Doughnut maker
From DDL Wiki
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- | | style="text-align: center;" |Poor design, motor rotates too quickly|| 9 || Lab test with various motor rotational outputs|| 5 || style="text-align: center;" |270 | + | | style="text-align: center;" |Poor design, motor rotates too quickly|| 9 || Lab test with various motor rotational outputs|| 5 || style="text-align: center;" |270 || Redesign is necessary. Alternative motor or larger rotational output (part 011)|| Research and development||None||6||9||5||270 |
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|style="text-align: center;" | Fractured | |style="text-align: center;" | Fractured |
Revision as of 14:56, 16 September 2009
Contents |
Executive Summary
Bill of Materials
Main Components
Additional Parts
Screws |
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Nuts and Washers |
Assembly Diagrams
Dough Dispenser Cup Assembly |
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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
Mechanical Function
Design for Manufacturing and Assembly (DFMA)
Failure Modes and Effects Analysis (FMEA)
Part # | Item and Function | Failure Mode | Effects of Failure | S | Causes of Failure | O | Design Controls | D | RPN | Recommended Actions | Responsibility and Deadline | Actions Taken | S | O | D | RPN |
---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
001 | "Dispenser spring"
| Deformed spring (too long/short) | Unable to fully open/close causing incorrect dough dispensing | 7 | Improper manufacturing | 2 | Inspecting dispenser spring | 2 | 28 | Introduce quality control measures to ascertain accurate spring dimension | Manufacturing and Quality Control | None | 7 | 2 | 2 | 28 |
002 | "Dispenser support"
| Warped | Dispenser plunger moving at angle disrupting dough shaping | 6 | Improper manufacturing | 2 | Inspecting dispenser support or dispenser plunger | 2 | 24 | Introduce quality control measures to ascertain dispenser quality | Manufacturing and Quality Control | None | 6 | 2 | 2 | 24 |
003 | "Dispenser plunger"
| Cracked? | # | # | # | # | X | X | None | # | # | # | # | |||
005 | "Dispenser stop"
| Leaking or cracked | Dough seeps from dispenser cup to machine | 6 | Improper manufacturing | 3 | Inspect dispenser assembly for leaks | 3 | 54 | Introduce quality control measures to ascertain dispenser quality | Manufacturing and Quality Control | None | 6 | 3 | 3 | 54 |
006 | "Dispenser cup"
| Cracked | Dough seeps from dispenser cup to machine | 6 | Improper manufacturing | 3 | Inspect dispenser assembly for leaks | 2 | 36 | Introduce quality control measures to ascertain dispenser quality | Manufacturing and Quality Control | None | 6 | 3 | 2 | 36 |
007 | "Switch cover"
| Warped | Misalignment of components | 8 | Improper manufacturing | 1 | Specify process, Material selection | 1 | 8 | None | Manufacturing | None | 8 | 1 | 1 | 8 |
Fractured | Exposure / Misalignment of components | 8 | Improper handling | 2 | Material Selection, Packaging | 2 | 32 | Drop test with and without packaging | Reliability | None | 8 | 1 | 1 | 8 | ||
008-010 | "Dispenser motor assembly"
| Operates for too short time | Insufficient dough released from dispenser | 6 | Poor design, motor rotates too quickly | 9 | Lab test with various motor rotational outputs | 5 | 270 | Redesign is necessary. Alternative motor or larger rotational output (part 011) | Research and development | None | 6 | 9 | 5 | 270 |
Fractured | Exposure / Misalignment of components | 8 | Improper handling | 2 | Material Selection, Packaging | 2 | 32 | Drop test with and without packaging | Reliability | None | 8 | 1 | 1 | 8 | ||
008 | "Dispenser motor assembly"
| # | # | # | # | X | X | None | # | # | # | # | ||||
011 | "Dispenser motor housing"
| Fractured | Motor is moved off position, disrupting dispensing process | 7 | Improper manufacturing | 1 | Material selection, placement | 3 | 21 | Introduce quality control actions to check dispenser motor assembly | Reliability | None | 7 | 1 | 3 | 21 |
012 | "Dispenser switch 1"
| Sticking | Plunger stays open, dough pours into oil tub | 8 | Improper manufacturing or assembling | 1 | Inspect control systems | 5 | 40 | Take quality control actions or may redesign for extra clearance | Manufacturing | None | 8 | 1 | 5 | 40 |
013 | "Dispenser switch 2"
Halts the dispensing process | Sticking | Plunger does not open, no dough released | 8 | Improper manufacturing or assembling | 1 | Inspect control system | 5 | 40 | Take quality control actions or may redesign for extra clearance | Manufacturing | None | 8 | 1 | 5 | 40 |
014 | "Dispenser switch housing"
| Fractured | Plunger stays open/closed | 8 | Improper manufacturing | 1 | Inspect dispenser motor assembly | 2 | 16 | Introduce quality control measures on dispenser motor assembly | Manufacturing | None | 8 | 1 | 2 | 16 |
018 | "Conveyor belt motor"
| # | # | # | # | X | X | None | # | # | # | # | ||||
019 | "Drive gear 2"
| ?? | # | # | # | # | X | X | None | # | # | # | # | |||
023 | "Wire guide"
| # | # | # | # | X | X | None | # | # | # | # | ||||
024 | "Power jack"
| Short circuit | Unable to function | 8 | Internal problem | 1 | Choose reliable supplier | 4 | 32 | Test completed units before distribution | Assembly | None | 8 | 1 | 4 | 32 |
026 | "Belt motor gear"
| Fractured | Conveyor belt unable to move | 8 | Improper handling | 2 | Material selection, packaging | 2 | 32 | Drop test with and without packaging | Reliability | None | 8 | 2 | 2 | 32 |
027 | "Conveyor belt link assembly"
| Fractured | Doughnut unable to move through system, machine unable to perform function | 8 | Improper manufacturing | 1 | Inspect conveyor belt assembly | 4 | 32 | Introduce quality control measures on conveyor assembly | Manufacturing | None | 8 | 1 | 4 | 32 |
046-048 | "Oil drain tube, clamps, and valve"
| Leaking | Hot oil released into machine and possibly onto user | 7 | Improper manufacturing | 2 | Inspect oil drain assembly | 4 | 56 | Introduce quality control measures on oil drain assembly | Assembly | None | 7 | 2 | 4 | 56
|
049 | "Oil collection tray"
| Warped/Deformed | Misalignment of components, improper fit | 7 | Improper manufacturing | 1 | Specify process, Material selection | 1 | 7 | None | Manufacturing | None | 7 | 1 | 1 | 7 |
Fractured/Leaking | Hot oil released from machine, possibly onto user | 9 | Improper handling or manufacturing | 3 | Material Selection, Packaging, Quality control measures | 4 | 108 | Drop test with and without packaging | Reliability | None | 6 | 3 | 4 | 108
| ||
051 - 052 | "Front and Back Panels"
| Warped | Misalignment of components, improper fit | 8 | Improper manufacturing | 1 | Specify process, Material selection | 1 | 8 | None | Manufacturing | None | 8 | 1 | 1 | 8 |
Fractured | Exposure/Misalignment of components and heat release | 6 | Improper handling | 4 | Material Selection, Packaging | 4 | 96 | Drop test with and without packaging | Reliability | None | 6 | 4 | 4 | 96
| ||
055 | "Power cord"
| Short circuit | Unit unable to function | 8 | Cord Pinching | 2 | Set assembly process | 4 | 80 | Test completed units before distribution | Assembly | None | 8 | 2 | 4 | 64 |
Internal cord problem | 1 | Choose reliable supplier | 4 | 32 | Test completed units before distribution | Assembly | None | 8 | 1 | 4 | 32 |
Design for Environment (DFE)
Mechanical Analysis
Team Members & Roles
Michael Barako - DFE, Mechanical Analysis
Meng Yee Chuah - Mechanical Function
Katie McManus - Assembly Photos, DFMA
Sam Powers - Bill of Materials, FMEA
Sara Whitby - Executive Summary, Major Stakeholders, Usage and Usability