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Oster DuraCeramic Belgian 
Waffle Maker 
JECK Engineering 
Jordan Crandall 
Cyrus Vakili 
Ken Pond 
Eddie Krische 
Team 1, Section 56-1 
WTSN 103
Outline 
● Appliance Description 
o Overview 
o Solid Edge Models 
o Bill of Materials/Functional Decomposition 
● Problems 
● Redesign 
o Possible Modifications 
o Evaluations (Pugh/Paul & Beitz) 
o Solid Edge Models of Final Solution 
o Bill of Materials/Functional Decomposition of Final 
Solution 
● Conclusion
Oster Waffle Maker 
Advertised as: 
● Makes good waffles 
● Economically efficient 
● Easy to use 
● Safe to use 
o Problem - burns user 
http://www.target.com/p/oster-duraceramic-waffle- 
maker/-/A-14678520
Problem Statement 
● The Waffle Maker doesn’t allow the user to 
access the finished waffle without the 
serious danger of being burned. 
http://unifiedconstructs.com/wp-content/ 
uploads/2011/05/bigstock_Safety_First_Vector_7
Solid Edge Assembly
Solid Edge Exploded View
Bill of Materials I 
Part Number Part Name Classification 
(Custom or Standard) 
Quantity Material 
1 Black Phillips head screw Standard 4 18-8 Stainless Steel 
2 Silver Phillips head screw Standard 3 18-8 Stainless Steel 
3 Cover for leg with three screws Standard 1 Polypropylene 
4 Short silver flips head screw Standard 9 18-8 Stainless Steel 
5 Leg with the two screws Custom 1 Phenol - formaldehyde resin 
6 Bottom metal cover Custom 1 18-8 Stainless Steel 
7 Small sliver Philips head screw Standard 13 18-8 Stainless Steel 
8 Horse-shoe shape heating 
element cover 
Custom 2 Weaved Phenol - 
Formaldehyde Resin 
9 Tiny washer Standard 3 Black Ox - Stainless Steel
Bill of Materials II 
Part Number Part Name Classification 
(Custom or Standard) 
Quantity Material 
10 Metal clamp Custom 1 Aluminum - 3200 
11 Clear Crimp-Style Wire Nuts Custom 2 Plastic Aluminum - 3200 
12 Power cord Standard 1 Copper 10100 Polypropylene Brass 
13 Leg with three screws Custom 1 Phenol -formaldehyde resin 
14 Handle Custom 1 High Density Polyethylene 
15 Top element cover Custom 1 18-8 Stainless Steel 
16 Metallic cover of wires Custom 1 Phenol-formaldehyde resin 
17 Temperature controlling unit Custom 1 Phenol -formaldehyde resin 
18 Handle fastener Custom 1 18-8 stainless steel
Bill of Materials III 
Part Number Part Name Classification 
(Custom or Standard) 
Quantity Material 
19 Bigger washer Standard 1 Black Ox - Stainless Steel 
20 Big Phillips head screw Standard 1 18-8 Stainless Steel 
21 Wire Ties Standard 3 Nylon 6 
22 Heating metal Custom 2 Copper 10100 
23 Lights Custom 2 Ceramic 
24 Dial Custom 1 18-8 stainless Steel Copper 
10100 
25 Metal Body Custom 2 Duraceramic 
26 Wire with cover Custom 3 Nylon 6
Handle Detail Drawing
Top Cover Detail Drawing
Functional Decomposition Spreadsheet 
Part Input(s) Function(s) Output(s) 
Black Screw Mechanical Force Connects top and bottom of the metal body Mechanical Force 
Silver Screw Mechanical Force Connect legs to metal covering Mechanical Force 
Cover Applied Force Provides a stable bottom for the legs Stable Force 
Short Silver 
Screw 
Applied Force Connects many different parts in different 
areas 
Normal Force 
Leg Applied Force Holds the metal body above the ground and 
makes it stable 
Stable Force 
Metal 
Housing/Cover 
Metal Body Protects the wires and heating elements of 
the metal body 
Metal Body 
Handle Mechanical Motion Allows for metal body to move up Mechanical Motion
Functional Decomposition Spreadsheet II 
Part Input(s) Function(s) Output(s) 
Tiny washer Screw Prevent damage on the object the 
screw is going into 
Screw 
Clamp Wires Keeps wires organized Wires 
Wire Cover Wires Protect the fragile parts of the wire Wires 
Power Cord Electrical Energy Brings in the electrical energy from 
the socket to the waffle maker 
Electrical Energy 
Small Silver Screw Applied Force Connects many different parts in 
different areas 
Stable Force 
Temperature 
Controlling Unit 
Mechanical Energy Moves and protects the dial Mechanical Energy 
Heating Cover Thermal Energy Stores thermal energy Thermal Energy 
Handle fastener Handle holds handle in place Handle
Functional Decomposition Spreadsheet III 
Part Input(s) Function(s) Output(s) 
Bigger Washer Screw Prevent damage on the object 
the screw is going into 
Screw 
Big Screw Applied Force Connects top and bottom of the 
metal body 
Normal Force 
Ties Mechanical Energy holds wires together Mechanical Energy 
Heating Metal Electrical Energy Converts electrical energy to 
thermal energy 
Thermal Energy 
Lights Electrical Energy Converts electrical energy into 
light 
Light Energy 
Dial Mechanical Motion Separate and join contacts Mechanical Motion 
Metal Body Materials Holds the waffle batter while the 
batter heats 
Materials
Waffle Maker Functional Flowchart
Waffle Maker Schematic 
• Mechanical Force 
• Flow of Heat 
• Flow of Electricity 
Handle 
Heat Control Mechanism 
Contains and heats batter
Modified Schematic (View 2) 
Mechanical 
Force
Problems Encountered 
● Identification of some materials 
● Difficulty re-assembling 
o Many parts broke when rebuilding 
o ex: “Power” and “Ready” light cover broke 
● Difficulty with Solid edge waffle maker part 
http://www.magicalexperiments.com/wp-content/ 
uploads/2013/06/problems.jpg
Possible Modifications 
More-open, longer handle 
-More space between hand and waffle iron 
Latch with a Vent 
- Latch locks waffle iron close, vent releases excess heat 
Additional Cooking Instrument 
- Detachable utility (i.e. fork or spatula) 
Temperature Display 
-Indicate Temperature of Waffle Iron
Criteria for Matrices 
● Safety (.30)- materials are safe for the user 
● Cost (.20)- keep the materials at low prices 
● Heat Efficiency (.15)- produces enough heat to cook 
waffle batter 
● Reliability (.15)- produces crisp, cooked waffles 
● Portability (.15)- Easy to store and move 
● Aesthetics (.05)- looks pleasing for the user
Pugh’s Method 
Handle Change Addition of a latch w/ a vent Additional Cooking Instrument Temperature display 
Safety (+) (+) (+) (+) 
Cost S (-) (-) (-) 
Heat Efficiency (+) S (+) (+) 
Reliability S S S S 
Portability S S S (-) 
Aesthetics (+) (-) S (-) 
(+) 3 1 2 2 
S 3 3 3 1 
(-) 0 2 1 3
Pahl and Beitz’s Method 
Handle Change 
Addition of a latch w/ a 
vent 
Additional Cooking 
Instrument Temperature display 
Criterion 
Weighting 
Factor (W) 
Numerical 
Value (NV1) 
Weighted 
Value 
(W*NV1) 
Numerical 
Value (NV2) 
Weighted 
Value 
(W*NV2) 
Numerical 
Value (NV3) 
Weighted 
Value 
(W*NV3) 
Numerical 
Value (NV4) 
Weighted 
Value 
(W*NV4) 
Safety 0.30 4 1.20 3 0.90 4 1.20 4 1.20 
Cost 0.20 3 0.60 2 0.40 2 0.40 2 0.40 
Heat 
Efficiency 0.15 3 0.45 3 0.45 3 0.45 3 0.45 
Reliability 0.15 3 0.45 2 0.30 3 0.45 4 0.60 
Portability 0.15 2 0.30 1 0.15 2 0.30 1 0.15 
Aesthetics 0.05 2 0.10 1 0.05 1 0.05 1 0.05 
Sum 1 3.10 2.25 2.85 2.85
Modified Solid Edge Assembly
Modified Solid Edge Exploded View
Modified Handle Detail Drawing
Modified Top Cover Detail Drawing
Modified Bill of Materials 
Part Number Part Name Classification 
(Custom or Standard) 
Quantity Material 
2 Silver Phillips head screw Standard 7 18-8 Stainless Steel 
14 Handle Custom 1 High Density 
Polyethylene 
15 Top element cover Custom 1 18-8 Stainless Steel
Modified Functional Decomposition 
Spreadsheet I 
Part Input(s) Function(s) Output(s) 
Black Screw Mechanical Force Connects top and bottom of the metal body Mechanical Force 
Silver Screw Mechanical Force Connect legs to metal covering Mechanical Force 
Cover Applied Force Provides a stable bottom for the legs Stable Force 
Short Silver Screw Applied Force Connects many different parts in different 
areas 
Normal Force 
Leg Applied Force Holds the metal body above the ground and 
makes it stable 
Stable Force 
Metal Housing/Cover Metal Body Protects the wires and heating elements of 
the metal body 
Metal body 
Small Silver Screw Applied Force Connects many different parts in different 
areas 
Stable Force
Modified Functional Decomposition 
Spreadsheet II 
Part Input(s) Function(s) Output(s) 
Handle Mechanical motion Allows for metal body to move up Mechanical motion 
Handle Mechanical Motion Allows user to safely access their waffle Mechanical Motion 
Tiny washer Screw Prevent damage on the object the screw 
is going into 
Screw 
Clamp Wires Keeps wires organized Wires 
Wire Cover Wires Protect the fragile parts of the wire Wires 
Power Cord Electrical Energy Brings in the electrical energy from the 
socket to the waffle maker 
Electrical energy 
Temperature 
Controlling Unit 
Mechanical energy Moves and protects the dial Mechanical energy 
Heating Cover Thermal Energy Stores thermal energy Thermal energy
Modified Functional Flowchart
Modified Schematic (View 1) 
• Mechanical Force 
• Flow of Heat 
• Flow of Electricity 
Handle 
Heat Control Mechanism 
Contains and heats batter
Modified Schematic (View 2) 
Mechanical 
Force
Conclusion 
● Problem: User injured by 
accessing waffles 
● Solution: Longer handle to 
access cooked waffles 
o Makes sure user does not 
get burned 
● Thank you for your time, 
Questions?
Bibliography 
● "Oster Waffle Maker." Target. N.p., n.d. Web. 03 Dec. 2013. 
● The Role of Magic In Solving Problems. (n.d.). Magical Experiments. Retrieved 
December 7, 2013, from http://www.magicalexperiments.com/wp-content/ 
uploads/2013/06/problems.jpg 
● Unified’s Safety Management Program. (n.d.). UNIFIED. Retrieved December 9, 
2013, from http://unifiedconstructs.com/about-us/approach-safety/

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Reverse Engineering of an Oster Waffle Maker

  • 1. Oster DuraCeramic Belgian Waffle Maker JECK Engineering Jordan Crandall Cyrus Vakili Ken Pond Eddie Krische Team 1, Section 56-1 WTSN 103
  • 2. Outline ● Appliance Description o Overview o Solid Edge Models o Bill of Materials/Functional Decomposition ● Problems ● Redesign o Possible Modifications o Evaluations (Pugh/Paul & Beitz) o Solid Edge Models of Final Solution o Bill of Materials/Functional Decomposition of Final Solution ● Conclusion
  • 3. Oster Waffle Maker Advertised as: ● Makes good waffles ● Economically efficient ● Easy to use ● Safe to use o Problem - burns user http://www.target.com/p/oster-duraceramic-waffle- maker/-/A-14678520
  • 4. Problem Statement ● The Waffle Maker doesn’t allow the user to access the finished waffle without the serious danger of being burned. http://unifiedconstructs.com/wp-content/ uploads/2011/05/bigstock_Safety_First_Vector_7
  • 7. Bill of Materials I Part Number Part Name Classification (Custom or Standard) Quantity Material 1 Black Phillips head screw Standard 4 18-8 Stainless Steel 2 Silver Phillips head screw Standard 3 18-8 Stainless Steel 3 Cover for leg with three screws Standard 1 Polypropylene 4 Short silver flips head screw Standard 9 18-8 Stainless Steel 5 Leg with the two screws Custom 1 Phenol - formaldehyde resin 6 Bottom metal cover Custom 1 18-8 Stainless Steel 7 Small sliver Philips head screw Standard 13 18-8 Stainless Steel 8 Horse-shoe shape heating element cover Custom 2 Weaved Phenol - Formaldehyde Resin 9 Tiny washer Standard 3 Black Ox - Stainless Steel
  • 8. Bill of Materials II Part Number Part Name Classification (Custom or Standard) Quantity Material 10 Metal clamp Custom 1 Aluminum - 3200 11 Clear Crimp-Style Wire Nuts Custom 2 Plastic Aluminum - 3200 12 Power cord Standard 1 Copper 10100 Polypropylene Brass 13 Leg with three screws Custom 1 Phenol -formaldehyde resin 14 Handle Custom 1 High Density Polyethylene 15 Top element cover Custom 1 18-8 Stainless Steel 16 Metallic cover of wires Custom 1 Phenol-formaldehyde resin 17 Temperature controlling unit Custom 1 Phenol -formaldehyde resin 18 Handle fastener Custom 1 18-8 stainless steel
  • 9. Bill of Materials III Part Number Part Name Classification (Custom or Standard) Quantity Material 19 Bigger washer Standard 1 Black Ox - Stainless Steel 20 Big Phillips head screw Standard 1 18-8 Stainless Steel 21 Wire Ties Standard 3 Nylon 6 22 Heating metal Custom 2 Copper 10100 23 Lights Custom 2 Ceramic 24 Dial Custom 1 18-8 stainless Steel Copper 10100 25 Metal Body Custom 2 Duraceramic 26 Wire with cover Custom 3 Nylon 6
  • 11. Top Cover Detail Drawing
  • 12. Functional Decomposition Spreadsheet Part Input(s) Function(s) Output(s) Black Screw Mechanical Force Connects top and bottom of the metal body Mechanical Force Silver Screw Mechanical Force Connect legs to metal covering Mechanical Force Cover Applied Force Provides a stable bottom for the legs Stable Force Short Silver Screw Applied Force Connects many different parts in different areas Normal Force Leg Applied Force Holds the metal body above the ground and makes it stable Stable Force Metal Housing/Cover Metal Body Protects the wires and heating elements of the metal body Metal Body Handle Mechanical Motion Allows for metal body to move up Mechanical Motion
  • 13. Functional Decomposition Spreadsheet II Part Input(s) Function(s) Output(s) Tiny washer Screw Prevent damage on the object the screw is going into Screw Clamp Wires Keeps wires organized Wires Wire Cover Wires Protect the fragile parts of the wire Wires Power Cord Electrical Energy Brings in the electrical energy from the socket to the waffle maker Electrical Energy Small Silver Screw Applied Force Connects many different parts in different areas Stable Force Temperature Controlling Unit Mechanical Energy Moves and protects the dial Mechanical Energy Heating Cover Thermal Energy Stores thermal energy Thermal Energy Handle fastener Handle holds handle in place Handle
  • 14. Functional Decomposition Spreadsheet III Part Input(s) Function(s) Output(s) Bigger Washer Screw Prevent damage on the object the screw is going into Screw Big Screw Applied Force Connects top and bottom of the metal body Normal Force Ties Mechanical Energy holds wires together Mechanical Energy Heating Metal Electrical Energy Converts electrical energy to thermal energy Thermal Energy Lights Electrical Energy Converts electrical energy into light Light Energy Dial Mechanical Motion Separate and join contacts Mechanical Motion Metal Body Materials Holds the waffle batter while the batter heats Materials
  • 16. Waffle Maker Schematic • Mechanical Force • Flow of Heat • Flow of Electricity Handle Heat Control Mechanism Contains and heats batter
  • 17. Modified Schematic (View 2) Mechanical Force
  • 18. Problems Encountered ● Identification of some materials ● Difficulty re-assembling o Many parts broke when rebuilding o ex: “Power” and “Ready” light cover broke ● Difficulty with Solid edge waffle maker part http://www.magicalexperiments.com/wp-content/ uploads/2013/06/problems.jpg
  • 19. Possible Modifications More-open, longer handle -More space between hand and waffle iron Latch with a Vent - Latch locks waffle iron close, vent releases excess heat Additional Cooking Instrument - Detachable utility (i.e. fork or spatula) Temperature Display -Indicate Temperature of Waffle Iron
  • 20. Criteria for Matrices ● Safety (.30)- materials are safe for the user ● Cost (.20)- keep the materials at low prices ● Heat Efficiency (.15)- produces enough heat to cook waffle batter ● Reliability (.15)- produces crisp, cooked waffles ● Portability (.15)- Easy to store and move ● Aesthetics (.05)- looks pleasing for the user
  • 21. Pugh’s Method Handle Change Addition of a latch w/ a vent Additional Cooking Instrument Temperature display Safety (+) (+) (+) (+) Cost S (-) (-) (-) Heat Efficiency (+) S (+) (+) Reliability S S S S Portability S S S (-) Aesthetics (+) (-) S (-) (+) 3 1 2 2 S 3 3 3 1 (-) 0 2 1 3
  • 22. Pahl and Beitz’s Method Handle Change Addition of a latch w/ a vent Additional Cooking Instrument Temperature display Criterion Weighting Factor (W) Numerical Value (NV1) Weighted Value (W*NV1) Numerical Value (NV2) Weighted Value (W*NV2) Numerical Value (NV3) Weighted Value (W*NV3) Numerical Value (NV4) Weighted Value (W*NV4) Safety 0.30 4 1.20 3 0.90 4 1.20 4 1.20 Cost 0.20 3 0.60 2 0.40 2 0.40 2 0.40 Heat Efficiency 0.15 3 0.45 3 0.45 3 0.45 3 0.45 Reliability 0.15 3 0.45 2 0.30 3 0.45 4 0.60 Portability 0.15 2 0.30 1 0.15 2 0.30 1 0.15 Aesthetics 0.05 2 0.10 1 0.05 1 0.05 1 0.05 Sum 1 3.10 2.25 2.85 2.85
  • 24. Modified Solid Edge Exploded View
  • 26. Modified Top Cover Detail Drawing
  • 27. Modified Bill of Materials Part Number Part Name Classification (Custom or Standard) Quantity Material 2 Silver Phillips head screw Standard 7 18-8 Stainless Steel 14 Handle Custom 1 High Density Polyethylene 15 Top element cover Custom 1 18-8 Stainless Steel
  • 28. Modified Functional Decomposition Spreadsheet I Part Input(s) Function(s) Output(s) Black Screw Mechanical Force Connects top and bottom of the metal body Mechanical Force Silver Screw Mechanical Force Connect legs to metal covering Mechanical Force Cover Applied Force Provides a stable bottom for the legs Stable Force Short Silver Screw Applied Force Connects many different parts in different areas Normal Force Leg Applied Force Holds the metal body above the ground and makes it stable Stable Force Metal Housing/Cover Metal Body Protects the wires and heating elements of the metal body Metal body Small Silver Screw Applied Force Connects many different parts in different areas Stable Force
  • 29. Modified Functional Decomposition Spreadsheet II Part Input(s) Function(s) Output(s) Handle Mechanical motion Allows for metal body to move up Mechanical motion Handle Mechanical Motion Allows user to safely access their waffle Mechanical Motion Tiny washer Screw Prevent damage on the object the screw is going into Screw Clamp Wires Keeps wires organized Wires Wire Cover Wires Protect the fragile parts of the wire Wires Power Cord Electrical Energy Brings in the electrical energy from the socket to the waffle maker Electrical energy Temperature Controlling Unit Mechanical energy Moves and protects the dial Mechanical energy Heating Cover Thermal Energy Stores thermal energy Thermal energy
  • 31. Modified Schematic (View 1) • Mechanical Force • Flow of Heat • Flow of Electricity Handle Heat Control Mechanism Contains and heats batter
  • 32. Modified Schematic (View 2) Mechanical Force
  • 33. Conclusion ● Problem: User injured by accessing waffles ● Solution: Longer handle to access cooked waffles o Makes sure user does not get burned ● Thank you for your time, Questions?
  • 34. Bibliography ● "Oster Waffle Maker." Target. N.p., n.d. Web. 03 Dec. 2013. ● The Role of Magic In Solving Problems. (n.d.). Magical Experiments. Retrieved December 7, 2013, from http://www.magicalexperiments.com/wp-content/ uploads/2013/06/problems.jpg ● Unified’s Safety Management Program. (n.d.). UNIFIED. Retrieved December 9, 2013, from http://unifiedconstructs.com/about-us/approach-safety/