Iron
From DDL Wiki
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===Production=== | ===Production=== | ||
| - | Iron production produces the greatest cost to the environment and therefore has the largest tax of any phase of the product’s life cycle. Iron manufacturing employs many other sectors | + | Iron production produces the greatest cost to the environment and therefore has the largest tax of any phase of the product’s life cycle. Iron manufacturing employs many other sectors of the economy. For our EIO-LCA analysis, we looked at the environmental impact of only $1 million economic production. The figures below provide a rough idea of what sectors are most involved in the small electrical appliance manufacturing, of which household appliance manufacturing composes only 5.14% (http://bea.gov/industry/io_benchmark.htm#2002data). When observing the following figures, it is important to remember household appliance manufacturing is a relatively small percentage of the entire sector represented. |
<center>[[Image:Iron_production_sectors.png]]</center> | <center>[[Image:Iron_production_sectors.png]]</center> | ||
Revision as of 15:56, 22 September 2012
Contents |
Executive Summary
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Product Stakeholders
Stakeholders Major stake holders for our product would include: dry cleaners, home cleaning services, busy mothers, iron manufactures such as Black & Decker and Sunbeam, and major department stores.
| Stakeholder Needs | |||
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| Stakeholder | Consumer | Needs | |
| Consumers |
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| Retailers |
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| Manufacturer |
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Product Use Study
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Product Mechanical Function
An average iron uses a lot of mechanical systems to heat up the iron base plate. The particular iron we dissected revealed three main mechanical systems. The first mechanism is the steam mechanism which utilizes pump and a compression spring. When the steam button is pressed a pressure gradient is created and the water is pushed up and out into a tube that leads to a drip nozzle. The second mechanism is the temperature sensor control. This is mechanism uses a FPA223-80 temperature sensor that expands and flips a switch when the temperature reaches just over the boiling point. The switch gets flipped and pushes on the bottom of the drip nozzle. On top of the drip nozzle is a compressive spring that get compressed which allows for water from the steam tube to flow down into base plate. Therefore when the temperature of the plate surpasses the boiling point the water from the steam tube is allowed to move toward the hot iron plate to get vaporized. The clean button mechanism works in a similar fashion except the compression spring has a different stiffness so that all the water in the water reservoir is allowed to flow out. The third mechanism is the temperature control/selector mechanism utilized in fabrics selection. The temperature is modified by changing the resistance in the heating mechanism. This is accomplished when the user picks a fabric by using the slider that moves horizontally. Underneath the slider is a circular attachment that converts the translational motion into rotational motion. This rotational movement rotates the resistance modifier mechanism which will either add or subtract resistance to the depending on whether it need to get hotter (add resistance) or colder (subtract resistance). Another basic mechanism that this iron uses is a reset feature. This reset features uses a button pressing mechanism that resets the circuit that controls the power of the heating element. When the reset button is pressed a pin hits the circuit and which resets the power to the heating element.
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.
Sub-Assembly
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Bill of Materials
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.
| 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 | *** |  |
| 2 | Nut | 5 | 1 | Attaches screws (#1) to metal base (#31) | Steel | *** |  |
Design for Manufacture and Assembly (DFMA)
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Manufacturing
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 Manufacturing Features and Improvements | ||
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| Design Objective | Strengths | Areas of Improvement |
| Minimize Part Count |
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| Standardize Design Features |
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| Keep Designs Simple |
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| Multifunctional Parts |
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| Ease of fabrication |
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| Avoid Tight Tolerances |
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| Minimize Secondary & Finishing Operations |
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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 | ||
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| Design Objective | Strengths | Areas of Improvement |
| Minimize Part Count |
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| Minimize Assembly Surfaces |
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| Use Sub-assemblies |
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| Mistake-Proof |
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| Minimize Fasteners |
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| Minimize Handling |
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| Minimize Assembly Direction |
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| Provide Unobstructed Access |
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| Maximize Assembly Compliance |
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Failure Modes & Effects Analysis (FMEA)
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| Failure Modes and Effects Analysis - Floor Bike Pump | |||||||||
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| 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)
In analyzing our product, we were asked to consider its design and the impact design choices made on the environment. We used the Environmental Input-Output Life Cycle Analysis tool to analyze the production process of an iron and the use cycle of the products that are used in the operation of an iron (mainly water and electricity). The table below gives a rough estimate of the CO2 equivalent produced by the production and use cycle processes and the tax that would be implemented for each process. The end of the product’s life was not considered in the EIO-LCA analysis.
By observing the table and subsequent graph, the process that seems to be have the greatest CO2 impact and largest tax is the actual iron manufacturing, or the production phase. This result makes sense as the iron manufacturing process utilizes other sectors of the economy that have high environmental impacts.
Production
Iron production produces the greatest cost to the environment and therefore has the largest tax of any phase of the product’s life cycle. Iron manufacturing employs many other sectors of the economy. For our EIO-LCA analysis, we looked at the environmental impact of only $1 million economic production. The figures below provide a rough idea of what sectors are most involved in the small electrical appliance manufacturing, of which household appliance manufacturing composes only 5.14% (http://bea.gov/industry/io_benchmark.htm#2002data). When observing the following figures, it is important to remember household appliance manufacturing is a relatively small percentage of the entire sector represented.
Use
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. Sector #336991: Motorcycle, bicycle, and parts manufacturing
Economic Activity: $1 Million Dollars
Displaying: Greenhouse Gases
Number of Sectors: Top 10
Group Dynamic
Team Leader: Brian Koskey
DFMA Lead: John Howland
FMEA Lead: John Ellis
DFE Lead: Alex Campbell
Wiki Page Programmer/Report Compilation: Pace Nalbone
References
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