Doughnut maker
From DDL Wiki
Contents |
Executive Summary
Bill of Materials
Main Components
| Dough Dispenser Cup Assembly | ||||||||
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| 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 | 
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| 002 | Dispenser support | 1 | 19 | Guides the plunger for straight release | Plastic | Injection molding | 
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| 003 | Dispenser plunger | 1 | 9 | Pushes the dough from the cup into the machine | Plastic | Injection molding | 
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| 004 | Dispenser funnel | 1 | 27 | Guides the dough to the hole in the cup | Plastic | Injection molding | 
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| 005 | Dispenser stop | 1 | 4 | Stops the dough from leaving dispenser and gives the doughnut its \"hole\" | Plastic | Injection molding | 
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| 006 | Dispenser cup | 1 | 122 | Holds the dough for dispensing | Plastic | Injection molding | 
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| 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 | 
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| 008 | Dispenser motor | 1 | 204 | Drives the dispenser assembly | N/A | Purchased part | 
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| 009 | Motor rotational output | 1 | 4 | Connects to the motor and rotates with it | Plastic | Injection molding | 
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| 010 | Dispenser motor guide | 1 | 11 | Moved by motor to push the dispenser spring down | Plastic | Injection molding | 
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| 011 | Dispenser motor housing | 1 | 113 | Houses and protects the dispenser motor assembly | Plastic | Injection molding | 
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| 012 | Dispenser motor switch 1 | 1 | 5 | Alerts for dough release | N/A | Purchased part | 
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| 013 | Dispenser motor switch 2 | 1 | 5 | Halts the dispensing process | N/A | Purchased part | 
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| 014 | Dispenser switch housing | 1 | 4 | Positions switch to alert for dough release | Plastic | Injection molding | 
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| 015 | Capacitor | 2 | 5 | Stores electrical charge | N/A | Purchased part | 
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| 016 | Doughnut dispenser motor cover | 1 | 52 | Gives access to and protects the motor | Plastic | Injection molding | 
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| 017 | Dispenser motor latch | 1 | 4 | Secures and aligns the motor dispenser assembly | Plastic | Injection molding | 
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| 018 | Conveyor belt motor | 1 | 219 | Drives the conveyor belt assembly | N/A | Purchased part | 
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| 019 | Drive gear 2 | 1 | 4 | Moved by the motor and translates motion to conveyor gear | Plastic | Injection molding | 
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| 020 | Conveyor motor switch 1 | 2 | 23 | Connects and controls dials | N/A | Purchased part | 
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| 021 | Motor switch holder | 1 | 10 | Holds the switch and cradles the motor | Plastic | Injection molding | 
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| 022 | Adjustment Knob | 2 | 6 | Used to open and close the oil drain. | Plastic | Injection molding | 
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| 023 | Wire guide | 1 | 0.5 | Secures wires to housing | Steel | Stamping | 
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| 024 | Power jack | 1 | 15 | Connects to power cord | N/A | Purchased part | 
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| 025 | Power jack housing | 1 | 5 | Covers and protects the power jack | Plastic | Injection molding | 
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| 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 | 
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| 027 | Conveyor belt link assembly (60 links with 60 rivets) | 1 | 123 | Driven by the motor to move doughnuts through system. | Plastic | Injection molding | 
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| Release link | 4 | 1 | Alerts the motor to release the dough | Plastic | Injection molding | 
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| 028 | Doughnut carriage | 4 | 22 | Used to carry doughnuts through the system during operation | Aluminum alloy | Punching then Stamping then Welding | 
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| Doughnut carriage arm | 4 | 5 | Connects carriage to conveyor belt | Plastic | Injection molding | 
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| 029 | Conveyer belt holder | 2 | 0.5 | Guides and supports the conveyor system in its cycle | Plastic | Injection molding | 
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| 030 | Conveyor belt gear (doughnut side) | 1 | 85 | Rotates and moves conveyor belt system | Plastic | Injection molding | 
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| 031 | Conveyor belt gear (dough side) | 1 | 109 | Rotates and moves conveyor belt system | Plastic | Injection molding | 
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| 032 | Belt gear washers, thick | 2 | 5 | Holds belt gears in place | Steel | Punching | 
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| 033 | Belt gear washers, thin | 2 | 2 | Separates the belt gear from back housing | Steel | Punching | 
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| 034 | Belt guides | 2 | 14 | Guides the belt on lower portion of the cycle | Plastic | Injection molding | 
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| 035 | Yellow Washer, belt guide | 3 | 0.25 | Separates the belt guide from housing | Plastic | Injection molding | 
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| 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 | 
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| Oil bath tub | 1 | 313 | Fills with oil and becomes very hot. | Aluminum Alloy | Drawing then cutting | 
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| Oil bath heating unit | 1 | Causes the oil bath tub to become hot. | N/A | Purchased part | 
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| 037 | Oil bath supports | 4 | 6 | Holds the oil bath in place | Plastic | Injection molding | 
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| 038 | Temperature controller bracket | 1 | 13 | Connects heating element to the oil bath | Steel | Stamping | 
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| 039 | Temperature controller | 1 | 20 | Regulates the heating element | N/A | Purchased part | 
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| 040 | Knob housing | 1 | 32 | Protects oil drain components and user | Plastic | Injection molding | 
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| 041 | Drain switch cover | 1 | 12 | Protects from accidentally enabling the drain switch | Plastic | Injection molding | 
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| 042 | Adjustment Knob | 1 | 6 | Used to open and close the oil drain. | Plastic | Injection molding |
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| 043 | Dial connector | 1 | 3 | Translates knob movement through the housing | Plastic | Injection molding | 
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| 044 | Drain lever | 1 | 6 | Used for securing switch in both positions | Plastic | Injection molding | 
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| 045 | Oil drain valve mount | 1 | 4 | Mounts the drain in appropriate location | Plastic | Injection molding | 
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| 046 | Oil drain valve | 1 | 33 | Controls the flow of the oil | Brass | Purchased part | 
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| 047 | Oil drain tube | 1 | 2 | Channels the flow of the oil | Rubber | Purchased part | 
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| 048 | Oil drain tube clamp | 2 | .5 | Secures the tube onto the valve and drain | Steel | Purchased part | 
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| 049 | Oil collection tray | 1 | 237 | Collects the oil that drains after use | Plastic | Injection molding | 
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| 050 | Oil collection tray guide | 1 | 7 | Guides the oil collection tray into place. | Plastic | Injection molding | 
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| 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 | 
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| 052 | Back panel | 1 | 1160 | Protects the inside machinery from the outside | Plastic | Injection molding | 
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| 053 | Top window 1 | 1 | 55 | Allows heat to escape when opened during production | Plastic | Injection molding | 
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| 054 | Top window 2 | 1 | 123 | Cannot be opened. Allows user to view doughnut production | Plastic | Injection molding | 
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| 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 | 
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| 056 | Measuring cup | 1 | 27 | Used to measure out correct amount of ingredients | Plastic | Injection molding | 
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| 057 | Doughnut slide | 1 | 36 | Removes doughnut from machine and into the doughnut bin | Plastic | Injection molding | 
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| 058 | Doughnut bin with oil drain | 1 | 100 | Collects doughnuts after production and drains oil off doughnuts after production | Plastic | Injection molding | 
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| 059 | Doughnut cover feet | 4 | 3 | Contacts surface | Plastic | Injection molding | 
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Additional Parts
| Screws |
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| Nuts and Washers |
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Assembly Diagrams
| Dough Dispenser Cup Assembly |
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| Dispenser Motor and Conveyor Motor Assembly |
 
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| Dispenser Motor and Conveyor Motor Assembly Schematic |
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| Conveyor Belt Assembly |
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| Cooking Oil Assembly |
 
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| Exterior Panel Assembly |
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Major Stakeholders and Needs
Usage and Usability
Mechanical Function
Design for Manufacturing and Assembly (DFMA)
Failure Modes and Effects Analysis (FMEA)
| Part # | Item and Function | Failure Mode | Effects of Failure | S | Causes of Failure | O | Design Controls | D | RPN | Recommended Actions | Responsibility and Deadline | Actions Taken | S | O | D | RPN |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| 001 | "Dispenser spring"
| Deformed spring (too long/short) | Unable to fully open/close causing incorrect dough dispensing | 7 | Improper manufacturing | 2 | Inspecting dispenser spring | 2 | 28 | Introduce quality control measures to ascertain accurate spring dimension | Manufacturing and Quality Control | None | 7 | 2 | 2 | 28 |
| 002 | "Dispenser support"
| Warped | Dispenser plunger moving at angle disrupting dough shaping | 6 | Improper manufacturing | 2 | Inspecting dispenser support or dispenser plunger | 2 | 24 | Introduce quality control measures to ascertain dispenser quality | Manufacturing and Quality Control | None | 6 | 2 | 2 | 24 |
| 003 | "Dispenser plunger"
| Cracked? | # | # | # | # | X | X | None | # | # | # | # | |||
| 005 | "Dispenser stop"
| Leaking or cracked | Dough seeps from dispenser cup to machine | 6 | Improper manufacturing | 3 | Inspect dispenser assembly for leaks | 3 | 54 | Introduce quality control measures to ascertain dispenser quality | Manufacturing and Quality Control | None | 6 | 3 | 3 | 54 |
| 006 | "Dispenser cup"
| Cracked | Dough seeps from dispenser cup to machine | 6 | Improper manufacturing | 3 | Inspect dispenser assembly for leaks | 2 | 36 | Introduce quality control measures to ascertain dispenser quality | Manufacturing and Quality Control | None | 6 | 3 | 2 | 36 |
| 007 | "Switch cover"
| Warped | Misalignment of components | 8 | Improper manufacturing | 1 | Specify process, Material selection | 1 | 8 | None | Manufacturing | None | 8 | 1 | 1 | 8 |
| Fractured | Exposure / Misalignment of components | 8 | Improper handling | 2 | Material Selection, Packaging | 2 | 32 | Drop test with and without packaging | Reliability | None | 8 | 1 | 1 | 8 | ||
| 008 | "Dispenser motor"
| # | # | # | # | X | X | None | # | # | # | # | ||||
| 011 | "Dispenser motor housing"
| Fractured | Motor is moved off position, disrupting dispensing process | 7 | Improper manufacturing | 1 | Material selection, placement | 3 | 21 | Introduce quality control actions to check dispenser motor assembly | Reliability | None | 7 | 1 | 3 | 21 |
| 012 | "Dispenser switch 1"
| Sticking | Plunger stays open, dough pours into oil tub | 8 | Improper manufacturing or assembling | 1 | Inspect control systems | 5 | 40 | Take quality control actions or may redesign for extra clearance | Manufacturing | None | 8 | 1 | 5 | 40 |
| 013 | "Dispenser switch 2"
Halts the dispensing process | Sticking | Plunger does not open, no dough released | 8 | Improper manufacturing or assembling | 1 | Inspect control system | 5 | 40 | Take quality control actions or may redesign for extra clearance | Manufacturing | None | 8 | 1 | 5 | 40 |
| 014 | "Dispenser switch housing"
| Fractured | Plunger stays open/closed | 8 | Improper manufacturing | 1 | Inspect dispenser motor assembly | 2 | 16 | Introduce quality control measures on dispenser motor assembly | Manufacturing | None | 8 | 1 | 2 | 16 |
| 018 | "Conveyor belt motor"
| # | # | # | # | X | X | None | # | # | # | # | ||||
| 019 | "Drive gear 2"
| ?? | # | # | # | # | X | X | None | # | # | # | # | |||
| 023 | "Wire guide"
| # | # | # | # | X | X | None | # | # | # | # | ||||
| 024 | "Power jack"
| Short circuit | Unable to function | 8 | Internal problem | 1 | Choose reliable supplier | 4 | 32 | Test completed units before distribution | Assembly | None | 8 | 1 | 4 | 32 |
| 026 | "Belt motor gear"
| Fractured | Conveyor belt unable to move | 8 | Improper handling | 2 | Material selection, packaging | 2 | 32 | Drop test with and without packaging | Reliability | None | 8 | 2 | 2 | 32 |
| 027 | "Conveyor belt link assembly"
| Fractured | Doughnut unable to move through system, machine unable to perform function | 8 | Improper manufacturing | 1 | Inspect conveyor belt assembly | 4 | 32 | Introduce quality control measures on conveyor assembly | Manufacturing | None | 8 | 1 | 4 | 32 |
| 046-048 | "Oil drain tube, clamps, and valve"
| Leaking | Hot oil released into machine and possibly onto user | 7 | Improper manufacturing | 2 | Inspect oil drain assembly | 4 | 56 | Introduce quality control measures on oil drain assembly | Assembly | None | 7 | 2 | 4 | 56
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| 049 | "Oil collection tray"
| Warped/Deformed | Misalignment of components, improper fit | 7 | Improper manufacturing | 1 | Specify process, Material selection | 1 | 7 | None | Manufacturing | None | 7 | 1 | 1 | 7 |
| Fractured/Leaking | Hot oil released from machine, possibly onto user | 9 | Improper handling or manufacturing | 3 | Material Selection, Packaging, Quality control measures | 4 | 108 | Drop test with and without packaging | Reliability | None | 6 | 3 | 4 | 108
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| 051 - 052 | "Front and Back Panels"
| Warped | Misalignment of components, improper fit | 8 | Improper manufacturing | 1 | Specify process, Material selection | 1 | 8 | None | Manufacturing | None | 8 | 1 | 1 | 8 |
| Fractured | Exposure/Misalignment of components and heat release | 6 | Improper handling | 4 | Material Selection, Packaging | 4 | 96 | Drop test with and without packaging | Reliability | None | 6 | 4 | 4 | 96
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| 055 | "Power cord"
| Short circuit | Unit unable to function | 8 | Cord Pinching | 2 | Set assembly process | 4 | 80 | Test completed units before distribution | Assembly | None | 8 | 2 | 4 | 64 |
| Internal cord problem | 1 | Choose reliable supplier | 4 | 32 | Test completed units before distribution | Assembly | None | 8 | 1 | 4 | 32 |
Design for Environment (DFE)
Mechanical Analysis
Team Members & Roles
Michael Barako - DFE, Mechanical Analysis
Meng Yee Chuah - Mechanical Function
Katie McManus - Assembly Photos, DFMA
Sam Powers - Bill of Materials, FMEA
Sara Whitby - Executive Summary, Major Stakeholders, Usage and Usability
