Background
Product Realization
This course explores the end-to-end process of bringing a product from concept to consumer-ready form.
Central to the course is the development and prototyping of a small production system, with extensive documentation required throughout the phases of Engineering Validation Testing (EVT), Design Validation Testing (DVT), and Production Validation Testing (PVT). The course highlights the equal importance of both technical execution and high-quality documentation in successful product realization.
About the Product
This salt and pepper grinder is designed to provide an efficient and durable grinding mechanism while maintaining an elegant, modern aesthetic.
The design chosen eliminates the need for threads in the body or a shaft to link the bottom and top components. This grinder uses magnetism to seamlessly attach the body to the bottom part. The rotor and stator work together to gradually grind salt and pepper into finer particles, making seasoning effortless and consistent.
Technical Details
1) Product Requirements
Geometric Constraints
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Overall Maximum Length (L): 6 in
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Overall Maximum Width (W): 2.25 in
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Twist Minimum Length (T): 0.75 in
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Overall Maximum Weight:
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Pepper Storage Minimum Capacity: 50g of pepper (⅓ cup)
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Grinder should be stable when placed on either end
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3-9 Components
Output Constraints
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Grinder should be easy to use
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Average grind size should be on the order of 200µm (Ultra fine)-1600µm (Coarse)
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No dispensed pepper should be larger than 2000µm
Life Cycle Constraints
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Grinder should last for >5 years of daily kitchen use
General Considerations
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Grinder should be usable blindfolded
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Grinder should not accidentally release pepper
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Grinder should be easily refillable
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Grinder should be suitable to be used in kitchen environment
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Grinder should not spill if knocked over
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Grinder should be food safe
Burr Constraints
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Outer grinder maximum angle should be 12 degree (EPIC EDM restriction)
2) Exploded view & Parts Description
Click on the image to pop-up
3) Manufacturing Methods
4) Concept Generation
5)Product Evolution
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6) Validation Testing Process
1) EVT (Engineering Validation Testing)- 1 prototype
2) DVT (Design Validation Testing)- 3 prototypes
3) PVT (Production Validation Testing)- 10 prototypes
Challenges, Root Causes, and Solutions:
7) Other Documentation
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Standard Operating Procedures (SOP): click here
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Manufacturing BOM: click here
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RASCI Chart: click Here
Outcomes/lesson learned
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Developed a complete product from initial concept to a functional working prototype, supported by a scalable mass production plan.
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Conducted market research and generated product concepts aligned with user requirements for the project.
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Produced comprehensive documentation to guide design decisions and process improvements throughout development.
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Validated manufacturability of all major components (epoxy body, CNC base, screw retention mechanism, magnetic rings, and male/female grinder sets ) using a combination of additive, subtractive, and casting processes.
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Confirmed full assembly functionality when parts were fabricated and aligned to specifications.
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Created a detailed manufacturing Bill of Materials (BOM) and demonstrated cost reductions with increasing production volumes.