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VANDERBILT UNIVERSITY – CARDBOARD INSERT FOLDING DEVICE
Group 18 – NISH Projects: Improvements in Industry for Disabled Workers
Walter Yehl – Principal Investigator
Austin Healy – Development Specialist
David Sharvin – Research Analyst
Brian Piazza – Design Engineer
April 22, 2008
ABSTRACT
This report describes, analyzes and reviews the NISH-sponsored project at Vanderbilt University.
The project is that of a cardboard insert folding device used to help mentally challenged workers at
New Horizons not only learn how to correctly piece together a complicated folding process, but to
do it efficiently as well. This paper will describe in detail the ultimate goals of the project, the
design and function of the box folding device, show the tested results of the constructed prototype
system and analyze these results to show that the project requirements were met and the ultimate
goals of improving worker efficiency and production were fulfilled.
INTRODUCTION
Our project was started when we chose to work on a NISH-sponsored project for our senior design
class. We chose to work with NISH (4) because it became obvious to us that by doing so, the
impact of the project could make an immediate difference in someone’s life. This project, described
in detail in the next few sections, will strive to accomplish this goal.
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Once the project was collectively selected, we contacted our sponsor Tommy Hall at New Horizons
Corporation (3) to set-up an initial meeting. New Horizons Corporation is a non-profit company
that employs adults with mental and developmental disabilities. Their mission is to advance the
assimilation of adults with developmental disabilities into the community by advocating for their
rights and dignity, and providing the specialized supports necessary for developing individualized
choices in meaningful, productive work, and also providing places to live and access to the
community.
At their production center in Nashville, service recipients are trained to perform supervised work for
which they earn wages. The project we undertook involves a contractor, Austin Foam Plastics, for
whom New Horizons assembles up to 400,000 cardboard inserts for Dell computer boxes each
month.
METHODOLOGY
Statement of the Problem
The nature of the problem at hand sought to answer the question: how can we make this box-folding
process easier and/or faster for the people working there? New Horizons asked us to create a
relatively inexpensive solution to simplify the 15-step box-folding process in order to help their
employees work more efficiently. The other aspect of the design approach was to create a process
that worked to help those previously unable to fold the entire box, whether as a result of physical or
mental limitations, to be able to complete all 15 essential folds in the process. A picture of the
initial unfolded piece of cardboard and the completed folded box are shown below:
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Figure 1. The images above show the box in its unfolded form (left) and after the folding process (right). Employees perform all the intermediate steps that change the box from its flat unfolded
form to its finished form.
Rationale
The first part of the design consideration was to isolate the folding motion. In the current process,
the employees of New Horizons are handed an unfolded box insert and are taught one fold at a time
how to do it. The supervisor would work with the employees until they could fold the box, or until
they could manage as many of the folds as they could. This process allowed the employees to fold
the box in the air or on the table, whichever they preferred. To simplify the process, we first
considered it best to isolate the folding movements by immobilizing the cardboard insert. We
sought to create a design that would remain stationary as it assisted the workers. By keeping the
insert locked in one spot on the table, it would assist with the most difficult folds that tended to be
hardest for workers to complete and remember. The device would assist with both of these
dilemmas.
The second part of the design consideration was to assist with the learning process. Some
employees would come in and be trained on the folding process for weeks, only to forget it within
the next few months, weeks, or even days. The design was to include some sort of device that
would continually walk them through the steps to complete the folds, or perhaps guide them
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through the process. This was initially a daunting task. We considered using an LED lighting
scheme, numbering scheme, color-coordinated folding cycle, and finally settled on a laptop-
presented video guidance system. We progressed through the different ideas and discarded ideas
based on cost and feasibility with the help of Professor of Special Education at Vanderbilt, Kim
Paulsen, who expressed much support in the cyclic visual video guidance system (1).
The decisions made throughout the design process were based on a number of factors, including but
not limited to: cost, effectiveness, size, and safety. The device is designed to be very safe since the
majority of the parts are nonmoving. The design is also cost effective, made solely out of materials
that can be purchased at a local home improvement retailer. The materials had to comply with size
standards so that the device could be utilized on a table top accessible to both wheelchair and non-
wheelchair dependent persons. Additionally, anything that appeared to have no usefulness in the
final design was discarded to get to our final prototype.
Design
The prototype design consists of a wooden base cut out to the match the size of the unfolded
cardboard insert. Wood was chosen to provide a sturdy base, and rubber stoppers were attached to
the bottom to prevent the base from moving, especially on the initial fold, which tends to push the
base away from the folder as the cardboard cutout is slid into place. In the center of the wooden
base, there is a piece of thin Plexiglas positioned perpendicular to the underlying surface. This is
held upright by brass joint fixtures glued to the base and Plexiglas with epoxy. The Plexiglas serves
as the initial folding support. As the cardboard cutout is placed on the base, it slides into place over
the Plexiglas, immediately providing support for the first and often very confusing initial fold to
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start the folding process. A plastic clamp is then fixed over the cardboard on the Plexiglas to hold
the box in place as the subsequent folds are made. Once held in place, the worker can then make
the remainder of the folds on a sturdy platform, allowing them to use both hands to complete the
folds rather than using one to hold that initial fold in place while trying to make the remaining folds.
The previous steps, along with the remaining folds, are individually played on a looped laptop
PowerPoint presentation. This enables the workers to start right away on the first step after
completion, reducing the interaction with the laptop to a simple push of a button. Each slide
corresponds to a different fold, where a video of somebody acting out the folds is also looped. This
allows the workers to repeatedly watch each step for as long as they need to until the process is
clearly picked up and able to be repeated by the workers. As each step is performed and completed,
the worker then presses the right arrow button, which was marked with green tape for the ease of
locating it and eliminating any confusion in the small interaction with the laptop. As the folder
completes the last step and the box is removed from the base, the video is automatically looped to
the beginning of the slideshow marked with the first step. This once again enables the worker to
immediately start the next box without the added effort of interacting with the laptop.
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Figure 2. The picture above shows all the components of the workstation: the insert folding device,
the interactive learning device, the hand tool, and the middle fold clip.
Development
The cardboard insert folding device was developed for use by individuals working at New Horizons
Corporation folding the specific Dell insert box shown above. It was developed with the intent that
all workers, whether mentally or physically challenged (or both), would be given the opportunity to
fold a box to its completion without any support or guidance from supervisors. The development of
the device would ultimately provide many workers a sense of independence and accomplishment in
the workplace that was previously unattainable. There is currently no product comparable to this
device on the market. Before its creation, workers had nothing but a folding table, a supervisor, and
their hands to complete this complicated folding process.
Throughout the various stages of development, the NISH supervisor Tommy Hall, as well as
Special Education Professor Kim Paulsen, were contacted and informed on the design progress and
effectiveness. They, along with the workers’ individual supervisors at New Horizons, were
questioned to provide valuable input on the design and its implementation for the workers based on
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their professional and personal opinions. Below one will see a complete list of the materials used to
create the prototype and their associated costs.
Prototype Cost
Item Quantity Cost Total
Plywood Base 1 $9.98 $9.98
Plexiglass (usable for 4) 1 $13.65 $13.65
1-1/2" Angle Brackets 3 $0.78 $2.34
3/4" Angle Brackets 2 $0.50 $1.00
Epoxy Adhesive 1 $2.97 $2.97
Handle (for Hand Tool) 1 $2.00 $2.00
Hinge (for Hand Tool) 1 $1.99 $1.99
Bag Clip (to hold middle fold) 1 $1.99 $1.99
Bending Stopping Rod (from a lamp) 1 $10.00 $10.00
Non-slip Rubber Pads (package of 4) 1 $3.99 $3.99
Laptop (variable, could be donated or old) 1 - -
TOTAL COST = $49.91
Table 1. The above table details the costs associated with construction of the project. Keeping the costs to a minimum was important to potentially create multiple reproductions of the device for
large-scale adoption of the process.
RESULTS
Test Subject One
0:00
0:14
0:28
0:43
0:57
1:12
1:26
0 2 4 6 8
Trial
Tim
e
First Trial w/ Device
Without Device
Second Trial w/ Device
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Graph 1. The plot of test subject one shows three different sets of data: the first trial with the device, the second trial with the device, and time trials without using the device. The first trial did not show much improvement due to training and learning. The second trial displayed significant
improvement.
Test Subject Two
0:00
0:28
0:57
1:26
1:55
2:24
2:52
0 5 10 15 20 25
Trial
Tim
e
First Trial w/ Device
Graph 2. The plot of test subject two shows the gradual improvement of the subject using the device. Most importantly, this test subject could not previously fold an entire box without
assistance.
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Test Subject 3
0:00
0:28
0:57
1:26
1:55
2:24
2:52
3:21
0 1 2 3 4 5 6 7 8
Trial
Tim
e
First Trial w/ Device
Without Device
Graph 3. The plot of test subject three shows two sets of data: the subject using the device and using her own method. The subject’s time improved quite drastically in the first seven attempts at
using the device.
Discussion
Test Subject One was able to fold the box sufficiently without any assistance. She folded the insert
on the table so that adjusting to the device was not difficult. The first try with it proved to be
somewhat effective, but she struggled with the last fold. After completing seven trials, the folding
process was demonstrated to the test subject as many times as she wanted so that she felt
comfortable with the last step of the insert. Another adjustment was that the chair she sat in was
moved closer to the table so that she could reach the end of the jig easier. The second try with the
jig was much more effective after the training and seat adjustment and by the end of seven trials the
test subject was folding inserts faster than when she folded them using her own method.
Test Subject Two was one worker that beforehand was unable to complete a full box. He was only
capable of making the first few folds. He did not possess the motor skills needed to hold the box
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and simultaneously make the remaining folds. The folding device proved to be successful in that it
provided a sturdy base where the box could rest, which thus allowed him to complete the folding
process. Additionally, the video helped the individual see and process the steps so that he could
apply them to the box in front of him. The most complicated of the folds had to be further broken
down into several steps for this to work.
Test Subject Three was an employee who was already successful at folding the box and had
extensive experience in folding it without the table at all. The execution of the folding process on
the table was consequently awkward for her. She preferred to fold the box in the air in front of
herself. Despite her preference, she was still able to reduce the amount of time required to fold a
box using the device. This indicates that given time and repeated use, she could be as productive
with the device as without it.
The device proved to be successful in teaching one how to properly carry out all folds in the box-
folding process. Despite previously being unable to fold an entire box, a New Horizons worker
walked away from the test period having folded twenty complete boxes with only minor
supervision. The device allowed him to free his hands from holding the box, allowing him to focus
strictly on the folds. The videos allowed him to see the correct folding technique over and over
again and apply it to the box in front of him. Without the device, he was averaging twenty seconds,
completing only a fraction of the box. With the device he was averaging about a minute to
complete the whole box.
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Development was planned to deliver a final product that would be as user-friendly as possible. The
simplicity of the application and execution of the folding process was of the utmost importance in
the development of this prototype. Other concerns were cost, transportability, and safety. The
device falls within cost restraints as shown by the relatively low cost shown in Table 1 (Page 7).
The device is heavy enough to remain stationary when in use, but also light enough to be
transported to the workstation. Safety was taken into consideration as well. All cut edges were
sanded smooth, and the folding device contains no moving parts to avoid injuries caused by such
devices (pinching fingers, hands, cuts, etc). The clamp to hold the middle fold is strong enough to
hold the box, yet not strong enough to injure a worker. The tab-inserting hand tool has a blunt edge.
There are rubber non-slip pads attached to the bottom corners of the device to prevent slipping and
sliding.
Economically the project was fully capable of fulfilling the niche market present at New Horizons
for the assistive technology. At most New Horizons would probably utilize anywhere from 5-15 of
these prototypes to assist their employees in the folding process. They would most likely just
purchase these units to assist those who are currently unable to completely fold a box themselves.
The development costs consisted of 4 students @ $20/hour, 430 hours, and parts for one prototype
($50) = $34,450. The potential benefits when assuming that we increase the speed of only 10
workers from 2 minutes to 1 minute and 30 seconds = an increase in pay of $40 each per day or
$400 per day total for all workers. That increase total when totaled over a year (assuming at least
two weeks of non-pay vacation) = $140,000 increase in wages for employees. Cost of maintenance
is minimal due to the nature of the work and the non-moving construction. There would be no
marketing costs associated with the product and the lifecycle would be at least a couple years. The
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risk is minimal while showing significant potential benefits. This device could also potentially
reduce time and money spent on re-training current employees and training new employees. There
are no regulatory hurdles to implementation.
CONCLUSIONS
Our device has shown through testing to be successful in assisting individuals with mental and
physical handicaps in the workplace. In summary, our device through the use of the interactive
learning program and folding device allowed all test subjects to completely fold the cardboard insert
regardless of their ability to fold the insert before. After minimal training time, all test subjects
were able to fold the box in at least or less time then before, meaning that workers’ wages will
either increase, or at least stay the same, since wages are based on number of inserts folded.
Our results show that our system succeeded in improving the ability of workers with disabilities to
function and succeed in the workplace while simultaneously meeting the restraints of size and cost.
RECOMMENDATIONS
Ethically this project provides a great benefit to a sector of society. The severely mentally and
physically handicapped community deserves a chance like everyone else to earn a respectable
living. Our device helps them in achieving that goal of becoming self-sufficient in the workplace.
The device is safe by OSHA standards and considered ready for implementation (5). These devices
would also keep New Horizons aligned with EEOC (6) standards.
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REFERENCES
1. Paulsen, Dr. Kim. Personal interview. 6 Feb. 2008.
2. Goodwill Industries of Middle Tennessee, Inc http://www.goodwillmidten.org/
3. New Horizons Corporation http://www.newhorizonscorp.com/
4. NISH - National Institute for the Severely Handicapped http://www.nish.org
5. OSHA – Occupational Safety & Health Administration http://www.osha.gov/
6. EEOC – Equal Employment Opportunity Commission http://www.eeoc.gov/
ACKNOWLEDGEMENTS
Kevin Ryan
Professor Paul King
Tommy Hall
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Appendix A – New Horizons Corporation
INNOVATION WORKBENCH SOLUTIONS
Ideation Process
Project Initiation
Project name:
NISH Projects: Improvements in Industry for Disabled Workers
Project timeline:
Expected Completion Date: NISH Submission Deadline-April 11, 2008
Project team:
Walter Yehl
Austin Healy
Brian Piazza
David Sharvin
Innovation Situation Questionnaire
Brief description of the situation
The project will focus on expanding and improving opportunities for disabled workers.
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Detailed description of the situation
The main goal of this project is to create opportunities for disabled workers. Improving working
conditions, increasing wages, and breaking complex tasks into simpler tasks are all project
guidelines.
The project consists of a prototype design for an assembly station where flat cardboard cutouts are
folded into computer box inserts. The box inserts are currently folded for wages at a rate of $0.045
per insert. If the insert folding station can assist their fold more quickly, it will increase their wages.
Measurement of success will be quantitatively and qualitatively assessed by New Horizons
Corporation and NISH review board for the NISH project. More details of this will be discussed in
further detail with the project advisors Tommy Hall and Kevin Ryan.
Supersystem - System - Subsystems
System name
Box Insert Assembly
System structure
The system consists of a table holding the cardboard cutouts. The employee picks up one of the
cutouts and executes a series of folds. The folds produce an insert that is then stacked on a palette
in a uniform format that maximizes the number that can fit on an individual palette.
Supersystems and environment
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The employee is working inside a manufacturing assembly warehouse. The Supervisor monitors
the process from the assembly floor.
Systems with similar problems
Assembly plants often try to make processes as simple and efficient as possible when making
foldable inserts. Similar processes are probably used in assembly of cardboard athletic equipment
holders made for basketballs, footballs, and soccer balls sold in stores.
Input - Process - Output
Functioning of the system
The cardboard cutout is delivered to New Horizons. They are stacked and placed near the
workstations. The employees grab a stack of cardboard cutouts and fold them one after another.
This employee stacks the folded cutouts on the palette for shipment.
System inputs
New Horizons provides the cardboard cutout to its employees.
System outputs
A palette of cardboard cutouts folded and ready for shipping to the customer.
Cause - Problem - Effect
Problem to be resolved
Create a faster means of folding the cardboard inserts for mentally handicapped individuals
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Undesirable consequences if the problem is not resolved
New device may cause a decrease in salary for individuals and decrease efficiency if not efficient
Other problems to be solved
The process the company used to deliver boxes to individual workstations, in order to increase
efficiency
Past - Present - Future
History of the problem
The basic problem is to create a more efficient process by using a tool or device and humans have
been using devices to accomplish better efficiency throughout history. We are taking an
occupation of folding cardboard inserts and are working to devise a tool to expedite the process
Pre-process time
Non-available because we can make changes to the box itself
Post-process time
Since the process is simple there are no post-process advancements that can currently be made
Resources, constraints and limitations
Available resources
Vanderbilt Library for research materials
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Vanderbilt Professors
BME 272 construction lab
NISH Contact Kevin Ryan
Constraints and limitations
The prototype must be completed by Senior Design Day-April 2008. The prototype must also be
able to fit on a standard tabletop (96” x 30”).
Criteria for selecting solution concepts
The criteria for selecting these solution concepts are timelines, economic impact and safety. These
solutions will hopefully allow for both of these companies to accomplish work more efficiently.
This will result in an economic impact. The cost is also important criteria for selecting these
concepts. Both of the solution we are considering will have low cost and lead to more profits with
the increased efficiency. Safety is also a concern for this product. These devices need to be as safe
or increase the safety of the jobs performed in the way they currently are.
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Image 1 IWB Conflict Map New Horizons
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Appendix B – Goodwill Report
Goodwill Report
Abstract
Goodwill in middle Tennessee collects all of the donated clothes and sorts them for
distribution to the area stores. Before the clothes can go to the stores, they must be tagged according
to size and price, which is denoted by a certain color tag and label. The system consists of clothes
that are all waiting to be tagged and sized. Currently, the items must be tagged while hanging on
racks, which require the worker to stand and operate a tagging gun. Disabled workers in
wheelchairs or canes and those that struggle with basic motor skills are not able to perform this job
function. The security tags are applied to the clothing by needle that is inserted on a seam with a
handheld tagging gun.
The main goal of this project is to create opportunities for disabled workers. Improving
working conditions, increasing wages, and breaking complex tasks into simpler tasks are all great
project guidelines.
Proposed Solution
The solution would consist of a prototype that will streamline a process for tagging and
sizing clothing for sale. A table station for tagging and sizing would allow wheelchair individuals
an opportunity to execute the job function as well and streamline the process. Additionally, the
handheld tagging gun would be replaced with a mountable model that would increase safety
because of the guards around the needle in place on the device.
The table mounted tagging gun is manufactured by Avery Dennison Fasteners and is the
Industrial Long Needle Tool (1). A simple table can be made using wood or any other commercially
viable material that has clearance for a wheelchair. The Innovation Workbench in figure 1 shows
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how the new tagging table and process would improve worker efficiency and expand opportunities
for disabled workers.
Figure 1: Innovation Workbench- Goodwill Project
Goodwill Contact: Mike Eisenbraun
References
Avery Dennison Fasteners. February 6 2008
http://www.fastener.averydennison.com/sub.aspx?id=460
