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	= Executive Summary =		= Executive Summary =
-	Toasters are commonly used kitchen appliances, and are typically not too expensive to purchase.  They can be found at most department stores from anywhere between 6$ to 50$. They are small and compact, and are used to toast or heat slices of bread, and other bread-like foods.  There are 3 kinds of toasters; pop-up, toaster oven, and toaster conveyer.  For this design project, we will focus on the pop-up toaster.	+	Since our first report, we conducted a thorough user survey, from observing toaster use, to questioning customers at retail stores, to receiving 90 responses to an online survey. From these surveys, we learned many important things about what consumers think of current toaster products, briefly summarized here:
-	The following study involves analysis of a $10.00 Chefmate toaster which was purchased from Target.  In the course of this semester, we may analyze a more expensive toaster to compare what extra features are included for the price.  Our hope is to find an innovative way to change current toaster designs, to address some common problems which users complain about most frequently.	+	'''Issues with toaster'''
		+	*Inconsistent toasting and inaccurate toast settings
		+	*Food product getting stuck in toaster
-	Our analysis involves studying how the toaster is usually operated and how it works, combined with evaluating the toaster through Design for Manufacture and Assembly (DFMA), Failure Mode Evaluation and Analysis (FMEA), Design for the Environment (DFE), and a quantitative mechanical analysis.	+	'''Necessary Attributes'''
		+	*Accurate settings
		+	*Wide slots
		+	*Crumb Tray
-	Our first steps were to disassemble the toaster, to figure out what parts and components were involved in its operation. We were also able to understand the basics about how each of the parts of the toaster functioned.  We categorized all the parts and assemblies, which can be seen in the assembly parts list.	+	Based on these stakeholder needs, we generated over one hundred concepts for toaster innovation. From those, we narrowed our options down to four concept designs. The designs were:
-	After disassembly, we concluded that there were far too many parts in a toaster.  We believe that this makes assembly extremely tedious, and increases the complexity of the product.	+	*Clear Walled Toaster
		+	*Fold Out Wall Toaster
		+	*Front Load Toaster
		+	*Enclosed Toaster
-	= Product =	+	A Pugh Chart was made in order to help us decide which concept to recommend for prototyping. We have decided to pursue the Fold Out Toaster design, for the following reasons:
-	Our product to dissect and analyze was a toaster.  For this part of the project, we purchased a $9.99 Chefmate toaster to dissect.  We also purchased a $29.99 Hamilton Beach toaster that we hope to compare with our first toaster at a later date.	+	*Virtually eliminates the problem of having toast stuck in the toaster
		+	*Easier to maintain and clean
		+	*Easier to load and start
		+	*Should maintain affordability of the toaster
-	== Function ==	+	We received feedback from our peers, who were concerned about the safety of this concept. We believe it will be just as safe as a conventional toaster, and will aim to prove this with our prototypes.
-	The purpose of a toaster is to assist in the making of food. Specifically, if the user wants toasted bread or bagels, warmed up waffles, etc. The toaster provides these functions.	+	For the next milestone, we will create a prototype of the mechanism for the fold out walls. This will be a proof of concept. Following that, we will produce a functional prototype. A detailed schedule can be found in our Gantt Chart, in Section 4.
-	To pictorially explain how a toaster is used, pictures from our <u>[[usability study]]</u> were taken to show customer product interaction. Following from that, we will delve into how a toaster actually works. From the outside, one might not think a toaster is a complex piece of equipment, but its internals are actually quite intricate. The inputs to the toaster are:	+	= Research and Observations =
-	*800 Watts of power	+	In order to help determine and evaluate potential conceptual designs, our team researched users, stakeholders, design problems, patents, and current products.  This research allowed us to determine our design problems as far as toasters go and move forward to narrow down our ideas to four concepts.
-	*food into the slot	+
-	*a toast setting	+
-	*a force to activate the latching and heating mechanisms.	+
-	With these inputs provided, the activating handle is depressed, which completes two separate circuits:	+	== Users Survey==
-	*First, a circuit is completed which provides power to an electromagnet and the timing circuit, holding the toastee inside the toaster where it can be heated.	+
-	*The second circuit that is completed is the heating circuit. A current is run through high resistance Nichrome wire, creating heat.	+
-	[[Image:ToasterElectroboard.jpg|700px]]	+	We really wanted to know what our users thought about and how they interacted with toasters.  This would give us a good idea of what was good and what needed improvements.  We created our
		+	<u>[[toaster survey]]</u> using www.surveymonkey.com and sent it to all our family, friends, organizations on campus, and to Misc Market. We received responses from 90 people.  Here are our results:
-	The timing system works as such:	+	*59% Female
-	*The variable resistor (regulator knob) controls current to a capacitor, regulating its charge rate. As soon as the capacitor reaches its maximum voltage, it discharges and breaks the power to the electromagnet.	+	*41% Male
-	*A spring then pulls the bread holder and toastee back up to where it can be safely removed from the toaster.	+
-	*As the spring pulls up the bread tray, the mechanism breaks the heating circuit.	+
-	[[Image:ToasterControlBoard.jpg|700px]]	+
-	Thus, the outputs of the toaster are heat and warmed food.	+	*Mean Age: 36
-	== Stakeholders ==	+	*66% of people would spend between $19.99 and $39.99 on a toaster
		+	*29% of people would spend $19.99 on a toaster
		+
		+	When asked what was necessary in a toaster, people responded:
		+	*Accurate Toast Settings – 92%
		+	*Crumb Tray – 81%
		+	*Wide Slots – 67%
		+	*Cool Touch Sides – 53%
		+	*Cancel Button – 50%
		+
		+	The biggest problems with toasters were:
		+	*Overcooked/uneven & other  issues with timing – 41%
		+	*Toast stuck in toaster – 21%
		+
		+	In the survey, only 8% reported that there was nothing wrong and no improvements on their toaster.
		+
		+	This survey was a good representation of our users, as the mean age was 36.  We had people from all ages and all occupations, a real random representative of users.  The results of the survey relayed to us that there is a great deal of room for improvement and innovation in a toaster.  Not only are there many issues that need to be addressed, but there are also a restraint of keeping the toaster low price.
		+
		+	== Expert Interview: Pamela's in Squirrel Hill ==
		+
		+	[[Image:Pamelas.jpg|300px]]
		+	[[Image:Pamelas_hotcake.jpg|300px]]
		+
		+	For getting more information about what users like or dislike about toasters, we decided to ask the people preparing food at Pamela's Restaurant in Squirrel Hill for their expert advice.  Information was gathered on the type of toaster in use, and how they felt about it.  A conveyor toaster was being used at the restaurant, due to the high volume of bread that needed to be toasted quickly and efficiently.  On asked why a pop up toaster was not desired, the employee said that he thought the conveyor toaster worked very well for the needs of the restaurant.  A pop up toaster would not be able to cope up with the large demand of toast during breakfast and rush hours, and would need to have many toasting slots in order to keep up.  This would be impractical as space was a limiting factor at Pamela's.  Another reason that the employee mentioned was the fact that no one had to keep watch to see if a pop up toaster was toasting right or not.  The conveyor toaster's slow continuous tread surface also ensures reasonably even toasting, and little supervision.  This information was useful to us, as we could understand what markets our toaster could target, and what needs need to be met.  We believe that Pamela's is a good example of a business that would use a toaster, and think that the information gathered here would be very similar to other restaurants as well.
		+
		+	== User and Stakeholder Needs ==
		+
		+	We focused on three major stakeholders in the production and distribution of a toaster.  These stakeholders are very influential to the design process and the decisions made.  Each represent a different viewpoint and have various needs that are important to them.
-	There are at least four major stakeholders in the production and distribution of a toaster:
	* Customer		* Customer
-	* Company	+	** affordable
-	* Distributors	+	** intuitive design and use
-	* Engineers	+	** reliability
		+	** quick toasting
		+	** safe
-	The customer is only interested in a product if it fulfills their specific needs.  In this case, the users need to be able to toast their bread easily and quickly. This is why they are going to purchase a toaster.  Although the toaster does fulfill their basic needs, the customers also have minor needs that go along with using the toaster.  If these types of needs can be met (ie. containment of crumbs, easy to use, easy retrieval of bread, cool-touch exterior), the toaster would be in much higher demand. In order to fully understand the customer's interactions with the product a <u>[[usability study]]</u> was conducted, which helped us further identify the customer's specific needs and opinions of the product.
-	The company needs are mostly limited to marketing and finance. They main interest and need is to make a profit.  This requires finding customers, low manufacturing costs, and low material costs.  This requires the company to decipher customer needs and apply them to their product. It also requires the company to work with the engineers and suppliers to ensure a low-cost product that can easily be sold to stores, or distributors, and thus bought by customers.	+	* Manufacturing
		+	** low part count
		+	** affordable
		+	** least amount of tools necessary
-	The distributors have similar needs to the company, they are looking to make a profit.  Thus their need is to purchase products from various companies that fulfill needs of their customers.  So they depend on the company to have come up with the lowest cost product possible.
-	The engineers are critical stakeholders, since every other stakeholder's needs has to be met by the engineer's design. The engineers needs are to decrease the amount and cost of material used in the toaster design.  It is also the engineers job to design the product using cost and time efficient methods of manufacturing and assembly.  Another need of the engineer is to balance cost and design of the product with the environmental impacts caused by the products production/use.	+	* Retail
		+	** low volume
		+	** easy stacking packaging
-	== Assembly ==	+	== Existing Toasters and Relevant Patents ==
-	{| class="wikitable" border="1"
-	|-
-	! Part Number !! Name !! Qty. !! Weight !! Function !! Material !! Maunfacturing Process !! Image !!
-	|-
-	| style="text-align: center;" | 001	+	[[Image:dyson-toaster.jpg|300px]]
-	| Plastic Casing	+
-	| style="text-align: center;" | 1	+
-	| style="text-align: center;" | 224g	+
-	| Seperates the internal heating mechanisms from the user.	+
-	| Polypropylene (PP)	+
-	| Injection Molded	+
-	| [[Image:toaster-001.jpg|200px]]	+
-	|-	+
-	| style="text-align: center;" | 002	+
-	| Crumb Tray	+
-	| style="text-align: center;" | 1	+
-	| style="text-align: center;" | 36g	+
-	| Collects bread crumbs.	+
-	| Aluminum	+
-	| Stamp	+
-	| [[Image:toaster-002.jpg|200px]]	+
-	|-	+
-	| style="text-align: center;" | 003	+
-	| Crumb Tray Handle	+
-	| style="text-align: center;" | 1	+
-	| style="text-align: center;" | 10 g	+
-	| Handle to pull out crumb tray.	+
-	| Plastic	+
-	| Injection Molded	+
-	| [[Image:toaster-003.jpg|200px]]	+
-	|-	+
-	| style="text-align: center;" | 004	+
-	| Toaster Loader Top	+
-	| style="text-align: center;" | 1	+
-	| style="text-align: center;" | 62g	+
-	| Bread is loaded through slots.	+
-	| Stainless Steel	+
-	| Stamping, Deep Drawing	+
-	| [[Image:toaster-004.jpg|200px]]	+
-	|-	+
-	| style="text-align: center;" | 005	+
-	| Toaster Base	+
-	| style="text-align: center;" | 1	+
-	| style="text-align: center;" | 108g	+
-	| Base of toaster.	+
-	| Polypropylene (PP)	+
-	| Injection Molding	+
-	| [[Image:toaster-005.jpg|200px]]	+
-	|-	+
-	| style="text-align: center;" | 006	+
-	| Regulator Knob	+
-	| style="text-align: center;" | 1	+
-	| style="text-align: center;" | 2g	+
-	| Adjusts Toast time.	+
-	| Polypropylene (PP)	+
-	| Injection Molding	+
-	| [[Image:toaster-006.jpg|200px]]	+
-	|-	+
-	| style="text-align: center;" | 007	+
-	| Press handle	+
-	| style="text-align: center;" | 1	+
-	| style="text-align: center;" | 8g	+
-	| Easy surface to press, to lower bread into toaster.	+
-	| Polypropylene (PP)	+
-	| Injection Molded	+
-	| [[Image:toaster-007.jpg|200px]]	+
-	|-	+
-	| style="text-align: center;" | 008	+
-	| Cancel button	+
-	| style="text-align: center;" | 1	+
-	| style="text-align: center;" | 2g	+
-	| Cancels toast process	+
-	| Polypropylene (PP)	+
-	| Injection Molded	+
-	| [[Image:toaster-008.jpg|200px]]	+
-	|-	+
-	| style="text-align: center;" | 009	+
-	| Power Cord	+
-	| style="text-align: center;" | 1	+
-	| style="text-align: center;" | 12g	+
-	| Used to power toaster	+
-	| Rubber and Copper	+
-	| Extrusion	+
-	| [[Image:toaster-009.jpg|200px]]	+
-	|-	+
-	| style="text-align: center;" | 010	+
-	| Ejection Assembly: Shaft	+
-	| style="text-align: center;" | 1	+
-	| style="text-align: center;" | 12g	+
-	| Guide rail for ejection assembly	+
-	| Steel	+
-	| Extrusion	+
-	| [[Image:toaster-010.jpg|200px]]	+
-	|-	+
-	| style="text-align: center;" | 011	+
-	| Handle and Locking Part 1	+
-	| style="text-align: center;" | 1	+
-	| style="text-align: center;" | 18g	+
-	| Assists in triggering toasting.	+
-	| Steel	+
-	| Stamped and Bent	+
-	| [[Image:toaster-011.jpg|200px]]	+
-	|-	+
-	| style="text-align: center;" | 012	+
-	| Handle and Locking Part 2	+
-	| style="text-align: center;" | 1	+
-	| style="text-align: center;" | 20g	+
-	| Assists in triggering toasting.	+
-	| Steel	+
-	| Stamped and Bent	+
-	| [[Image:toaster-012.jpg|200px]]	+
-	|-	+
-	| style="text-align: center;" | 013	+
-	| Toast Shelf	+
-	| style="text-align: center;" | 2	+
-	| style="text-align: center;" | 10g	+
-	| Holds toast in place	+
-	| Aluminum	+
-	| Bent	+
-	| [[Image:toaster-013.jpg|200px]]	+
-	|-	+
-	| style="text-align: center;" | 014	+
-	| Mystery Spring	+
-	| style="text-align: center;" | 1	+
-	| style="text-align: center;" | 1g	+
-	| Used as a spacer, preventing ejection assembly from moving beyond a certain distance.	+
-	| Steel	+
-	| Extrusion	+
-	| [[Image:toaster-014.jpg|200px]]	+
-	|-	+
-	| style="text-align: center;" | 015	+
-	| Restoring Spring	+
-	| style="text-align: center;" | 1	+
-	| style="text-align: center;" | 4g	+
-	| Restoring Spring	+
-	| Steel	+
-	| Extrusion	+
-	| [[Image:toaster-015.jpg|200px]]	+
-	|-	+
-	| style="text-align: center;" | 016	+
-	| Magnetic Lock Piece	+
-	| style="text-align: center;" | 1	+
-	| style="text-align: center;" | 8g	+
-	| Attracts to magnet to lock the toasting shelf.	+
-	| Steel	+
-	| Stamped and Bent	+
-	| [[Image:toaster-016.jpg|200px]]	+
-	|-	+
-	| style="text-align: center;" | 017	+
-	| Insulating caps for locking mechanism.	+
-	| style="text-align: center;" | 2	+
-	| style="text-align: center;" | 2g	+
-	| N/A	+
-	| ABS	+
-	| Injection Molding	+
-	| [[Image:toaster-017.jpg|200px]]	+
-	|-	+
-	| style="text-align: center;" | 018	+
-	| Shaft Spacer	+
-	| style="text-align: center;" | 1	+
-	| style="text-align: center;" | 2g	+
-	| Spacer	+
-	| ABS	+
-	| Extrusion	+
-	| [[Image:toaster-018.jpg|200px]]	+
-	|-	+
-	| style="text-align: center;" | 019	+
-	| Trigger Switch	+
-	| style="text-align: center;" | 1	+
-	| style="text-align: center;" | 2	+
-	| Triggers switch that activates the heating coils.	+
-	| ABS	+
-	| Injection Molding	+
-	| [[Image:toaster-019.jpg|200px]]	+
-	|-	+
-	| style="text-align: center;" | 020	+
-	| Circuit Board	+
-	| style="text-align: center;" | 1	+
-	| style="text-align: center;" | 12g	+
-	| Controls heating mechanism and switch release.	+
-	| Silicon and Electrical Components	+
-	| N/A	+
-	| [[Image:toaster-020.jpg|200px]]	+
-	|-	+
-	| style="text-align: center;" | 021	+
-	| Electromagnet, Switch Release, Circuit Board #2	+
-	| style="text-align: center;" | 1	+
-	| style="text-align: center;" | 46g	+
-	| Electromagnet releases shelf, releasing the switch.  Also powers the heating elements.	+
-	| Silicon and Electrical components	+
-	| N/A	+
-	| [[Image:toaster-021.jpg|200px]]	+
-	|-	+
-	| style="text-align: center;" | 022	+
-	| Heating Coil	+
-	| style="text-align: center;" | 3	+
-	| style="text-align: center;" | 1g	+
-	| Heats up when current passes through it.	+
-	| Nichrome	+
-	| Extrusion	+
-	| [[Image:toaster-022.jpg|200px]]	+
-	|-	+
-	| style="text-align: center;" | 023	+
-	| Mica Insulating Sheet	+
-	| style="text-align: center;" | 3	+
-	| style="text-align: center;" | 14g	+
-	| Insulating sheet, also carries the heating coil.	+
-	| Mica	+
-	| Pressed and chemically treated	+
-	| [[Image:toaster-023.jpg|200px]]	+
-	|-	+
-	| style="text-align: center;" | 024	+
-	| Mica Aligning Strips	+
-	| style="text-align: center;" | 6	+
-	| style="text-align: center;" | 1g	+
-	| Used to keep heating coils in place.	+
-	| Mica	+
-	| Pressed and chemically treated	+
-	| [[Image:toaster-024.jpg|200px]]	+
-	|-	+
-	| style="text-align: center;" | 025	+
-	| Circut Board Insulator	+
-	| style="text-align: center;" | 1	+
-	| style="text-align: center;" | 1g	+
-	| Prevents the two circuit boards from shorting.	+
-	| Mica	+
-	| Pressed and chemically treated	+
-	| [[Image:toaster-025.jpg|200px]]	+
-	|-	+
-	| style="text-align: center;" | 026	+
-	| Heater leads	+
-	| style="text-align: center;" | 3	+
-	| style="text-align: center;" | 2g	+
-	| Used to carry current to heater coils	+
-	| Steel	+
-	| Extruded and Bent	+
-	| [[Image:toaster-026.jpg|200px]]	+
-	|-	+
-	| style="text-align: center;" | 027	+
-	| Smaller Mica Insulator	+
-	| style="text-align: center;" | 2	+
-	| style="text-align: center;" | 1g	+
-	| Insulating purposes	+
-	| Mica	+
-	| Pressed chemically treated	+
-	| [[Image:toaster-027.jpg|200px]]	+
-	|-	+
-	| style="text-align: center;" | 028	+
-	| Toaster wall #1	+
-	| style="text-align: center;" | 1	+
-	| style="text-align: center;" | 32g	+
-	| Structural support, guides toast shelf	+
-	| Steel	+
-	| Stamped and Bent	+
-	| [[Image:toaster-028.jpg|200px]]	+
-	|-	+
-	| style="text-align: center;" | 029	+
-	| Base Plate	+
-	| style="text-align: center;" | 1	+
-	| style="text-align: center;" | 60g	+
-	| Holds everything in place, structural support	+
-	| Steel	+
-	| Stamped and Bent	+
-	| [[Image:toaster-029.jpg|200px]]	+
-	|-	+
-	| style="text-align: center;" | 030	+
-	| Toaster wall #2	+
-	| style="text-align: center;" | 1	+
-	| style="text-align: center;" | 24g	+
-	| Guides far end of toast shelf	+
-	| Steel	+
-	| Stamped and Bent	+
-	| [[Image:toaster-030.jpg|200px]]	+
-	|-	+
-	| style="text-align: center;" | 031	+
-	| Radiation Shield	+
-	| style="text-align: center;" | 2	+
-	| style="text-align: center;" | 32g	+
-	| Prevents heat from radiating to the walls of the toaster.	+
-	| Steel	+
-	| Stamped and Bent	+
-	| [[Image:toaster-031.jpg|200px]]	+
-	|-	+
-	| style="text-align: center;" | 032	+
-	| Small mica tabs	+
-	| style="text-align: center;" | 7	+
-	| style="text-align: center;" | 1g	+
-	| Holds various wires in place	+
-	| Mica	+
-	| Pressed and chemically treated	+
-	| [[Image:toaster-032.jpg|200px]]	+
-	|-	+
-	| style="text-align: center;" | 033	+
-	| Bread Holder support wires	+
-	| style="text-align: center;" | 8	+
-	| style="text-align: center;" | 2g	+
-	| Supports the toastee to be upright.	+
-	| Aluminum	+
-	| Extrusion and Bent	+
-	| [[Image:toaster-033.jpg|200px]]	+
-	|-	+
-	| style="text-align: center;" | 034	+
-	| Mica sheet support beams	+
-	| style="text-align: center;" | 3	+
-	| style="text-align: center;" | 4g	+
-	| Helps keep mica sheets in place.	+
-	| Steel	+
-	| Stamped and Bent	+
-	| [[Image:toaster-034.jpg|200px]]	+
-	|-	+
-	| style="text-align: center;" | 035	+
-	| Rubberized No slip pads	+
-	| style="text-align: center;" | 2	+
-	| style="text-align: center;" | 0.5g	+
-	| Helps keep toaster from sliding	+
-	| Urethane	+
-	| Extruded, Cut	+
-	| [[Image:toaster-035.jpg|200px]]	+
-	|-	+
-	| style="text-align: center;" | 036	+
-	| Control knob ring	+
-	| style="text-align: center;" | 1	+
-	| style="text-align: center;" | 6g	+
-	| Support for knob	+
-	| Polypropylene (PP)	+
-	| Injection Molded	+
-	| [[Image:toaster-036.jpg|200px]]	+
-	|-	+
-	| style="text-align: center;" | 037	+
-	| Clamp for power cord	+
-	| style="text-align: center;" | 1	+
-	| style="text-align: center;" | 1g	+
-	| Prevents power cord from being pulled out	+
-	| Polypropylene (PP)	+
-	| Injection Molded	+
-	| [[Image:toaster-037.jpg|200px]]	+
-	|-	+
-	| style="text-align: center;" | 038	+
-	| 1/2'' Philips screw	+
-	| style="text-align: center;" | 6	+
-	| style="text-align: center;" | 1g	+
-	| Screw	+
-	| Steel	+
-	| Machined	+
-	| [[Image:toaster-038.jpg|200px]]	+
-	|-	+
-	| style="text-align: center;" | 039	+
-	| 1/4'' Philips screw	+
-	| style="text-align: center;" | 4	+
-	| style="text-align: center;" | 1g	+
-	| Screw	+
-	| Steel	+
-	| Machined	+
-	| [[Image:toaster-039.jpg|200px]]	+
-	|-	+
-	|}	+
-	=Product Analysis=	+	*Clear-wall glass toaster, with heating coils between two plates of glass. Only a single slice toaster.
-	For our product evaluation, we looked at four different types of analysis.  Design for Manufacture and Assembly (DFMA), Failure Mode Evaluation and Analysis (FMEA), Design for Environment (DFE), and a quantitative mechanical analysis.
-	==DFMA Analysis==
-	The toaster is a fairly inexpensive kitchen appliance which is always in demand.  Almost everyone owns a toaster or has access to it, meaning that it needs to be designed to allow mass production.
-	=== Design for Manufacture ===	+	[[Image:transparent_toaster.jpg|300px]]
-	The toaster is manufactured using several different processes. The main two process used are injection molding and stamping.  Extrusion, deep draw methods, and an hydraulic press were also used.	+	*Glass walled toaster. Glass is heated from the base. Also, only a single slice toaster. Both these clear toasters show the toast as it is cooking, and allow the user better control over the done-ness of their food.
-	Exterior of Toaster - <br/>
-	The case, bottom, and user interface of the toaster were all injection molded. Although injection molding is an expensive process due to its high price equipment and molds, with the toaster it is probably a good option.  With the number of toasters being made and the consistency of the toaster design, the mold for a toaster is more than paid for.  There are probably three different injection molds for this product: one mold for the case, one for the bottom, and one for the various buttons and knobs on the user interface.  This combination of multiple parts in one mold is allowable due to the small size of the various parts and the lack of detail needed for each part.  The shape of each of these parts were designed to be most efficient for injection molding. The bottom, which consists of many slots or vents, is the most complex of the shapes and is made up for this by having four locations that the plastic is injected.
-	Exterior Metal Slots- <br/>
-	The slots of the toaster was made through a deep draw process.  This is a special type of stamping that gives radial stress to the flanges of the metal, and allows it to be stretched radially as well linearly.  This gives the metal a rounder finish, making it look more complete and attractive.  This process was used only for the exterior metal on the slots for the toaster. Its purpose was to make the toaster attractive.  Although this process is more expensive than just stamping and bending metal, in mass quantities the cost is not unreasonable.  This process in the toaster manufacturing could definitely be taken out, but it would also hinder the quality and attractiveness of the product.
-	[[Image:Toaster-deepdraw2.jpg]]	+	[[Image:toaster-modern.jpg|300px]]
-	Interior Metal Plates and strips- <br/>	+	*Recently patented toaster, with programmable toast settings and memory of up to 3 settings.
-	The metal in the interior of the toaster was all stamped and bent.  This is an easy process which uses sheet metal and then stamps out the shape of the metal needed. All unused sections of sheet metal can then be re-melted and used again. This is a very cost-effective method of manufacturing.  You start of with the sheet metal, cut it in to shape by stamping it and then bend it to give it more strength and durability. This process is easy, low time, and easy to automate.	+
-	[[Image:Toaster-Stamping.jpg]]
-	Metal Rods and Wires-<br/>
-	All of the metal rods and wires in the toaster were made through metal extrusion. Where metal is heated and then pushed through a die to its desired shape.  This process is easy to do, and it is cost-efficient as while extruding the pieces can be easily cut to their desired length.  This creates very little waste in material and makes the whole process extremely quick.
-	Mica Sheets- <br/>	+	[[Image:dropdowntoaster-1.jpg|300px]]
-	Mica is a great insulator and hard to burn.  Thus is a great choice to contact the heating wires and insulate the various circuits and wires. In order to produce mica sheets, mica is ground fine and mixed with a colloid agent and water. A single sheet of uniform thickness is formed by pouring the mixture onto a mesh screen. Vacuum means and a hydraulic press are used to complete the formation of a sheet.  Mica is not inexpensive, but its special properties make it a extremely valuable material, its used in a wide variance of products from dry wall to cosmetics for this reason. In this product's case, due to the restraints of needing an insulation, structure, and resistance to heat, mica was a perfect choice.	+
-	=== Design for Assembly ===	+	*Toaster which drops food out the bottom when cycle is complete, making it easier to access toast, but is much less space efficient. It seems more suited for commercial applications.
-	The toaster is designed to be assembled by hand.  It is made in China, where labor is cheap, and its parts were designed to allow easy and quick assembly.
-	Each of the metal plates in the entire were connected together with a series of tabs.  The plates connected together when the tabs fit into small slots and were then folded over by hand. This allowed the plates to be easily and quickly adhered together.  The one problem is that is it requires a lot of tedious work for the laborer.  It was easy to see that different people worked on the tabs on our toaster, as different tabs were folded dramatically different for each plate.
-	There were also holes punched into the metal plates to allow for easy assembly of having either rods, wires, or metal pieces fit easily through a space into their correct location.  This once again was optimized for hands-on assembly. As you can see from the picture below, this design was even incorporated for somewhat complex shapes and assembly to quicken the process and keep it accurate.	+	[[Image:orb-toaster.jpg|300px]]
-	[[Image:Toaster-_hole_punched.JPG]]	+	*Another drop down toaster, with an artistic twist to it. More of a residential drop down toaster.
-	The injection molded bottom had some built in slots that the circuit boards easily slipped into, making the circuit board addition a last minute process.  All that needed to be done was to slide them in, connect the two boards together, and solder the wires to the leads.
-	Looking at the whole assembly process, the toaster has a lot of parts to put together.  Automating more of this process would be beneficial for time and getting rid of labor.  This would also increase costs due to machinery and maintenance. Although the toaster is made entirely by hand, the parts were designed to limit the laborer to easy tasks, improving time and reliability of the assembly.
-	==FMEA Analysis==	+	[[Image:conveyor-toaster.jpg|300px]]
-	Off the shelf, this product should function just fine. Most failures should be found before the product leaves the factory.  The major failure modes mostly involve fatiguing of parts and mechanisms. Therefore, this product should be put through Hyper Accelerated Life Testing (HALT) to determine an average lifespan and address major failures. This testing should include average and heavy use under normal and extreme conditions.	+	*Commercial conveyor type toaster. Is very effective for toasting large amounts of toast. Thus, it is the choice of many food service establishments. Downsides are space usage and large power consumption.
-	The risk may also be lowered if the properties of the metals used are already known.  If the components will be able to function properly after 4 years of use, then the product will have reached an acceptable lifespan.  This will cut down on reliability testing costs and keep the overall product costs low.	+	== Design Problem ==
-	The following table outlines the basic Failure Modes and Effects Analysis (FMEA) for the toaster.  The first nine parts on the list were analyzed at the component level while the rest were at assembly level.  Since most failures for the assembly level parts had similar failures and effects, they were analyzed together.	+	'''Modes of Dissatisfaction (MoD)'''
-	{| class="wikitable" border="1"	+	Here are a few examples of situations which user may not like when using a toaster, and is actually quite common from our user survey data.
-	|-	+	*Bread gets stuck in the toaster, and is hard to get out.
-	! Part # !! Name & Function !! Failure Mode !! Effects of Failure !! S !! Causes of Failure !! O !! Design Controls !! D !! RPN !! Recommended Actions !! Responsibility	+
-	|- valgin="center"	+
-	| rowspan=4 style="text-align: center;" | 001	+
-	| rowspan=4 | Plastic Casing	+
-	* Enclose and protect internal components	+
-	* Shield user from internal components and heat	+
-	| rowspan=2 | Warped	+
-	| rowspan=2 | Improper fit, Unintended contact with heating element	+
-	| rowspan=2 style="text-align: center;" | '''6'''	+
-	| Repeated heating and cooling || '''4''' || Material Selection || '''8''' || style="text-align: center;" | '''192''' || HALT for Temperature Variations || Reliability	+
-	|-	+
-	| Improper Manufacturing || '''1''' || Material Selection, Mold Design || '''1''' || style="text-align: center;" | '''6''' || None || Manufacturing	+
-	|-	+
-	| Fractured	+
-	| Exposure of internal components	+
-	| style="text-align: center;" | '''8'''	+
-	| Improper handling || '''5''' || Material Selection, Packaging || '''4''' || style="text-align: center;" | '''160''' || Drop Test with and without packaging || Reliability	+
-	|-	+
-	| Wrong color / surface finish	+
-	| User dissatisfaction	+
-	| style="text-align: center;" | '''1'''	+
-	| 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	+
-	|-	+
-	|-	+
-	|}	+
-	==DFE Analysis==	+	[[Image:toaster_mod1.JPG|300px]]
		+	[[Image:toaster_mod2.JPG|300px]]
		+	[[Image:toaster_mod3.JPG|150px]]
		+	[[Image:toaster_mod4.JPG|150px]]
-	Putting a slice of bread in the toaster, one does not often think about the environmental implications this act may have: “What steps were taken to enable this toaster to arrive on my countertop, how much power is it using while toasting, and what will happen to it after it I throw it away?” Delving into the life cycle of a toaster, we see that there is much room for improvement.	+	*Uneven toasting
-	While nearly all the materials in the toaster are recyclable, due to the complex nature of a toaster, it is costly to fully recycle one. Thus, toasters generally end up in landfills at the end of their lives.	+	[[Image:toaster_mod5.JPG|300px]]
-		+
-	However, the key element in the life cycle of this appliance is energy. In both the production and use phases of a toaster, power generation and supply is the overwhelming contributor of greenhouse gas emissions. This seems fairly straightforward for the use end – in use, toasters produce little more than heat, from electrical power, and (hopefully) golden brown toast – but this may come as a surprise for the manufacturing end. Indeed, power generation and supply produces nearly four times as much CO2-equivalent than the nearest sectors, truck transportation and steel mills, during the manufacturing of such appliances.	+
-	Using the EIO-LCA software from Carnegie Mellon University’s Green Design Institute (results pictured below), we see that every $1,000,000 of production in the ‘Electric housewares and household fans’ sector produces 693 MTCO2E. Given our $10 toaster, this shows us that approximately 0.007 MTCO2E caused by the manufacturing of one toaster.  To compare that to the use end, a simple calculation is done:	+	*Extremely Burnt toast
-	From the EIO-LCA, we see that for every $1,000,000 of production in the ‘Power generation and supply’ sector, 9910 MTCO2E are emitted.	+	[[Image:toaster_mod6.JPG|300px]]
-	Assuming: $0.10/kWh electricity cost, power consumption is 800W, usage is 6 min (0.1hr) per day, used 300 days out of the year, over the course of a 4 year use-life.	+	*Toast does not pop up all the way
-	We see that it would cost approximately $9.60 to run this toaster over the course of its life. Given this information, it is seen that the use phase of a toaster’s life emits approximately 0.095 MTCO2E. This is an entire order of magnitude higher than the emissions production phase. Clearly, one of our assumptions, above, needs to be modified. The only option which may not impact the functionality and longevity of the toaster is the power consumption. Furthermore, looking at other toasters, we see that this 800W usage is on the low end of the spectrum. All residential toasters use the same heating method – running current through a filament, which generates heat.	+	[[Image:toaster_mod7.JPG|300px]]
-		+
-	The results for conventional air pollutants, such as SO2, NOx, and CO, show the same result: power generation, both for the creation and use of a toaster, is the largest contributor to harmful emissions.	+
-	The numerical results of GHG emissions, above, come with a good level of confidence. Though there are many sub-sectors of the ‘Electric housewares and household fans’ segment, the ‘Small electric household cooking appliances’ sub-sector represents nearly 1/3 of the overall sector.	+	*Toast catching on fire
-	From our analysis, it appears the best way to approach the DFE is to reduce the power consumption of a toaster. Perhaps an alternative heating method should be considered. A more realistic and attainable possibility is to better insulate the toasting area, as to reduce the amount of heat lost during the toasting process. Also, reducing the complexity of a toaster would increase its potential to be recycled, further reducing its environmental footprint.	+	[[Image:FireFIREfire.gif|300px]]
-	{|-	+	= Design Concepts =
-	| '''EIO-LCA GHG Results for Electric Housewares and Household Fans'''	+
-	|-	+	From our brainstorming and list of 100 ideas, we have narrowed down our ideas to 4 concepts.  These concepts are the ideas that we thought were most tangible and were chosen based on user study research.
-	| [[Image:ToasterghgTable.jpg]]	+
-	|-	+	== Concept 1: Clear Walled Toaster ==
-	| [[Image:ToasterghgChart.jpg]]	+
-	|-	+
-	| '''EIO-LCA GHG Results for Power Generation and Supply'''	+
-	|-	+	[[Image:Toaster-ClearWall-Overall.jpg|500px]]
-	| [[Image:ToasterghgPowertable.jpg]]	+
-	|-	+	One of the concepts that was considered from the 103 brainstorming ideas was a clear walled toaster.  The reasoning behind this was that from the data we gathered from the survey, it was noted that one of the issues that users has with toasters was that they had no idea how toasted the bread was, until it popped out.  The concept of a clear walled toaster would alleviate this problem.  The user would always know how toasted the bread was at any given instant, and if no more toasting was deemed necessary, the user could terminate the toasting process if he/she wished.  This design would require higher maintenance compared to the other conceptual ideas and the stock toaster, as the user would have to continually clean the toaster to keep it looking its best all the time.  This cleaning upkeep may not be all a waste of time though.  With care and cleaning, the toaster would be a very chic addition to any kitchen, with its shiny glass walls and look of sophistication.
-	| [[Image:ToasterghgPowerchart.jpg]]	+
-	|-	+	The glass walled toaster would have the following interesting features for practical operation:
		+
		+	*The glass used in the toaster would be tempered so it would be able to withstand the high temperatures of a toaster.
		+	*The heating element would be stuck onto the glass sheets in a similar grid like arrangement like that of a normal toaster.
		+	*Multiple layers of glass would be placed in between the heating glass, and the outside of the toaster (the user side).  The layers of air in between the glass sheets would insulate the user from the heat of the heating glass.  As glass and air are BOTH insulators, this would allow for safe operation of the toaster.
		+	*A cancel button and toasting selection dial would also be standard.  Everything else resembles a classic toaster.
		+
		+	This toaster would clearly be able to address some stakeholder needs, but we think that the cost of of manufacture would be higher than what we would like.  The toaster does not address the scenario of what happens when the bread gets stuck in the slot, and it may be difficult to get out.  The summary of advantages and disadvantages are listed below.
		+
		+	Advantages:
		+
		+	*Can see toast 'toast'
		+	*Looks cool
		+
		+	Disadvantages:
		+
		+	*May be expensive to manufacture
		+	*Toast may get stuck in slot
		+	*High maintenance
		+
		+	== Concept 2: Fold Out Toaster ==
		+
		+	The fold out toaster design is intended to solve several problems users have with toasters as well as major failure modes.  The heating sides will use a solid sheet of conductive material to promote more even heating and protect the internal components.  These sheets will also protect the user from internal components and make it nearly impossible for the toast to get caught and shred during ejection.  Small shelves will run up and down the fold out sides to push the toast up, similar to a conventional toaster.  This will allow the user to pick up the toast from the top of the ejected side.
		+
		+	[[Image:toaster-FoldOut-Overall.jpg|300px]][[Image:toaster-FoldOut-Open.jpg|300px]]
		+
		+	This new toaster will begin operation whenever the user pushes the handle down OR closes the fold out sides manually.  Pushing together the sides of the toaster is a much easier action than pushing down the small handle on conventional toasters.  The inside heating panels will be able to "float", allowing various sizes of bread to be toasted equally.  The fold out panel will push the bread flat against the inside panel, such that both sides of the bread are pushed up against the conductive material.
		+
		+	[[Image:Toaster-FoldOut-Mechanism.jpg|300px]]
		+
		+	Fold out sides allow for much easier loading of toasting products as well.  Different shape and size products can simply be placed on the diagonal panel and pushed in to toast.  Smaller items that would normally be difficult to remove after toasting will be much more accessible.  No more sticking a fork in the toaster to remove inadequately ejected food products.
		+
		+	{|
		+	|
		+	Advantages:
		+	* More even, consistent heating
		+	* Easier to load and start
		+	* Accessible for easy cleaning
		+	* More reliable ejection system
		+	|
		+	Disadvantages:
		+	* More parts to assemble
		+	* Difficulty in storing
		+	* Expensive
		+	* Possibly less safe for the user
		+	|
	|}		|}
-	==Mechanical Analysis==	+	== Concept 3: Enclosed Toaster ==
-	The toaster bread shelf is a very important part of the toaster.  Not only does it pop the toast back up after it has completed the heating cycle, but it keeps the bread at the appropriate position between the heating coils.  If the shelf happens to fail, the toaster becomes a potentially dangerous appliance.  This analysis is intended to find the probability of failure for the shelf.	+
-	[[Image:Toaster-Model.jpg|500px]]	+	The enclosed toaster concept addresses certain, key stakeholder needs. Specifically, an enclosed design would allow for more uniform heat distribution within the toaster, helping to uniformly toast the food. Another important improvement over the standard toaster is that it would lessen the heat and power needed for each toasting cycle. In current toasters, energy is wasted because of the open toaster slots. Having a capping system would prevent much of this convection to the environment. Thus, the cycle times could be shortened, and less power could be used.
-	This part is made from steel sheets, stamped and bent into the above shape. The bent tabs are intended to support the bread while fitting in between the side guide wires of the toaster. A long indent along the side of the shelf helps improve lateral stiffness.	+	There are, however, issues with such a design. First, it does not address the issue of the bread, bagel, or pastry becoming stuck in the toaster. In fact, it would likely make removing such a piece of food even more difficult. Also, it brings about more complexity in a toaster. This has two effects on the stakeholders. For the manufacturer, it introduces more steps and parts to be assembled on the toaster, raising production costs. For the user, more complexity often decreases reliability. In this case, it may cause more nuisances with toasters; for example, the lid getting stuck closed.
-	[[Image:Toaster-Stress.jpg|500px]]	+	The basic mechanism is shown below. Essentially, a thin rod would connect the bread holder to the lid. As the bread holder rises, it pushes up the lid. In this way, the main mechanism of ejecting the toast would not be modified, so it would be a relatively simple addition to the toaster and toaster manufacturing process.
-	The above picture shows a basic stress distribution when the  shelf is supporting one pound of weight.	+	[[Image:Toaster-Enclosed-Front.jpg|300px]]
		+	[[Image:Toaster-Enclosed-Mechanism.jpg|150px]]
-	[[Image:Toaster-disp.jpg|500px]]	+	To summarize:
-	As seen above, even with the heaviest anticipated load of one pound, the shelf only deflects 0.0004" at the furthest point.  The probability of shelf deformation is very low.  Accordingly, this failure mode, while potentially serious, is extremely unlikely.  The shelf was obviously designed to withstand much more than it should ever encounter.	+	'''Advantages'''
		+	*More even toasting
		+	*Less power consumption
-	=References=	+	'''Disadvantages'''
		+	*Potentially more difficult to remove toast
		+	*Adds complexity
		+	*Reliability issues
-	Degentesh, Drew. "Metal Processing." 24-443: Design for Manufacture. Carnegie Mellon University. 11 Sept. 2008.	+	== Concept 4: Front Loading Toaster ==
-	Degentesh, Drew. "Injection Molding." 24-443: Design for Manufacture. Carnegie Mellon University. 4 Sept. 2008.	+	[[Image:Toaster-FrontLoad-Overall.jpg|300px]] [[Image:Toaster-FrontLoad-ToastTray.jpg|300px]]
-	Degentesh, Drew. "Plastics Processing." 24-443: Design for Manufacture. Carnegie Mellon University. 2 Sept. 2008.	+	The front loading toaster concept came about in the attempt to come up with an innovative way of making the toaster more user friendly and help toasting stay uniform and even.  The toaster still would have a toaster settings knob that would adjust the level of browning, but the loading and ejection methods would be different.
-	Thompson, Rob. Manufacturing Processes for Design Professionals. London: Thames & Hudson, 2007.	+	The toast is loaded side by side horizontally, which makes the toaster much wider but also a lot shorter. By doing this, the heating coils are not doubled up like the middle section of a traditional toaster.  This will keep one side of the toast from being more toasted than others.
-	[http://ddl.me.cmu.edu/ddwiki/index.php/ED2 Engineering Design II Course]	+	When loading the toast, the toast is placed on a toasting tray. This tray then is brought into the toaster and ejected just like a DVD toaster. This should keep people from using bread that is too big for the toaster, and thus also address the issue of toast being stuck in the toaster.   Another thought was that having this front loading toaster made toaster much easier for elderly and children as it was easier to reach and extremely intuitive. (Most people are familiar with DVD players or computer CD drives)
-	Carnegie Mellon University Green Design Institute. [http://www.eiolca.net/ (2008) Economic Input-Output Life Cycle Assessment (EIO-LCA) model]	+
		+	|
		+	Advantages:
		+	* More even, consistent heating
		+	* Easier to load and use
		+	* Keeps bread from getting stuck in the toaster
		+	* Address young and old users
		+	|
		+	Disadvantages:
		+	* More parts to assemble
		+	* Larger counter footprint
		+	* Expensive Ejection system
		+
		+	== Concept Comparison with Pugh Chart ==
		+
		+	{| class="wikitable" border="1" cellspacing="0" align="center"
		+
		+	|- align="center"
		+	! colspan="2" | Description
		+	|  Standard Toaster || Clear Wall Toaster || Fold Out Toaster || Enclosed Toaster || Front Load Toaster
		+	|- align="center"
		+	! colspan="2" | Sketch ||  [[Image:toaster.jpg|100px]] || [[Image:Toaster-ClearWall-Overall.jpg|100px]] || [[Image:toaster-FoldOut-Open.jpg|100px]] || [[Image:Toaster-Enclosed-Front.jpg|100px]] || [[Image:Toaster-FrontLoad-Overall.jpg|100px]]
		+	|- align="center"
		+	| style="border-bottom:3px solid grey;" | '''Criteria''' || style="border-bottom:3px solid grey;" |'''Weight''' || style="border-bottom:3px solid grey;" | '''Datum 1''' || style="border-bottom:3px solid grey;" | '''Design 1''' || style="border-bottom:3px solid grey;" | '''Design 2''' || style="border-bottom:3px solid grey;" | '''Design 3''' || style="border-bottom:3px solid grey;" | '''Design 4'''
		+	|- align="center"
		+	! Manufacture/Assembly
		+	| 2 || 0 || - || - || - || -
		+	|- align="center"
		+	! Affordable
		+	| 3 || 0 || - || - || 0 || 0
		+	|- align="center"
		+	! Toasting Consistency
		+	| 2 || 0 || ++ || 0 || + || 0
		+	|- align="center"
		+	! Toast Retrieval/Ejection
		+	| 3 || 0 || 0 || ++ || 0 || ++
		+	|- align="center"
		+	! Storage
		+	| 1 || 0 || 0 || - || 0 || --
		+	|- align="center"
		+	! Maintenance
		+	| 1 || 0 || - || ++ || 0 || 0
		+	|- align="center"
		+	! Safety
		+	| 1 || 0 || - || 0 || - || +
		+	|- align="center"
		+	! style="border-bottom:3px solid grey;" | Easy to Use
		+	| style="border-bottom:3px solid grey;" | 1 || style="border-bottom:3px solid grey;" | 0 || style="border-bottom:3px solid grey;" | ++ || style="border-bottom:3px solid grey;" | + || style="border-bottom:3px solid grey;" | 0 || style="border-bottom:3px solid grey;" | 0
		+	|- align="center" style="border-bottom:3px solid grey;"
		+	! colspan="2" | +
		+	| 0 || 6 || 9 || 2 || 7
		+	|- align="center"
		+	! colspan="2" | 0
		+	| 9 || 2 || 2 || 5 || 4
		+	|- align="center"
		+	! colspan="2" | -
		+	| 0 || 7 || 6 || 3 || 2
		+	|- align="center"
		+	! colspan="2" style="border-top:3px solid grey;" | Net Score
		+	| style="border-top:3px solid grey;" | 0 || style="border-top:3px solid grey;" | -1 || style="border-top:3px solid grey;" | 3 || style="border-top:3px solid grey;" | -1 || style="border-top:3px solid grey;" | 3
		+	|}
		+
		+	= Design Schedule =
		+
		+	[[Image:ToasterSchedule.jpg]]
		+
		+	= Recommendation Summary =
		+
		+	[[Image:Toaster-FoldOut-Overall.jpg|300px]][[Image:Toaster-FoldOut-Open.jpg|300px]]
		+
		+	After considering many potential designs and comparing the top concepts, we decided to prototype the fold out toaster design.  This design was chosen over the others because it address more problems.  We believe this design has the potential to become a breakthrough in toaster technology.  Not only does it toast bread, but it ejects it in a way that is easier to retrieve.
		+
		+	The other top concepts attempt to address the even and consistent heating problem while ignoring the problems users encounter with ejection systems.  The fold out design provides a potential solution to even heating with its solid conductive plates lining both sides.  The inner "floating" plate pushing the bread against these plates helps maximize the even heating potential.
		+
		+	The innovative ejection system makes toastable products of all sizes easier and safer to toast.  The enclosed and clear walled toasters use the same ejection mechanism that has failed in the past, while the front loading toaster may be easier for the user to manually pull out, but may have issues ejecting on its own.  A fold out toaster would have a much harder time getting stuck closed.  In the unlikely event that it does, the user could actually pull it open by force, while the clear walled and enclosed toasters make this impossible to do safely.
		+
		+	The three other toaster designs also are much more difficult to clean properly.  The clear walled toaster makes cleaning more necessary, but would be difficult to clean well since it would have to be partially disassembled.  A fold out toaster would easily expose all surfaces the user would usually want to keep clean.  Overall, the fold out toaster seems to have the most potential to replace the old style toaster.  It will perform most the functions users would want in a good, reliable toaster.
	=Team Members=		=Team Members=
Line 724:		Line 336:
	|[[Image:Toaster-Jon.JPG|200px]]		|[[Image:Toaster-Jon.JPG|200px]]
	|[[Image:ToasterAkshay.JPG|200px]]		|[[Image:ToasterAkshay.JPG|200px]]
-	|[[Image:Toaster-Ian.JPG|200px]]	+	|[[Image:Toaster-Ian2.JPG|200px]]
	|-		|-
-	| style="text-align: center;" | DFMA, Usability study, and Stakeholders	+	| style="text-align: center;" | Front Loading Toaster Concept, User Study, Design Problems
-	| style="text-align: center;" | FMEA and Mechanical Analysis	+	| style="text-align: center;" | Fold Out Toaster Concept, Recommendation Summary
-	| style="text-align: center;" | Component List, Photography, and Executive Summary	+	| style="text-align: center;" | Clear Wall Toaster Concept, Expert Interview, Design Problems
-	| style="text-align: center;" | DFE, Product and System Function	+	| style="text-align: center;" | Enclosed Toaster Concept, Executive Summary, Patent and Market Research
	|-		|-
-	|}	+	|}
-	<br/>	+	= Appendix =
-	Future plans:	+	== Possible Innovations ==
-	* Dissect second toaster to continue analysis	+
-	* Brainstorm Innovations and Improvements	+	List of 100 ways to innovate a toaster:
		+	{|
		+	|
		+	# Pre-Heat button for toaster
		+	# Enclosed toaster (to keep heat inside)
		+	# Open toaster- toaster walls fold down for easy access to done toast
		+	# Illegal toaster.
		+	# NOS toaster + turbo button
		+	# Intercooled Toaster
		+	# Toaster powered by a Honda Civic
		+	# Carbon Fiber Toaster
		+	# Open flame toaster.
		+	# Self Extinguish Toaster
		+	# Turret Toaster (shoots toast at people, motion sensitive, SENTRY toast)
		+	# Toast Launcher
		+	# Optional slot load toaster drive for laptops
		+	# Toaster instead of FlexFan idea.
		+	# Toaster that acts as an electric space heater (built in fan)
		+	# Built in counter top toaster (space saver idea)
		+	# Smore maker addition
		+	# Talking toaster (“You’ll still need a tray. “)
		+	# High Tech Toaster with LCD Display
		+	# Temperature and Time Control
		+	# Bread Clip for self loading toaster.
		+	# Cruton Mode toaster
		+	# Toaster that turns into a portable stove
		+	# Ground effects (Neon Lights on bottom) toaster/
		+	# One slice USB Toaster
		+	# Solar Slow-Toast Toaster
		+	# HydroPowered Toaster (sink faucet attachment)
		+	# InfraRed heating Toaster
		+	# RollerPress Toaster (two rollers insert and remove toast)
		+	# Battery powered toaster
		+	# Horizontal Eject Toaster
		+	# Toaster which drops toast out of bottom after done. (Top insert)
		+	# Computer controlled Toaster (Toaster Toast Software)
		+	# Military Grade Toaster- Kevlar walls
		+	# Floating Toaster-Put it in your pool!
		+	# Hover Toaster-Give em to your kids!
		+	# Brave little Toaster
		+	# Flamethrower Toaster
		+	# Collapsible toaster
		+	# Dishwasher safe toaster (break apart)
		+	# Team Fortress 2 themed Toaster
		+	# Wireless Extender Toaster
		+	# Voice activated Toaster (for arthritis people)
		+	# Toaster with beeper for blind people. (to let them know where it is)
		+	# Toaster with beeper for not blind people. (just to let you know when its done)
		+	# George Foreman toaster. (Burns the fat away!!)
		+	# Conduction Toaster
		+	# Clear walled toaster
		+	# Build-It-Yourself Toaster
		+	# K’Nex Toaster
		+	# MP3 Toaster
		+	# Spy/Recon/Surveillance Toaster
		+	|
		+	# 5.1 channel Toaster Speaker System (5 Single slice toasters spread around kitchen)
		+	# Butter dispenser toaster (‘Lightly buttered, or HEAVY GREASE…’)
		+	# Crumb compacter, to make crutons.
		+	# Breakfast super combo toaster (Coffee + Toast + Eggs)
		+	# Disposable toaster
		+	# ULET- Ulta Low Emissions Toaster
		+	# Cigar Lighting Cuban Toaster
		+	# Thermo Color change toaster
		+	# Glow in the Dark Toaster
		+	# Nite Light Toaster
		+	# Ironing Toaster
		+	# Front Loading Toaster
		+	# Conveyor-like toaster (front load, come out back)
		+	# Camping Toaster (fire powered)
		+	# Engine Block Toaster
		+	# Warning Toaster (countdown)
		+	# Alternate Fuel Toaster (furnace powered)
		+	# Crank toaster (electricity generating)
		+	# Button/knob for lowering toaster instead of lever
		+	# Window to see toast and determine toasting status
		+	# Customizable toaster (different heating inserts with pictures etc)
		+	# No mica sheet, add heat shield
		+	# clock toaster (classy, alarm clock?)
		+	# Radio Toaster
		+	# Toaster Lamp
		+	# CD player or CD burner that looks like a toaster
		+	# Load internal hard drives into
		+	# Defrost/thawing
		+	#      Power Shut off when bread done (toast sensor)
		+	# Launches fireworks
		+	# Drop Down 360 degree rotation
		+	# Open up on side, but drop down normally
		+	# Recycle heat
		+	# VCR toaster
		+	# Enclosed toaster with sliding door
		+	# Laser toaster (scanning)
		+	# Tray drive with eject that brings toast in
		+	# Cooking with light toaster
		+	# Tanning toaster
		+	# Convection heating, add fan
		+	# Flexible toaster (roll up)
		+	# Toaster purse
		+	# Heat wires on glass so you can see it
		+	#      Vacuum between glass for cool touch
		+	# Cut toaster for diagonal slices
		+	# Bread crumb maker, shreds toast
		+	# Roller toaster, roll on toasting power
		+	# Expanding width
		+	# Vertical conveyor toaster
		+	# Hot water toaster, attached to house water heater
		+	# Extension cord toaster, allow other things to be plugged into it
		+	|-
		+	|}

---

Current revision

Contents 1 Executive Summary 2 Research and Observations 2.1 Users Survey 2.2 Expert Interview: Pamela's in Squirrel Hill 2.3 User and Stakeholder Needs 2.4 Existing Toasters and Relevant Patents 2.5 Design Problem 3 Design Concepts 3.1 Concept 1: Clear Walled Toaster 3.2 Concept 2: Fold Out Toaster 3.3 Concept 3: Enclosed Toaster 3.4 Concept 4: Front Loading Toaster 3.5 Concept Comparison with Pugh Chart 4 Design Schedule 5 Recommendation Summary 6 Team Members 7 Appendix 7.1 Possible Innovations

Executive Summary

Since our first report, we conducted a thorough user survey, from observing toaster use, to questioning customers at retail stores, to receiving 90 responses to an online survey. From these surveys, we learned many important things about what consumers think of current toaster products, briefly summarized here:

Issues with toaster

• Inconsistent toasting and inaccurate toast settings
• Food product getting stuck in toaster

Necessary Attributes

• Accurate settings
• Wide slots
• Crumb Tray

Based on these stakeholder needs, we generated over one hundred concepts for toaster innovation. From those, we narrowed our options down to four concept designs. The designs were:

• Clear Walled Toaster
• Fold Out Wall Toaster
• Front Load Toaster
• Enclosed Toaster

A Pugh Chart was made in order to help us decide which concept to recommend for prototyping. We have decided to pursue the Fold Out Toaster design, for the following reasons:

• Virtually eliminates the problem of having toast stuck in the toaster
• Easier to maintain and clean
• Easier to load and start
• Should maintain affordability of the toaster

We received feedback from our peers, who were concerned about the safety of this concept. We believe it will be just as safe as a conventional toaster, and will aim to prove this with our prototypes.

For the next milestone, we will create a prototype of the mechanism for the fold out walls. This will be a proof of concept. Following that, we will produce a functional prototype. A detailed schedule can be found in our Gantt Chart, in Section 4.

Research and Observations

In order to help determine and evaluate potential conceptual designs, our team researched users, stakeholders, design problems, patents, and current products. This research allowed us to determine our design problems as far as toasters go and move forward to narrow down our ideas to four concepts.

Users Survey

We really wanted to know what our users thought about and how they interacted with toasters. This would give us a good idea of what was good and what needed improvements. We created our toaster survey using www.surveymonkey.com and sent it to all our family, friends, organizations on campus, and to Misc Market. We received responses from 90 people. Here are our results:

• 59% Female
• 41% Male

• Mean Age: 36

• 66% of people would spend between $19.99 and $39.99 on a toaster
• 29% of people would spend $19.99 on a toaster

When asked what was necessary in a toaster, people responded:

• Accurate Toast Settings – 92%
• Crumb Tray – 81%
• Wide Slots – 67%
• Cool Touch Sides – 53%
• Cancel Button – 50%

The biggest problems with toasters were:

• Overcooked/uneven & other issues with timing – 41%
• Toast stuck in toaster – 21%

In the survey, only 8% reported that there was nothing wrong and no improvements on their toaster.

This survey was a good representation of our users, as the mean age was 36. We had people from all ages and all occupations, a real random representative of users. The results of the survey relayed to us that there is a great deal of room for improvement and innovation in a toaster. Not only are there many issues that need to be addressed, but there are also a restraint of keeping the toaster low price.

Expert Interview: Pamela's in Squirrel Hill

For getting more information about what users like or dislike about toasters, we decided to ask the people preparing food at Pamela's Restaurant in Squirrel Hill for their expert advice. Information was gathered on the type of toaster in use, and how they felt about it. A conveyor toaster was being used at the restaurant, due to the high volume of bread that needed to be toasted quickly and efficiently. On asked why a pop up toaster was not desired, the employee said that he thought the conveyor toaster worked very well for the needs of the restaurant. A pop up toaster would not be able to cope up with the large demand of toast during breakfast and rush hours, and would need to have many toasting slots in order to keep up. This would be impractical as space was a limiting factor at Pamela's. Another reason that the employee mentioned was the fact that no one had to keep watch to see if a pop up toaster was toasting right or not. The conveyor toaster's slow continuous tread surface also ensures reasonably even toasting, and little supervision. This information was useful to us, as we could understand what markets our toaster could target, and what needs need to be met. We believe that Pamela's is a good example of a business that would use a toaster, and think that the information gathered here would be very similar to other restaurants as well.

User and Stakeholder Needs

We focused on three major stakeholders in the production and distribution of a toaster. These stakeholders are very influential to the design process and the decisions made. Each represent a different viewpoint and have various needs that are important to them.

• Customer
  • affordable
  • intuitive design and use
  • reliability
  • quick toasting
  • safe

• Manufacturing
  • low part count
  • affordable
  • least amount of tools necessary

• Retail
  • low volume
  • easy stacking packaging

Existing Toasters and Relevant Patents

• Clear-wall glass toaster, with heating coils between two plates of glass. Only a single slice toaster.

• Glass walled toaster. Glass is heated from the base. Also, only a single slice toaster. Both these clear toasters show the toast as it is cooking, and allow the user better control over the done-ness of their food.

• Recently patented toaster, with programmable toast settings and memory of up to 3 settings.

• Toaster which drops food out the bottom when cycle is complete, making it easier to access toast, but is much less space efficient. It seems more suited for commercial applications.

• Another drop down toaster, with an artistic twist to it. More of a residential drop down toaster.

• Commercial conveyor type toaster. Is very effective for toasting large amounts of toast. Thus, it is the choice of many food service establishments. Downsides are space usage and large power consumption.

Design Problem

Modes of Dissatisfaction (MoD)

Here are a few examples of situations which user may not like when using a toaster, and is actually quite common from our user survey data.

• Bread gets stuck in the toaster, and is hard to get out.

• Uneven toasting

• Extremely Burnt toast

• Toast does not pop up all the way

• Toast catching on fire

Design Concepts

From our brainstorming and list of 100 ideas, we have narrowed down our ideas to 4 concepts. These concepts are the ideas that we thought were most tangible and were chosen based on user study research.

Concept 1: Clear Walled Toaster

One of the concepts that was considered from the 103 brainstorming ideas was a clear walled toaster. The reasoning behind this was that from the data we gathered from the survey, it was noted that one of the issues that users has with toasters was that they had no idea how toasted the bread was, until it popped out. The concept of a clear walled toaster would alleviate this problem. The user would always know how toasted the bread was at any given instant, and if no more toasting was deemed necessary, the user could terminate the toasting process if he/she wished. This design would require higher maintenance compared to the other conceptual ideas and the stock toaster, as the user would have to continually clean the toaster to keep it looking its best all the time. This cleaning upkeep may not be all a waste of time though. With care and cleaning, the toaster would be a very chic addition to any kitchen, with its shiny glass walls and look of sophistication.

The glass walled toaster would have the following interesting features for practical operation:

• The glass used in the toaster would be tempered so it would be able to withstand the high temperatures of a toaster.
• The heating element would be stuck onto the glass sheets in a similar grid like arrangement like that of a normal toaster.
• Multiple layers of glass would be placed in between the heating glass, and the outside of the toaster (the user side). The layers of air in between the glass sheets would insulate the user from the heat of the heating glass. As glass and air are BOTH insulators, this would allow for safe operation of the toaster.
• A cancel button and toasting selection dial would also be standard. Everything else resembles a classic toaster.

This toaster would clearly be able to address some stakeholder needs, but we think that the cost of of manufacture would be higher than what we would like. The toaster does not address the scenario of what happens when the bread gets stuck in the slot, and it may be difficult to get out. The summary of advantages and disadvantages are listed below.

Advantages:

• Can see toast 'toast'
• Looks cool

Disadvantages:

• May be expensive to manufacture
• Toast may get stuck in slot
• High maintenance

Concept 2: Fold Out Toaster

The fold out toaster design is intended to solve several problems users have with toasters as well as major failure modes. The heating sides will use a solid sheet of conductive material to promote more even heating and protect the internal components. These sheets will also protect the user from internal components and make it nearly impossible for the toast to get caught and shred during ejection. Small shelves will run up and down the fold out sides to push the toast up, similar to a conventional toaster. This will allow the user to pick up the toast from the top of the ejected side.

This new toaster will begin operation whenever the user pushes the handle down OR closes the fold out sides manually. Pushing together the sides of the toaster is a much easier action than pushing down the small handle on conventional toasters. The inside heating panels will be able to "float", allowing various sizes of bread to be toasted equally. The fold out panel will push the bread flat against the inside panel, such that both sides of the bread are pushed up against the conductive material.

Fold out sides allow for much easier loading of toasting products as well. Different shape and size products can simply be placed on the diagonal panel and pushed in to toast. Smaller items that would normally be difficult to remove after toasting will be much more accessible. No more sticking a fork in the toaster to remove inadequately ejected food products.

Advantages: More even, consistent heating Easier to load and start Accessible for easy cleaning More reliable ejection system

Disadvantages: More parts to assemble Difficulty in storing Expensive Possibly less safe for the user

Concept 3: Enclosed Toaster

The enclosed toaster concept addresses certain, key stakeholder needs. Specifically, an enclosed design would allow for more uniform heat distribution within the toaster, helping to uniformly toast the food. Another important improvement over the standard toaster is that it would lessen the heat and power needed for each toasting cycle. In current toasters, energy is wasted because of the open toaster slots. Having a capping system would prevent much of this convection to the environment. Thus, the cycle times could be shortened, and less power could be used.

There are, however, issues with such a design. First, it does not address the issue of the bread, bagel, or pastry becoming stuck in the toaster. In fact, it would likely make removing such a piece of food even more difficult. Also, it brings about more complexity in a toaster. This has two effects on the stakeholders. For the manufacturer, it introduces more steps and parts to be assembled on the toaster, raising production costs. For the user, more complexity often decreases reliability. In this case, it may cause more nuisances with toasters; for example, the lid getting stuck closed.

The basic mechanism is shown below. Essentially, a thin rod would connect the bread holder to the lid. As the bread holder rises, it pushes up the lid. In this way, the main mechanism of ejecting the toast would not be modified, so it would be a relatively simple addition to the toaster and toaster manufacturing process.

To summarize:

Advantages

• More even toasting
• Less power consumption

Disadvantages

• Potentially more difficult to remove toast
• Adds complexity
• Reliability issues

Concept 4: Front Loading Toaster

The front loading toaster concept came about in the attempt to come up with an innovative way of making the toaster more user friendly and help toasting stay uniform and even. The toaster still would have a toaster settings knob that would adjust the level of browning, but the loading and ejection methods would be different.

The toast is loaded side by side horizontally, which makes the toaster much wider but also a lot shorter. By doing this, the heating coils are not doubled up like the middle section of a traditional toaster. This will keep one side of the toast from being more toasted than others.

When loading the toast, the toast is placed on a toasting tray. This tray then is brought into the toaster and ejected just like a DVD toaster. This should keep people from using bread that is too big for the toaster, and thus also address the issue of toast being stuck in the toaster. Another thought was that having this front loading toaster made toaster much easier for elderly and children as it was easier to reach and extremely intuitive. (Most people are familiar with DVD players or computer CD drives)

| Advantages:

• More even, consistent heating
• Easier to load and use
• Keeps bread from getting stuck in the toaster
• Address young and old users

| Disadvantages:

• More parts to assemble
• Larger counter footprint
• Expensive Ejection system

Concept Comparison with Pugh Chart

Description		Standard Toaster	Clear Wall Toaster	Fold Out Toaster	Enclosed Toaster	Front Load Toaster
Sketch
Criteria	Weight	Datum 1	Design 1	Design 2	Design 3	Design 4
Manufacture/Assembly	2	0	-	-	-	-
Affordable	3	0	-	-	0	0
Toasting Consistency	2	0	++	0	+	0
Toast Retrieval/Ejection	3	0	0	++	0	++
Storage	1	0	0	-	0	--
Maintenance	1	0	-	++	0	0
Safety	1	0	-	0	-	+
Easy to Use	1	0	++	+	0	0
+		0	6	9	2	7
0		9	2	2	5	4
-		0	7	6	3	2
Net Score		0	-1	3	-1	3

Design Schedule

Recommendation Summary

After considering many potential designs and comparing the top concepts, we decided to prototype the fold out toaster design. This design was chosen over the others because it address more problems. We believe this design has the potential to become a breakthrough in toaster technology. Not only does it toast bread, but it ejects it in a way that is easier to retrieve.

The other top concepts attempt to address the even and consistent heating problem while ignoring the problems users encounter with ejection systems. The fold out design provides a potential solution to even heating with its solid conductive plates lining both sides. The inner "floating" plate pushing the bread against these plates helps maximize the even heating potential.

The innovative ejection system makes toastable products of all sizes easier and safer to toast. The enclosed and clear walled toasters use the same ejection mechanism that has failed in the past, while the front loading toaster may be easier for the user to manually pull out, but may have issues ejecting on its own. A fold out toaster would have a much harder time getting stuck closed. In the unlikely event that it does, the user could actually pull it open by force, while the clear walled and enclosed toasters make this impossible to do safely.

The three other toaster designs also are much more difficult to clean properly. The clear walled toaster makes cleaning more necessary, but would be difficult to clean well since it would have to be partially disassembled. A fold out toaster would easily expose all surfaces the user would usually want to keep clean. Overall, the fold out toaster seems to have the most potential to replace the old style toaster. It will perform most the functions users would want in a good, reliable toaster.

Team Members

Leigh Fortenberry	Jon Goettler	Akshay Jayaram	Ian Price
Front Loading Toaster Concept, User Study, Design Problems	Fold Out Toaster Concept, Recommendation Summary	Clear Wall Toaster Concept, Expert Interview, Design Problems	Enclosed Toaster Concept, Executive Summary, Patent and Market Research

Appendix

Possible Innovations

List of 100 ways to innovate a toaster:

Pre-Heat button for toaster Enclosed toaster (to keep heat inside) Open toaster- toaster walls fold down for easy access to done toast Illegal toaster. NOS toaster + turbo button Intercooled Toaster Toaster powered by a Honda Civic Carbon Fiber Toaster Open flame toaster. Self Extinguish Toaster Turret Toaster (shoots toast at people, motion sensitive, SENTRY toast) Toast Launcher Optional slot load toaster drive for laptops Toaster instead of FlexFan idea. Toaster that acts as an electric space heater (built in fan) Built in counter top toaster (space saver idea) Smore maker addition Talking toaster (“You’ll still need a tray. “) High Tech Toaster with LCD Display Temperature and Time Control Bread Clip for self loading toaster. Cruton Mode toaster Toaster that turns into a portable stove Ground effects (Neon Lights on bottom) toaster/ One slice USB Toaster Solar Slow-Toast Toaster HydroPowered Toaster (sink faucet attachment) InfraRed heating Toaster RollerPress Toaster (two rollers insert and remove toast) Battery powered toaster Horizontal Eject Toaster Toaster which drops toast out of bottom after done. (Top insert) Computer controlled Toaster (Toaster Toast Software) Military Grade Toaster- Kevlar walls Floating Toaster-Put it in your pool! Hover Toaster-Give em to your kids! Brave little Toaster Flamethrower Toaster Collapsible toaster Dishwasher safe toaster (break apart) Team Fortress 2 themed Toaster Wireless Extender Toaster Voice activated Toaster (for arthritis people) Toaster with beeper for blind people. (to let them know where it is) Toaster with beeper for not blind people. (just to let you know when its done) George Foreman toaster. (Burns the fat away!!) Conduction Toaster Clear walled toaster Build-It-Yourself Toaster K’Nex Toaster MP3 Toaster Spy/Recon/Surveillance Toaster

5.1 channel Toaster Speaker System (5 Single slice toasters spread around kitchen) Butter dispenser toaster (‘Lightly buttered, or HEAVY GREASE…’) Crumb compacter, to make crutons. Breakfast super combo toaster (Coffee + Toast + Eggs) Disposable toaster ULET- Ulta Low Emissions Toaster Cigar Lighting Cuban Toaster Thermo Color change toaster Glow in the Dark Toaster Nite Light Toaster Ironing Toaster Front Loading Toaster Conveyor-like toaster (front load, come out back) Camping Toaster (fire powered) Engine Block Toaster Warning Toaster (countdown) Alternate Fuel Toaster (furnace powered) Crank toaster (electricity generating) Button/knob for lowering toaster instead of lever Window to see toast and determine toasting status Customizable toaster (different heating inserts with pictures etc) No mica sheet, add heat shield clock toaster (classy, alarm clock?) Radio Toaster Toaster Lamp CD player or CD burner that looks like a toaster Load internal hard drives into Defrost/thawing Power Shut off when bread done (toast sensor) Launches fireworks Drop Down 360 degree rotation Open up on side, but drop down normally Recycle heat VCR toaster Enclosed toaster with sliding door Laser toaster (scanning) Tray drive with eject that brings toast in Cooking with light toaster Tanning toaster Convection heating, add fan Flexible toaster (roll up) Toaster purse Heat wires on glass so you can see it Vacuum between glass for cool touch Cut toaster for diagonal slices Bread crumb maker, shreds toast Roller toaster, roll on toasting power Expanding width Vertical conveyor toaster Hot water toaster, attached to house water heater Extension cord toaster, allow other things to be plugged into it