Accessible Test

Technical Research Division

Technical Research Division Activities

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Purpose

The Technical Research Division functions as a “bridge” between the concepts of the Project Leader’s product and the concrete reality on the production floor. The purpose of the division is to remain as faithful as possible to the Project Leader’s intent and function of the product while making it as inexpensive and as easily produced on the manufacturing plant’s floor as possible. The division is involved in all aspects of the product including design work, materials selection, vendor selection, and process development. After developing and documenting the product’s specifications the Technical Research Division works with production workers, floor supervisors, upper levels of APH management, and outside vendors to shepherd the Project Leader’s product throughout its entire pilot and first production runs.

This development, documentation, and preparation of the product for actual manufacture, along with the monitoring of the manufacturing process by the division, help to assure the greatest probability of success for a new product.
Division Staff

Frank Hayden A.A.S., C.E.T., Manager

David McGee A.A.S, C.E.T., Manufacturing Specialist

James Robinson M.S, Manufacturing Specialist

Darlene Donhoff, Manufacturing Specialist

Nancy Etter, Administrative Assistant

Work During FY 2009

Address Earth: Section 2

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In early April 2009, the Project Leader reported that there was enough information about the content to verify that Section 2 would be significantly larger than Section 1, both in the number of map pages in the atlas and the pages in the textbooks. Since the overall weight of Section 1 had already brought up discussions of dividing product into two carry cases, there was little discussion of dividing this section into two, but only on how to distribute the materials evenly between the cases. The decision was to divide the materials as follows: Section 2 will have maps and textbooks for Chapters 1-3 in the first case, and maps and textbooks for Chapters 4-6 in the second. To help the user differentiate which case contains which set of chapters, the two cases will be screen-printed with gold as the primary color and either red or blue trim. By dividing Section 2 into two sets, the depth of the existing Section 1 carry case would be too great, allowing the materials (primarily the textbooks) to slide around, possibly damaging the books. The vendor was contacted in order to determine the minimum depth to which they could manufacture a case. The vendor reported that they are capable of making the cases to a dimension less than that specified by APH. The ongoing investigation into the concerns from the field of the map pages ripping or tearing out of the rings in the Address Earth: Section 1 Atlas binder is mandating changes on how this product will be manufactured. At a May meeting with the Project Leader and production departments, a plan was developed for testing various synthetic papers and binder options to eliminate the concerns with page tear out. Production took the lead in testing, verifying that possible paper samples would run on the IGEN, and obtaining measurements for the amount of force necessary to pull out pages that have been 3, 5 and 7 hole drilled. The material originally used for the map pages is a synthetic based paper that is rated “tear resistant.” Initial testing of this material with a standard 3-ring binding system proved adequate, but based on feedback following the release of the Section 1 indicates a new material or other options will be necessary to remedy the problem. Other than change the Atlas page material, possible solutions are having a clear re-enforcement strip applied to the binding edge and/or changing from the existing 3-ring to a 5 or 7-ring configuration binder. Sets of the Section 1 Atlas pages were obtained and sent to a vendor to test the re-enforcement strip concept. This added a tremendous amount of strength to the binding edge of the sheet. Cost of this binding improvement would add about $5.00 per set of map pages. It would also introduce delays, as the map pages printed at APH would have to be sent out and worked into an outside vendor's production queue. Since the release of the product, new synthetic papers have been approved by Xerox for use on the IGEN. Samples were obtained and run in early 2009. Nekoosa “Thermanent” 8mil synthetic paper was selected as being substantially stronger/with increased resistance to tear-out at the binding holes. This material will be used on production of Address Earth: Section 2 and future production of Sections 1 and 3, the latter of which is in development. Information is being gathered and work on specifications is still in preliminary informational gathering stages for the kit and for the separately available components listed below.
Address Earth: Section 2 Maps and Charts

Address Earth: Section 2 Large Print Textbook Set

Address Earth: Section 2 Braille Textbook Set

Address Earth: Section 2 Symbol Guide

Addition/Subtraction Tables

(New)
An initial “Brainstorming” PDC meeting was held in March 2009 to lay out the concept of product. Technical Research worked with the Project Leader to develop tooling needed to allow for a full 0 through 10 grid that has both print and braille numbers. Spacing, based on standard braille cell-to-cell spacing necessitated a grid size that would need to be placed on an 11.5” x 11” sheet. The Project Leader wanted a material that would hold up better than standard 80# braille paper. Technical Research suggested several options, printing the table on each of the materials to assist the Project Leader in making a decision. After several revisions, including the addition of light yellow banding of every other row down the table, the material selected is 100# white index stock. Technical Research is currently working with production departments in order that materials can be produced for field- testing. This involves getting the print file to Production in order to have materials printed and working with Braille Transcription and Tooling departments to create a plate that will be used to emboss the printed sheets. Work on specifications will begin after the results of field-testing have been completed.