2.008 Design & Manufacturing I! Fall 2023 Challenge 1: Week 1: Introduction to Manufacturing, Process Planning September 6, 2023 Your Name: Toye Jandy U 2.008-F22: Process Planning ChallengeWelcome to 2,008! Today we will do a short challenge to introduce you to the type of activities we will be doing in class each Wednesday. We understand that the insights discussed in this challenge will be new to some of you. In subsequent weeks, you will have “attended” on-line lecture sequences (videos) that will provide you with knowledge that you will need to take on the week's challenge. For this week's challenge, we ask that you provide us with your most well-reasoned understanding regarding the questions below. Please ask questions! We expect that you will attempt to answer all of the questions with your partner, and we will be sharing information about the challenge questions freely in the classroom. This first challenge is not graded, but we hope you make an honest attempt at all of the problems with the intent of preparing for the challenge next Week. Future challenges will be graded based on completion and solutions will be provided in or at the end of class with the expectation that you review the problems on your own, ask us questions about any concepts that gave you trouble, and use the challenges to prepare for the weekly check-offs, as well as the quiz. Scenario You have been invited to consult with a company that designs and manufactures beauty and grooming appliances. You will take apart and analyze a hair dryer before brainstorming how to improve the hair dryer or reduce its cost to consumers and the product's impact on the environment. Each person should have one hair dryer and one screwdriver. Learning objectives ‘* Introduction to flipped-classroom style: Get comfortable asking questions and learning through hands-on discovery and discussion © How was it made: ‘©. Identify part features that indicate the manufacturing process that was used. ‘© Recognize how material selection and part geometry are interrelated. ‘© Process planning: Determine a logical sequence of operations for manufacturing and assembling a product. © Cost, Rate, Quality, Flexibility, and Sustainability: Introduction to these metrics for a real-life product. 2,008-F22: Process Planning ChallengeNSTRUCTIONS (FOR EVERY CHALLENGE): You must complete and submit this packet individually, though jually. ae ee ee ae © Answer the questions in order, keep track of time, and complete as much can: earn yu dant hoed to complate everyting to get alien (sj [Performance [Completes all of the challenge_ ‘Completes 75% of the challenge Completes 50% of the challenge Minor effort. sparse responses “Absent or did not complete any challenge questions incomporate both visual communication (state reer Jutions to the challenges and check-offs should mmunication (cleat, annotated sketches) and written sumptions, justify, explain)QUESTIONS ary’ reasoning. je. '2) What is the purpose ofthis packaging? we Peotedion frowe secatees/ mater (bag) * Preven hv fie, cron 6% ») Daye ihe wal a gd by a person 4. (5 min) Open’ the box and remove the hair dryer. Note the packaging around the hair « Tacatetrer (predic around plas) a i by a machine or both? Explain your Bot. The fre aronud He Coral eins le T Wad oleae bog baud . Tt baa 3 Pectut Vee of was fect Ing & maint. The plastic on ru plu alto 2. (10 min) Remove the hair dryer from the packaging. aud fits tf aad 0 bf 4 acacline, EMA stands for design for manufacturing and assembly and is an important part of paw a product like this hair dryer is designed die process by which itis made. This is also often separated into DFM and DFA. What exterior features on the hair dryer give You CME about its manufacturing and reembiy? List at least three features, and indicate their locations on a simple sketch. Hint; Are there fasteners like the ones you ar fastening strategies that are new to you? Make fabricated and ask the staff if you're not sure. 1 Heles for sevens en Hae back J Tea parts ave Luld Tegettur by 2 Stet 7 feu 1A 2.6?] 3 familiar with from 2.007? Are there ‘some guesses about how things were — sit elena pre wai Woocly| + Tu plate | agian wea | wwruufathared FT wins mam Ht paws nae wee comured tree a “\e ages pout wat ae _ po erate ae Sepowntelyy aud wad traded ou raround rey cop 2.008-F22: Process Planning Challengesel time to disas: Now it ss for assemblin: reverse proc’ 3, (6 min) Once you have taken apart the housing (the largest plastic parts), take 2 look seine inside. Youll learn more about injection molding i the next ‘week but two features t was injeotion moided are {ne ribs and ejector ‘on the inside of the housing indicate that i pin marks. (Ejector pin marks Iook like circles on the inner face of the housing). a) Make a quick sketch of the housing and indicate these features. If you're not sure where they are, ‘ask the staff or a neighbor! | Ted | loto | en ae F o| mel! ol Cen \ b) You will incorporate ejector pins into your YoYo molds x is. Based on fo you think ejector pins do? And why might there be more e| Peace nt some areas of a mold than others? ee ees Te epost pat are alte ‘ ve ett pat po Mas wrbenral ejected fats Mae Hertel, Areas nit nid mort matlet hawt We te es sore chelate Jobst purpose of the ribs are? Hint Ue paris Cette imagine how the deflection would change if ion uae eras aa Te bs ewe Huere fe peri reg tt he Shape awd aive Hee 7 MATE HAteartoy 2,008-F22: Process Planning Challenge Sener 5(5 min) Look at the interfaces between the parts that you have disassembled. Name least three joining methods (how parts fit together) that you observe between plastic arts, note which parts correspond to each method, and why you believe this method ras chosen. Joining Method —_| Parts Why? Commects tHe Stroy connciror , Sues For beat rounbe, | inetas five paaite pewts Eas tigdtece Conmects Can be rewered/ te clean Tweets Ca Pat at rae hawrdnger tock wud te ran ood Snag ™ Alou te edged qe hidp te Feauet slots of Whe ee comer heats pert nN a Top } haw Mert decurt conmet™ Dt Anger Fee Hee snap on vlcbt 2.008-F22: Process Planning Challenge6. (15 min) Remove the grating from the front of the hairdryer and look at it carefully. a) What material is it made of? Think about both the type (e.g. aluminum, bronze, copper, steel, nylon, rubber, etc.) and form of the stock/raw material (e.g. billets, bars, rods, sheets, extrusion, etc.) Why did the manufacturer choose this material and form? Auwaatiein Cue Beat wood eat acl peut? Tits wo ef wore ae elaseeacivan it Irghter ek as He matenal dees wth require rv otter Conner b) Ifyou were to make this par for &prcto/pe (in LMP, Pappaardo, or another machine shop of your choice), write a step-by-step fabrication process plan (a logical sequence of operations) in a table below, starting with the format of your raw material and concluding with the finished part. Sketches are encouraged but not required. * Sak Suet ward, 4 Wate [er MI ity rod Shape nit flanaes one 4 bead Haat aus ©) Is your fabrication process above efficient? How long do you think it would take you? Ne. Trivadld tate 4 long toe 1 heud eeule flange boy hase d) How might the mass manufacturing of this part at scale (mass manufacturing) differ from your fabrication process? A wuzlune Cau be olengued be hewd fags a ak once 2.008-F22: Process Planning Challenge7, (10 min) Soon, you will time yourself reassembling the hair dryer! a) List and number the steps you will take to reassemble the hair dryer 1 Pla grate athe tp & Alig Fo Mewtteg peut + Spr hy Bm Bye matters eat Lamp at Ce attelt trends 7 tr 'b) Lay out the pieces in an order that you think will allow you to assemble it most °“? quickly and sketch the pieces in order below, attempting something like the exploded view that Prof. Becker showed in the slides. For each part, either briefly explain the associated assembly process, or put a number from your list next to the sketched part. c) Did you change your answer to part (a) at all after ‘working through part (b)? L forget anette atiqniny He wired Fi d) Next to each step in (a), note whether it was done by a person or a machine. Keep the number of steps, time, and complexity in mind when answering Question #1. 1. Hasna Haat Mectluint aclatne Maclin Maclin 20 QF ue Hua 2.008-F22: Process Planning Challenge 83. (15 min) For this question, identify a partner. One of you should assemble your hair dryer while your partner times each step (and doesn't help you otherwise). Then, switch roles. Record how long each of the assembly steps you defined took when you assembled your hair dryer. (a) Name: _ Jz: 2 | Step # I L 3 4 r 6 1 = = sq | sete | feud 2579-07] 37-19] 42% Total time to reassemble (minutes:seconds):_ot SS - #1 (b) Now, name and briefly discuss at least 1 step that you found to be easy/fast when assembling the hair dryer, and 1 step that you found to be difficult/siow. Macling te grey Cap Hed easy haw wited wad ov Arrewui (©) For the slow step, think of a method for doing it that would have been faster. What ‘questions did you ask yourself when assembling this part that may have gone into the design for assembly (DFA) process? At vad Slory because you Uae IF bold on te afferent PUES & eutusre Hat Huy doatt pou pak ont: TE varght he foctber f Mere tw Hay of eappiy AH pet ia | secur) Me mutton 2.008-F22: Process Planning Challenge 9 mn9. (5 min) The cost of this hait-dryer to the consumer is $10.49. There is a mark-up from the manufacturer to the retailer that includes several teams like logistics and sales as well as a significant profit, so the total cost of goods (i.., of the manufactured product) was approximately $3.50. a) Qualitatively, considering the manufacturing and assembly process from earlier questions, explain how you believe this manufacturing cost is distributed among equipment, materials, labor, and overhead (e.g., facility)? Equipment > overtwadl > labo 7 mateniald 'b) What do you think are the most expensive and least expensive components? Why do you think this is the case? 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