Alcoa Design Project. EDSGN 100 SECTION 009 Team 3:

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1 2013 Alcoa Design Project EDSGN 100 SECTION 009 Team 3: Shelby Mychayliw Bryce Connelly Chris Campbell Collin Foster Submitted to: Wallace Catanach 12/16/2013

2 1 Index Abstract 2 Executive Summary 2 Introduction 3 Customer Needs 3 External Research 7 Concept Generation and Selection 9 Final Design 13 Conclusions 16 References 17

3 2 Abstract Aluminum is a highly sustainable and easily recycled material that can be used in construction, in wiring, and in household applications. We are taking advantage of the properties of aluminum by creating a buffet in a dining hall. The buffet area we are creating will consist of a buffet counter, tables, and chairs. By replacing commonly used materials like wood and particle board with aluminum we will be able to create a cost effective and efficient dining area. Executive Summary Our team has been assigned the task of finding a new innovative place to use aluminum on campus at Penn State that improves efficiency and sustainability. This semester we are all taking Engineering Design 100 because of our preengineering status. Dining commons are full of items that could be made of aluminum rather than other non-recycled materials. Our goal is to replace tables, chairs, counter tops, dishware, and shelving with similar products that are made of aluminum. All the products will be made of recycled aluminum and also have the ability to be recycled when no longer in use to maintain a high level of sustainability. The products that will be implemented will meet a high standard of durability. While meeting both a durability and recyclability standard, the products will be designed to be visually appealing. While developing our design we researched many different uses of aluminum. One of our team members also attended the Alcoa Project Launch presentation. From the presentation we learned about the evolution aluminum manufacturing technics and products over the past hundred years. Additionally, we were informed of new innovative designs and products that are being developed. Initial customer needs and product specification surveys were used to help generate a final concept. The possible specifications and designes where scored in a Pugh scoring matrix to determine the most efficient and appealing design. We

4 3 decided to use aluminum powder in place of paint, and aluminum tables, chairs, and other various aluminum items to replace previously non-recyclable items. Technical Risks include failure of key structural components in the tables and chairs. For example, major weight bearing supports could fail if not properly supported, causing a collapse. Additionally, as with any installation, components must be properly installed and maintained to prevent failures and unsightly defects. The programmatic risks include meeting deadlines and the budget. Technical risks can be avoided by using proper building plans and strong, reliable material. To prevent failure to meet major deadlines we use the project plan with short-term deadlines. The budget will be maintained by using low cost materials and clear budgeting techniques. Introduction Our team was presented with the task of remodeling a system where aluminum could be used as a replacement for another building material in the vicinity of campus. Aluminum is a highly likeable product as it is flexible, light, and has a high strength yield. Aluminum can replace many of the plastic and wood products that are currently in use and still be economically viable. Our project focus is remodeling a dining commons and flipping the area with aluminum products. This new area will be more effective, sustainable, and economically viable. Our brainstorming, compacting, and review of our ideas has led to a brand new dining area for all to enjoy. Customer Needs Alcoa offered us with a sponsorship to jumpstart the project and presented us with the needs that we would need for the final products. As a group we needed to locate places on campus where aluminum could be used. After synthesizing our original ideas we decided to remodel a dining area. The dining area as a system has many inputs and outputs that we will describe later. Our idea

4 had to improve on the efficiency and sustainability of the campus as a whole. Doing this will in turn increase energy efficiency of campus and use aluminum which is abundant and plentiful.

5 4 had to improve on the efficiency and sustainability of the campus as a whole. Doing this will in turn increase energy efficiency of campus and use aluminum which is abundant and plentiful. Our idea also needed to be connected to the safety and building regulations that are already in place here on campus. Finally, we will take our dining common and connect Centre County and the Penn State University community as a whole. Below, you will these customer needs in a selection matrix which gives value to each individual customer need. To begin our needs analysis, we knew we would need the current recycling behaviors. From a small sample size of friends, we obtained survey results. Their responses and feelings can be viewed below. The breakdown of the surveys reveals that 54% of people always recycle aluminum and more than 80% recycle on a regular basis. Also, 70% of those who recycle do so using a weekly pick up, and 30% take their recyclables to a recycling center. Aluminum and plastic were the most widely recycled products, followed by glass and paper. We also learned from our survey that more people would recycle if it was easier to do. Around 40% of people who took he survey want to see aluminum in more everyday applications and 50% don t think aluminum could be used in any more everyday products. Additionally, 60% of people are in support of our idea to use aluminum in a dining hall application. Their surveys follow below.

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6 1 2 3 4 5 6 7 8 9 Customer Needs 1 Found in a Dining Common X X X X X X X X 2 Improve Efficiency and Sustainability X X X X X X X X 3 Increase Recyclability

Regulatory Codes X X X X X X X X Metrics Five tables (3ft high) Five tables (4.5ft x 3.5ft) 20 Chairs (1.5ft off ground, 3ft tall, 1.

7 Customer Needs 1 Found in a Dining Common X X X X X X X X 2 Improve Efficiency and Sustainability X X X X X X X X 3 Increase Recyclability X X X X X X X X 4 Identify All Parts of an Aluminum System X X X X X X X X X 5 Solution is Economically Viable X X X X X X X X 6 Ensure that it Meets Regulatory Codes X X X X X X X X Metrics Five tables (3ft high) Five tables (4.5ft x 3.5ft) 20 Chairs (1.5ft off ground, 3ft tall, 1.5 ft deep) Buffet Counter (4 ft off ground, 5ft 4in tall, covers 20 ft arc) Food Holders (1 Ft^3) Cups (8oz.) Trays (2 sq. ft.) Walls (10ft high x 20ft wide, 1 ft thick) Energy Use (watt hour)

8 7 External Research The Aluminum Recycling Process: Recycling aluminum is highly effective and can save tons of energy. The process saves 95% of the energy of remaking aluminum then producing the product from raw material. Aluminum is made from bauxite ore, which is mined, and then smelted down into the everyday products we use like soda cans, food cans, and foil wrap. However, all of these products can be recycled and made back into the same material. Aluminum collecting begins with the consumer who places them in designated recycling bins. The aluminum is collected by trucks and taken to a treatment plant to be processed. At the plant, the aluminum is sorted and cleaned before reprocessing occurs. First, the aluminum is melted down to remove the coating and inks that may be present on the containers. The melting aluminum is cooled and make into ingots, or bars, which are equivalent to about 1.6 million drink cans. The blocks of aluminum are sent to mills where they are flattened and rolled out into large sheets. This step in the process gives the aluminum more flexibility and strength. These sheets can then be cut and molded into the cans and containers all again. The entire process takes about 6 weeks and the fresh aluminum products can be sent back to the shops to be used and recycled again. Literary Analysis: Aluminum is able to be recycled infinitely, and it holds its temperature better than glass. This means that it is able to stay hot longer and cold longer. There is a large economic incentive for recycling aluminum because of how much cheaper it is to create products from recycled aluminum than from ore. Alcoa, founded in 1888 is a major aluminum manufacturing company that is mainly known for creating cans and bottles. It started out by making kitchen supplies such as teapots. ColorKast is a die-casting technology used to finish products with any color desired, which is economically effective.

9 8 Price Research: The size of our aluminum buffet counter that we created came out to be roughly 245 square feet. By building the entire counter with aluminum, we estimated the price to be about $1,365. This is a lot cheaper than having a buffet counter that is made out of marble. Those types of buffet counters can cost up to about $7,280 depending on what materials are used to build the entire thing. By creating our counter out of only aluminum, we are not only able to save money, but also energy and materials. Total Costs for Buffet Base Aluminum ($15 / sq. foot) Marble ($80/ sq. foot) Front Face (50 sq. ft.) $750 $4000 Back Face (25 sq. ft.) $375 $2000 Two flat surfaces (16 sq. ft.) $240 $1280 Total: (91 sq. ft.) $1365 $7280 Patent Search: There are many existing patents for products we are using such as aluminum tables and chairs, as well as utensils and dishes. There are also existing patents for a refrigerator door. We will take each of these into consideration when go through our concept generation and selection. These patents will allow us to select the proper aluminum to maximize efficiency. In the end, we plan to take these ideas and apply them to the dining commons across campus.

10 9 Concept Generation and Selection Next we took the results from the surveys and combined them with our customer needs. As a team we went to Pollock Dining Commons to get a sample of what we can improve with aluminum. Altogether, we came up with the following ideas. We first looked at where students sit, like tables, chairs, shelves, and couches. After selecting the material, we found that tables and chairs can be remade with aluminum. Selection Criteria A Table B Chair C Shelves D Couches Efficiency of System Sustainability Found in Dining Area Aluminum Friendly Economically Viable Satisfies Regulatory Codes Sum +'s Sum 0's Sum -'s Net Score Rank Continue? Yes Yes Yes No

11 10 Next we looked at the food service area in Pollock commons. We took into consideration the buffet counter, trays, lights, food holders, silverware, and cups. From here, we use the customer needs again and found that all of these can continue to a final design. Selection Criteria A Buffet Counter B Trays C Light Casings D Food Holders E Silverware F Cups Efficiency of System Sustainability Found in Dining Area Aluminum Friendly Economically Viable Satisfies Regulatory Codes Sum +'s Sum 0's Sum -'s Net Score Rank Continue? Yes Yes Yes Yes Yes Yes We also took looked into ovens and fridges and how aluminum could be applied to them. We decided that the properties of aluminum do not allow for the best results as aluminum does not insulate very well and can deform under the hot temperature in the ovens. We did not continue with these ideas. Selection Criteria A Ovens B Fridge Efficiency of System - 0 Sustainability 0 0 Found in Dining Area + + Aluminum Friendly - - Economically Viable - 0 Satisfies Regulatory Codes - - Sum +'s 1 1 Sum 0's 1 3 Sum -'s 4 2 Net Score -3-1 Rank 2 1 Continue? No No

12 11 Next, decided to look at the entire building as a whole. Below you can see our ideas from flooring and wiring to the entire air duct system. F Air Duct System Selection Criteria A Flooring B Walls C Paint D Stairs E Siding G Wiring Efficiency of System Sustainability Found in Dining Area Aluminum Friendly Economically Viable Satisfies Regulatory Codes H Insulation Sum +'s Sum 0's Sum -'s Net Score Rank Continue? Combine Combine Combine Yes Yes Yes Yes Yes Finally, we took each of the ideas and scored them based off the current ideas. We decided to continue with many of the aluminum products. Concepts A Table B Chair C Shelves D Couches Selection Criteria Weight Rating Score Rating Score Rating Score Rating Score Efficiency of System 20% Sustainability 20% Found in Dining Area 5% Aluminum Friendly 25% Economically Viable 20% Satisfies Regulatory Codes 10% Total Score Rank Continue? Yes Yes Yes No

13 12 A Buffet Counter Selection Criteria Weight Rating Score B Trays Rating Score C Light castings Rating Score Concepts D Food Holders Rating Score E Silverware Rating Score F Cups Rating Score Efficiency of System 20% Sustainability 20% Found in Dining Area 5% Aluminum Friendly 25% Economically Viable 20% Satisfies Regulatory Codes 10% Total Score Rank Continue? Yes Yes No Yes Yes Yes Concepts A Ovens B Fridge Selection Criteria Weight Rating Score Rating Score Efficiency of System 20% Sustainability 20% Found in Dining Area 5% Aluminum Friendly 25% Economically Viable 20% Satisfies Regulatory Codes 10% Total Score Rank 1 1 Continue? No No

13 Concepts A Flooring B Walls C Paint D Stairs E Siding F Air Duct System G Wiring H Insulation Weigh Weigh Weigh Weigh Weigh Weigh Weigh Selection Criteria Weig ht Rati ng ted Score Rati ng ted

6 5 1 2 0.4 3 0.6 5 1 3 0.6 3 0.6 Found in Dining Area 5% 3 0.15 5 0.25 5 0.25 3 0.15 4 0.2 5 0.25 4 0.2 5 0.25 Aluminu m Friendly 25% 3 0.75 3 0.75 5 1.25 3 0.75 4 1 5 1.25 2 0.

14 13 Concepts A Flooring B Walls C Paint D Stairs E Siding F Air Duct System G Wiring H Insulation Weigh Weigh Weigh Weigh Weigh Weigh Weigh Selection Criteria Weig ht Rati ng ted Score Rati ng ted Score Rati ng ted Score Rati ng ted Score Rati ng ted Score Rati ng ted Score Rati ng Score Rati ng ted Score Efficiency of System 20% Sustaina bility 20% Found in Dining Area 5% Aluminu m Friendly 25% Economi cally Viable 20% Satisfies Regulato ry Codes 10% Total Score Rank Continue? No Combine Yes No Yes Yes No Combine Final Design Many of our original ideas had passed but we were assigned specifically to design a buffet counter, tables, and chairs. The final solid works model and the scale model can all be seen below. The buffet counter has about a 20 feet circumference, the tables are four feet high and the chairs fit right under the table like normal.

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16 15 Price Research: The size of our aluminum buffet counter that we created came out to be roughly 245 square feet. By building the entire counter with aluminum, we estimated the price to be about $1,365. This is a lot cheaper than having a buffet counter that is made out of marble. Those types of buffet counters can cost up to about $7,280 depending on what materials are used to build the entire thing. By creating our counter out of only aluminum, we are not only able to save money, but also energy and materials. We ignored the actual counter as we assume it is already made out of an aluminum alloy. The underside will be nearly hollow on the underside which will save material cost when compared to marble. The table and chairs were left out of the price total as they should result in a net zero cost. Aluminum chairs and tables cost more outright than the current wood and plastic tables used in the commons. However, the aluminum tables last longer than the plastic and wood tables and chairs. These types of tables and chairs will need to be replaced more often and be made from new material unlike the aluminum tables and chairs. For example, if an aluminum table breaks, it can be melted down and formed into the exact same table without any need to buy another table. The current plastic and wood tables cannot be remade into their exact shape. One would need to cut down another tree to replace a wooden table. With this idea in mind, we know in the long run the high initial costs of the aluminum tables and chairs will cancel out with the plastic and wooden tables and chairs. Total Costs for Buffet Base

17 16 Aluminum ($15 / sq. foot) Marble ($80/ sq. foot) Front Face (50 sq. ft.) $750 $4000 Back Face (25 sq. ft.) $375 $2000 Two flat surfaces (16 sq. ft.) $240 $1280 Total: (91 sq. ft.) $1365 $7280 Conclusions As a group, we learned a lot about the design process and about aluminum while doing this project. After brainstorming, evaluating customer needs, and researching the properties of aluminum we were able to create a buffet counter, table, and chairs. These are environmentally sustainable, practical, and economically viable. Replacing the current buffets, tables, and chairs with our models will increase sustainability of the dining commons and save money in the long run. We can apply this idea to many surrounding companies such as McDonalds, Are U Hungry, and Penn State Diner. These companies can invest in aluminum tables, chairs, and kitchens to allow for sustainability. Overall, our idea will introduce the food service industry of an aluminum world that can cut cost and save money in the long term.

18 17 References "Alsa Corp FXSheeting : Brushed Aluminum." Alsa Corp FXSheeting : Brushed Aluminum. N.p., n.d. Web. 13 Dec "Aluminum Aluminium Alcoa. Advancing Each Generation Alcoa Inc." Aluminum Aluminium Alcoa. Advancing Each Generation Alcoa Inc. N.p., n.d. Web. 11 Dec "The Aluminum Association." The Aluminum Association. N.p., n.d. Web. 13 Dec "Aluminum Extrusions & Custom Aluminum Extrusions Sapa Extrusions Sapa Group." Aluminum Extrusions & Custom Aluminum Extrusions Sapa Extrusions Sapa Group. N.p., n.d. Web. 13 Dec "Aluminum Prices and Aluminum Price Charts." - InvestmentMine. N.p., n.d. Web. 13 Dec "How Aluminium Is Recycled «Recycling Guide." How Aluminium Is Recycled «Recycling Guide. N.p., n.d. Web. 13 Dec "Marble and Granite, Inc." Marble Slabs. N.p., n.d. Web. 13 Dec "Metals Depot - America's Metal Superstore!" MetalsDepot. N.p., n.d. Web. 13 Dec

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