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Line 204: |
Line 204: |
| |- valgin="center" | | |- valgin="center" |
| | rowspan=4 style="text-align: center;" | 001 | | | rowspan=4 style="text-align: center;" | 001 |
- | | rowspan=4 | Plastic Casing | + | | rowspan=4 | Dispensor spring |
- | * Enclose and protect internal components | + | * Closes dispensor when not in use |
- | * Shield user from internal components and heat | + | * Prevents dough from escaping when not desired |
- | | rowspan=2 | Warped | + | | rowspan=2 | ?? |
| | rowspan=2 | Improper fit, Unintended contact with heating element | | | rowspan=2 | Improper fit, Unintended contact with heating element |
| | rowspan=2 style="text-align: center;" | '''6''' | | | rowspan=2 style="text-align: center;" | '''6''' |
Line 223: |
Line 223: |
| | style="text-align: center;" | '''1''' | | | style="text-align: center;" | '''1''' |
| | Incorrect material / process || '''1''' || Material Selection, Mold Specs || '''1''' || style="text-align: center;" | '''1''' || None || Manufacturing | | | Incorrect material / process || '''1''' || Material Selection, Mold Specs || '''1''' || style="text-align: center;" | '''1''' || None || Manufacturing |
- | |-
| |
- | | rowspan=2 style="text-align: center;" | 002
| |
- | | rowspan=2 | Crumb Tray
| |
- | * Ease the process of removing crumbs
| |
- | * Keep toaster clean
| |
- | | rowspan=2 | Warped, Bent
| |
- | | rowspan=2 | Will no longer fit in bottom of toaster, may get stuck in toaster
| |
- | | rowspan=2 | '''3'''
| |
- | | Improper manufacturing || '''4''' || Assign process and tolerance || '''1''' || style="text-align: center;" | '''12''' || none || Manufacturing
| |
- | |-
| |
- | | Cleaning, bent while in use || '''7''' || Material selection || '''4''' || style="text-align: center;" | '''84''' || HALT for typical washing cycles || Reliability
| |
- | |-
| |
- | | rowspan=3 style="text-align: center;" | 003
| |
- | | rowspan=3 | Crumb Tray Handle
| |
- | * Enable removal of crumb tray
| |
- | | rowspan=2 | Warped
| |
- | | Improper fit onto crumb tray
| |
- | | '''4'''
| |
- | | Incorrect manufacturing || '''1''' || Assign process and tolerance || '''1''' || style="text-align: center;" | '''4''' || None || Assembly
| |
- | |-
| |
- | | Improper fit when slid into assembly, may stick out too far
| |
- | | '''3'''
| |
- | | Incorrect manufacturing || '''1''' || Assign process and tolerance || '''1''' || style="text-align: center;" | '''3''' || None || Assembly
| |
- | |-
| |
- | | Broken attachment clip
| |
- | | Handle may disconnect from tray
| |
- | | '''4'''
| |
- | | Incorrect manufacturing or assembly || '''2''' || Assign process || '''1''' || style="text-align: center;" | '''8''' || None || Assembly
| |
- | |-
| |
- | | rowspan=2 style="text-align: center;" | 004
| |
- | | rowspan=2 | Toaster Top
| |
- | * Protects user from internal components
| |
- | * Aligns components and material to be toasted
| |
- | | Warped, Bent
| |
- | | Misaligned components
| |
- | | '''8'''
| |
- | | Improper Manufacturing || '''2''' || Assign process, Material selection || '''1''' || style="text-align: center;" | '''16''' || None || Manufacturing
| |
- | |-
| |
- | | Corroded
| |
- | | Deterioration of part
| |
- | | '''2'''
| |
- | | Heavy use, poor upkeep || '''2''' || Material selection || '''1''' || style="text-align: center;" | '''4''' || None || Design
| |
- | |-
| |
- | | rowspan=2 style="text-align: center;" | 005
| |
- | | rowspan=2 | Toaster Base
| |
- | * Protects user from internal components
| |
- | * Aligns components
| |
- | | Warped
| |
- | | Misalignment of components
| |
- | | '''8'''
| |
- | | Improper manufacturing || '''1''' || Specify process, Material selection || '''1''' || style="text-align: center;" | '''8''' || None || Manufacturing
| |
- | |-
| |
- | | Fractured
| |
- | | Exposure / Misalignment of components
| |
- | | '''8'''
| |
- | | Improper handling || '''3''' || Material Selection, Packaging || '''2''' || style="text-align: center;" | '''48''' || Drop test with and without packaging || Reliability
| |
- | |-
| |
- | | rowspan=2 style="text-align: center;" | 006
| |
- | | rowspan=2 | Regulator Knob
| |
- | * Enables user to adjust toasting time
| |
- | | Warped
| |
- | | Improper fit onto variable resistor or into casing
| |
- | | '''6'''
| |
- | | Improper manufacturing || '''2''' || Material selection || '''1''' || style="text-align: center;" | '''12''' || None || Manufacturing
| |
- | |-
| |
- | | Fractured
| |
- | | May detach from variable resistor
| |
- | | '''5'''
| |
- | | Poor handling, Impact || '''4''' || Material Selection, Packaging || '''1''' || style="text-align: center;" | '''24''' || None || Manufacturing, Assembly
| |
- | |-
| |
- | | rowspan=2 style="text-align: center;" | 007
| |
- | | rowspan=2 | Press Handle
| |
- | * Allows user to easily start toaster
| |
- | | rowspan=2 | Warped
| |
- | | Detaches from ejection system too easily
| |
- | | '''4'''
| |
- | | Improper Manufacturing || '''2''' || Material selection, mold design || '''5''' || style="text-align: center;" | '''40''' || None || Assembly
| |
- | |-
| |
- | | Incorrect fit into casing channel, toaster may stick
| |
- | | '''8'''
| |
- | | Improper Manufacturing || '''1''' || Material selection, mold design || '''2''' || style="text-align: center;" | '''16''' || None || Assembly
| |
- | |-
| |
- | | rowspan=2 style="text-align: center;" | 008
| |
- | | rowspan=2 | Cancel Button
| |
- | * Allows user to cancel toaster operation
| |
- | | rowspan=2 | Warped
| |
- | | Detaches from toaster
| |
- | | '''4'''
| |
- | | Improper Manufacturing || '''1''' || Material selection, injection mold design || '''5''' || style="text-align: center;" | '''20''' || None || Manufacturing, Assembly
| |
- | |-
| |
- | | Does not fit into casing or gets stuck
| |
- | | '''8'''
| |
- | | Improper Manufacturing || '''1''' || Material selection || '''1''' || style="text-align: center;" | '''8''' || None || Assembly
| |
- | |-
| |
- | | rowspan=2 style="text-align: center;" | 009
| |
- | | rowspan=2 | AC Power Cord
| |
- | *Provides electricity for toaster unit
| |
- | | rowspan=2 | Short circuit
| |
- | | rowspan=2 | Unit cannot function
| |
- | | rowspan=2 | '''10'''
| |
- | | Cord pinching || '''2''' || Set assembly process || '''5''' || style="text-align: center;" | '''100''' || Test completed units before distribution || Assembly
| |
- | |-
| |
- | | Internal cord problem || '''1''' || Choose reliable supplier || '''5''' || style="text-align: center;" | '''50''' || Test completed units before distribution || Assembly
| |
- | |-
| |
- | | rowspan=7 style="text-align: center;" | 010 - 019
| |
- | | rowspan=7 | Ejection Assembly
| |
- | * Ease the process of inserting and removing toasted materials
| |
- | * Activate heating wires and timing circuit
| |
- | | rowspan=2 | Mechanism fails to activate circuit
| |
- | | rowspan=2 | Unit is inoperable
| |
- | | rowspan=2 | '''8'''
| |
- | | Warped switch || '''1''' || Material selection || '''1''' || style="text-align: center;" | '''8''' || None || Assembly
| |
- | |-
| |
- | | Switch fatigue || '''4''' || Material selection || '''5''' || style="text-align: center;" | '''160''' || HALT for normal use || Reliability
| |
- | |-
| |
- | | rowspan=5 | Mechanism fails to release
| |
- | | rowspan=3 | Heating elements stay on
| |
- | | rowspan=3 | '''9'''
| |
- | | Internal circuit failure || '''1''' || Circuit test || '''1''' || style="text-align: center;" | '''9''' || None || Assembly
| |
- | |-
| |
- | | Warped internal components || '''2''' || Material selection, Set manufacturing process specifications || '''1''' || style="text-align: center;" | '''18''' || None || Assembly
| |
- | |-
| |
- | | Fatigue || '''5''' || Material selection || '''5''' || style="text-align: center;" | '''225''' || HALT for normal use || Reliability
| |
- | |-
| |
- | | rowspan=2 | Finished product does not eject
| |
- | | rowspan=2 | '''6'''
| |
- | | Warped internal components || '''2''' || Material selection, Set manufacturing process specifications || '''1''' || style="text-align: center;" | '''12''' || None || Assembly
| |
- | |-
| |
- | | Fatigue || '''5''' || Material selection || '''5''' || style="text-align: center;" | '''150''' || HALT for normal use || Reliability
| |
- | |-
| |
- | | rowspan=5 style="text-align: center;" | 020 - 034
| |
- | | rowspan=5 | Heating and alignment assembly
| |
- | * Heat product for time provided by user
| |
- | * Properly align product for even heating
| |
- | | rowspan=2 | Heating elements turn on partially
| |
- | | rowspan=2 | Uneven heating
| |
- | | rowspan=2 | '''7'''
| |
- | | Short circuit || '''1''' || Ensure electrical elements have sufficient clearance || '''1''' || style="text-align: center;" | '''7''' || None || Manufacturing and Assembly
| |
- | |-
| |
- | | Fatigue || '''5''' || Material selection || '''5''' || style="text-align: center;" | '''175''' || HALT for normal use || Reliability
| |
- | |-
| |
- | | rowspan=2 | Heating elements do not turn on
| |
- | | rowspan=2 | No heating of product
| |
- | | rowspan=2 | '''8'''
| |
- | | Short circuit || '''1''' || Ensure electrical components have sufficient clearance || '''1''' || style="text-align: center;" | '''8''' || None || Manufacturing and Assembly
| |
- | |-
| |
- | | Fatigue || '''5''' || Material selection || '''5''' || style="text-align: center;" | '''200''' || HALT for normal use || Reliability
| |
- | |-
| |
- | | Improperly aligned product
| |
- | | Uneven heating
| |
- | | '''7'''
| |
- | | Wrong dimensions || '''1''' || Material selection, set tolerances || '''1''' || style="text-align: center;" | '''7''' || None || Assembly
| |
| |- | | |- |
| |- | | |- |
Dough Dispenser Cup Assembly
|
Part Number | Name | QTY | Weight (g) | Function | Material | Manufacturing Process | Image
|
001 | Dispenser spring | 1 | 1 | Keeps dispenser closed when not in use | Steel | bending |
|
002 | Dispenser support | 1 | 19 | Guides the plunger for straight release | Plastic | Injection molding |
|
003 | Dispenser plunger | 1 | 9 | Pushes the dough from the cup into the machine | Plastic | Injection molding |
|
004 | Dispenser funnel | 1 | 27 | Guides the dough to the hole in the cup | Plastic | Injection molding |
|
005 | Dispenser stop | 1 | 4 | Stops the dough from leaving dispenser and gives the doughnut its \"hole\" | Plastic | Injection molding |
|
006 | Dispenser cup | 1 | 122 | Holds the dough for dispensing | Plastic | Injection molding |
|
Dispenser Motor and Conveyer Motor Assembly
|
Part Number | Name | QTY | Weight (g) | Function | Material | Manufacturing Process | Image
|
007 | Switch cover | 1 | 23 | Covers and protects the two switch connected to the housing | Plastic | Injection molding |
|
008 | Dispenser motor | 1 | 204 | Drives the dispenser assembly | N/A | Purchased part |
|
009 | Motor rotational output | 1 | 4 | Connects to the motor and rotates with it | Plastic | Injection molding |
|
010 | Dispenser motor guide | 1 | 11 | Guides the motor's movement. Stationary | Plastic | Injection molding |
|
011 | Dispenser motor housing | 1 | 113 | Houses and protects the dispenser motor assembly | Plastic | Injection molding |
|
012 | Dispenser motor switch 1 | 1 | 5 | Alerts for dough release | N/A | Purchased part |
|
013 | Dispenser motor switch 2 | 1 | 5 | Halts the dispensing process | N/A | Purchased part |
|
014 | Dispenser switch housing | 1 | 4 | Positions switch to alert for dough release | Plastic | Injection molding |
|
015 | Capacitor | 2 | 5 | Stores electrical charge | N/A | Purchased part |
|
016 | Doughnut dispenser motor cover | 1 | 52 | Gives access to and protects the motor | Plastic | Injection molding |
|
017 | Dispenser motor latch | 1 | 4 | Secures and aligns the motor dispenser assembly | Plastic | Injection molding |
|
018 | Conveyor belt motor | 1 | 219 | Drives the conveyor belt assembly | N/A | Purchased part |
|
019 | Drive gear 2 | 1 | 4 | Moved by the motor and translates motion to conveyor gear | Plastic | Injection molding |
|
020 | Conveyor motor switch 1 | 2 | 23 | Connects and controls dials | N/A | Purchased part |
|
021 | Motor switch holder | 1 | 10 | Holds the switch and cradles the motor | Plastic | Injection molding |
|
022 | Adjustment Knob | 2 | 6 | Used to open and close the oil drain. | Plastic | Injection molding |
|
023 | Wire guide | 1 | 0.5 | Secures wires to housing | Steel | Stamping |
|
024 | Power jack | 1 | 15 | Connects to power cord | N/A | Purchased part |
|
025 | Power jack housing | 1 | 5 | Covers and protects the power jack | Plastic | Injection molding |
|
Conveyor Belt Assembly
|
Part Number | Name | QTY | Weight (g) | Function | Material | Manufacturing Process | Image
|
026 | Belt motor gear | 1 | 14 | Translates motion from motor to conveyor belt | Plastic | Injection molding |
|
027 | Conveyor belt link assembly (60 links with 60 rivets) | 1 | 123 | Driven by the motor to move doughnuts through system. | Plastic | Injection molding |
|
Release link | 4 | 1 | Alerts the motor to release the dough | Plastic | Injection molding |
|
028 | Doughnut carriage | 4 | 22 | Used to carry doughnuts through the system during operation | Aluminum alloy | Punching then Stamping then Welding |
|
Doughnut carriage arm | 4 | 5 | Connects carriage to conveyor belt | Plastic | Injection molding |
|
029 | Conveyer belt holder | 2 | 0.5 | Guides and supports the conveyor system in its cycle | Plastic | Injection molding |
|
030 | Conveyor belt gear (doughnut side) | 1 | 85 | Rotates and moves conveyor belt system | Plastic | Injection molding |
|
031 | Conveyor belt gear (dough side) | 1 | 109 | Rotates and moves conveyor belt system | Plastic | Injection molding |
|
032 | Belt gear washers, thick | 2 | 5 | Holds belt gears in place | Steel | Punching |
|
033 | Belt gear washers, thin | 2 | 2 | Separates the belt gear from back housing | Steel | Punching |
|
034 | Belt guides | 2 | 14 | Guides the belt on lower portion of the cycle | Plastic | Injection molding |
|
035 | Yellow Washer, belt guide | 3 | 0.25 | Separates the belt guide from housing | Plastic | Injection molding |
|
Oil System Assembly
|
Part Number | Name | QTY | Weight (g) | Function | Material | Manufacturing Process | Image
|
036 | Doughnut flipper | 1 | 10 | Flips donuts to opposite side | Steel | Cut then drawn |
|
Oil bath tub | 1 | 313 | Fills with oil and becomes very hot. | Aluminum Alloy | Drawing then cutting |
|
Oil bath heating unit | 1 | Causes the oil bath tub to become hot. | N/A | Purchased part |
|
037 | Oil bath supports | 4 | 6 | Holds the oil bath in place | Plastic | Injection molding |
|
038 | Temperature controller bracket | 1 | 13 | Connects heating element to the oil bath | Steel | Stamping |
|
039 | Temperature controller | 1 | 20 | Regulates the heating element | N/A | Purchased part |
|
040 | Knob housing | 1 | 32 | Protects oil drain components and user | Plastic | Injection molding |
|
041 | Drain switch cover | 1 | 12 | Protects from accidentally enabling the drain switch | Plastic | Injection molding |
|
042 | Adjustment Knob | 1 | 6 | Used to open and close the oil drain. | Plastic | Injection molding |
|
043 | Dial connector | 1 | 3 | Translates knob movement through the housing | Plastic | Injection molding |
|
044 | Drain lever | 1 | 6 | Used for securing switch in both positions | Plastic | Injection molding |
|
045 | Oil drain valve mount | 1 | 4 | Mounts the drain in appropriate location | Plastic | Injection molding |
|
046 | Oil drain valve | 1 | 33 | Controls the flow of the oil | Brass | Purchased part |
|
047 | Oil drain tube | 1 | 2 | Channels the flow of the oil | Rubber | Purchased part |
|
048 | Oil drain tube clamp | 2 | .5 | Secures the tube onto the valve and drain | Steel | Purchased part |
|
049 | Oil collection tray | 1 | 237 | Collects the oil that drains after use | Plastic | Injection molding |
|
050 | Oil collection tray guide | 1 | 7 | Guides the oil collection tray into place. | Plastic | Injection molding |
|
Exterior Panel Assembly
|
Part Number | Name | QTY | Weight (g) | Function | Material | Manufacturing Process | Image
|
051 | Front panel | 1 | 1160 | Protects the inside machinery from the outside | Plastic | Injection molding |
|
052 | Back panel | 1 | 1160 | Protects the inside machinery from the outside | Plastic | Injection molding |
|
053 | Top window 1 | 1 | 55 | Allows heat to escape when opened during production | Plastic | Injection molding |
|
054 | Top window 2 | 1 | 123 | Cannot be opened. Allows user to view doughnut production | Plastic | Injection molding |
|
Miscellaneous Components
|
Part Number | Name | QTY | Weight (g) | Function | Material | Manufacturing Process | Image
|
055 | Power cord | 1 | 107 | Connects to the outlet and supplies power to the machine | N/A | Purchased part |
|
056 | Measuring cup | 1 | 27 | Used to measure out correct amount of ingredients | Plastic | Injection molding |
|
057 | Doughnut slide | 1 | 36 | Removes doughnut from machine and into the doughnut bin | Plastic | Injection molding |
|
058 | Doughnut bin with oil drain | 1 | 100 | Collects doughnuts after production and drains oil off doughnuts after production | Plastic | Injection molding |
|
059 | Doughnut cover feet | 4 | 3 | Contacts surface | Plastic | Injection molding |
|