Select a consumer product consisting of at least five piece parts, then analyze it with the intention of improving the design to make it more robust for the overall manufacturing process. Assume you and your company manufacture and assemble all of the component parts (except for commercially available but special purchased parts; e.g., common fasteners, springs, light bulbs, blades, etc.) and intend to continue doing so. Your selected product must contain at least one of each of the following type of components (parts can only count in one category):

Metal Plastic (not overmolded/insert molded)

Discrete fastener Spring (different than the metal part)

Your product must be approved before you begin any of the report (first come, first served). At that time, we will come to an agreement on which components are purchased and which are made. Then, thoroughly analyze the current design in order to make recommendations to improve the manufacturability of each piece part as well as the entire assembly. Application of the DFMA principles covered in class and from other sources is highly encouraged.

Once your analysis is complete, prepare a report detailing all of your work. This final paper must include the following sections: Cover Page Brief introduction Analysis of current product Discuss the functions of the product Outline the basic components of the assembly, their function, along with manufacturing and assembly methods. Provide an exploded assembly drawing calling out all components Discuss the redesign of the product and the benefits which result Discuss any new added features to the product and their benefits. Outline the basic components of the new assembly, their function, along with manufacturing and assembly methods. Provide an exploded assembly type drawing calling out all components. Discuss how the new design incorporates the principles of DFMA and their positive impact on manufacturing Discuss any cost savings (material, labor, etc.) or increases in quality that the new design will generate Summary of findings, conclusions, and recommendations (typically no more than 1-2 paragraphs) Appendix (if necessary for figures, charts, pictures, etc.)

Use of figures and diagrams is highly recommended!! The report should be typed with 1.5 spacing, and look professional, i.e. spelling and grammar correct. References should be cited in the body of the report. Your report will be graded on effort, content, and structure (grammar, spelling, etc.), and should include a minimum of 2-3 references. Overall length should be 4 to 5 pages of text with additional pages for figures, bibliography, cover page, etc.

Advice - There is no set number of changes required. What is required is an analysis of each individual part as well as the assembly as a whole according to the DFMA guidelines. So optimize each part, then optimize the assembly as a whole. E.g., you might want to reduce the size of a pin to save material, but then also add a chamfer to it to make it easier to insert into a hole. Im looking for thoroughness.