
affect or are affected by the design of this subsystem
84
Figure D-3. System diagram for the Funnel subsystem outlining the inputs and outputs that affect
the design of the subsystem.
Figure D-4. System diagram for the Adjustable Table Legs subsystem outlining the inputs and
outputs that affect or are affected by the design of this subsystem (relevant subsystems are colored
to match their color in the assembly.
85
XI. Personnel and Responsibilities
Two-Way Punch Subsystem
The lead designer of this subsystem was Becca Poppel.
Tabletop Subsystem
The lead designer of this subsystem was Ellese Petty.
Funnel Subsystem
The lead designer of this subsystem was Camille Blaisdell.

The lead designer of this subsystem was Lindsey Fagerberg.
Documentation
The documentation was evenly distributed between each team member.
86

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Executive Summary

I. Design Scope ............................................................................... 2

II. Evaluation Criteria ...................................................................... 14

III. Design Concepts ........................................................................ 19

IV. Design Concept Evaluation .......................................................... 26

V. Design Overview ......................................................................... 34

VI. Design Project Specifications ....................................................... 40

VII. Budget/Projected Costs ............................................................... 61

VIII. Conclusions & Recommendations ................................................. 66

IX. References ................................................................................ 67

XI. Personnel and Responsibilities ..................................................... 86

Compass Circle Cutter

Laundry Folding Board

In the article, Accommodating Employees in Manufacturing Settings, the Job Accommodation

Collect removed plugs

Ability to remove the plugs without tearing the welds

Estimated time to complete one mattress (35%)

Hand Tool Designs

Ability to remove plugs without tearing the welds

The Captain Hook

Ability to remove plugs without tearing the welds

Plug Sucker Punch

Ability to remove plugs without tearing welds

Lock ‘N Load Plug Remover

Ability to remove plugs without tearing welds

Ability to remove plugs without tearing welds

Ease of use of hand tool

Ease of use of table

The Captain Hook

Ease of use of table

Plug Sucker Punch

Ease of use of hand tool

Ease of use of table

Lock ‘N Load Plug Remover

Ease of use of hand tool

Ease of use of table

Ease of use of hand tool

Ease of use of table

Two-Way Punch Subsystem

Adjustable Table Legs Subsystem

The Tabletop Subsystem

Holes and Pegs

Materials and Manufacturing

Strengths/Weakness of the Tabletop Subsystem

Funnel Subsystem Details

Meeting the Client’s Needs

Rack and Pinion Mechanism

Table Leg Base

Part # Part Name Vendor Unit Cost/Unit Quantity Shipping/Handling Total

741000069- 3D Printer Filament 1.75 mm Hobby King 1 KG $12.90 2 $10.25 $36.05

Subsystem 1 – Two-Way Punch Subtotal $55.84

Part # Part Name Vendor Unit Cost/Unit Quantity Shipping/Handling Total

127- MDF: Menards 1 $25.59 1 N/A $25.59

N/A Wood Glue BBE 1 Donated 1 N/A N/A

N/A 90x40in Paper BIC 1 $31.25 1 N/A $31.25

N/A 1/4in 4x8ft wood board Menards 1 $13.98 1 N/A $13.98

Subsystem 2 – Tabletop Subtotal $81.76

Part # Part Name Vendor Unit Cost/Unit Quantity Shipping/Handling Total

1528- 100% Nylon Joann Yard $7.99 5 N/A $39.95

N/A Sewing Thread BBE Donated 1 roll N/A $0.00

Subsystem 3- Funnel Subtotal $64.36

Part # Part Name Vendor Unit Cost/Unit Quantity Shipping/ Total

741000011- 3D Printer Filament 1.75 HobbyKing 1.75mm $12.03 3 $42.65 $78.74