Ski boot walking attachment initial
From DDL Wiki
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'''Locking mechanisms''' – Each boot has four locking mechanisms (sub-assemblies) that consist of a geared belt and a spring loaded hook that hold the two sides of the boot tight to provide better fit for users. For more user friendly design, one of the buckling mechanisms (the bottom buckling mechanism of high ankle component) needs to have a rotating hook. However, manufacturing rotating hook requires production of two parts (the outer frame that will secure the hook to the boot and an inner hook that locks on the channel). In order to reduce the cost of manufacturing, the ski boot uses two rotating hooks and two rigid hooks as opposed to using four rotating hooks. Rigid hook (which is a single component as opposed to a sub-assembly) allows lower cost of manufacturing; therefore, by replacing rotating hooks with rigid ones where the hooks do not need to rotate, the manufacturing cost goes down. What is even more interesting about the buckling mechanisms used in this particular ski boot is that as opposed to using three rigid hooks and one rotating hook (the boot only needs one hook that needs to rotate), it uses two of each. This decision was made in order to reduce the time of production. While manufacturing rigid hooks would cost less, having to manufacture three rigid hooks for every rotating hook manufactured would cause idle time for the machinery that manufactures rotating hooks. By using equal numbers of the two hooks, manufactures not only reduce the cost, but also achieve the minimum time of production achievable. For a product like a ski boot (whose market demand fluctuates from season to season), minimal time of production could be essential as that would allow the manufactures to meet volatile market demand without having to spend significant amount of inventory cost. | '''Locking mechanisms''' – Each boot has four locking mechanisms (sub-assemblies) that consist of a geared belt and a spring loaded hook that hold the two sides of the boot tight to provide better fit for users. For more user friendly design, one of the buckling mechanisms (the bottom buckling mechanism of high ankle component) needs to have a rotating hook. However, manufacturing rotating hook requires production of two parts (the outer frame that will secure the hook to the boot and an inner hook that locks on the channel). In order to reduce the cost of manufacturing, the ski boot uses two rotating hooks and two rigid hooks as opposed to using four rotating hooks. Rigid hook (which is a single component as opposed to a sub-assembly) allows lower cost of manufacturing; therefore, by replacing rotating hooks with rigid ones where the hooks do not need to rotate, the manufacturing cost goes down. What is even more interesting about the buckling mechanisms used in this particular ski boot is that as opposed to using three rigid hooks and one rotating hook (the boot only needs one hook that needs to rotate), it uses two of each. This decision was made in order to reduce the time of production. While manufacturing rigid hooks would cost less, having to manufacture three rigid hooks for every rotating hook manufactured would cause idle time for the machinery that manufactures rotating hooks. By using equal numbers of the two hooks, manufactures not only reduce the cost, but also achieve the minimum time of production achievable. For a product like a ski boot (whose market demand fluctuates from season to season), minimal time of production could be essential as that would allow the manufactures to meet volatile market demand without having to spend significant amount of inventory cost. | ||
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'''Front and Rear rubber covers of the ski boot''' – Although ski boot itself requires separate castings for manufacturing right boot and left boot, the rubber covers for both feet are identical (just like the attachments). Also, the pattern on the bottom of the covers (made to provide the user with more traction) suggest that the front and the rear halves of the covers were manufactured in one casting, then cut into two separate pieces. Thus, identical designs used for both feet; and use of one casting for manufacturing both front and rear halves lead to significant reduction in capital cost. | '''Front and Rear rubber covers of the ski boot''' – Although ski boot itself requires separate castings for manufacturing right boot and left boot, the rubber covers for both feet are identical (just like the attachments). Also, the pattern on the bottom of the covers (made to provide the user with more traction) suggest that the front and the rear halves of the covers were manufactured in one casting, then cut into two separate pieces. Thus, identical designs used for both feet; and use of one casting for manufacturing both front and rear halves lead to significant reduction in capital cost. | ||
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'''''Attachment''''' | '''''Attachment''''' | ||
The ski boot attachment consists of three main sub-assemblies – front and rear soles, joint sub-assemblies (five joint pieces and a pair of pins), and spring loaded locking sub-assemblies. | The ski boot attachment consists of three main sub-assemblies – front and rear soles, joint sub-assemblies (five joint pieces and a pair of pins), and spring loaded locking sub-assemblies. | ||
| - | '''Front and Rear soles of the attachment''' – The soles of the attachment provide the user with better traction and more comfort during walking process than a normal ski boots do. These components are made of rubber to allow reasonable amount of elastic deformation under operations to serve as cushions that absorb impact of landing while providing the user’s feet with sufficient support. | + | |
| - | Unlike the ski boot itself (or any other foot ware), the attachment soles’ design are identical for both feet. This leads to a significant reduction in manufacturing cost as the manufacturing process requires only one set of casting for rubber molding as opposed to two. | + | '''Front and Rear soles of the attachment''' – The soles of the attachment provide the user with better traction and more comfort during walking process than a normal ski boots do. These components are made of rubber to allow reasonable amount of elastic deformation under operations to serve as cushions that absorb impact of landing while providing the user’s feet with sufficient support. Unlike the ski boot itself (or any other foot ware), the attachment soles’ design are identical for both feet. This leads to a significant reduction in manufacturing cost as the manufacturing process requires only one set of casting for rubber molding as opposed to two. |
| + | |||
'''Spring loaded adjustable locking mechanism''' – | '''Spring loaded adjustable locking mechanism''' – | ||
=Design for Assembly (DFA)= | =Design for Assembly (DFA)= | ||
A design for assembly analysis discusses how each component of the product was designed to minimize the time and cost of assembly. The DFA on the main components (and sub-assemblies) of the ski boot and the attachment are listed below. | A design for assembly analysis discusses how each component of the product was designed to minimize the time and cost of assembly. The DFA on the main components (and sub-assemblies) of the ski boot and the attachment are listed below. | ||
| - | Ski Boot | + | '''''Ski Boot''''' |
| - | Plastic frame of the boot – The bottom of the ski-boot (where the rubber covers are put on) has series of channels so that the covers can be secured even without using screws. This allows manufactures to easily place the covers on the right place without having to line up the parts. | + | |
| + | '''Plastic frame of the boot''' – The bottom of the ski-boot (where the rubber covers are put on) has series of channels so that the covers can be secured even without using screws. This allows manufactures to easily place the covers on the right place without having to line up the parts. | ||
Revision as of 20:09, 20 September 2008
Contents |
Executive Summary
Brandon
Needs & Stakeholders
Brandon
Product Use & Function
Jarrett, Brandon
Bill of Materials
Jarrett
| Part Number | Image | Name | Qty | Function | Material | Manuf. Process |
|---|---|---|---|---|---|---|
| 1 |  | Widget | .618 | Be a widget | Widgetite | Sorcery |
| 2 |
Design for Manufacture and Assembly (DFMA)
A “Design for Manufacture and Assembly” (DFMA) analysis of a product evaluates the efficiency of the product design in terms of the ease and low cost of the manufacturing and assembly stages. The following discussion examines why certain components of the ski boot and its attachment were made in the specific manufacturing process. It also discusses the possibilities and feasibilities of improving the product design through either reducing the number of components (for reduced manufacturing costs) or redesigning of components (for easier and quicker; hence, more cost efficient assembly). In addition, a DFMA analysis complements a Failure Modes Effects Analysis (FMEA) as it seeks to improve the overall product design rather than just focusing on preventions of a failure.
Design for Manufacture (DFM)
The design for manufacture analysis discusses how individual components of the ski boot and its attachment were manufactured in order to optimize the ease and cost of manufacturing process. The analyses on the main components of the ski boot and the attachment are provided below.
Ski Boot The components of ski boot could be divided into five major categories – the plastic frame, the inner plastic sole, the inner boot, series of (four sets for each foot) locking mechanisms, and front and rear bottom covers. In the following analyses, the design features that optimize the efficiency of manufacturing process, found in the plastic frame, locking mechanisms, and bottom covers are summarized. Plastic frame of the boot –
Locking mechanisms – Each boot has four locking mechanisms (sub-assemblies) that consist of a geared belt and a spring loaded hook that hold the two sides of the boot tight to provide better fit for users. For more user friendly design, one of the buckling mechanisms (the bottom buckling mechanism of high ankle component) needs to have a rotating hook. However, manufacturing rotating hook requires production of two parts (the outer frame that will secure the hook to the boot and an inner hook that locks on the channel). In order to reduce the cost of manufacturing, the ski boot uses two rotating hooks and two rigid hooks as opposed to using four rotating hooks. Rigid hook (which is a single component as opposed to a sub-assembly) allows lower cost of manufacturing; therefore, by replacing rotating hooks with rigid ones where the hooks do not need to rotate, the manufacturing cost goes down. What is even more interesting about the buckling mechanisms used in this particular ski boot is that as opposed to using three rigid hooks and one rotating hook (the boot only needs one hook that needs to rotate), it uses two of each. This decision was made in order to reduce the time of production. While manufacturing rigid hooks would cost less, having to manufacture three rigid hooks for every rotating hook manufactured would cause idle time for the machinery that manufactures rotating hooks. By using equal numbers of the two hooks, manufactures not only reduce the cost, but also achieve the minimum time of production achievable. For a product like a ski boot (whose market demand fluctuates from season to season), minimal time of production could be essential as that would allow the manufactures to meet volatile market demand without having to spend significant amount of inventory cost.
Front and Rear rubber covers of the ski boot – Although ski boot itself requires separate castings for manufacturing right boot and left boot, the rubber covers for both feet are identical (just like the attachments). Also, the pattern on the bottom of the covers (made to provide the user with more traction) suggest that the front and the rear halves of the covers were manufactured in one casting, then cut into two separate pieces. Thus, identical designs used for both feet; and use of one casting for manufacturing both front and rear halves lead to significant reduction in capital cost.
Attachment The ski boot attachment consists of three main sub-assemblies – front and rear soles, joint sub-assemblies (five joint pieces and a pair of pins), and spring loaded locking sub-assemblies.
Front and Rear soles of the attachment – The soles of the attachment provide the user with better traction and more comfort during walking process than a normal ski boots do. These components are made of rubber to allow reasonable amount of elastic deformation under operations to serve as cushions that absorb impact of landing while providing the user’s feet with sufficient support. Unlike the ski boot itself (or any other foot ware), the attachment soles’ design are identical for both feet. This leads to a significant reduction in manufacturing cost as the manufacturing process requires only one set of casting for rubber molding as opposed to two.
Spring loaded adjustable locking mechanism –
Design for Assembly (DFA)
A design for assembly analysis discusses how each component of the product was designed to minimize the time and cost of assembly. The DFA on the main components (and sub-assemblies) of the ski boot and the attachment are listed below. Ski Boot
Plastic frame of the boot – The bottom of the ski-boot (where the rubber covers are put on) has series of channels so that the covers can be secured even without using screws. This allows manufactures to easily place the covers on the right place without having to line up the parts.
More texts to come
DFE
Taka
FMEA
Randy
| Item & Function | Failure Mode | Effects of Failure | S | Causes of Failure | O | Design Controls | D | RPN | Recommended Actions | Responsibility & Deadline | Actions Taken | S | O | D | RPN |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Perpetual Motion Driver | three | point | one | four | one | five | ten | just kidding | nine | two | six | five | three | five | eight |
| Cold Fusion Reactor | Talc | Gypsum | Calcite | Fluorite | Apatite | Feldspar | Quartz | Topaz | Corundum | Diamond | Social interaction | Walking in ski boots | ? | ? | ? |
Analysis
Taka, Jarrett, Randy, Brandon
