The document describes an Oster waffle maker that has a safety issue where the user can get burned when accessing cooked waffles. The team analyzed the product and proposed redesigning the handle to be longer to prevent burns. Alternatives like adding a latch and vent or temperature display were considered. The modified design with a longer handle was found to improve safety while maintaining performance based on evaluation matrices. Drawings and bills of materials of the original and redesigned product were included.

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

5. Solid Edge Assembly

6. Solid Edge Exploded View

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

10. Handle Detail Drawing

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

15. Waffle Maker Functional Flowchart

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

23. Modified Solid Edge Assembly

24. Modified Solid Edge Exploded View

25. Modified Handle Detail Drawing

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

30. Modified Functional Flowchart

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/