Engineering Foundations- Principles and Communications

Semester 1, 2017

STAGE 1: DESIGN PACKAGE

AXLE CORP
 COMPANY EMPLOYEE LIST AND CONTACT DETAILS

Please dont hesitate to contact the people below for any inquiries:

Shanil Sonny (Designer)- CURTIN MIRI ID-700019882 PERTH ID-19214382

Phone: +60 10-262 7573 or Email: 700019882@student.curtin.edu.my

Wah Keng Wo (Designer)-700020824 PERTH ID- 19045854

Phone: +60 10-949 8895 or Email: 700020824@student.curtin.edu.my

Sim Hant Shen (Contractor)-700019997 PERTH ID- 19219141

Phone: +60 11-3548 4828 or Email: 700019997@student.curtin.edu.my

Sulaimaan Hassan (Contractor)-700021369 PERTH ID-19202138

Phone: +94 77 337 2100/ +60 11-2507 2778 or Email: 700021369@student.curtin.edu.my

Nathan Nyasha (Contractor)-700021658 PERTH ID-19202125

Phone: +60 11-5138 3645 or Email: 700021658@student.curtin.edu.my

Haziq Fakhri (Designer)-700019997 PERTH ID-19202222

Phone: +6737156554/ +60 11-5178 5706 or Email: 700022121@student.curtin.edu.my

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 INDEX Page
SECTION 1.0: Drawings ........ 5

1.1: Front View 6

1.2: Side View ... 7
1.3: Top View 8
1.4: Wheel View .. 9
1.5: Materials list 10

SECTION 2.0: Specifications........ 11

2.0: Chassis Construction Sequence .. 12

2.1: Wheel Construction Sequence . 13
2.2: Suspension Construction Sequence ..... 14
2.3: Completing Car Design 14
2.4: Material Price list 15
SECTION 3.0: Tender Evaluation Criteria.... 16

3.0: TEC Introduction and Purpose 16

3.1: Time management and punctuality 17
3.2: Effective communication 18
3.3: Cost efficiency and maintenance of a safe environment . 19
3.4: Professionalism and dedication 20
3.5: Standard expectation table . 22
3.6: Contractor score chart 23
SECTION 4.0: Risk Management Plan 24

4.0: Risk Management Plan Introduction .. 25

4.1: Stage 1: Design Stage . 25

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 4.1: Stage 2: Construction Stage 27
4.2: Stage 3: Testing Stage . 29
SECTION 5.0: Gantt Chart. 30

5.1: Designer Gantt chart 31

5.2: Contractor Gantt chart .. 32

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 DRAWINGS

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Materials

Car body

Wood sheet (car body): 259mm(L) x 147mm(W) x 12mm(H)

Wooden box for bottle front and back plank: 69mm x 92mm x 6mm

Wooden block for bottle left and right plank: 81mm x 92mm x 6mm

Wooden plank for bottle box base: 81mm x 81mm x 3mm

Suspension

Horizontal arm bush holder x 2 = 73mm x 15mm x 6mm

Vertical arm bush holder x 4 = 30mm x 15mm x 6mm

Metal dowel for suspension top axle (metal rod) x8: 18mm x 8 = 144mm

Metal dowel for suspension bottom axle x4 = 60mm x 4 =240mm

- Total up to have at least 4 dowel to be used and being cut w/total length per rod is 14cm
Metal hook eye x 6

Rubber band x 8

Screw (25mm length & 3mm diameter.) x 4

Escutcheon pin 1 box ~ 50pcs

Wheel

Upper suspension arm bush x 8 = 67mm x 6mm x 3mm

Lower suspension arm bush x 4 = 65mm x 33mm x 6mm

Wheel rod x 4 = 12mm (diameter) x 45mm(L)

Wheel hub x 4 = 19mm x 15mm x 6mm

Wheel rim x 4 = hollow wooden cylinder 15mm diameter.

Wheel sponge x 4 = 80mm(Diameter) x 37mm(Width)

Rubber band x 12

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 SPECIFICATIONS

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Construction Sequence
(All measurements in mm) (Millimeter), (Diameter is in mm as well)

(Note that all screw needed wood must have a 1mm hole drilled before
installing the screw to its position)

2.0: Chassis (FRONT VIEW, TOP VIEW, & SIDE

VIEW)
1. Saw the body of the chassis so that it is 147mm in width and 259mm for the
length by using a 12mm thick wood sheet.
2. Saw a 81 mm width and 81 mm length hole in the middle of the chassis with
33mm left on both sides and 25mm left on front and back so that container can be
inserted to hold the bottle.
3. 6mm wooden sheet is then saw into 81mm width and 92mm height (Qty. 2).
Another wood plank with 69mm width and 92mm height is then saw (Qty. 2).
Nail and glue all 4 planks together to make a box with 81mm length x 81mm
width x 92mm height.
4. Wooden box is then slot into the hole of the body chassis what was saw out and 2
escutcheon pin on each of the side is then nailed into the body plank from the
surface of the box into the body plank.
5. On four of the edges of the body plank, saw off 37mm width and 64mm length but
leave 2 bumps on the side of the plank with 12mm length each and 40mm
between the 2 bumps. (see design for clearer information.).
6. Trim 6mm off the bumps to make it 6mm thick.
7. Horizontal arm bush holder will be made by using a 6mm wood sheet with 73mm
length and 15mm width. The end of both the sawed off ends will have a 3mm
holes being drilled to allow a 3mm metal rod to be slide in. (Qty. 2)
8. Vertical arm bush holder will be made by using a 6mm wood sheet with 30mm
height and 15mm width. (Qty. 4)
9. Horizontal arm bush holder will then have 12mm length and 4mm width saw off
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 on all the edges.
10. Vertical arm bush holder will have 7mm trimmed off on either one side in the
middle which will results 4mm left on each of the side on one of the end.
11. The arm bush holder will be then assemble by combining 1 horizontal arm bush
and 2 vertical arm bush and the position will be fixed by using nails.(Qty. 2)
12. The arm bush holder will then installed onto the body of the chassis by using 1
screw (25mm length & 3mm diameter) on each leg at 32nd mm on each of the
end of the body chassis.
13. A metal hook eye will be installed directly below the arm bush holder in the
middle of the body of the chassis.

2.1: Wheels (Qty. 4) (WHEEL VIEW)

1. (Wheel Rim) A 15mm diameter hollow cylinder rod is saw 37mm width
2. A 150mm diameter foam with 15mm hole in the middle is then slot into the wheel
rim and the foam will then compressed with rubber bands until the foam is
approx. 80mm diameter.

2.2: Suspension system (WHEEL VIEW) (Qty 4)

1. (Upper suspension arm bush)Saw a 6mm wood sheet to make 6mm width and
65mm length wood log. (Qty. 8)
2. Drill a 3mm holes on each end of the log. (holes on each log)
3. (Lower suspension arm bush) Saw a rectangular plane with 6mm wood sheet
where 65mm in length and 33 mm width. (Qty. 4)
4. Trim off 6mm on one of the end and leave only 2 bumps which is 9mm apart.
5. Drill a 3mm hole across the bumps to allow insert of axle.
6. (Wheel hub) Then make a wheel hub with a 6mm thick wooden sheet with 15mm
width and 19mm height.
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 7. For the top of the wooden part, trim off 6mm height and
3mm width at both of the edges.
8. All the edges of the wheel hub must be smoothen.
9. A 3mm diameter hole is needed to be made so that a 3mm diameter dowel can be
inserted. The hole is at the smoothen side.( Refer to Figure 2)
10. (Wheel rod) A 45mm cylindrical wood with 12mm diameter and 13mm tail
(similar as nail).
11. 3mm diameter metal rod is cut into 12mm. (Qty. 4)
12. 3mm diameter metal rod is cut into 15mm. (Qty. 4)
13. Wheel is then slot into the wheel rod and screw(25mm(L) , 3mm diameter) to
wheel hub.
14. 2 upper suspension arm bush will be then attached the top part of the wheel hub
by using a 12mm metal rod and both end of the rod will be glued using super glue.
15. Then attach lower suspension arm bush to the wheel hub by using 15mm metal
rod and both the end of the rod must be glued using super glue.
16. A metal eye hook is then screwed into the exact middle of the lower suspension
arm bush.
17. The model of suspension system is then done.

2.3: Completing the car design.

1. A 64mm metal rod will be cut to connect the lower arm bush suspension onto the
main chassis. (Qty. 4)
2. A 17mm metal rod will be cut to connect the upper arm bush suspension onto the
main chassis. (Qty. 4)
3. Use one 64mm metal rod and one 17mm metal rod to fix the position of the
suspension system onto the main chassis and both the end of the top and bottom
suspension connection on the main chassis must be glued firmly to fix the position
to avoid swirling of the car.
4. Attach rubber bands from the body metal eye hook to the suspension metal eye
hook.
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2.4: MATERIALS PRICE LIST

ITEM ORDER RAW MATERIAL PURPOSE COST/UNIT QTY SUBTOTAL

DESCRIPTION

MDF wood 6mm thick, For constructing RM5 per 3 RM15

12mm thick car suspension unit
system and
body chassis

Metal rods 144mm (L) To hold the RM0.20 per 8 RM1..60

240(L) suspension in rod
place

rubber band Normal Work as Recyclable 30 FOC

rubber band suspension of
car

sponge 150mm Make as the RM0.50 4 RM2.00

diameter wheel of the car each

Metal hook Normal hooks To make sure RM1.60/pkt 1 RM1.20

eye the rubber band
will stay in the
position.

Escutcheon Normal nails Hold wood RM3.00/box 1 box RM3.00

pin together

Hollow Rod of wood To work as car RM0.50 per 2 rods RM1.00

wooden cylinder rim unit
cylinder

Super Glue Hold the To stick metal RM3.00per 1 RM3.00

position of rod to the bottle
the object chassis

Screw 3mm To tighten and RM1.50/pkt 1 RM1.50

diameter and make sure the
25mm length wood stay in
place

TOTAL RM28.30

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 3.0:Tender Evaluation Criteria.

What is tender evaluation criteria?

- It can help to qualify the tender opportunity and to improve scores at the
same time.
- It helps to identify which bid will offer them the highest profits or better deal.

All the expectation of the criteria entirely based on SMART (Specific, Measurable,
Attainable, Realistic and Time Controlled).
- Specific : Have to be extremely detailed and clearly stated what to be done.
- Measurable : Ensure the project to be able to be judged and scored by manager.
- Attainable : Ensure that the project can be able to be done by students with
limited supplies and resources.
- Realistic : Must have relation with the scope and fit the rules and regulation of the
unit.
- Time Controlled : Must set a deadline for every single task so it will be up to date and
also have to follow the project stages.

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 3.1:

Time management and Punctuality

At Axle Corp the team greatly highlights the importance of time management and
punctuality. The respective company should have solid time management system and hence
will be able to carry out the execution of the construction of the vehicle to the specified
deadlines. If this is not followed by the whole team there will be an imbalance in the
workload and this could result in the construction of the vehicle not going as competently as
hoped.

Requirements:
Provide minutes of meeting at a maximum of 24 hours from last meeting.

Awarding System: Time management and Punctuality carries 20% of the total marks
awarded. Marks are awarded as follows:

Marks: 5 10 15 20

Criteria: Lack of time Little sense of time Good sense of time Perfect sense of time
management: Rarely management: No management: management: Attend all
attended meetings punctuality when Punctual for 90+% of meetings on time and
and did not provide attending meetings and all meetings and provided the minutes of
the minutes of did not provide the provided minutes of meeting before
meeting as minutes of meeting at meeting at the given requested date.
requested. Summary: the requested time. date. Summary: Met Summary: Successfully
Not meeting Summary: Meets the requirements. met all requirements
requirements even to minimum requirements and more.
the minimum level. to a certain extent.

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 3.2:

Effective communication
The terms communication and effective communication while being similar in meaning to a
certain extent result in two completely different outcomes. Communication could mean that
the team could be high responsive, but at the same time respond in ways that are not
effective and not necessary.
At Axle Corp we consider the definition of effective communication to be as follows: Effective
communication is the key that helps you strengthen your connections to your team and
vastly improve teamwork, decision making, and problem solving. It helps you to
communicate even negative or difficult messages without creating conflict or destroying
trust.
Without effective communication the teams may be uniformed and this may lead to time
wastage in the construction stage.
Requirements:
Responds to email as soon as possible
Make sure the notification from the phone are noticed
Be tolerant and flexible while responding

Awarding System: Effective Communication carries 20% of the total marks awarded. Marks
are awarded as follows:

Marks: 5 10 15 20

Criteria: No effective Lack of effective Good level of effective Great level of effective
communication communication: Replies communication: Replies communication: Replies
whatsoever: to client within a time client within a time to client before hour.
Replies to the period of 1-2 hours. period of to 1 hour. Summary: Done more
contractor after 2 Summary: Not within Summary: Within than expected.
hours. requirements. requirements.
Summary: Way off
requirements.

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 3.3:
Cost Efficiency:
This is one of the most common tide turning factors in businesses all over the world. If
followed well this can lead a company to great success.
We require that the the contracting team have a good system for cost efficiency. This can be
achieved by firstly finding various sources to obtain the required materials from. Then
choose the materials that have a good balance between quality and cost.
By doing this the product constructed will not only be economically feasible, but also of a
quality build.
Requirements:
Recyclable materials
Use materials that are already available so no purchase is needed

Awarding System: Cost Efficiency carries 15% of the total marks awarded. Marks are
awarded as follows:

Marks: 5 10 15

Criteria: No cost efficiency
whatsoever: Did not provide
the sources as requested, no
bills and quotations provided.
Summary: Did not meet the
requirements at all.
A general sense of cost efficiency: Great sense of cost efficiency:
Provided at least 90% of sources, Provided all sources, bills and
bills and quotations. Summary: Met quotations. Summary: Met all
the requirements to a certain extent. expectations.

Maintaining a safe environment:

Axle Corp will implement and provide a set of guidelines that will ensure all the contractors
are well within the safety limit.
Requirements:
Advise them to wear safety gear that are appropriate (gloves, etc.)
Ensure the workplace is not dangerous or near any hazards

Awarding System: Maintaining a safe environment carries 15% of the total marks awarded.
Marks are awarded as follows:

Marks: 5 10 15

Criteria: Did not maintain a safe environment Maintained a safe A great sense of maintaining

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 at all: Did not follow the guidelines
whatsoever. Waste materials not
disposed or not recycled. Summary:
Did not meet the requirements at all.
environment to a certain safe environment: Followed all
extent: Followed the guidelines to the word (100%).
guidelines to a certain Summary: Met all the
extent (70%). expectations.
Summary: Met the
requirements somewhat.

3.4:

Professionalism:
Axle Corp would appreciate to work with a company that has a high level of
professionalism. The Merriam-Webster dictionary defines professionalism as "the conduct,
aims, or qualities that characterize or mark a profession or a professional person"; and it
defines a profession as "a calling requiring specialized knowledge and often long and
intensive academic preparation."
These definitions signify that professionalism consists a number of different attributes, and,
together, these attributes identify and define a professional.

Without professionalism the teams may come to certain disagreements.

Requirements:

Knows what they are supposed to do

Does not play around and focus on the work at hand

Awarding System: Professional carries 15% of the total marks awarded. Marks are awarded
as follows:

Marks: 5 10 15

Criteria: No professionalism whatsoever: General sense of A good level of professionalism:

Lack of questions and did not
provide any suggestions which
implies that there is lack of
understanding of the design.
Summary: The requirements were
not met.
professional: Asked some
questions and provided some
suggestion on how to alter
and improve the design.
Summary: Met the minimum
requirements.
Asks many questions and
provides many suggestions as
to how to improve the design.
Summary: Meeting all the
requirements well.

Dedication:
The design will be a bit more complex as Axle Corp will use a real car as a draft and try to
implement it to the design We would like a Contractor that is dedicated to his job as he or
she might have to go through nights to build this project. Without dedication the teams may
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 lose interest in the project.
Requirements
Does research early on how to build a car before the design comes
Does not lose interest in a project after a few days or weeks
Requirement of weekly progress report on request to show proof of dedication
Awarding System: Dedication carries 15% of the total marks awarded. Marks are awarded
as follows :

Marks: 5 10 15

Criteria: No dedication at all: Has no
interest and no commitment
to the the project
whatsoever.
Summary: Has not met the
required criteria.
General sense of dedication:
Provides most to all WPRs on
request.
Summary: Meets the
requirements to the minimum.
A good level of dedication: Has a
high level of commitment to the
project, provides all the WPRs for
proof. Summary: Meets all
requirements.

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 3.5:

Standard Expectation Table

50-65% 65%-80% >80%

Time Lack of time Has a good sense of time Has high time
management management skills, management and follows management skills
and Punctuality does not follow a a schedule to complete and follows a strict
timetable and hence tasks on the given date. systematic schedule to
is late to submit the to complete tasks on
tasks. or before due date.

Effective Does not Communicates effectively Communicates well

communication communicate well only to a certain extent and effectively so that
which leads to time that does result in a small it provides a positive
wastage and positive impact. impact.
frustration between
two teams.

Cost Efficiency Has no cost Has a decent level of cost Sources the materials
efficiency, using efficiency. Keeps some of well,keeps all the bills
almost the whole, if the bills and sources the and has a great
not whole budget. items so a certain extent. balance between cost
Having no balance Some balance between and quality.
between cost and cost and quality.
quality.

Maintaining safe Does not follow the Follows some to most of Follows the safety
environment guidelines well and the guidelines and guidelines well in
this leads to maintains a somewhat order to create a safe
accidents to happen. safe environment. and suitable working
environment.

Professionalism Has a lack of Has a general sense of Behaves

professional professionalism. Asks professionally. Asks a
behaviour. Asks little some questions and lot of good questions
to no question and provides a decent and provides valuable
does not provide feedback on the feedback on the
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 feedback on the proposed design. proposed design.
proposed design.

Dedication Does not study or Asks questions when Studies on the design
ask questions on there are problems thoroughly and asks
design and follows without studying the the designer on it as if
through whether it design. there are problems.
works or not.

3.6:

Contractor Score Chart

Contractor 1: Contractor 2: Contractor 3:

Time management and Punctuality(20%)

Effective communication(20%)

Cost Efficiency(15%)

Maintaining safe environment(15%)

Professionalism (15%)

Dedication (15%)

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 4.0: RISK MANAGEMENT PLAN
-This document is prepared to foresee risks, estimate impacts, and define responses to issues.

A risk is "an uncertain event or condition that, if it occurs, affects the project in a negative sense.
Risk is inherent with any task. The risk management plan contains an analysis of likely risks with
both high and low impact, as well with set of guidelines to minimize the possible risks.

The risk management plan is divided based on the 3 stages of the project.

4.1: STAGE 1: DESIGN STAGE

RISK: LOSS OF VALUABLE DATA

HAZARD: LOSS OF DESIGN

SUMMARY:There is a chance data loss during the process of designing. This can be divided
into two types. First being losing the designs made through software and second being the loss
of the physically drawn designs. This could be due to corruption and viruses for the first case
and being irresponsible for the second case.

-A residual risk being that the backups kept are only partial.

-There is a possible likelihood of this happening with the level of severity being moderate.
Resulting in an overall risk level of moderate.

-This can be avoided by having multiple backups of the latest designs on multiple storage
mediums and by keeping photocopies of the physically drawn designs.

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HAZARD: INCONSISTENCY OF SCALE RISK: ERRORS IN CONSTRUCTION

During the design process due to complexity of the design software there may be
inconsistencies of the design scale in the specifications. This could lead to a faulty construction
model and will cause the model to be unstable as the parts would not compatible with each
other.

-A residual risk being that the model may have to undergo redesigning which would require
more time and resources.

-There is a possible likelihood of this hazard taking place with the level of severity being
critical. Resulting in an overall risk level of extreme.

-Checked by multiple designers and also the contractors to ensure that the design is error free
and suitable to move on to the next phase.

HAZARD: UNREALISTIC DESIGN RISK: FAIL TO CONSTRUCT

During the design process the designers may design a vehicle that may be impractical and
theoretically impossible given the constraints of the project. Such as the experience of the
contractors and the budget.

-A residual risk being that the design is only partly unrealistic due to the lack of resources to
build it.

-The likelihood of this happening is unlikely and has a minor level of severity. Resulting in a low
overall level of risk.

-The design has to be done realistically and practically based on the constraints of the project.

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HAZARD: HEAVY WORKLOAD RISK: MENTAL STRESS

Due to overload of work and the need to make the design to high level of perfection the
designers maybe heavily pressurized and this may result in a high level stress.

-A residual risk being that the design missed out on the details because stress will make
someone forget about important details.

-There is a likely chance of this happening and there is a critical level of severity. Resulting
in an overall risk of level of extreme.

-The key points to avoid this is to be calm and also have a good level of preparation for the
task and start early to ensure the whole process goes smoothly.

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4.1: STAGE 2: CONSTRUCTION STAGE

HAZARD: COMPLEXITY OF TOOLS RISK: PHYSICAL INJURY

SUMMARY:The tools required to construct the design may be too complex to use and this
may result in there being physical injuries to the body during the use of tools such as hacksaws
and power drills.

RESIDUAL RISK: There is also a residual risk of people in the background getting hurt due to
improper use of tools.

RISK LEVEL: There is likely chance of this happening with a major level of severity. Resulting
in an overall risk level of extreme.

MITIGATION: This can be avoided by using appropriate protective gear and by also having a
general amount of practice with the tools.

HAZARD: RECKLESS HANDLING RISK: DAMAGE TO THE VEHICLE

SUMMARY: During the construction phase of the design the vehicle may get damaged due to
the lack of caution shown by the constructors. This leads to added expenses for the company
due to the requirement of rebuilding or repairing the vehicle.

RESIDUAL RISK:The residual risk being that the deadlines may not be met due to the extra
time needed to repair the damages done.

RISK LEVEL: There is possible chance of this happening with a major level of severity.
Resulting in an overall risk level of extreme.

MITIGATION: While under construction vehicle should be handled with great caution and by
someone who has experience.

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HAZARD: VEHICLE NOT BUILT TO SPECS RISK: INSTABILITY OF VEHICLE

SUMMARY:Due to the complexity of the vehicle design the contractors may not the build the
design as required and this could lead to the vehicle not being stable and may fail.

RESIDUAL RISKThe residual risk being that more time will be needed as the vehicle may
have to be rebuilt and also more time will be needed.

RISK LEVEL: The possibility of this happening is unlikely with moderate level of severity.
Resulting in a moderate overall risk level.

MITIGATION: The contractors should study the design package thoroughly to grasp all
available information, also the contractors should consult the designers to get more
information.

HAZARD: USE OF HARMFUL MATERIALS RISK: PHYSICAL INJURIES

Due to inexperience of the contractors they may get physically injured during the use of
materials such as wood and high temperature metal.

-The residual risk being that the contractors will need time to heal from their injuries.

-There is an unlikely chance of this happening with a major level of severity. Resulting in a high
overall risk level.

-The contractor should use safety protection gear and exercise high levels of caution.

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 4.2: STAGE 3: TESTING STAGE

Hazard and Risk: VEHICLE COLLAPSE DUE TO FAULTY CONSTRUCTION

HAZARD: FAULTY CONSTRUCTION RISK: FAILURE OF PROJECT

Due to the errors done by the contractors during the construction phase such as faulty
connectors between wheels, the vehicle may not successfully absorb the force of the impact
resulting in a collapse of the vehicle. This may lead to failure to pass the project and loss of time
and resources.

-The residual risk may be that there may be rise in tension and anger between the designing
and contracting group.

-There is a possible chance of this happening with a critical level of severity. Resulting in an
extreme overall risk level.

-Contractors should be highly focused and committed to ensure that the quality of the product is
maintained throughout the construction period.

HAZARD: VEHICLE UNDER PERFORMANCE RISK: HIGH LEVELS OF STRESS

Similar to the previous hazard, due to the faulty construction of the vehicle there may be a build
of mental stress in both the contracting and designing team and this may lead to both teams
blaming each other.

- The residual risk being that the stress continues to build even after inspection of the vehicle.

-There is a possible chance of this taking place with critical level of severity. Resulting in an
extreme overall risk level.

-Perform severe and thorough vehicle checks before resulting vehicle for testing.

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 Gantt Chart

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5.1: Design Gantt Chart

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5.2: Contractor Gantt Chart