Date of Award

2022

Degree Type

Capstone Project

First Advisor

Dr. Bahram Nassersharif

Abstract

Through the filtration process used in Amgen, pods are used to filter out cell particles and extract the protein. These filter pods are disposed of after every filtration process, and the disposal process can take a long time. Employees currently must remove filter pods manually from unsafe heights, which could potentially cause issues. Along with the unsafe heights, the filters weigh around 30 pounds when soiled and two employees currently remove 30 pods per rack with 5 racks in the centrifuge room. Pods are removed one-by-one from multiple levels and placed into a trash bin, which is then wheeled to a disposal area. Since these pods are bulky and heavy, this can cause ergonomic issues for employees, putting strain on their arms and backs and creating an unsafe working environment.

The objective of this project is to help reduce the ergonomic stress put on employees while making the pod removal process more efficient and fitting within the constraints of the facility. To solve this issue, this team first designed a mechanism that would fit within the rack itself and lift the pods up above the level of the side tension rods. This allowed the pods to be slid onto a separate Removal Rack. This design proved to be very costly and complicated to implement so the team designed another simpler solution. The final design was a removable bar to alleviate strain from employees and speed up the pod loading and removal process. The removable bar directly replaced the current unremovable side tensile rod. The implementation of the removeable bar removes the need for employees to lift the 30-pound pods up over the bar. Instead, the pods can be pulled out with minimal lifting, decreasing the ergonomic stress while not drastically changing the current process employees have become familiar with.

The team accomplished a final machined device capable of being fit into the current Amgen rack configuration. The team also completed engineering analysis as well as tensile testing to ensure the design would be able to withstand the load applied. For the engineering analysis, the calculations were done on this concept in order to prove the effectiveness and safety using SolidWorks, MATLAB, Excel, and by hand. As for the tensile testing a modified testing specimen was manufactured and tested to the maximum load 14 consecutive times, recording the displacement each time. This concept also fits within other constraining factors such as cleanability and fitting in the tight dimensions of the cleanroom. This was accomplished by prioritizing safety and size.

Overall, after moving on from the initial Pod Puller concept the team focused on simplicity. This resulted in the final Pod Rod concept, a simple and easy to use replacement to the side tension rods of the pod racks. The team was able to install The Pod Rod on an Amgen rack and gather feedback from various Amgen employees. The overall feedback was very positive, and the team has handed off the concept to Amgen to further develop to fit their needs.

Comments

Team Name: Team 27, Nothings Im-pods-ible

Sponsor: Amgen

Document Reference: URI-MCE-402-027-2022

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