Design For Manufacture - Ying Cheung

- Ying Cheung -13019879

Arvum- Ying Cheung -

13019879

BriefDesign a mass produced stationery holder that can be displayed as a sculptural piece on the user’s desk. The retail price must not exceed £25 and has no more than 3 parts.

The stationery holder must not tip over when average size pens/pencils are loaded into the cavity.

The stationery holder must not be dull due to majority of existing products are unattractive.

Specification• Must be elegant ✓

• Must be aesthetically pleasing ✓

• Must be Sold under £25 ✓

• Must be hard wearing ✓

• Suitable for mass production ✓

• Must be space saving ✓

• Must be easy for user to pick up stationery ✓

Content

Content…………………………………………… 4

Final Design……………………………………… 5

Eco Audit Report……………………………….. 6 – 8

Engineering Drawings…………………………. 9 – 11

Assembly………………………………………… 12

Bill Of Materials…………………………………. 13

Quotations……………………………………….. 14 - 15

Cost Calculator………………………………….. 16

Profit Calculator………………………………… 17

Lead Time………………………………………... 18

Packaging……………………………………....... 19

Invoice……………………………………………. 20

Project Plan……………………………………… 21P4

Final Design

P5

Eco Audit Report

Product Name

Product

Product Life (years)

50

Energy and CO2 Footprint Summary:

Energy Details...

CO2 Details...

Phase Energy (MJ) Energy (%) CO2 (kg) CO2 (%)

Material 7.75e+04 82.7 4.41e+03 78.5

Manufacture 1.56e+04 16.6 1.17e+03 20.8

Transport 165 0.2 11.7 0.2

Use 0 0.0 0 0.0

Disposal 451 0.5 31.6 0.6

Total (for first life) 9.37e+04 100 5.63e+03 100

End of life potential -5.12e+04 -2.92e+03

Eco Audit Report

Eco Audit Report

Product Name

Product


50


Energy Details...

CO2 Details...


Material 7.75e+04 82.7 4.41e+03 78.5

Manufacture 1.56e+04 16.6 1.17e+03 20.8

Transport 165 0.2 11.7 0.2

Use 0 0.0 0 0.0

Disposal 451 0.5 31.6 0.6



Eco Audit Report

Product Name

Product


50


Energy Details...

CO2 Details...


Material 7.75e+04 82.7 4.41e+03 78.5

Manufacture 1.56e+04 16.6 1.17e+03 20.8

Transport 165 0.2 11.7 0.2

Use 0 0.0 0 0.0

Disposal 451 0.5 31.6 0.6



P6

Eco Audit Report

Energy and CO2 Summary Energy Analysis

Energy (MJ/year)

Equivalent annual environmental burden (averaged over 50 year product life): 1.86e+03

Detailed breakdown of individual life phases

Material:

Energy and CO2 Summary

Component Material Recycled

content* (%)

Part mass (kg)

Qty. Total mass processed**

(kg)

Energy (MJ)

%

Corn Left PP (copolymer, UV stabilized) Virgin (0%) 0.015 10000 1.5e+02 1.2e+04 15.3

Corn Right PP (copolymer, UV stabilized) Virgin (0%) 0.015 10000 1.5e+02 1.2e+04 15.3

Field ABS/PC (injection molding

and extrusion) Virgin (0%) 0.035 10000 3.5e+02 5.4e+04 69.4

Total 30000 6.4e+02 7.7e+04 100

*Typical: Includes 'recycle fraction in current supply'

**Where applicable, includes material mass removed by secondary processes

Manufacture:


Component Process % Removed Amount processed Energy (MJ) %

Corn Left Polymer molding - 1.5e+02 kg 3.7e+03 23.6

Corn Right Polymer molding - 1.5e+02 kg 3.7e+03 23.6

Field Polymer molding - 3.5e+02 kg 7.4e+03 47.3

Assembly Fasteners, small - 3e+04 8.4e+02 5.4

Total 1.6e+04 100

Transport:


Breakdown by transport stage

Stage name Transport type Distance (km) Energy (MJ) %

China - UK Sea freight 1.6e+03 1.6e+02 100.0

Total 1.6e+03 1.6e+02 100

Breakdown by components

Component Mass (kg) Energy (MJ) %

Corn Left 1.5e+02 38 23.1

Corn Right 1.5e+02 38 23.1

Field 3.5e+02 89 53.7

Eco Audit Report

Energy and CO2 Summary CO2 Footprint Analysis

CO2 (kg/year)

Equivalent annual environmental burden (averaged over 50 year product life): 113

Detailed breakdown of individual life phases

Material:


Component Material Recycled

content* (%)

Part mass (kg)

Qty. Total mass processed**

(kg)

CO2 footprint

(kg) %

Corn Left PP (copolymer, UV stabilized) Virgin (0%) 0.015 10000 1.5e+02 4.6e+02 10.5

Corn Right PP (copolymer, UV stabilized) Virgin (0%) 0.015 10000 1.5e+02 4.6e+02 10.5

Field ABS/PC (injection molding

and extrusion) Virgin (0%) 0.035 10000 3.5e+02 3.5e+03 79.0

Total 30000 6.4e+02 4.4e+03 100

*Typical: Includes 'recycle fraction in current supply'

**Where applicable, includes material mass removed by secondary processes

Manufacture:


Component Process % Removed Amount processed CO2

footprint (kg)

%

Corn Left Polymer molding - 1.5e+02 kg 2.8e+02 23.6

Corn Right Polymer molding - 1.5e+02 kg 2.8e+02 23.6

Field Polymer molding - 3.5e+02 kg 5.5e+02 47.3

Assembly Fasteners, small - 3e+04 63 5.4

Total 1.2e+03 100

P7

Transport:



Stage name Transport type Distance (km) CO2 footprint

(kg) %

China - UK Sea freight 1.6e+03 12 100.0

Total 1.6e+03 12 100


Component Mass (kg) CO2 footprint

(kg) %

Corn Left 1.5e+02 2.7 23.1

Corn Right 1.5e+02 2.7 23.1

Field 3.5e+02 6.3 53.7

Total 6.4e+02 12 100

Use:


Relative contribution of static and mobile modes

Mode CO2 footprint (kg) %

Static 0

Mobile 0

Total 0 100

Disposal:


Component End of life

option % recovered

CO2 footprint

(kg) %

Corn Left Recycle 100.0 7.3 23.1

Corn Right Recycle 100.0 7.3 23.1

Field Recycle 100.0 17 53.7

Total 32 100

EoL potential:


option % recovered

CO2 footprint

(kg) %

Corn Left Recycle 100.0 -3.1e+02 10.5

Corn Right Recycle 100.0 -3.1e+02 10.5

Field Recycle 100.0 -2.3e+03 79.0

Total -2.9e+03 100

Transport:



Stage name Transport type Distance (km) CO2 footprint

(kg) %

China - UK Sea freight 1.6e+03 12 100.0

Total 1.6e+03 12 100


Component Mass (kg) CO2 footprint

(kg) %

Corn Left 1.5e+02 2.7 23.1

Corn Right 1.5e+02 2.7 23.1

Field 3.5e+02 6.3 53.7

Total 6.4e+02 12 100

Use:



Mode CO2 footprint (kg) %

Static 0

Mobile 0

Total 0 100

Disposal:



option % recovered

CO2 footprint

(kg) %

Corn Left Recycle 100.0 7.3 23.1

Corn Right Recycle 100.0 7.3 23.1

Field Recycle 100.0 17 53.7

Total 32 100

EoL potential:


option % recovered

CO2 footprint

(kg) %



Field Recycle 100.0 -2.3e+03 79.0

Total -2.9e+03 100

Transport:



Stage name Transport type Distance (km) Energy (MJ) %

China - UK Sea freight 1.6e+03 1.6e+02 100.0

Total 1.6e+03 1.6e+02 100


Component Mass (kg) Energy (MJ) %

Corn Left 1.5e+02 38 23.1

Corn Right 1.5e+02 38 23.1

Field 3.5e+02 89 53.7

Total 6.4e+02 1.6e+02 100

Use:



Mode Energy (MJ) %

Static 0

Mobile 0

Total 0 100

Use:



Mode Energy (MJ) %

Static 0

Mobile 0

Total 0 100

Disposal:



option % recovered

Energy (MJ)

%

Corn Left Recycle 100.0 1e+02 23.1

Corn Right Recycle 100.0 1e+02 23.1

Field Recycle 100.0 2.4e+02 53.7

Total 4.5e+02 100

EoL potential:


option % recovered

Energy (MJ)

%



Field Recycle 100.0 -3.5e+04 69.4

Total -5.1e+04 100

Notes:


P8

Engineering drawings

P9


P10

Assembly Engineering drawings

P11


• Fastener Cantilever Snaps

• Fastener Internal Cantilever Snaps

• Field Part

• Magnet - Bought In Part

• Corn Parts

Assembly

P12

Bill of Materials

Part name Corn (left) Corn (Right) FieldMagnet

Bought in part

Material PP PP ABS/PC Neodymium

Weight (g) 14.9g 14.9g 34.6g -

Finish High Polish High Polish High Polish Ni Coated

Quantity 1 1 1 1

SemanticsAllow flexibility

for snap fit feature

Allow flexibility for snap fit

feature

High quality, age well

High magnetic strength

Performance Requirements

Ability to withstand normal

operational stress

Ability to withstand normal

operational stress

UV resistance

Strength to hold large amount of

small metal stationery

Durability Requirements

Wear resistance Wear resistance Wear resistance Permanent

Tooling costs £85950 £6,574.00 -

Price per part £0.46 £0.46 £1.10 £0.35

Alternative Material

ConsideredABS ABS - -

Manufacturing Cost for 1 unit £2.37

Part name Corn (left) Corn (Right) FieldMagnet

Bought in part

Recyclability 100% 100% 100% -

Reusability 0% 0% 0% 100%

Corn (Left)

Corn (Right)

Field

Magnet

P13

Quotationhttp://www.protomold.co.uk/

P14

$0.514 (USD) = £0.35 (GBP)

Diameter: 20mmThickness: 5mm

http://nbsongke.en.alibaba.com/product/651222197-213295448/cylinder_shape_NdFeB_magnets.html

P15

Retail Price (include VAT)

Retail Price (exclude VAT)

Retail MarginWhole Sale

PriceDistribution

Margininclude DDP FOB Price slam Margin % Slam Margin £

Max Manufacturing Cost £

£25.00 £20.83 50.00% £10.42 40.00% £6.25 £5.68 35.00% £1.99 £3.69

£15.00 £12.50 50.00% £6.25 40.00% £3.75 £3.41 35.00% £1.19 £2.22

£12.00 £10.00 50.00% £5.00 40.00% £3.00 £2.73 35.00% £0.95 £1.77

Cost Calculator

VAT rate 20%

DDP rate 10%

Max Retail Price

Price £15.49Price £12.95

http://www.amazon.co.uk/Original-Desktop-Pen-Holder-Organizer/dp/B00ODKE5CW/ref=sr_1_3?ie=UTF8&qid=1429654263&sr=8-3&keywords=original+green+bud+design

http://www.amazon.co.uk/Herlitz-Big-Butler-Desk-Organiser/dp/B00191WN5E/ref=sr_1_4?ie=UTF8&qid=1429654155&sr=8-4&keywords=herlitz+big

P16

Price calculation based on Quotation

Retail Price £16.45VAT (20%) £2.74Retail (50%) £6.85Distribution (40%) £2.74DDP (0%) £0.00 (excluded due to manufacture in UK)Cost of Manufacture £2.37 (Protomold, Alibaba)Tooling / unit £0.30 (Protomold)Profit per unit £1.44 (35%)

Profit of selling 50,000 units £71,976

Break Even at 8703 units

£0.00

£10,000.00

£20,000.00

£30,000.00

£40,000.00

£50,000.00

£60,000.00

CO

ST £

SALES

Cost

Revenue

Profit Calculator

P17

Week

Reference Lead time 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Bought in part - magnet

http://www.alibaba.com/product-detail/cylinder-shape-NdFeB-

magnets_651222197.html7 - 20 Days

Materialhttp://www.alibaba.com/product-detail/Plastic-

raw-material-plastic-pellets-ABS_60195426444.html?s=p

7 working Days

Tooling http://www.skar.co.uk/plastic-injection-moulding-lead-times 5 - 6 Weeks

Moulding http://www.cypressindustries.com/plastics-tooling.html 3 – 5 Weeks

Assembly Estimate 1 – 2 Weeks

Shippinghttp://www.searates.com/reference/portdistan

ce/ 33 Days

Lead Time

Time required for Send off design to manufacture in China – Product arrive at the port in UK

Estimate Lead-Time 18 Weeks

P18

Packaging

P19

Invoice

P20

Qty Description Unit Price Line Total

2.5 hrs Final design £25 £62.5

5 hrs CAD £25 £125

8 hrs Quote and calculation £25 £200

3 hrs Materials and Finishes £25 £75

15 hrs Presentation Model £25 £200

3 hrs Overhead cost research £25 £75

2 hrs Lead time research £25 £50

2 hrs User profile £25 £50

1 hrs Packaging consideration £25 £25

12 hrs CAD rendering £25 £300

18 hrs Presentation £25 £450

6.5 hrs Design pack £25 £162.5

Total £1950

Line Total

Phase 1 £1187.5

Phase 2 962.5

Project Plan

Tasks Phase 0 Phase 1 Phase 2 Phase 3

Produce ideas for design for

manufacture

Chose a Design

Market research

Sketch development

Modelling

Chose material and colour

Manufacturing process

Costing

Functional demonstration

ECO assessment

CAD

Finalise design

quotation

Packaging

Producepresentation and

Design pack

P21

Design For Manufacture - Ying Cheung

Documents

Transcript of Design For Manufacture - Ying Cheung