Iron

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Revision as of 13:43, 21 September 2012 (view source) Snalbone@andrew.cmu.edu (Talk | contribs) ← Older edit		Revision as of 13:45, 21 September 2012 (view source) Snalbone@andrew.cmu.edu (Talk | contribs) Newer edit →
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	==Design for Manufacture and Assembly (DFMA)==		==Design for Manufacture and Assembly (DFMA)==
-	DFMA is a combination of two practices, Design for Manufacture (DFM) and Design for Assembly (DFA). DFM is the method of designing part so that they're manufacturing processes are simplest, and DFA is the method of designing parts that will lead to a simple assembly process at the plant or by the user.	+	Lorem ipsum dolor sit amet, consectetur adipiscing elit. Ut elementum elit vel tortor scelerisque auctor. Donec urna dui, eleifend eget adipiscing vulputate, feugiat id nisl. Donec mattis, quam in tincidunt ullamcorper, orci tellus condimentum dui, aliquet faucibus risus nunc et nunc. Vestibulum metus justo, volutpat sed consequat eget, mollis sed neque. Maecenas dignissim hendrerit malesuada. Aliquam dictum gravida orci ut rutrum. Fusce eros lectus, accumsan sed rhoncus eu, tempor sed magna. In ac lacus urna, ut cursus nisl. Curabitur ac dui nisl, in imperdiet orci. Aliquam quam dui, tincidunt quis volutpat quis, convallis a ipsum. Suspendisse quis molestie lorem. Nunc vel magna commodo nunc viverra tempor id blandit neque. Donec nec elementum ligula. Cras accumsan, urna eget dictum varius, arcu nunc porttitor tortor, sit amet feugiat nisl elit vitae elit. Proin eget tellus lectus, tempus tincidunt augue. Sed sagittis iaculis orci, sit amet tempus dui tincidunt in.
-		+
	===Manufacturing===		===Manufacturing===
-	The competitor product we analyzed displayed numerous positive manufacturing features that would minimize cost and complexity. The overall design is surprisingly simple, a result of combining features into single parts where possible, using only a few different materials, and minimizing the overall part count. (INSERT COMPONENT WITH BIGGEST ROOM FOR IMPROVEMENT AND WHY).	+	Lorem ipsum dolor sit amet, consectetur adipiscing elit. Ut elementum elit vel tortor scelerisque auctor. Donec urna dui, eleifend eget adipiscing vulputate, feugiat id nisl. Donec mattis, quam in tincidunt ullamcorper, orci tellus condimentum dui, aliquet faucibus risus nunc et nunc. Vestibulum metus justo, volutpat sed consequat eget, mollis sed neque. Maecenas dignissim hendrerit malesuada. Aliquam dictum gravida orci ut rutrum. Fusce eros lectus, accumsan sed rhoncus eu, tempor sed magna. In ac lacus urna, ut cursus nisl. Curabitur ac dui nisl, in imperdiet orci. Aliquam quam dui, tincidunt quis volutpat quis, convallis a ipsum. Suspendisse quis molestie lorem. Nunc vel magna commodo nunc viverra tempor id blandit neque. Donec nec elementum ligula. Cras accumsan, urna eget dictum varius, arcu nunc porttitor tortor, sit amet feugiat nisl elit vitae elit. Proin eget tellus lectus, tempus tincidunt augue. Sed sagittis iaculis orci, sit amet tempus dui tincidunt in.
-		+
-	Below are some of the DFM Guidelines and the observations we made of how our competitor designed their product with those guidelines in mind and some areas we believe they could improve.	+
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	! scope="row" | Minimize Part Count		! scope="row" | Minimize Part Count
	|		|
-	* Few fasteners, mostly everything screws and locks together	+	* sdfgesrgaerg
-	* Many multifunctional components leading to less parts overall	+	* gsergdsxrgxrg
	|		|
	*		*
Line 116:		Line 113:
	! scope="row" | Standardize Design Features		! scope="row" | Standardize Design Features
	|		|
-	* All screws in the system are identical	+	* zdrggzdrgzd
	|		|
-	* Since there are few fasteners, most parts are custom-made for this product	+	* Szdrgzdrgdrg
	|-style="vertical-align: left;"		|-style="vertical-align: left;"
	! scope="row" | Keep Designs Simple		! scope="row" | Keep Designs Simple
	|		|
-	* Piston shows a clever design to allow air into the pump on upstroke while eliminating lost air on downstroke, while still remaining very simple	+	* zdrgdrgzdrg
	|		|
-	* Pressure gauge is very complex, needs fine adjustment and much protection	+	* zdrgzdrgzdrg
	|-style="vertical-align: center;"		|-style="vertical-align: center;"
	! scope="row" | Multifunctional Parts		! scope="row" | Multifunctional Parts
	|		|
-	* Many parts serve a specific purpose while also screwing into the next assembling acting as both a functional piece and connector	+	* zdrgdrgzdrg
	|		|
	*		*
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	! scope="row" | Ease of fabrication		! scope="row" | Ease of fabrication
	|		|
-	* Mostly composed of some type of plastic and steel	+	* zdrgzdrg
	|		|
-	* The plastic parts are for the most part unique and would each need their own mold	+	* zdrgzdrgz
	|-style="vertical-align: center;"		|-style="vertical-align: center;"
	! scope="row" | Avoid Tight Tolerances		! scope="row" | Avoid Tight Tolerances
	|		|
-	* Uses flexible rubber o-rings to allow for larger tolerances while remaining airtight	+	* zdrgzdrgzdr
	|		|
	*		*
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	*		*
	|		|
-	* Since parts are multifunctional, most would require at least would need a secondary threading operation	+	* zgdrgzdrgz
	|}		|}
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-	Assembly of the competitor's product is not the consumer's responsibility and occurs prior to the retail stages in the supply chain. The product requires tools and fasteners only where the piston chamber attaches to the base, and nearly all of the remaining interfaces are threaded. While minimizing toolage, this raises many challenges with orientation and radial symmetry where the assembly process could be made clearer. The variety of O-rings, springs, and cylinder diameters is another weakness that has room for improvement.	+	Lorem ipsum dolor sit amet, consectetur adipiscing elit. Ut elementum elit vel tortor scelerisque auctor. Donec urna dui, eleifend eget adipiscing vulputate, feugiat id nisl. Donec mattis, quam in tincidunt ullamcorper, orci tellus condimentum dui, aliquet faucibus risus nunc et nunc. Vestibulum metus justo, volutpat sed consequat eget, mollis sed neque. Maecenas dignissim hendrerit malesuada. Aliquam dictum gravida orci ut rutrum. Fusce eros lectus, accumsan sed rhoncus eu, tempor sed magna. In ac lacus urna, ut cursus nisl. Curabitur ac dui nisl, in imperdiet orci. Aliquam quam dui, tincidunt quis volutpat quis, convallis a ipsum. Suspendisse quis molestie lorem. Nunc vel magna commodo nunc viverra tempor id blandit neque. Donec nec elementum ligula. Cras accumsan, urna eget dictum varius, arcu nunc porttitor tortor, sit amet feugiat nisl elit vitae elit. Proin eget tellus lectus, tempus tincidunt augue. Sed sagittis iaculis orci, sit amet tempus dui tincidunt in.
-		+
-	Due to the assembly process being deliberately separated from the consumer, ease of assembly is not a high priority and leaves room for redesign towards simplicity.	+
Line 169:		Line 164:
	*		*
	|		|
-	* There’s the metal piece in the handle we can’t account for	+	* gsdrgxdrgx
-	* Air flow pathway has several components	+	* rgxdrgxdrgzsder
	|-style="vertical-align: center;"		|-style="vertical-align: center;"
	! scope="row" | Minimize Assembly Surfaces		! scope="row" | Minimize Assembly Surfaces
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	*		*
	|		|
-	* Baseplate has multiple interfaces, axes	+	* zdrgdxrgzd
-	* Piston has multiple planes and axes	+	* zdrgzdrgz
	|-style="vertical-align: center;"		|-style="vertical-align: center;"
	! scope="row" | Use Sub-assemblies		! scope="row" | Use Sub-assemblies
	|		|
-	* Pressure Gauge is a discrete system	+	* zdrgzdrgdz
-	* Air compression mechanics are limited to main tube	+	* zdrgzdrgz
-	* Nozzle is a discrete system	+	* zdrgzdrgzr
	|		|
-	* Functional testing requires end-to-end assembly	+	* zdrgzdrgz
	|-style="vertical-align: center;"		|-style="vertical-align: center;"
	! scope="row" | Mistake-Proof		! scope="row" | Mistake-Proof
	|		|
-	* Asymmetric Handlebar	+	* zdrgzdrgzdrgzdr
	|		|
-	* Many radially symmetric parts	+	* Mzdrgzdrgzrgzdr
	|-style="vertical-align: center;"		|-style="vertical-align: center;"
	! scope="row" | Minimize Fasteners		! scope="row" | Minimize Fasteners
	|		|
-	* Most of the assembly is screwed together	+	* zdrgzdrgz
	|		|
-	* Tools and fasteners required for fixing main tube to base	+	* zdrgzdxrgzdrgz
	|-style="vertical-align: center;"		|-style="vertical-align: center;"
	! scope="row" | Minimize Handling		! scope="row" | Minimize Handling
	|		|
-	* Hose attachments have conical guides	+	* gzdrgzdrgzdrgzd
	|		|
-	* Interfaces have many different axes and planes	+	* zdrgzdrgzdrg
	|-style="vertical-align: center;"		|-style="vertical-align: center;"
	! scope="row" | Minimize Assembly Direction		! scope="row" | Minimize Assembly Direction
Line 209:		Line 204:
	*		*
	|		|
-	* Two distinct possible assembly directions (Nozzle or Handle)	+	* gzdgrdgzdrgz
	|-style="vertical-align: center;"		|-style="vertical-align: center;"
	! scope="row" | Provide Unobstructed Access		! scope="row" | Provide Unobstructed Access
Line 215:		Line 210:
	*		*
	|		|
-	* Base plate obscures airflow components	+	* Bzdrgzdrgz
-	* Nozzle has multiple hidden components	+	* zdrgzdrgzdrgnts
-	* Pressure gauge mechanics are hard to access	+	* gzdrgzdrgzgess
	|-style="vertical-align: center;"		|-style="vertical-align: center;"
	! scope="row" | Maximize Assembly Compliance		! scope="row" | Maximize Assembly Compliance
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	==Failure Modes & Effects Analysis (FMEA)==		==Failure Modes & Effects Analysis (FMEA)==
-	*NEED TO INCLUDE INTO AS TO WHAT FMEA IS	+	Lorem ipsum dolor sit amet, consectetur adipiscing elit. Ut elementum elit vel tortor scelerisque auctor. Donec urna dui, eleifend eget adipiscing vulputate, feugiat id nisl. Donec mattis, quam in tincidunt ullamcorper, orci tellus condimentum dui, aliquet faucibus risus nunc et nunc. Vestibulum metus justo, volutpat sed consequat eget, mollis sed neque. Maecenas dignissim hendrerit malesuada. Aliquam dictum gravida orci ut rutrum. Fusce eros lectus, accumsan sed rhoncus eu, tempor sed magna. In ac lacus urna, ut cursus nisl. Curabitur ac dui nisl, in imperdiet orci. Aliquam quam dui, tincidunt quis volutpat quis, convallis a ipsum. Suspendisse quis molestie lorem. Nunc vel magna commodo nunc viverra tempor id blandit neque. Donec nec elementum ligula. Cras accumsan, urna eget dictum varius, arcu nunc porttitor tortor, sit amet feugiat nisl elit vitae elit. Proin eget tellus lectus, tempus tincidunt augue. Sed sagittis iaculis orci, sit amet tempus dui tincidunt in.
-	*INCLUDE THE SCALE USED TO DETERMINE S/O/D VALUES	+
-	*THEN, ADD TO REFERENCE SECTION THE SOURCE FOR THE SCALE	+

---

Revision as of 13:45, 21 September 2012

Figure 1: Competitor product used for dissection study

Contents 1 Executive Summary 2 Product Stakeholders 3 Product Use Study 4 Product Mechanical Function 5 Assembly 5.1 Sub-Assembly 5.2 Bill of Materials 6 Design for Manufacture and Assembly (DFMA) 6.1 Manufacturing 6.2 Assembly 7 Failure Modes & Effects Analysis (FMEA) 8 Design for Environment (DFE) 8.1 Production 8.2 Use 9 Group Dynamic 10 References

Executive Summary

This will be a brief executive summary that describes the key findings and recommendations.

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Product Stakeholders

Lorem ipsum dolor sit amet, consectetur adipiscing elit. Ut elementum elit vel tortor scelerisque auctor. Donec urna dui, eleifend eget adipiscing vulputate, feugiat id nisl. Donec mattis, quam in tincidunt ullamcorper, orci tellus condimentum dui, aliquet faucibus risus nunc et nunc. Vestibulum metus justo, volutpat sed consequat eget, mollis sed neque. Maecenas dignissim hendrerit malesuada. Aliquam dictum gravida orci ut rutrum. Fusce eros lectus, accumsan sed rhoncus eu, tempor sed magna. In ac lacus urna, ut cursus nisl. Curabitur ac dui nisl, in imperdiet orci. Aliquam quam dui, tincidunt quis volutpat quis, convallis a ipsum. Suspendisse quis molestie lorem. Nunc vel magna commodo nunc viverra tempor id blandit neque. Donec nec elementum ligula. Cras accumsan, urna eget dictum varius, arcu nunc porttitor tortor, sit amet feugiat nisl elit vitae elit. Proin eget tellus lectus, tempus tincidunt augue. Sed sagittis iaculis orci, sit amet tempus dui tincidunt in.

Stakeholder Needs and Wants
Stakeholder	Needs	Wants
Consumer	sdfhsdfhfsdghsfgh dsfgsdghsfh fgsdfgsdf	sdghdfhfrgh dfghfdghdfg sfghdfhtr sdfhdrtnbrtbes
Retailer	fwaefawef wsefwefaf	afeszf fzsefgsaef
Manufacturer	SEFawsefs fsefzsefsFse sEFAESfSEF	FSEFsEFsefe
Shipping & Transportation	SEFSEfSEf EFsef	SSEfsefSEFS

Product Use Study

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Product Mechanical Function

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Assembly

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Sub-Assembly

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Bill of Materials

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Part Number	Name	QTY	Weight (g)	Function	Material	Manufacturing Process	Image
1	Screw	5	4	Holds base support (#8) in place to metal base (#31)	Steel	***	Screw
2	Nut	5	1	Attaches screws (#1) to metal base (#31)	Steel	***	Nut

Design for Manufacture and Assembly (DFMA)

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Manufacturing

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Design for Manufacturing Features and Improvements
Design Objective	Strengths	Areas of Improvement
Minimize Part Count	sdfgesrgaerg gsergdsxrgxrg
Standardize Design Features	zdrggzdrgzd	Szdrgzdrgdrg
Keep Designs Simple	zdrgdrgzdrg	zdrgzdrgzdrg
Multifunctional Parts	zdrgdrgzdrg
Ease of fabrication	zdrgzdrg	zdrgzdrgz
Avoid Tight Tolerances	zdrgzdrgzdr
Minimize Secondary & Finishing Operations		zgdrgzdrgz

Assembly

Lorem ipsum dolor sit amet, consectetur adipiscing elit. Ut elementum elit vel tortor scelerisque auctor. Donec urna dui, eleifend eget adipiscing vulputate, feugiat id nisl. Donec mattis, quam in tincidunt ullamcorper, orci tellus condimentum dui, aliquet faucibus risus nunc et nunc. Vestibulum metus justo, volutpat sed consequat eget, mollis sed neque. Maecenas dignissim hendrerit malesuada. Aliquam dictum gravida orci ut rutrum. Fusce eros lectus, accumsan sed rhoncus eu, tempor sed magna. In ac lacus urna, ut cursus nisl. Curabitur ac dui nisl, in imperdiet orci. Aliquam quam dui, tincidunt quis volutpat quis, convallis a ipsum. Suspendisse quis molestie lorem. Nunc vel magna commodo nunc viverra tempor id blandit neque. Donec nec elementum ligula. Cras accumsan, urna eget dictum varius, arcu nunc porttitor tortor, sit amet feugiat nisl elit vitae elit. Proin eget tellus lectus, tempus tincidunt augue. Sed sagittis iaculis orci, sit amet tempus dui tincidunt in.

Design for Assembly Features and Improvements
Design Objective	Strengths	Areas of Improvement
Minimize Part Count		gsdrgxdrgx rgxdrgxdrgzsder
Minimize Assembly Surfaces		zdrgdxrgzd zdrgzdrgz
Use Sub-assemblies	zdrgzdrgdz zdrgzdrgz zdrgzdrgzr	zdrgzdrgz
Mistake-Proof	zdrgzdrgzdrgzdr	Mzdrgzdrgzrgzdr
Minimize Fasteners	zdrgzdrgz	zdrgzdxrgzdrgz
Minimize Handling	gzdrgzdrgzdrgzd	zdrgzdrgzdrg
Minimize Assembly Direction		gzdgrdgzdrgz
Provide Unobstructed Access		Bzdrgzdrgz zdrgzdrgzdrgnts gzdrgzdrgzgess
Maximize Assembly Compliance

Failure Modes & Effects Analysis (FMEA)

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Failure Modes and Effects Analysis - Floor Bike Pump
Item & Function	Failure Mode	Effects of Failure	S	Causes of Failure	O	Design Controls	D	RPN	Recommended Actions
Valve Nozzle Connector	Air leaking out of wheel	Bike tube loses air	3	Misalignment to valve	2	Check if it locks	2	12	Something to help user better secure nozzle properly
	Does not lock	No air transfer into wheel	3	User not using it correctly	2	Check if it locks	3	18	Something that does not use a lock, Make it easier to lock
	Valve may not fit	No air transfer into wheel	1	Wrong valve type	4	Check if it locks	4	16	Make a universal valve, Provide adapters
Pressure Gauge	Air leaking out of wheel	Won't display pressure	2	Broken gauge	1	Test in manufacturing plant	2	4	Better pressure gauge tube seal, Different pressure reading technique
	Incorrectly calibrated	Displays incorrect pressure reading	2	Dropping gauge, Manufacturing error	1	Test in manufacturing plant	7	14	--
Handle rod	Bends	Can not apply downward force, Breaks rod	5	Bars are physically bent forward and not down, Damaged, Improper use	2	--	7	70	Stronger rod
Tube	Air leaking out of wheel	Loss of air from tire	3	Misuse, Damage	3	--	4	36	Tube wrapped in durable material

Design for Environment (DFE)

Design for Environment (DFE) can help bring focus to specific areas when improving a design. By analyzing the entire life cycle, the areas of the largest impact can be determined and minimized.

Design for Environment
--	Production	Use
Item Consumed	Bike Pump	Bike
Sector # and Name	#339920: Sporting and athletic goods manufacturing	#336991: Motorcycle, bicycle, and parts manufacturing
Reference Unit	1 Bike Pump	1 Bike
Units consumed per product life	1	1
Cost Per Unit*	$39.04	$234.27
Lifetime Cost*	$39.04	$234.27
Sector mtCO2e per $1M	613	543
Implied mtCO2e per product life	0.0239	0.1272
CO2e Tax @ $30/mtCO2e	$0.72	$3.82

*2002 USD

Production

Using the sporting and athletic goods manufacturing sector of EIO-LCA, we were able to estimate the environmental impact of producing the bike pump. The bike pump costs $50 today, which is about $39.04 in 2002. Power generation and supply has the largest contribution to the 613 mtCO2e per 1 million dollars spent in the sporting and athletic goods manufacturing category. Therefore we can estimate that for every bike pump produced 0.0239 mtCO2e is released into the environment, resulting in a minor $0.72 tax per pump.

Sector #339920: Sporting and athletic goods manufacturing

Economic Activity: $1 Million Dollars

Displaying: Greenhouse Gases

Number of Sectors: Top 10

NEED TO CITE: http://www.eiolca.net/cgi-bin/dft/display.pl?hybrid=no&first_level_sector=Other+Miscellaneous+Manufacturing&second_level_sector=339920&newmatrix=US430CIDOC2002&key=23253747582&value=2527872121&incdemand=1&selectvect=gwp&select_button1=Run+Model

Use

If the consumer purchases a bike pump, we can assume that they own at least one bike. Therefore we used the EIO-LCA Motorcycle, bicycle, and parts manufacturing sector to study the environmental impact of use of the pump. We estimated that today the average bike costs $300 which equates to about $234.27 in 2002. Our analysis approximated a small $3.82 tax per bike.

Sector #336991: Motorcycle, bicycle, and parts manufacturing

Economic Activity: $1 Million Dollars

Displaying: Greenhouse Gases

Number of Sectors: Top 10

NEED TO CITE: http://www.eiolca.net/cgi-bin/dft/display.pl?hybrid=no&first_level_sector=Vehicles+and+Other+Transportation+Equipment&second_level_sector=336991&newmatrix=US428PURCH2002&key=5727070922&value=1515705675&incdemand=1&selectvect=gwp&select_button1=Run+Model

Group Dynamic

Team Leader: Dinesh Ayyappan

DFMA Lead: Patrick Hogan

FMEA Lead: Jonathan Wong

DFE Lead: Amber Ohiokpehai

Wiki Page Programmer/Report Compilation: Lauren Milisits

References

This is where we should list any references that we used throughout the process of our report.