Document15

Design for ManufactureDocument

Student Number:1101492

INITIAL CONCEPT MARKET RESEARCHEXISTING PRODUCTS

INITIAL SKETCHESDEVELOPMENTPROTOTYPEFURTHER DEVELOPMENTNEW PROTOTYPE

MATERIAL SELECTIONPLASTIC SELECTIONFINAL MATERIAL SELECTIONMANUFACTURING PROCESS SELECTIONINJECTION MOULDINGCHANGES: PROTOMOLD CORRESPONDENCECOSTING: NEW DESIGNIN-MOULD DECORATION PROCESS

SWOT ANALYSISMANUFACTURING SYSTEMS

REFERENCES

FINAL INDUSTRIAL PROPOSAL

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When having a beautifully chilled bottle of beer, what happens to the cap once you’ve opened it? Does it get slid across the table, or flipped over in the vague direction of the bin or corner?

This part of drinking was what the project was inspired from. Almost every household will have a bottle, whether it is an alcoholic beverage like Desperados or a J20 soft drink, meaning that there are a large number of caps which are binned straight away, or left somewhere in the home. Therefore, these caps can be used for other things, which this project will develop on.

A beer cap integrates promotional aspects in the design, as well as the obvious function. Some have great designs, and incorporating this into a promotional product would be a good idea to visibly see the brand, rather than an object which is used just for the brand.

INITIAL CONCEPT

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Research was done on the drinks market, as the final idea would have to be supported with statistics showing how successful the outcome would be.

What was discovered was that for alcoholic drinks, glass bottles were preferred over cans, plastic bottles, or any other packaging type. This was due to its naturally attractive appearance, as well as the freshness of the drink inside that they can retain (Mintel, 2013). The quality in terms of appearance and function remains a high factor in why consumers tend to choose glass over other materials.

When consumers were asked what was the most important quality for packaging of beer/cider, wine, and spirits, the top answers for all three were that they were in a glass bottle (Mintel, 2013): Cider/Beer - 52%Wine - 65%Spirits - 46%

Although wines and spirits do not come with a metal cap on their glass bottles, cider and beer do, and as more than half the people prefer glass, this means as long as different brands do what their customers want, glass bottles will still be largely used in the present and future until consumer needs change, so that a concept using caps will be usable and there is indeed a market position for it in terms of availability of caps.

Similarly to alcoholic beverages, a lot of people preferred glass bottles, and from those asked, 41% males and 34% of females said that this was due to the drinks in glass bottles tasting better than those in plastic ones (Mintel, 2013).

The infographic to the right shows the leading brands’ market shares in value sales of beer in the off-trade in 2011, so these could be potential brands that could be promoted with the product.

MARKET RESEARCH

Other Brands/ Own Labels

46%

Stella Artois14%

Fosters12%

Carlsberg12%

Carling9%

Budweiser7%

Above:Pub visiting frequencies (Data from Mintel, 2012b.)

Opposite page:Ye Olde Mitre Pub (Ye Olde Mitre, 2013).

An important factor when developing a product is to think about the environments it will be used in, as this will contribute a lot towards the final concept, whether the style or material of the end item.

The settings that were looked at for the product were pubs and in the home. Mintel (2011) states that although women prefer drinking a wine at home, the most popular alcoholic beverage to drink at home for men is lager. Lager is however, also in the top five drinks consumed at home for women, meaning lager and beers in general take up a large percentage of drinks within the home environment.

Pubs obviously sell a huge amount of variety of beers and other alcoholic beverages as well as soft drinks. The pub visiting frequencies are shown below (data from Mintel, 2012a).

The caps from these could be used for the product, and this will be a great way of promoting brands, as the majority of people do not tend to look closely at the caps. Having to use the caps for a part of the products function means that they will be more aware of the design of the caps, and therefore more likely to remember and buy more of the same brand in the future if they like the beer and design too.

ENVIRONMENT RESEARCH

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Left:Budweiser (OnlyHDWallpapers, 2012),Carling (Dexigner, 2012),Carlsberg (Law, 2011),Fosters (Warren Beer, 2012),Stella Artois (Reuters and Fraile, 2008),Beer selection (Dakeyne, 2012).

Background:Bottles (Nick, 2011).

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The sketches here show the initial concept generation process, where the concept of a coaster was produced which could have areas for the caps to be placed, so it could be used with the branded product, or with other beverages. It moved from a simple circular shape with a number of holes, to a more 3D structure-like object, which would be available as a flat pack, and then assembled to create the final product. Having something that is flat packed would be ideal, as there would be the human interaction aspect involved, making it perhaps more likely to stay in their minds.

To make the coaster more interesting, the idea developed to having the caps acting as gears. With a small area cut away to reveal an edge of the driving gear, this would allow the user to turn it, and acting as a gear train, the caps would all rotate. The driven gear on the other side of the coaster would have something like a flag attached onto it, so that the flag rotated when the gears turned. The part with the flag would be an additional area attached to the main coaster so that it does not interfere with the function of holding a bottle on it. As the flag could be removed, this smaller circle would allow space for a small pot or bowl of something such as peanuts; perfect with the promoted drink.

However, as the idea developed, the feasibility of the caps actually functioning as a gear train was beginning to be questioned. With only the small crimped edges acting as the sprockets, it would probably be hard to engage them all to act together as a gear train should. Therefore, the next generation of ideas began.

INITIAL SKETCHES

As caps are proven to be abundant in the majority of households and pubs, further research was done in order to see how they are being used in other ways. This was to see what was already out there, and what was not.

The products found were mostly crafted, and the caps were being manipulated into different shapes or forms to create other objects; in a lot of cases, jewellery.

There weren’t any through the research done, where the caps themselves were used in their usual form in order to do something together with another object, other than cap collections in frames or tables as a decorative piece.

This was the starting point for beginning to think about how they can be used to actually do something which would allow for better promotion of the brand.

EXISTING PRODUCTS

From Top Left, Clockwise:Cap necklace (Kotik, 2009),

Chunky cap necklace (Kotik, 2009),Candle caps (Craftaholics Anonymous, 2011),

Cap flowers (Kotik, 2009),Cap bracelet (Kotik, 2009).

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DEVELOPMENT

A quick prototype was produced using foam just to see the rough shape and form of the idea. Although it will be developed further, this was done to get a 3D visualisation which would allow for more areas to be improved and changed. This stage also gave more of an understanding in terms of sizes and how it would work when the caps were slotted down from the top. There were certain aspects that weren’t thought about before, such as the slight overlapping of the caps, meaning the hole positions would need to be adjusted.

PROTOTYPE

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After some more thinking and sketches, the concept that was to be developed throughout this project was the Cap Connect game, which involves dropping the used caps into the frame and see who can get a row of caps first. This can be used as a drinking game, or just a bit of fun any time.

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After many iterations and developments (shown via the sketches in the previous pages), a design was chosen, and to see how it would look, a new prototype was produced using laser cut acrylic for the main frame, and foamboard for the base. The end result looked good, so the next stages of defining each aspect of manufacturing this product began.

NEW PROTOTYPE

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The next step was to choose which material category the product was to be made of. The three main groups of woods, metals, and plastics were considered to see which one would suit it the product the best. Manufacturing the product out of wood would give the overall aesthetic a luxurious feel, especially if high quality timber was used. Having a fairly densely grained hardwood such as beech would mean a good finish, lovely natural aesthetics, and a strong product in terms of strength. However, woods tend to warp, so accuracy may drop slightly in different conditions. The manufacturing process would also be quite costly in mass manufacture, compared to the others materials.

Metal is another option, but due to their natural high densities in comparison to woods and plastics, the product would be heavy. Also, in this case of a fairly small game frame, metal doesn’t seem to fit in well with the concept; perhaps there needs to be a contrast from the metal caps to the game product. Additionally, metals tend to be more expensive, and as the concept needs to be done on a low individual cost, this may be a problem. The shape of the idea also means that forming it would be quite difficult, whether it is folded, pressed, or cast.

Plastics, consequently is the best choice for the concept, as production will be easily feasible in mass manufacture. Various methods could be used, and there are a large variety of polymers in which the final product could be made from. As well, aesthetics can vary hugely due to the vast number of colours available to apply, as well as finishes.

MATERIAL SELECTION

From Left to Right:Beech (Floorchoice, 2013),Mild Steel (VandF, 2013),High Impact Polystyrene (Partwell, 2013).

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As there are number of available thermoplastics typically used in the process of injection moulding, a few varieties were researched further for comparisons to see which suited the concept the best.

Acrylic, although rigid, and low/medium cost, is brittle (CustomPartNet, 2009) and therefore perhaps not the best material, as it may not be treated all that carefully, especially if the product was to be part of a drinking game...

ABS is strong, flexible, has good chemical resistance, is naturally opaque, and available at a low/medium cost also. This material is used often in toys, such as Lego, so this polymer could be the best option.

Nylon has high strength, low friction, and fatigue resistance (CustomPartNet, 2009), but is more expensive than the previous two materials mentioned.

Polycarbonate is very tough and has good dimensional stability, but is also at a higher cost (CustomPartNet, 2009).

Polyethylene is lightweight, tough and flexible, so suitable for a lot of kitchenware. This may not be appropriate for this particular product.

Another option is High Impact Polystyrene, due to it’s impact strength, rigidity, toughness, dimensional stability, and low cost (CustomPartNet, 2009). This polymer is also well used in toys amongst other things.

Another similar material is Polyvinyl Chloride, which is tough, flexible, available in transparent and opaque, and is fairly cheap (CustomPartNet, 2009).

PLASTIC SELECTION

Background:Mixed Plastics (PDMevent, 2011)

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After analysing the different properties of each potential polymer, the final material selected for the manufacture of the concept was ABS.

ABS is an amorphous thermoplastic blend so has the characteristics of each ingredient. The acrylnitrile gives the thermal and chemical resistance, and the rubberlike butadiene is what gives it its ductility and impact strength (Designinsite, 2003), with the styrene producing the glossy surface and making the material easily machinable and more cost effective.

Acrylonitrile butadiene styrene (ABS) has high impact resistance, so it will not break easily when the game is being played by the users. It will be able to withstand forces within reason, and this property is important due to possibilities of the product being used in a fairly careless manner.

This material is also lightweight, meaning less cost will be utilised in transportation, whether during the manufacturing process, or after production, to retail stores or warehouses. It also comes in a variety of colours, which will work well with the brands that it will help to promote.

ABS is also a great material which enables manufacture by various ways, such as injection moulding, thermoforming, pressure-forming, blow moulding, and cold stamping (Dynalab, n.d.). Joints can also be ultrasonic welded, thermo-welded, and chemically bonded. However, adhesives such as tensile cement will be avoided in this project, as this will change recyclability of the product. Making it so that it is as environmentally friendly as possible is very important.

FINAL MATERIAL SELECTION

Background:ABS Lego (Simpleengineering, 2011)

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ABS can be manufactured in a range of different ways, so a number of them were researched to see the most effective way of producing the final outcome.

Vacuum casting can be used for this product, but the speed of production is very low, as the variable cycle time takes typically between 45 minutes to 4 hours, depending on the size of the part. However, it gives a very high surface finish and reproduction of detail (Thompson, 2007). Using vacuum casting means having more flexible tooling and less pressure needed, meaning considerably lower tooling costs, but it is not a process suitable for such high production yields.

Injection moulding would be the best manufacturing method as it is ideal for high volume production, as well as there being some variations including gas assisted, multishot, and in-mold decoration. Although the tooling costs are very high, it will produce very low unit costs, making it suitable for this project of producing 100,000 units.

The high pressures ensure a great surface finish, good reproduction of detail as well as one of the most important factors of choosing a manufacturing process; repeatability. On the other hand, resolidified polymer tends to shrink and warp, with surface defects including weld lines which may occur with this concept, due to them appearing where the material is forced to flow around areas such as holes (Thompson, 2007). However, if finishes or prints are applied, this shouldn’t be much of a problem in terms of the final aesthetics.

MANUFACTURING PROCESS SELECTION

Background:Injection moulding (Beckett MIM, 2013)

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Although the mould would be simpler to produce one half, so that two of them would produce one part of the product, the mould could include the usual male and female tools, as well as two retractable cores controlled by cams or hydraulics (Thompson, 2007). This would mean only having to produce two parts for each product; the frame and the base. Lowering the number of parts by a third will decrease the time spent for manufacture of each product, and thus become more cost-efficient.

The base will also be injection moulded, but with the least expensive tooling of only 2 halves.

The process will involve the polymer granules being dried to the right water content (Thompson, 2007), and then placed into the hopper. Any desired colour for the end product will be done by adding pigments here too, at between 0.5% and 5% dilution (Thompson, 2007). The mixture is then mixed up and heated together, as it moves along towards the mould by the Archimedean screw. The pressure increases, ready for injection into the mould cavity. Once injected, the polymer is left to resolidify, which normally takes 30 to 60 seconds, depending on the size of the part. The clamping pressure is kept after the melted polymer flows around the cavity, to minimise warpage and shrinkage once the part is ejected (Thompson, 2007).

The part is ejected by the retractable cores being removed, and then the ejector pins protruding out to separate the product from the surface of the mould (Thompson, 2007).

The tools and cores used in the process are usually machined from aluminium or tool steel, and are made up of water cooling channels for temperature control, the gate where injection occurs, runner systems, and electronic measuring equipment showing the current temperature (Thompson, 2007). To maintain a steady flow of the injected polymer through the die cavity, good heat dispersal is vital.

INJECTION MOULDING

Background:Injection moulding mould (TradeKorea,n.d.)

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After getting into contact with Protomold, the design changed due to some issues which could occur during the injection moulding. Previously, the frame was to be made from one part, but the parts shown in red with blue lines (on the right) have undercut regions which aren’t capable of being produced.

Therefore, the design changed to having two halves of the same part as this will ensure no undercuts, and also a less complex mould without cavities, meaning less expensive tooling costs.

Another thing that changed after having correspondence with Protomold was having a draft angle on all sides of 0.5° for easier release when the ejector pins push the part out from the mould.

Additionally, the base was also changed by adding a draft angle of 0.5° on all needed faces similar to the frame part, and also shelling from the bottom to a thickness of 3mm.

Previously, apart from the main cavity where the frame slots into, the base was just one solid block of ABS. As the part thickness is significantly greater than nominal, sink marks, voids, and excessive shrink are possible and warping of these and other areas of the part may occur (Custompartnet, 2013). Therefore, to reduce thickness in the part and thus decrease material usage, the newly shelled base has much less volume than initially planned.

CHANGES: PROTOMOLD CORRESPONDANCE

After the changes done to the designs of the parts, they were sent for validation to Protomold once again to see any further changes should be made, as well as the new costing.

Custompart.net gave a cost estimation of:

Frame:Material costs: £33,318.50Production costs: £26,202.56Tooling costs: £18,805.29

Total cost: £78,327.01Cost per part: £0.78

Base:Material costs: £50,497.25Production costs: £23,086.23Tooling costs: £14048.02


Combined Total: £1.66 per unit

However, Protomold is more expensive due to having a quicker service and their quote was nearly double the estimate from Custompart.net:

Frame:Production costs:£152,000.00Setup costs:£333.00


Base:Production costs:£150,000.00Setup costs:£333.00



COSTING: NEW DESIGN

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This process will be used for the application of print during injection moulding. The in-mould decoration process will decrease time and money spent on other ways of finishing, such as printing or spraying, although the cycle of time of the injection moulding process will increase slightly (Thompson, 2007).

The first step is to load a printed PC film into the dive cavity of the injection moulding, with the printed side facing inwards so when injection of the hot polymer occurs, the print will be protected behind a thin layer of PC (Thompson, 2007).

As the melted plastic comes into contact with the PC film, they will bond, and the film will become integral with the injection moulded plastic and will have a seamless finish with a printed surface (Thompson, 2007).

This is the stage where the brand logo would be attached to the base for promotion.

IN-MOULD DECORATIONPROCESS

Background:Injection moulding (Beckett MIM, 2013)

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STRENGTHS- Easy mass manufacturability- Can change prints for different brands- Very visible advertising area- Uses brand’s products (caps) to function- Fun game to play with others- Using otherwise binned caps- Compact size

WEAKNESSES- Users need to have caps to play- Initial tooling cost is high- Will effect costs of brand’s actual products if sold together- Style may not fit into all interiors of homes

OPPORTUNITIES- Will encourage people to buy more capped bottles- Availability to promote by numerous potential brands- May give the opportunity for more personal interaction with others- Other advertising campaigns to promote this product- More sales in supermarkets so higher profits

THREATS- Consumers may not want the product- Branding area may be too prominent for people’s taste to use at home

SWOT ANALYSIS

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As there is an estimate of 100,000 units being manufactured, this will be classed into the category of mass manufacture. This will mean reduced cost in comparison to using batch production methods, such as using injection moulding machines rather than craftsmen, who would take so much more time to produce the parts, as well as having the possibilities of human error.

The tools produce consistently high quality identical products at a very high rate. Having machines to do the manufacturing also reduces labour costs as the workers do not need to be as skilled. Additionally, robots are being used more commonly throughout industry, which means that production can be running continuously without the need for breaks.

On the other hand, once the mould is produced, and the injection moulding set up, it is hard to change the manufacture due to the very high tooling and mould costs.

The manufacturing system of Kanban seems to be the most efficient and suitable for this product, as it triggers production as of when needed. Cards and bins are used at three points; at the point of production, at the factory store, and at the suppliers’ store. After a red Kanban card enters any of the bins, information would be sent via a computer system, through the supply chain, that more stock would be needed, so that production could begin again.

This reduces waste, as the process will only produce enough for current demand, maintains the level of quality due to the same machines being used, and minimises storage space.

MANUFACTURING SYSTEMS

Background:Warehouse storage (GAO, 2013).

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- Beckett MIM, 2013. Injection moulding. [image online] Available at: <http://www.beckettmim.com/process-benefits/> [Accessed 18th April 2013].- Craftaholics Anonymous, 2011. Bottle cap candles. [image online] Available at: <http://www.craftaholicsanonymous.net/bottle-cap-candles-tutorial> [Accessed 17th April 2013].- CustomPartNet, 2009. Injection Molding. [online] Available at: <http://www.custompartnet.com/wu/InjectionMolding> [Accessed 27th October 2012].- CustomPartNet, 2013. Injection molding cost estimator. [online] Available at: <http://www.custompartnet.com/estimate/injection-molding/> [Accessed 20th April 2013].- Dakeyne, P., 2012. Beer Selection. [image online] Available at: <http://www.dakeynephotography.com/blog/gallery/continental-beer-selection-photography> [Accessed 16th April 2013].- Designinsite, 2003. ABS. [online] Available at: <http://designinsite.dk/htmsider/m0007.htm> [Accessed 18th April 2013].- Dexigner, 2012. Echo Designs Limited Edition Carling Zest. [image online] Available at: <http://www.dexigner.com/news/24703> [Accessed 16th April 2013].- Dynalab, n.d. ABS. [online] Available at: <http://www.dynalabcorp.com/technical_info_abs.asp> [Accessed 18th April 2013].- Floorchoice, 2013. Beech. [image online] Available at: <http://www.floorchoice.co.uk/duropal-white-beech-textured-worktop-classic-profile-p-1335.html> [Accessed 17th April 2013].- GAO, 2013. Warehouse storage. [image online] Available at: <http://www.gaorfidassettracking.com/RFID_Asset_Tracking_Applications/RFID_Supply_Chain.php> [Accessed 20th April 2013].- Kotik, Y., 2009. Jewellery from Bottle Caps. [images online] Available at: <http://geniusbeauty.com/fashion-and-wear/fashion-amid-economic-crisis-jewelry-bottle-caps-yoav-kotik/> [Accessed 17th April 2013].- Law, J., 2011. Carlsberg Relaunch. [image online] Available at: http://joshualaw88.blogspot.co.uk/2011/04/carlsberg-re-launch-that-calls-for.html> [Accessed 16th April 2013].- Mintel, 2011. Drinking in the Home. [online] Available at: <http://academic.mintel.com/display/590240/> [Accessed 16th April 2013].- Mintel, 2012a. Pub Visiting. [online] Available at: <http://academic.mintel.com/display/607663/> [Accessed 16th April 2013].- Mintel, 2012b. Beer. [online] Available at: <http://academic.mintel.com/display/590472/> [Accessed 16th April 2013].- Mintel, 2013. Food and Drink Packaging Trends. [online] Available at: <http://academic.mintel.com/display/637870/> [Accessed 16th April 2013].- Nick, 2011. Bottles. [image online] Available at: <http://bordeaux-undiscovered.co.uk/blog/2011/08/is-the-wine-in-your-bottle-worth-the-5-you-spent-on-it/> [Accessed 16th April 2013].- OnlyHDWallpapers, 2012. Budweiser. [image online] Available at: <http://onlyhdwallpapers.com/high-definition-wallpaper/beers-budweiser-ice-cubes-desktop-hd-wallpaper-935484/> [Accessed 16th April 2013].- Partwell, 2013. High Impact Polystyrene. [image online] Available at: <http://www.partwell.com/products/business-unit-3/hips-high-impact-polystyrene-plastic-product.html> [Accessed 17th April 2013].- PDMevent, 2011. Mixed plastics. [image online] Available at: <http://pdmevent.wordpress.com/2011/05/16/the-future-is-green-and-in-3d-at-pdm11/> [Accessed 18th April 2013].- RandF, 2013. Mild Steel. [image online] Available at: <http://www.vandf.co.uk/cnc-punching-of-mild-steel-speaker-grilles/> [Accessed 17th April 2013].- Reuters. and Fraile, V., 2008. Stella Artois. [image online] Available at: <http://www.reuters.com/article/2008/06/12/us-anheuser-inbev-idUSN1125578520080612> [Accessed 16th April 2013].- Simpleengineering, 2011. ABS Lego. [image online] Available at: <http://simpleengineering.blogspot.co.uk/2011/02/fundamentals-of-legos.html> [Accessed 17th April 2013].- Thompson, R., 2007. Manufacturing Processes for Design Professionals. London: Thames & Hudson.- TradeKorea, n.d. Injection moulding mould. [image online] Available at: <http://www.tradekorea.com/sell-leads-detail/S00008988/plastic%20injection%20mold.html> [Accessed 18th April 2013].- Warren Beer, 2012. Fosters’ Lager. [image online] Available at: <http://www.warrenbeer.com/wn/portfolio/beer/product/millercoors/fosters/> [Accessed 16th April 2013]. - Ye Olde Mitre, 2013. Ye Olde Mitre Pub. [image online] Available at: <http://www.yeoldemitreholburn.co.uk/> [Accessed 16th April 2013].

REFERENCES

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These small cap fitting games can be enjoyed at any time with family and friends, inviting fun interaction whilst having a drink; whether an alcoholic beverage or soft drink.

Cap Connect

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Final Industrial Proposal

Final Concept-

Materials, Manufacture & Costing-

GA Drawing

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PART NO. PART MATERIAL MANUFACTURE QTY.

1 Frame ABS INJECTION MOULDING 22 Base ABS INJECTION MOULDING 1

BREAK SHARP

Q.A

MFG

A3

CHK'D

D

E

F

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1 2 3 4

B

A

321 5

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4 6 7 8

A

ALL DRAFT ANGLES: 0.7°

Cap Connect

FINISH:

EDGES

NAME

DEBUR AND

decoration for branding

B

on base

22/04/13

ABS

SHEET 1 OF 1SCALE:1:1.7

DWG NO.

TITLE:

REVISIONDO NOT SCALE DRAWING

DATE

GA DrawingAPPV'D

Yuko Tsuda

SIGNATURE

MATERIAL:

Glossy white with in-mould

WEIGHT:

UNLESS OTHERWISE SPECIFIED:DIMENSIONS ARE IN MILLIMETERS

TOLERANCES: ±0.5mm

DRAWN

116

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ConceptThis product will engage the users to play the game of dropping their used caps into the frame to try and get three in a line before the other. As a simple but effective game, its target market can range from children to the older generation. However, this may change, depending on the brand being promoted. If an alcoholic beverage brand is used, for example, Kronenbourg, the consumers will be over 18’s, but for soft drink companies such as Coca Cola, the demographic will be a much larger range.

These small game frames could be added as a set with the branded beverage, or sold individually for only those who want it. Seeing the caps as well as the branded area on the base insures enough visible promotion for all potential brands.

Materials and ManufactureThe material used for this product will be ABS for both the frame and base, due to its high impact resistance and colour availability. This ensures that whichever brand is being promoted, the product will be of a suitable colour to match.

Injection moulding will be used for both the frame and base as it is a mass manufacturing process which gives good finish, and excellent repeatability. Incorporated within this process is the in-mould decoration process, which will involve a thin PC film with the desired printed logo or graphic being bonded to the sides of the base.

CostingFrame:Material costs: £33,318.50Production costs: £26,202.56Tooling costs: £18,805.29


Base:Material costs: £50,497.25Production costs: £23,086.23Tooling costs: £14048.02



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