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Product plan
Functional analysis
Design for quality (soft and hard
issues)Anay Joshi | 513-302-3509 | joshia5@mail.uc.edu
Product DevelopmentAbility to brew, store and maintain desired temperatureFast and safe operationEasy to use and cleanPrice < $100
Capacity to brew up to 60 oz. of coffee from grounds (no grinder included)Brew time <120 secondsSet time to automatic brewCompatible with standard baket coffee filterWarmer plate heats coffee evenlyCapability to reach water temperature of 185°FAutomatic shut off if weight of coffee pot indicates it is empty Seven-year lifeMachine washable pot and filter componentsWarmer plate and other materials are compatible with conventional cleaning productsOverall height not to exceed 18" (allow clearance with standard counter to cabinet distance)
Development Cost: $1,250,000Tooling and Capital: $4,500,000Manufacturing Cost: $40Distribution and administration cost: 30%Rate of Return: 15%
Gain 12% of marketAdvertise through traditional techniques and social media (instagram and twitter)Potential to produce or purchase coffee grindsUse wholesale outlets and online sales with free shipping and returnsTarget to young professionals and adults
Phase Completion1. Customer Needs 1 month2. Product Concept 1 month3. Product Design 2 months4. Prototype Development 3 months5. Manufacturing 3.5 months6. Product Release 3 months
Weeks Phase5 Marketing28 Design Engineering20 Computer aided design32 Manufacturing engineering10 Quality and test engineering
MarketingResearch and development
Resource Requirements
Key Interfaces
Customer Needs
Key Product Atrributes
Product Financials
Market and Competition
Development Schedule
Manufacturing process selection and router sheet
Design for Manufacturing
and assembly
DFMEA
Department Number
Operation Number
Description Machine ToolStandard Time
[sec]Standard or special
fixture?
001 1Roll aluminum forging to 1/16th Roller machine
30Standard
002 2Stamp cut for outline shape Die cutter
15Standard
003 3 Punch press inset features (holes/slots) Punch and die
15Standard
004 4 Deburr Bench grinder 30 Standard
005 5Roll press to create first bend Slip roller
15Standard
006 6Roll press to create second bend Slip roller
15Standard
007 7Surface finish
Hand bench with wire brush wheel
240Special
008 8Rinse with hot deionized water Spray in bath
120Standard
009 9Quality inspection
go, no-go gage and visual inspection
60Special
Item: FMEA number:Model: Page :Core Team: FMEA Date (Orig):1/1/2008
Actions Taken
Sev
Occ
Det
RPN
Fuse in the electric heaters burned out
Coffee not consumable 7
Excess heat passed through the fuse
2Disassemble and check individual piece
9 126
Check fuse before assembly; provide easy access to fuse
0
Filter in charge of taking coffee beans out
Clogged
Coffee not available or Coffee beans present in the cof fee
3
Filter not cleaned properly or in time
5Disassemble and check individual piece
3 45Use optimized mesh size for filtering out coffee
0
Hot plate in charge of keeping brewed coffee hot
Not workingCoffee not at correct temperature
3
Electric heaters not working
2Bulb indicating ON/OFF of hot plate
2 12
Test the electric circuit randomly in each production batch
0
Plastic cover incharge of covering everything from top
Cracks/ not in place
Hot steam passes out and direct contact w ith customer
5Cracks or not sealed 2
Check if clicks are heard after placing the cover
2 20Check for clicks during assembly 0
Glass carafe in charge of holding hot brewed coffee
Cracks/ Leaks
Hot coffee spills out 7
Excessive wash/ too much contact with hot coffee
1
Check the material thickness and alternate materials
1 7Check for leaks and surface scratches
0
0 0
J. Doe (Engineering), J. Smith (Production), B. Jones (Quality)
Drill HoleCurrent
1234561 of 1
Rev: 1
Action Results
FAILURE MODE AND EFFECTS ANALYSIS
Potential Failure Mode
Potential Effect(s) of
Failure
Sev
Class
Potential Cause(s)/ Mechanis
m(s) of Failure
Occur
DesignControls
Detec
Recommended Action(s)
Responsibility and Target Completion
Date
RPN
Design function
Responsibility:Prepared by:
J. DoeJ. Doe
Design for Maintenance
Objective: 1. Product development of a coffee maker
Skills:1. Product plan2. Design for X: manufacturing, assembly, quality, and maintenance3. DFMEA4. Functional analysis5. Material selection
3. Software used: i. SolidWorks
Anay Joshi | 513-302-3509 | joshia5@mail.uc.edu
Direction of pull
CAD modeling in CATIA V5 Draft Analysis
Flow Analysis
Ease of fill Mold tools
Plastic Injection MoldingObjective: 1. Design an interior trim product for automobile2. Perform manufacturability analysis
Skills:1. Implemented design for plastic injection molding process
2. Performed flow analysis, draft analysis, and ease of fill
3. Software used: i. CATIA V5ii. SolidWorks 2016 Plasticsiii. SolidWorks 2016 Mold Tools
Voice of Customer
CAD model of a component
Design and analysis of progressive die in ProE and ANSYS
Drawing sent to manufacturing
Strip layout Manufacturing of die plate by wire
EDM Final productAnay Joshi | 513-302-3509 | joshia5@mail.uc.edu
Sheet Metal Manufacturingx
y
Objective: 1. Design a sheet metal component 2. Design die sets to manufacture a component3. Start mass manufacture
Skills:1. Entire product life cycle from VOC through start of mass manufacture
2. Implemented design for sheet metal process
3. Software used: i. SolidWorks Sheet Metalii. ANSYSiii. Pro/E
Anay Joshi | 513-302-3509 | joshia5@mail.uc.edu
Six Sigma Tools
0
5
10
15
Week 2 Histogram
X-AxisY-Axis
0
5
10
15
Week 9 Histogram
X-Axis# of Oc-
curences
Y-Axis
Capability check
Find root causes of variations
Controllability check
Build mechanism
Histograms Root cause analysis
Cause-Effect diagram
Objective: 1. Build a striker hitting mechanism and use Six Sigma tools to reduce variability of the process
Skills:1. Implemented following Six Sigma tools:i. Histogramii. Pareto analysisiii. Ishikawa diagramiv. Root cause analysisv. Statistical control
chartsvi. DMAICvii. SOP to reduce
human errors.
3. “Six Sigma Green Belt” certificate
Measure packaging space Roll center analysis CATIA V5 modeling
Analysis in HyperMesh
CAD modeling in NX Analysis using ANSYS
Anay Joshi | 513-302-3509 | joshia5@mail.uc.edu
PACE competition: Suspension and Brake Design
Topological optimization using Optistruct in HyperWorks v14.0
Objective: 1. Design and analyze suspension system and brake system for GM PACE reconfigurable vehicle
Skills:1. Designed double wishbone suspension and disc brake systems
2. Analytical solutions, FMVSS guidelines, roll center analysis 3. Weight reduction by topological optimization
3. Software used:i. CATIA V5ii. Siemens NX 10.0ii. Hypermesh v14.0
P&G | University of Cincinnati Am-tech Engineering Services Cummins Inc.
Miscellaneous
SOLIDWORKSSurfacingSheet MetalMold ToolsPlasticsAssemblyDrafting
Anay Joshi | 513-302-3509 | joshia5@mail.uc.edu
CATIA V5SketcherAssemblyPart DesignDraftingGenerative Shape Design
ProE ModelingAssemblyDrafting
CAD Tools Professional experience
Graduate research
Siemens NX
ModelingSurfacingAssembly
Drafting Decision making between CNC
machining, 3D printing and hybrid manufacturing based on geometric complexity
Decide whether 3D printing is cost effective
CAD model CNC machine tool
accessibility
Support structure for 3D printing
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