Skills: CAD/CAE tools, sheet metal stamping, plastic injection molding, brake and suspension design, rapid prototyping, product design and development

1.  Product plan
 Functional analysis
 Design for quality
(soft and hard issues)
Anay Joshi | 513-302-3509 | joshia5@mail.uc.edu
Product Development
Ability to brew, store and maintain desired temperature
Fast and safe operation
Easy to use and clean
Price < $100
Capacity to brew up to 60 oz. of coffee from grounds (no grinder included)
Brew time <120 seconds
Set time to automatic brew
Compatible with standard baket coffee filter
Warmer plate heats coffee evenly
Capability to reach water temperature of 185°F
Automatic shut off if weight of coffee pot indicates it is empty
Seven-year life
Machine washable pot and filter components
Warmer plate and other materials are compatible with conventional cleaning products
Overall height not to exceed 18" (allow clearance with standard counter to cabinet distance)
Development Cost: $1,250,000
Tooling and Capital: $4,500,000
Manufacturing Cost: $40
Distribution and administration cost: 30%
Rate of Return: 15%
Gain 12% of market
Advertise through traditional techniques and social media (instagram and twitter)
Potential to produce or purchase coffee grinds
Use wholesale outlets and online sales with free shipping and returns
Target to young professionals and adults
Phase Completion
1. Customer Needs 1 month
2. Product Concept 1 month
3. Product Design 2 months
4. Prototype Development 3 months
5. Manufacturing 3.5 months
6. Product Release 3 months
Weeks Phase
5 Marketing
28 Design Engineering
20 Computer aided design
32 Manufacturing engineering
10 Quality and test engineering
Marketing
Research and development
Resource Requirements
Key Interfaces
Customer Needs
Key Product Atrributes
Product Financials
Market and Competition
Development Schedule
 Manufacturing
process selection and
router sheet
 Design for
Manufacturing
and assembly
 DFMEA
Department
Number
Operation
Number
Description Machine Tool
Standard Time
[sec]
Standard or special
fixture?
001 1
Roll aluminum
forging to 1/16th Roller machine
30
Standard
002 2
Stamp cut for outline
shape Die cutter
15
Standard
003 3 Punch press inset
features (holes/slots) Punch and die
15
Standard
004 4 Deburr Bench grinder 30 Standard
005 5
Roll press to create
first bend Slip roller
15
Standard
006 6
Roll press to create
second bend Slip roller
15
Standard
007 7
Surface finish
Hand bench
with wire
brush wheel
240
Special
008 8
Rinse with hot
deionized water Spray in bath
120
Standard
009 9
Quality inspection
go, no-go gage
and visual
inspection
60
Special
Item: FMEA number:
Model: Page :
Core Team: FMEA Date (Orig):1/1/2008
Actions
Taken
S
e
v
O
c
c
D
e
t
R
P
N
Fuse in the
electric heaters
burned out
Coffee not
consumable
7
Excess
heat
passed
through
the fuse
2
Disassemble and
check individual
piece
9 126
Check fuse before
assembly; provide
easy access to
fuse
0
Filter in charge
of taking coffee
beans out
Clogged
Coffee not
available or
Coffee beans
present in the
coffee
3
Filter not
cleaned
properly or
in time
5
Disassemble and
check individual
piece
3 45
Use optimized
mesh size for
filtering out coffee
0
Hot plate in
charge of
keeping brewed
coffee hot
Not working
Coffee not at
correct
temperature
3
Electric
heaters
not
working
2
Bulb indicating
ON/OFF of hot
plate
2 12
Test the electric
circuit randomly in
each production
batch
0
Plastic cover
incharge of
covering
everything from
top
Cracks/ not
in place
Hot steam
passes out
and direct
contact w ith
customer
5
Cracks or
not sealed
2
Check if clicks
are heard after
placing the cover
2 20
Check for clicks
during assembly
0
Glass carafe in
charge of
holding hot
brewed coffee
Cracks/
Leaks
Hot coffee
spills out
7
Excessive
wash/ too
much
contact
with hot
coffee
1
Check the
material
thickness and
alternate
materials
1 7
Check for leaks
and surface
scratches
0
0 0
J. Doe (Engineering), J. Smith (Production), B. Jones (Quality)
Drill Hole
Current
123456
1 of 1
Rev: 1
Action Results
FAILURE MODE AND EFFECTS ANALYSIS
Potential
Failure
Mode
Potential
Effect(s) of
Failure
S
e
v
C
l
a
s
s
Potential
Cause(s)/
Mechanis
m(s) of
Failure
O
c
c
u
r
Design
Controls
D
e
t
e
c
Recommended
Action(s)
Responsibility
and Target
Completion
Date
R
P
N
Design
function
Responsibility:
Prepared by:
J. Doe
J. Doe
 Design for
Maintenance
Objective:
1. Product development of a
coffee maker
Skills:
1. Product plan
2. Design for X:
manufacturing, assembly,
quality, and maintenance
3. DFMEA
4. Functional analysis
5. Material selection
3. Software used:
i. SolidWorks

2. Anay Joshi | 513-302-3509 | joshia5@mail.uc.edu
Direction of pull
 CAD modeling in CATIAV5  Draft Analysis
 Flow Analysis
 Ease of fill  Mold tools
Plastic Injection Molding
Objective:
1. Design an interior trim
product for automobile
2. Perform manufacturability
analysis
Skills:
1. Implemented design for
plastic injection molding
process
2. Performed flow analysis,
draft analysis, and ease of fill
3. Software used:
i. CATIAV5
ii. SolidWorks 2016 Plastics
iii. SolidWorks 2016 Mold
Tools

3.  Voice of
Customer
 CAD model of a
component
 Design and analysis of progressive die in
ProE andANSYS
 Drawing sent to
manufacturing
 Strip layout Manufacturing of die
plate by wire EDM
 Final product
Anay Joshi | 513-302-3509 | joshia5@mail.uc.edu
Sheet Metal Manufacturing
x
y
Objective:
1. Design a sheet metal
component
2. Design die sets to
manufacture a component
3. Start mass manufacture
Skills:
1. Entire product life cycle
fromVOC through start of
mass manufacture
2. Implemented design for
sheet metal process
3. Software used:
i. SolidWorks Sheet Metal
ii. ANSYS
iii. Pro/E

4. Anay Joshi | 513-302-3509 | joshia5@mail.uc.edu
Six SigmaTools
0
5
10
15
Y-Axis X-Axis
Week 2 Histogram
0
5
10
15
Y-Axis
# of
Occur
ences
X-Axis
Week 9 Histogram
 Capability check
 Find root causes of
variations Controllability check
 Build mechanism
Histograms
Root cause analysis
Cause-Effect diagram
Objective:
1. Build a striker hitting
mechanism and use Six
Sigma tools to reduce
variability of the process
Skills:
1. Implemented following Six
Sigma tools:
i. Histogram
ii. Pareto analysis
iii. Ishikawa diagram
iv. Root cause analysis
v. Statistical control charts
vi. DMAIC
vii. SOP to reduce human
errors.
3. “Six Sigma Green Belt”
certificate

5.  Measure packaging space  Roll center analysis
 CATIA V5 modeling
 Analysis in HyperMesh  CAD modeling in NX  Analysis using ANSYS
Anay Joshi | 513-302-3509 | joshia5@mail.uc.edu
PACE competition: Suspension and Brake Design
 Topological optimization using Optistruct in HyperWorks v14.0
Objective:
1. Design and analyze
suspension system and
brake system for GM
PACE reconfigurable
vehicle
Skills:
1. Designed double
wishbone suspension and
disc brake systems
2. Analytical solutions,
FMVSS guidelines, roll
center analysis
3. Weight reduction by
topological optimization
3. Software used:
i. CATIA V5
ii. Siemens NX 10.0
ii. Hypermesh v14.0

6.  P&G | University of Cincinnati
 Am-tech Engineering Services
 Cummins Inc.
Miscellaneous
 SOLIDWORKS
Surfacing
Sheet Metal
MoldTools
Plastics
Assembly
Drafting
Anay Joshi | 513-302-3509 | joshia5@mail.uc.edu
 CATIAV5
Sketcher
Assembly
Part Design
Drafting
Generative Shape Design
 ProE
Modeling
Assembly
Drafting
CADTools Professional experience
Graduate research
 Siemens NX
Modeling
Surfacing
Assembly
Drafting  Decision making between CNC machining,
3D printing and hybrid manufacturing
based on geometric complexity
 Decide whether 3D printing is cost
effective
CAD model CNC machine
tool accessibility
Support structure
for 3D printing