Factory Automation Competition Game Manual 2024-25

FOUNDATION REC

GAME MANUAL 2024 2025

VERSION 1.0 ROBOTICSEDUCATION.ORG/FAC

FACTORY AUTOMATION COMPETITION

REC Foundation Permission This Competition Manual is the exclusive intellectual property of Robotics Education & Competition Foundation Inc. (“RECF”). RECF grants you a limited license to use this Competition Manual only in connection with official RECF events. All other uses are expressly prohibited without RECF’s written authorization. You may not modify, copy, prepare derivative works, publicly display, distribute, or remove any copyright or other proprietary notations in this manual. Any use of this manual for commercial purposes without RECF’s permission is strictly prohibited. To request authorization to use this manual for any other purpose, or if you have any questions about the scope of permissible uses, please contact RECF at support@recf.org.

Robotics Education & Competition Foundation Factory Automation Competition (FAC)

Version 1.0

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TABLE OF CONTENTS

Section Three 16 Global Competition 16 How to Register 16 Global Rankings 16 Video Parameters

Section One 05 The Game 06 Game Definitions 08 Competition Phases 10 Scoring 12 Rules

Appendix 18 Guide to Judging and Awards

Section Two 14 The Workcell

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INTRODUCTION FACTORY AUTOMATION COMPETITION

There has never been a higher demand for advanced manufacturing and STEM- related jobs, with an estimated 2.5 million STEM jobs going unfilled today.

The focus of this program is to offer a comprehensive and scalable competition that helps change attitudes toward advanced manufacturing careers, bestow critical workforce skills, reduce the growing skills gap, and ultimately create a stable pipeline of industry 4.0 employees. The Robotics Education & Competition Foundation’s mission is to provide every educator with competition, education, and workforce readiness programs to increase student engagement in science, technology, engineering, math, and computer science. The Factory Automation Competition is a classroom-based competition that provides students from across the world the opportunity to integrate and recognize how STEM skills translate to the workforce. This unique manufacturing competition exposes students to robotics manufacturing careers while providing curriculum, training, and hands-on problem- solving skills. The REC Foundation aims to improve workforce education and interest by providing a clear path for students to prepare for advanced manufacturing careers, help close manufacturing skills gaps for many employers, and prepare the future manufacturing workforce for continual development.

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THE GAME: ELEVATION INTEGRATION

Manufacturing

Teamwork

Communication

STEM Principles

Game Description The 2024-2025 Factory Automation Competition game, Elevation Integration, is a classroom-based competition where teams will compete to achieve the best Throughput and Run Time at different Competition Phases. Students design, build, and program a manufacturing Workcell to complete each Competition Phase. Participants submit a video of a Production Run to Robotevents.com, and their scores are recorded on a global leaderboard. Teams from across the world will compete from their classrooms to achieve the highest global rank based on their scores at each Competition Phase.

Elevation Integration Game Objects

Quantity Game Object

7 Red Products 7 Green Products 7 Blue Products 6 Defective Products

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GAME DEFINITIONS Adult Anyone who is not a Student. Auto Shipped

Delivery Zone An identified area where the Shipped Order will be placed. This can be an area outside of the Workcell or an addition to the Workcell. Designer The Student(s) on the Team who design(s) the Workcell to be built for competition. An Adult cannot be the Designer on a Team. Adults are permitted to teach the Designer associated concepts, but may never work on the design of the Workcell without the Student Designer present and actively participating. Elevated Storage Zone An area identified on the Workcell used to store the Packages compiled in Phase 1. This zone must be a minimum of 6 inches above the Package Zone. Emergency Stop (E-Stop) Button A simple, highly visible button designed to shut down the entire Workcell once pressed. This must use a V5 Bumper switch and be accessible at all times. Teams must demonstrate that the Emergency Stop Button works in each Production Run submission. Factory Area Flat work surface that contains the Beginning Inventory Storage, Defect Designation/Fix Zone, Package Zone, Elevated Storage Zone, and Shipping Zone. Home Base Plate The V5 Brain and the Team ID plate are required to be mounted to a VEX Robotics 15 x 30 Base Plate (276-1341). Mishandled Product Any dropped Product. Products may be dropped from the Workcell, by humans, or while moving through a Production Run. Order The combination of Packages, specified by an order card, that must be retrieved from the Elevated Storage Zone and Shipped to the Delivery Zone.

An order is Auto Shipped if it is moved from the Shipping Zone to the Delivery Zone without assistance from any team members. Beginning Inventory Storage The initial starting location for Products. The Beginning Inventory Storage should be randomized with (7) Red, (7) Green, (7) Blue, and (6) Defective Product. Builder The Student(s) on the Team who assemble(s) the Workcell. An Adult cannot be the Builder on a Team. Adults can teach the builder associated concepts but may never work on the Workcell without the student Builder present and actively participating. Competition Phase A defined set of goals or tasks required to be completed in order to advance to the next Competition Phase. Defect Designation/Fix Zone An identified area where the Defective Product will be placed by the Workcell and fixed by a Student before being returned to the Beginning Inventory Storage. Defective Product Product designated by the Team to not pass inspection. A Defective Product could be a combination of colors, missing the magnet, be too heavy, etc. The Defective Product must be presented at the beginning of the video submission for each phase with an explanation of why it is considered a Defective Product. The Defective Product must also have a visual mark to be able to visually identify it throughout the Production Run.

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Order Card A card listing the combination of Packages (2 Packages) required for the selected Order. Order Cards can be found here. Order Card(s) will be randomly selected by the Team prior to the Production Run in Competition Phase 3: Shipping. Package A container designed and created by the Team to hold three (3) Products of the same color. Examples of Packages could be 3D printed boxes or a container created with VEX parts that would contain 3 Red Products or 3 Blue Products or 3 Green Products. Package Zone An area identified on the Workcell where each Product must be compiled by color into a Package. Product Red, Green, or Blue Cylindrical shaped game objects included with the V5 Workcell kit. Students may also create their own 3D printed objects, provided that they are cylindrical or rectangular in shape and adhere to the following sizing: Cylindrical - 63.2mm (diameter) x 12.45mm (height) Rectangular- 63.2 x 12.45 x 63.2mm Production Run A Production Run consists of an attempt to complete a Competition Phase. Programmer The Student(s) on the Team who write(s) the computer code that is downloaded onto the Workcell. An Adult cannot be the Programmer on a Team. Adults are permitted to teach the Programmer associated concepts, but may never be working on the code that goes on the Workcell without the student Programmer present and actively participating. Run Time The amount of time it takes to complete a Competition Phase. The Competition Phase 3 Run Time will be used as a tiebreaker for the global leader board.

Shipped An Order is Shipped if it is moved as a unit from the Shipping Zone to the Delivery Zone with no human interaction. Shipping Zone An identified area on the lower level of the Workcell where Orders will be placed after retrieval from the Elevated Storage Zone. Student Anyone who is earning or has earned credit toward a secondary school (i.e., high school) diploma, certificate, or other equivalent during the six (6) months preceding June 1, 2025. Team One or more Students make up a Team. A Team is classified as a high school Team if any of its members are high school Students or made up of middle school Students who declare themselves "playing up" as high school Students by registering their team as a high school Team. A Team is classified as a college Team if any of the members are college Students. Teams may be associated with schools, community/youth organizations, or a group of neighborhood Students. Team ID Plates The Team ID Plate is included in the VEX V5 Workcell Kit. This allows the team to display their team number in video submissions. V5 Robot Arm The programmable mechanical arm used in the Factory Automation Competition (276-7151). Workcell A collection of VEX Robotics 15 x 30 Base Plates (276-1341) with the V5 Brain (276-4810), Products, Robotic Arm(s), and any supporting material attached.

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COMPETITION PHASES

PHASE 2

PHASE 3

PHASE 1

Sort and Package all Product and move all Packages

Fulfill Orders by pulling Packages from the Elevated Storage Zone to finalize Shipments.

Sort and Package Product by color while removing and fixing any Defective Product.

to an Elevated Storage Zone.

Competition Phase 1 (Packing) • Show on camera and verbally describe how the Defective Product is created. • Randomize the placement of Product and Defective Product in the Beginning Inventory Storage. • Assemble the Packages in the Package Zone. • Any Defective Products must be: • Identified by the Workcell within a Production Run. • Moved to the Defect Designation/Fix Zone. • Fixed by the Student. • Placed back into the Beginning Inventory Storage. (can be done by the student) • If a Package has been filled with the correct amount of Product, any additional Product of that same color moving through the Production Run must be returned to the Beginning Inventory Storage until all Packages have been assembled and the Production Run is complete. For Phase 1 the extra Product may be manually placed back in the Beginning Inventory Storage by a student once it is safely removed from the Workcell.

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Competition Phase 2 (Storing) • Show on camera and verbally describe how the Defective Product is created. • Randomize the placement of Product and Defective Product in the Beginning Inventory Storage. • Assemble the Packages in the Package Zone. • Any Defect Products must be: • Identified by the Workcell within a Production Run. • Moved to the Defect Designation/Fix Zone. • Fixed by the Student. • Placed back into the Beginning Inventory Storage. (can be done by the student) • If a Package has been filled with the correct amount of Product, any additional Product of that same color moving through the Production Run must be returned to the Beginning Inventory Storage until all Packages have been assembled and the Production Run is complete. For Phase 2, the extra Product must be moved to the Beginning Inventory Zone by the Workcell, without any human interaction. • All Packages must be moved from the Packing Zone to the Elevated Storage Zone with no human interaction. Competition Phase 3 (Shipping) • Show on camera and verbally describe how the Defective Product is created. • Randomize the placement of Product and Defective Product in the Beginning Inventory Storage. • Assemble the Packages in the Package Zone. • Any Defective Products must be: • Identified by the Workcell within a Production Run. • Moved to the Defect Designation/Fix Zone. • Fixed by the Student. • Placed back into the Beginning Inventory Storage. (must be automated) • If a Package has been filled with the correct amount of Product, any additional Product of that same color moving through the Production Run must be returned to the Beginning Inventory Storage until all Packages have been assembled and the Production Run is complete. The extra Product must be moved to the Beginning Inventory Zone by the Workcell, without any human interaction. • All Packages must be moved from the Packing Zone to the Elevated Storage Zone with no human interaction. • Orders must be entered into the Workcell by randomly choosing four (4) Order Cards. • All Orders must be retrieved from the Elevated Storage Zone and moved to the Shipping Zone. • The Workcell must fulfill all Orders. If Orders cannot be fulfilled due to not enough Packages in the Elevated Storage Zone, the Workcell must reject that Order and notify the team (This can be a sound, a message on the brain, etc). Teams must continue to input Orders until four (4) Orders have been completed. • All Orders must be Auto Shipped to the Delivery Zone.

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SCORING COMPETITION PHASES

Competition Phase 1: Packing • Identifies the Defective Product (2 Points) • Explains why the Product is Defective (2 Points) • Makes the Defective Product visibly identifiable (1 Point) • Each Defective Product that goes through the Production Run is removed and fixed (3 Points) • Any Defective Product that is placed in an order will negate (2 Points) • Any Mishandled Product or Defective Product will negate (2 Points) • Assemble all Package with three (3) Products of the same color; (1 Point per correct Product placed in each Package, up to 9 Points total, including the fixed Defective Product) • Bonus points for an automated process that places all extra Product back in the Beginning Inventory Storage (10 Points) Competition Phase 2: Storing • Identifies the Defective Product (2 Points) • Explains why the Product is Defective (2 Points) • Makes the Defective Product visibly identifiable (1 Point) • Each Defective Product that goes through the Production Run is removed and fixed (1 Point per Defective Product up to 6 Points total) • Any Defective Product that is placed in an order will negate (2 Points) • Any Mishandled Product or Defective Product will negate (2 Points) • Assemble a Package with three (3) Products of the same color; limit of one Package per color (1 Point per correct Product placed in each Package, up to 27 Points total) • Extra Product is placed back in the Beginning Inventory Storage using an automated process. (10 points) • Packages (3 Red Packages, 3 Blue Packages, 3 Green Packages) placed in the Elevated Storage Zone (1 point per package moved and an extra 5 points per color if they are organized by color up to 24 Points total, ex. All 9 packages moved and they are organized by color would be 9 points for moving the packages and 15 points for organization)

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Competition Phase 3: Shipping • Identifies the Defective Product (2 Points) • Explains why the Product is Defective (2 Points) • Makes the Defective Product visibly identifiable (1 Point) • Each Defective Product that goes through the Production Run is removed and fixed (1 Point per Defective Product up to 6 Points total) • Any Defective Product that is placed in an order will negate (2 Points) • Any Mishandled Product or Defective Product will negate (2 Points) • Assemble all Packages with three (3) Products of the same color; Package per color (1 Point per correct Product placed in each Package, up to 27 Points total, including the fixed Defective Product) • Extra Product is placed back in the Beginning Inventory Storage using an automated process (10 Points) • Packages (3 Red Packages, 3 Blue Packages, 3 Green Packages) placed in the Elevated Storage (1 point per package moved and an extra 5 points per color if they are organized by color up to 24 Points total) • All 4 Orders are removed from the Elevated Storage Zone (2 Points per Order up to 8 Points total) • All 4 Orders are Shipped (2 Points per Order up to 8 Points total)

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The intention of a Production Run is to have Product sorted into orders of like Products with any Defective Products removed and fixed. Packaged Product will be moved into an Elevated Storage Zone until Orders are needed to be filled, then Orders will be placed and filled by pulling Packages from the Elevated Storage Zone and Shipped. When designing your automated system, consider the possibility that your Product could be fragile and needs to be packed, handled, and shipped with care. Any Product that is just dropped or thrown off of the Workcell will be considered a Mishandled Product.

Safety Rules

S1: Each Workcell must contain a functioning Emergency Stop Button.

S2: Students must keep their hands outside the Workcell while the Workcell is running. Refer to <G5> if anything needs to be removed or fixed on the Workcell during a Production Run.

S3 : It is highly recommended that all Team members wear safety glasses while working on the Workcell.

S4 : Before attempting a Production Run, do a visual safety inspection to prevent damage to operators and equipment.

S 5 : Always power off the Workcell before making any adjustments.

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Game Rules

G1: Treat everyone with respect. This rule exists alongside the REC Foundation Code of Conduct. The Code of Conduct can be found here.

G2: FAC is a student-centered program. Adults should not make decisions about the Workcell’s build, design, or gameplay, and should not provide an unfair advantage by providing ‘help’ that is beyond the Students’ independent abilities. Students must be prepared to demonstrate an active understanding of their Workcell’s design, construction, and programming during their video interview. The Student-Centered Policy can be found here with this link included in that sentence like G1 above. G3 : Prior to the start of a Production Run, Students must verbally describe and show how each Defective Product has been created. Students must then randomize the Products and Defective Products in the Beginning Inventory Storage.

G4: Any Mishandled Product must remain where it is dropped until the end of the Production Run unless an error occurs and the E-stop is enabled.

G5: If an error occurs during a Production Run, students must use the E-stop to disable the Workcell and fix the error. Once the error is fixed, the Workcell may start up again. Any Product that Students interact with must go back into Beginning Inventory Storage before starting the Workcell again.

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SECTION TWO

WORKCELL RULES

W1: Workcells are built from the VEX V5 system Workcells may be built ONLY using official VEX V5 and VEX IQ components, unless otherwise specifically noted within these rules. Products from the VEXpro or VEX Robotics by HEXBUG* product line cannot be used for construction unless cross-listed as part of the VEX V5 system. Any parts which are identical to legal VEX parts are permitted. For the purposes of this rule, products which are identical in all ways except for color are permissible. *The HEXBUG brand is a registered trademark belonging to Spin Master Corp. W2: Custom Parts Teams are allowed to fabricate their own custom components for their Workcell utilizing the following additional raw materials: a. An unlimited amount of non-shattering plastic from the following list: polycarbonate, acetal homopolymer (Delrin), acetal copolymer (Acetron GP), POM (acetal), ABS, PEEK, PET, HDPE, LDPE, Nylon (all grades), Polypropylene, and FEP. b. An unlimited amount of silicone, polyurethane, or other rubber. c. An unlimited amount of composite materials, such as G10 (Garolite), FR-4, or carbon fiber. d. An unlimited number of plastic 3D printed parts. W3: A limited amount of tape is allowed Workcells may use a small amount of tape for the following purposes: a. For labeling wires and motors. b. For the purposes of preventing leaks on threaded portions of pneumatic fittings. This is the only acceptable use of Teflon tape. W4: Certain non-VEX screws, nuts, and washers are allowed #4, #6, #8, M3, M3.5, or M4 screws up to 2” (50.8mm) long (nominal), and any commercially available nut, washer, and/or spacer (up to 2” / 50.8mm long) to fit these screws may be used. The intent of this rule is to allow teams to purchase their own commodity hardware without introducing additional functionality not found in standard VEX equipment. W5: New VEX parts are legal Additional VEX components released during the competition season on vexrobotics.com are considered legal for use. Some “new” components may have certain restrictions placed on them upon their release. W6: Workcell Electronics Workcells must use exactly one (1) VEX V5 Robot Brain (276-4810). Workcells can only use up to twenty (20) 11 watt (276-4840) and/or 5.5 watt motors (276-4842). V5 Smart Motors, connected to Smart Ports, are the only motors that may be used with a V5 Robot Brain. The 3-wire ports may not be used to control motors of any kind.

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W7: Workcells must use one (1) VEX V5 Battery Pack There are no legal power expanders for the V5 Robot Battery (276-4811). V5 Robot Batteries may only be charged by the V5 Robot Battery Charger (276-4812). W8: Custom V5 Smart Cables are allowed Teams must use official V5 Smart Cable Stock but may use commodity 4P4C connectors and 4P4C crimping tools. Teams who create custom cables acknowledge that incorrect wiring may have undesired results. W9: No modifications to electronic components are allowed Motors (including Smart Motor firmware), micro controllers (including V5 Robot Brain firmware), extension cords, sensors, controllers, battery packs, reservoirs, solenoids, pneumatic cylinders, and any other electrical component or pneumatics component of the VEX platform may NOT be altered from their original state in ANY way. a. External wires on VEX electrical components may be repaired by soldering, using twist/crimp connectors, electrical tape, or shrink tubing such that the original functionality and length are not modified in any way. The wire used in repairs must be identical to VEX wire. b. Teams must use the latest official VEXos firmware updates, found at https://kb.vex.com/hc/en-us/ articles/360055338911-VEXos-V5-Firmware-Changelog. Custom firmware modifications are not permitted. c. Teams may change or replace the gear cartridge in the V5 Smart Motor with other official replacement gear cartridges. W10: Most modifications and repairs to non-electrical components are allowed Physical modifications such as bending or cutting are permitted and may be done to legal metal structures or plastic components. a. Metallurgical modifications that change fundamental material properties, such as heat treating, are not permitted. b. Teams may cut pneumatic tubing to the desired length. c. Teams are permitted to fuse/melt the end of the 1/8” nylon rope to prevent fraying. d. Welding, soldering, brazing, gluing, or attaching components in any way that is unsupported within the VEX platform is NOT permitted.

W11: Workcells must have a team identification plate attached The license plate with the team’s FAC Team ID# must be clearly visible on the Home Base Plate.

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SECTION THREE

GLOBAL COMPETITION

Overview Because the Factory Automation Competition is classroom-based, the REC Foundation has created a ranking system to allow teams to compete against themselves as well as other organizations. Teams will video record a Production Run with an explanation of the processes and how they function to achieve each Competition Phase. In order to be ranked globally, Teams must upload a video submission of their Production Run to Robotevents.com. Registration Learn how to register your Factory Automation Competition teams here. Registration is included in the purchase of a V5 Workcell for all teams.

Global Ranking T1: Teams must complete and submit phases sequentially.

Teams must complete each phase in sequence, starting with Competition Phase 1. To advance to the next phase, teams must successfully perform the specific tasks outlined in Section 2 for the current phase, submit a production run, and receive score verification. Only after these steps are completed can a team become eligible to move on to the next Competition Phase with:

T2: Teams are ranked within each Competition Phase based on the number of points scored.

T3: Team ranking tie breakers are determined as outlined below. a. Total Points Scored b. Total Throughput of Completed Orders c. Run Time for Competition Phase 3

Video Parameters V1: The Production Run video must be no longer than 5-minutes (5:00) in length, including credits. (Credits are not required).

V2: The video may be your team speaking, a voice-over storyboard, a voice-over PowerPoint, or any other video format of your choosing.

V3: Students must be the ones who research, design, write, edit, film, and produce the video. Mentors should have a very limited role in giving direction except for teaching the concepts of how to do something specific. The students should be able to produce a similar result on their own in the future without the aid of a mentor.

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V4: The video must be posted or uploaded to YouTube, SchoolTube, Youku, or an equivalent free video posting service. The link provided must open directly to the video and not require a password, login, or present any other impediment. Note: Links to Google Drive or Dropbox or any other “cloud drive” are not permitted.

V5: Teams must submit Production Run attempts via Robotevents.com.

V6: Video submissions must clearly state which Competition Phase the team is attempting.

V7: The video must have a stopwatch, clock timer on a smartphone, or another way of displaying time clearly visible to verify the Run Time. Any video without time verification will not be scored.

V8: The video must clearly display the Team ID Plate and Team number.

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APPENDIX

GUIDE TO JUDGING AND AWARDS

Overall Champion and Finalist Awards The Overall Champion and Finalist Awards celebrate excellence in a team’s Engineering Notebook, Interview, and Workcell performance. These honors recognize a team’s ability to approach the Engineering Design Process, project management, and team organization in a structured and professional manner. Demonstrating the Engineering Design Process is central to the educational value of REC Foundation programs, and these awards highlight a team’s ability to effectively document and explain their process through both the Engineering Notebook and Team Interview. The Overall Champion Award, in particular, acknowledges a well-crafted Workcell built with meticulous attention to detail, capable of efficiently completing the various phases of the competition. It also honors the most innovative and consistent use of coding techniques and programming design solutions to address the challenge. The Overall Champion and Finalist Awards will be determined based on the following criteria. The Overall Champion will be selected from the Finalists. A panel of judges will decide the award winners, and if necessary, an additional interview may be arranged with the Finalists. Key criteria of the Overall Champion Award are: • Be at or near the top of all Engineering Notebook Rubric rankings with a Fully Developed Notebook. The absolute minimum for a notebook to be considered Fully Developed is scores of two or higher for the first six criteria of the rubric. • Both the Team Interview and Engineering Notebook demonstrate independent inquiry from the beginning stages of their design process through execution. The team demonstrates how their inquiry guided their Workcell design and programming. Independent inquiry can take many forms, including speaking with engineers, touring factories virtually or in-person, and industry research. • Team embodies the student-centered ethos. • At the conclusion of the season, be in the top 30% of the global leaderboard . • Teams must be in the top 30% of the overall Engineering Notebook scores . • Teams must be in the top 30% of the overall Team Interview scores . • The Engineering Notebook is consistent with the qualities demonstrated in the team interview and Workcell design. • Team Interview demonstrates their ability to explain their workcell design and strategy. • Programs are cleanly written, well commented, and easy to follow. Team also clearly explains their management process/version control. • Students understand and explain how they worked together to develop their Workcell code.

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• Team demonstrates thorough testing throughout the design process by documenting the testing process and data used to make decisions. • Workcell construction is durable and robust, and is designed with attention to safety and detail. • Students understand and explain how they worked together to develop their Workcell design through effective project management. • Team Interview showcases effective communication skills, teamwork, and professionalism. • Team interview videos must be under 15 minutes. Any video submission that is longer than 15 minutes will be stopped at the 15 minute mark and nothing after that will be considered by the judges. Teams can incorporate presentations throughout their video to provide supporting evidence. All team members must be visible at all times during the video.

Questions