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Design For Manufacture - Ying Cheung

  1. - Ying Cheung - 13019879 Arvum- Ying Cheung - 13019879
  2. Brief Design 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 ✓
  3. 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……………………………………… 21 P4
  4. Final Design P5
  5. 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 Eco Audit Report 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 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 P6
  6. 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: Energy and CO2 Summary 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: Energy and CO2 Summary 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) % 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: Energy and CO2 Summary 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: Energy and CO2 Summary 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
  7. Transport: Energy and CO2 Summary Breakdown by transport stage 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 Breakdown by components 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: Energy and CO2 Summary Relative contribution of static and mobile modes Mode CO2 footprint (kg) % Static 0 Mobile 0 Total 0 100 Disposal: Energy and CO2 Summary 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: Component End of life % recovered CO2 footprint % Breakdown by transport stage 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 Breakdown by components 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: Energy and CO2 Summary Relative contribution of static and mobile modes Mode CO2 footprint (kg) % Static 0 Mobile 0 Total 0 100 Disposal: Energy and CO2 Summary 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: Component End of life 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: Energy and CO2 Summary 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 Total 6.4e+02 1.6e+02 100 Use: Energy and CO2 Summary Relative contribution of static and mobile modes Mode Energy (MJ) % Static 0 Mobile 0 Total 0 100 Use: Energy and CO2 Summary Relative contribution of static and mobile modes Mode Energy (MJ) % Static 0 Mobile 0 Total 0 100 Disposal: Energy and CO2 Summary Component End of life 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: Component End of life option % recovered Energy (MJ) % Corn Left Recycle 100.0 -7.8e+03 15.3 Corn Right Recycle 100.0 -7.8e+03 15.3 Field Recycle 100.0 -3.5e+04 69.4 Total -5.1e+04 100 Notes: Energy and CO2 Summary P8
  8. Engineering drawings P9
  9. Engineering drawings P10
  10. Assembly Engineering drawings P11
  11. Engineering drawings • Fastener Cantilever Snaps • Fastener Internal Cantilever Snaps • Field Part • Magnet - Bought In Part • Corn Parts Assembly P12
  12. Bill of Materials Part name Corn (left) Corn (Right) Field Magnet 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 Semantics Allow 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 Toolingcosts £85950 £6,574.00 - Price per part £0.46 £0.46 £1.10 £0.35 Alternative Material Considered ABS ABS - - Manufacturing Cost for 1 unit £2.37 Part name Corn (left) Corn (Right) Field Magnet Bought in part Recyclability 100% 100% 100% - Reusability 0% 0% 0% 100% Corn (Left) Corn (Right) Field Magnet P13
  13. Quotation http://www.protomold.co.uk/ P14
  14. $0.514 (USD) = £0.35 (GBP) Diameter: 20mm Thickness: 5mm http://nbsongke.en.alibaba.com/product/651222197-213295448/cylinder_shape_NdFeB_magnets.html P15
  15. Retail Price (include VAT) Retail Price (exclude VAT) Retail Margin Whole Sale Price Distribution Margin include 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&s r=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
  16. Price calculation based on Quotation Retail Price £16.45 VAT (20%) £2.74 Retail (50%) £6.85 Distribution (40%) £2.74 DDP (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 50,000units £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 COST£ SALES Cost Revenue Profit Calculator P17
  17. 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.html 7 - 20 Days Material http://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 Shipping http://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
  18. Packaging P19
  19. 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
  20. 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 Produce presentation and Design pack P21
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