Doughnut maker
From DDL Wiki
(Difference between revisions)
(→Failure Modes and Effects Analysis (FMEA)) |
(→Failure Modes and Effects Analysis (FMEA)) |
||
Line 366: | Line 366: | ||
|027 | |027 | ||
| "Conveyor belt link assembly" | | "Conveyor belt link assembly" | ||
- | *moves doughnut through | + | *moves doughnut through the system |
- | | | + | | Fracture |
| Doughnut unable to move through system, machine unable to perform function | | 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 | | 8 || Improper manufacturing|| 1 || Inspect conveyor belt assembly || 4 || 32|| Introduce quality control measures on conveyor assembly||Manufacturing|| None || 8 || 1 || 4 || 32 | ||
+ | |||
+ | |- | ||
+ | |- align="center" valign="center" | ||
+ | |028 | ||
+ | | "Doughnut carriage assembly" | ||
+ | * Used to carry doughnuts through oil bath | ||
+ | | Bends too easily | ||
+ | | Contributes to doughnut being unable to flip | ||
+ | | 5 || Poor design, part too flexible || 9 || Lab test different materials with various flexiblities || 4 || 180|| Redesign using a less flexible material||Research and development|| None || 5 || 9 || 4 || 180 | ||
|- | |- |
Revision as of 19:20, 16 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
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"
| Motor operates too fast | 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 speed or alternate motor | Research and development | None | 6 | 9 | 5 | 270 |
Rotational output (part 11) too small | 6 | Poor design, part too small to release sufficient dough | 9 | Lab test with various sized parts | 5 | 270 | Redesign is necessary. Larger sized rotational output (part 011) | Research and development | None | 6 | 9 | 5 | 270
| |||
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"
| Fracture | 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 |
028 | "Doughnut carriage assembly"
| Bends too easily | Contributes to doughnut being unable to flip | 5 | Poor design, part too flexible | 9 | Lab test different materials with various flexiblities | 4 | 180 | Redesign using a less flexible material | Research and development | None | 5 | 9 | 4 | 180 |
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