Prototype Assessment

Introduction

This is a template for documenting the lessons learned in a prototype build. This is to be adapted to any machine of interest.

Design Phase

• Describe the steps taken in the design process. What went well in the design phase? What could have been done better?
• Were there steps that should have been taken but were missing? Were there steps that were taken that should have been omitted? Explain.
• What review/quality assessment steps were taken throughout the design phase?
• What lessons were learned regarding the design after the machine was built?
• Describe what the ideal design process should look like.
• Estimate the materials cost reduction that can be attained by redesign, simplification, and design optimization.

Build Preparation

• Describe the steps taken to prepare for the build.
• Were you satisfied with the build preparation phase?
• What were the issues that were encountered? How were they resolved?
• Were the fabrication procedures satisfactory? What improvements could be made?
• Discuss how you would like the ideal fabrication procedures/drawings to look like.
• Describe how the ideal build preparation phase should look.
• Discuss any inventory/supplies that were difficult to acquire, and how this could be facilitated.
• Were there missing parts that were not accounted for until they were needed in a certain build step? What are the resulting additions to the BOM?
• Which build procedures were changed due to learnings obtained during the build?
• Which steps were missed in the build procedure documentation?

Build Phase

• What worked as planned regarding the build? What didn't work as planned?
• Describe the overall build sequence for the modules. Which modules/parts were built in parallel? What could have been improved about the sequence?
• Discuss the bottlenecks encountered in building the modules and assembling the different modules to each other.
• Discuss the bottlenecks encountered in assembling the hydraulics.
• Describe the most challenging aspect of the build.
• Describe any aspects that appeared easy but were not easy in practice.
• How many person hours should each of the above steps take? How many person hours did each step take in practice?
• If more skilled people were available, which additional steps could have been done in parallel?
• Were people utilized effectively throughout the build? How could they have been used more effectively?
• What quality control steps were taken throughout the build to assure build quality?
• List the consumables used throughout the build. Were any consumables missing?
• Were any necessary tools missing? What additional tools would be useful in the build?
• Was there any tool breakage? How could it have been avoided?

Quality Assessment and Performance Data

Quality Control Assessment

• What corrective measures were taken to address quality control issues?

Design

1. Did the machine attain practical functionality? Ie, is it usable? Are critical performance features missing?
2. Were some parts too big or too small?
3. Did any parts or modules have to be modified to fit properly? Explain the modifications that were required.
4. What design changes and additions should be made for the next iteration of a build?
5. Did the machine have the expected power or performance?
6. What things had to be modified between the CAD model and the actual build?
7. Which missing design features were added during the build that were not part of the CAD model?
8. What features/changes are required to make the machine functionally equivalent to industry standards?
9. In what ways does the machine or can the machine be made to exceed industry standards?
10. Does the steering and ground-hugging work?

Mechanical

1. Did all the parts fit together as expected? If not, please explain.
2. Were sharp edges and exposed rough torching areas ground down with a grinder?
3. Do all pins have a head on one side and a cotter pin on the other?

Welding and Fasteners

1. Discuss any welds that failed inspection.
2. Did all the bolts fit as expected? If not, pleas explain what prevented them from fitting.
3. Did any bolt lengths have to be modified? Please explain.

Hydraulics

1. Did any hydraulic fittings or hoses leak? How was this corrected?
2. Did all motors and cylinders work?
3. Were the correct fittings used? Which fittings should be replaced?
4. Were there any fittings that did not work and had to be modified?
5. Were there any cylinder tabs that had to be modified because

Performance Data and Settings

• What are the machine dimensions?
• What is the machine weight?
• What is the engine horsepower?
• What is the estimated hydraulic fluid horsepower? How was it calculated?
• What are the pressure relief settings for all the cylinders, motors, and valves?
• What is the lifting force of the loader?
• What is the speed of the vehicle at full power?
• What is the RPM of the wheel motors at full power?
• What is the hydraulic fluid flow rate calculation?
• What is the engine and pump RPM?
• What is the pump GPM?
• What is the traction force of the vehicle?
• What is the bending angle of the articulation?
• What is the height reach of the loader bucket edge at 60 degree dump angle?
• Was the performance data satisfactory? What improvements should be made?

General

• How many hours or days did the build take?
• Did you see any safety violations throughout the build?
• Were there any accidents? If so, how could they have been avoided?
• Describe your general level of satisfaction with the overall design/build and the resulting quality of the product.
• How was morale throughout the build?
• Were any conflicts encountered throughout the design/build regarding technical issues? How were these resolved?
• Discuss any personality/cultural conflicts that were encountered? How could these be addressed in the future?
• What are the overall lessons learned for improving future builds?
• Any other comments or pressing issues not covered in this assessment?
• What changes would you like to see in this assessment? Are the questions relevant? Are there glaring omissions?

Prototype Assessment Index

• LifeTrac 5 Prototype Assessment - July 2013
• Microhouse Prototype Assessment - October 9, 2013