Iron
From DDL Wiki
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==Design for Manufacture and Assembly (DFMA)== | ==Design for Manufacture and Assembly (DFMA)== | ||
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===Manufacturing=== | ===Manufacturing=== | ||
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! scope="row" | Minimize Part Count | ! scope="row" | Minimize Part Count | ||
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! scope="row" | Standardize Design Features | ! scope="row" | Standardize Design Features | ||
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|-style="vertical-align: left;" | |-style="vertical-align: left;" | ||
! scope="row" | Keep Designs Simple | ! scope="row" | Keep Designs Simple | ||
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! scope="row" | Multifunctional Parts | ! scope="row" | Multifunctional Parts | ||
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! scope="row" | Ease of fabrication | ! scope="row" | Ease of fabrication | ||
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|-style="vertical-align: center;" | |-style="vertical-align: center;" | ||
! scope="row" | Avoid Tight Tolerances | ! scope="row" | Avoid Tight Tolerances | ||
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|-style="vertical-align: center;" | |-style="vertical-align: center;" | ||
! scope="row" | Minimize Assembly Surfaces | ! scope="row" | Minimize Assembly Surfaces | ||
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|-style="vertical-align: center;" | |-style="vertical-align: center;" | ||
! scope="row" | Use Sub-assemblies | ! scope="row" | Use Sub-assemblies | ||
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! scope="row" | Mistake-Proof | ! scope="row" | Mistake-Proof | ||
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|-style="vertical-align: center;" | |-style="vertical-align: center;" | ||
! scope="row" | Minimize Fasteners | ! scope="row" | Minimize Fasteners | ||
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! scope="row" | Minimize Handling | ! scope="row" | Minimize Handling | ||
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! scope="row" | Minimize Assembly Direction | ! scope="row" | Minimize Assembly Direction | ||
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|-style="vertical-align: center;" | |-style="vertical-align: center;" | ||
! scope="row" | Provide Unobstructed Access | ! scope="row" | Provide Unobstructed Access | ||
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! scope="row" | Maximize Assembly Compliance | ! scope="row" | Maximize Assembly Compliance | ||
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==Failure Modes & Effects Analysis (FMEA)== | ==Failure Modes & Effects Analysis (FMEA)== | ||
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Revision as of 13:45, 21 September 2012
Figure 1: Competitor product used for dissection study
Contents |
Executive Summary
This will be a brief executive summary that describes the key findings and recommendations.
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Product Stakeholders
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Stakeholder Needs and Wants | ||
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Stakeholder | Needs | Wants |
Consumer |
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Retailer |
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Manufacturer |
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Shipping & Transportation |
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Product Use Study
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Product Mechanical Function
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Assembly
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Sub-Assembly
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Bill of Materials
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Part Number | Name | QTY | Weight (g) | Function | Material | Manufacturing Process | Image |
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1 | Screw | 5 | 4 | Holds base support (#8) in place to metal base (#31) | Steel | *** | |
2 | Nut | 5 | 1 | Attaches screws (#1) to metal base (#31) | Steel | *** |
Design for Manufacture and Assembly (DFMA)
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Manufacturing
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Design for Manufacturing Features and Improvements | ||
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Design Objective | Strengths | Areas of Improvement |
Minimize Part Count |
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Standardize Design Features |
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Keep Designs Simple |
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Multifunctional Parts |
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Ease of fabrication |
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Avoid Tight Tolerances |
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Minimize Secondary & Finishing Operations |
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Assembly
Lorem ipsum dolor sit amet, consectetur adipiscing elit. Ut elementum elit vel tortor scelerisque auctor. Donec urna dui, eleifend eget adipiscing vulputate, feugiat id nisl. Donec mattis, quam in tincidunt ullamcorper, orci tellus condimentum dui, aliquet faucibus risus nunc et nunc. Vestibulum metus justo, volutpat sed consequat eget, mollis sed neque. Maecenas dignissim hendrerit malesuada. Aliquam dictum gravida orci ut rutrum. Fusce eros lectus, accumsan sed rhoncus eu, tempor sed magna. In ac lacus urna, ut cursus nisl. Curabitur ac dui nisl, in imperdiet orci. Aliquam quam dui, tincidunt quis volutpat quis, convallis a ipsum. Suspendisse quis molestie lorem. Nunc vel magna commodo nunc viverra tempor id blandit neque. Donec nec elementum ligula. Cras accumsan, urna eget dictum varius, arcu nunc porttitor tortor, sit amet feugiat nisl elit vitae elit. Proin eget tellus lectus, tempus tincidunt augue. Sed sagittis iaculis orci, sit amet tempus dui tincidunt in.
Design for Assembly Features and Improvements | ||
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Design Objective | Strengths | Areas of Improvement |
Minimize Part Count |
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Minimize Assembly Surfaces |
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Use Sub-assemblies |
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Mistake-Proof |
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Minimize Fasteners |
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Minimize Handling |
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Minimize Assembly Direction |
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Provide Unobstructed Access |
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Maximize Assembly Compliance |
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Failure Modes & Effects Analysis (FMEA)
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Failure Modes and Effects Analysis - Floor Bike Pump | |||||||||
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Item & Function | Failure Mode | Effects of Failure | S | Causes of Failure | O | Design Controls | D | RPN | Recommended Actions |
Valve Nozzle Connector | Air leaking out of wheel | Bike tube loses air | 3 | Misalignment to valve | 2 | Check if it locks | 2 | 12 | Something to help user better secure nozzle properly |
Does not lock | No air transfer into wheel | 3 | User not using it correctly | 2 | Check if it locks | 3 | 18 | Something that does not use a lock, Make it easier to lock | |
Valve may not fit | No air transfer into wheel | 1 | Wrong valve type | 4 | Check if it locks | 4 | 16 | Make a universal valve, Provide adapters | |
Pressure Gauge | Air leaking out of wheel | Won't display pressure | 2 | Broken gauge | 1 | Test in manufacturing plant | 2 | 4 | Better pressure gauge tube seal, Different pressure reading technique |
Incorrectly calibrated | Displays incorrect pressure reading | 2 | Dropping gauge, Manufacturing error | 1 | Test in manufacturing plant | 7 | 14 | -- | |
Handle rod | Bends | Can not apply downward force, Breaks rod | 5 | Bars are physically bent forward and not down, Damaged, Improper use | 2 | -- | 7 | 70 | Stronger rod |
Tube | Air leaking out of wheel | Loss of air from tire | 3 | Misuse, Damage | 3 | -- | 4 | 36 | Tube wrapped in durable material |
Design for Environment (DFE)
Design for Environment (DFE) can help bring focus to specific areas when improving a design. By analyzing the entire life cycle, the areas of the largest impact can be determined and minimized.
Design for Environment | ||
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-- | Production | Use |
Item Consumed | Bike Pump | Bike |
Sector # and Name | #339920: Sporting and athletic goods manufacturing | #336991: Motorcycle, bicycle, and parts manufacturing |
Reference Unit | 1 Bike Pump | 1 Bike |
Units consumed per product life | 1 | 1 |
Cost Per Unit* | $39.04 | $234.27 |
Lifetime Cost* | $39.04 | $234.27 |
Sector mtCO2e per $1M | 613 | 543 |
Implied mtCO2e per product life | 0.0239 | 0.1272 |
CO2e Tax @ $30/mtCO2e | $0.72 | $3.82 |
*2002 USD
Production
Using the sporting and athletic goods manufacturing sector of EIO-LCA, we were able to estimate the environmental impact of producing the bike pump. The bike pump costs $50 today, which is about $39.04 in 2002. Power generation and supply has the largest contribution to the 613 mtCO2e per 1 million dollars spent in the sporting and athletic goods manufacturing category. Therefore we can estimate that for every bike pump produced 0.0239 mtCO2e is released into the environment, resulting in a minor $0.72 tax per pump.
Sector #339920: Sporting and athletic goods manufacturing
Economic Activity: $1 Million Dollars
Displaying: Greenhouse Gases
Number of Sectors: Top 10
Use
If the consumer purchases a bike pump, we can assume that they own at least one bike. Therefore we used the EIO-LCA Motorcycle, bicycle, and parts manufacturing sector to study the environmental impact of use of the pump. We estimated that today the average bike costs $300 which equates to about $234.27 in 2002. Our analysis approximated a small $3.82 tax per bike.
Sector #336991: Motorcycle, bicycle, and parts manufacturing
Economic Activity: $1 Million Dollars
Displaying: Greenhouse Gases
Number of Sectors: Top 10
Group Dynamic
Team Leader: Dinesh Ayyappan
DFMA Lead: Patrick Hogan
FMEA Lead: Jonathan Wong
DFE Lead: Amber Ohiokpehai
Wiki Page Programmer/Report Compilation: Lauren Milisits
References
This is where we should list any references that we used throughout the process of our report.