Doughnut maker
From DDL Wiki
(Difference between revisions)
(→Failure Modes and Effects Analysis (FMEA)) |
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| Improper manufacturing || '''2''' || Material selection || '''1''' || style="text-align: center;" | '''12''' || None || Manufacturing | | 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 | ||
+ | |- | ||
+ | |- | ||
+ | |} | ||
==Design for Environment (DFE)== | ==Design for Environment (DFE)== |
Revision as of 18:04, 15 September 2009
Contents |
Executive Summary
Bill of Materials
Main Components
Additional Parts
Screws |
---|
Nuts and Washers |
Assembly Diagrams
Dough Dispenser Cup Assembly |
---|
Dispenser Motor and Conveyor Motor Assembly |
Dispenser Motor and Conveyor Motor Assembly Schematic |
Conveyor Belt Assembly |
Cooking Oil Assembly |
Exterior Panel Assembly |
Major Stakeholders and Needs
Usage and Usability
Design for Manufacturing and Assembly (DFMA)
Failure Modes and Effects Analysis (FMEA)
Part # | Name & Function | Failure Mode | Effects of Failure | S | Causes of Failure | O | Design Controls | D | RPN | Recommended Actions | Responsibility |
---|---|---|---|---|---|---|---|---|---|---|---|
001 | Plastic Casing
| Warped | Improper fit, Unintended contact with heating element | 6 | Repeated heating and cooling | 4 | Material Selection | 8 | 192 | HALT for Temperature Variations | Reliability |
Improper Manufacturing | 1 | Material Selection, Mold Design | 1 | 6 | None | Manufacturing | |||||
Fractured | Exposure of internal components | 8 | Improper handling | 5 | Material Selection, Packaging | 4 | 160 | Drop Test with and without packaging | Reliability | ||
Wrong color / surface finish | User dissatisfaction | 1 | Incorrect material / process | 1 | Material Selection, Mold Specs | 1 | 1 | None | Manufacturing | ||
002 | Crumb Tray
| Warped, Bent | Will no longer fit in bottom of toaster, may get stuck in toaster | 3 | Improper manufacturing | 4 | Assign process and tolerance | 1 | 12 | none | Manufacturing |
Cleaning, bent while in use | 7 | Material selection | 4 | 84 | HALT for typical washing cycles | Reliability | |||||
003 | Crumb Tray Handle
| Warped | Improper fit onto crumb tray | 4 | Incorrect manufacturing | 1 | Assign process and tolerance | 1 | 4 | None | Assembly |
Improper fit when slid into assembly, may stick out too far | 3 | Incorrect manufacturing | 1 | Assign process and tolerance | 1 | 3 | None | Assembly | |||
Broken attachment clip | Handle may disconnect from tray | 4 | Incorrect manufacturing or assembly | 2 | Assign process | 1 | 8 | None | Assembly | ||
004 | Toaster Top
| Warped, Bent | Misaligned components | 8 | Improper Manufacturing | 2 | Assign process, Material selection | 1 | 16 | None | Manufacturing |
Corroded | Deterioration of part | 2 | Heavy use, poor upkeep | 2 | Material selection | 1 | 4 | None | Design | ||
005 | Toaster Base
| Warped | Misalignment of components | 8 | Improper manufacturing | 1 | Specify process, Material selection | 1 | 8 | None | Manufacturing |
Fractured | Exposure / Misalignment of components | 8 | Improper handling | 3 | Material Selection, Packaging | 2 | 48 | Drop test with and without packaging | Reliability | ||
006 | Regulator Knob
| Warped | Improper fit onto variable resistor or into casing | 6 | Improper manufacturing | 2 | Material selection | 1 | 12 | None | Manufacturing |
Fractured | May detach from variable resistor | 5 | Poor handling, Impact | 4 | Material Selection, Packaging | 1 | 24 | None | Manufacturing, Assembly | ||
007 | Press Handle
| Warped | Detaches from ejection system too easily | 4 | Improper Manufacturing | 2 | Material selection, mold design | 5 | 40 | None | Assembly |
Incorrect fit into casing channel, toaster may stick | 8 | Improper Manufacturing | 1 | Material selection, mold design | 2 | 16 | None | Assembly | |||
008 | Cancel Button
| Warped | Detaches from toaster | 4 | Improper Manufacturing | 1 | Material selection, injection mold design | 5 | 20 | None | Manufacturing, Assembly |
Does not fit into casing or gets stuck | 8 | Improper Manufacturing | 1 | Material selection | 1 | 8 | None | Assembly | |||
009 | AC Power Cord
| Short circuit | Unit cannot function | 10 | Cord pinching | 2 | Set assembly process | 5 | 100 | Test completed units before distribution | Assembly |
Internal cord problem | 1 | Choose reliable supplier | 5 | 50 | Test completed units before distribution | Assembly | |||||
010 - 019 | Ejection Assembly
| Mechanism fails to activate circuit | Unit is inoperable | 8 | Warped switch | 1 | Material selection | 1 | 8 | None | Assembly |
Switch fatigue | 4 | Material selection | 5 | 160 | HALT for normal use | Reliability | |||||
Mechanism fails to release | Heating elements stay on | 9 | Internal circuit failure | 1 | Circuit test | 1 | 9 | None | Assembly | ||
Warped internal components | 2 | Material selection, Set manufacturing process specifications | 1 | 18 | None | Assembly | |||||
Fatigue | 5 | Material selection | 5 | 225 | HALT for normal use | Reliability | |||||
Finished product does not eject | 6 | Warped internal components | 2 | Material selection, Set manufacturing process specifications | 1 | 12 | None | Assembly | |||
Fatigue | 5 | Material selection | 5 | 150 | HALT for normal use | Reliability | |||||
020 - 034 | Heating and alignment assembly
| Heating elements turn on partially | Uneven heating | 7 | Short circuit | 1 | Ensure electrical elements have sufficient clearance | 1 | 7 | None | Manufacturing and Assembly |
Fatigue | 5 | Material selection | 5 | 175 | HALT for normal use | Reliability | |||||
Heating elements do not turn on | No heating of product | 8 | Short circuit | 1 | Ensure electrical components have sufficient clearance | 1 | 8 | None | Manufacturing and Assembly | ||
Fatigue | 5 | Material selection | 5 | 200 | HALT for normal use | Reliability | |||||
Improperly aligned product | Uneven heating | 7 | Wrong dimensions | 1 | Material selection, set tolerances | 1 | 7 | None | Assembly |