nutcracker manufacture - compressed

AS Product Design | Product Manufacture

Ewan HarrisCandidate Number: 0224

Centre Number: 51537

Page No:

Name: Ewan Harris

Cand. No: 0224 Centre No: 51537

AS Product Design: Product Manufacture

Orthographic Projection

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Name: Ewan Harris



Exploded View

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Name: Ewan Harris



Speci�cation1. Function: a. The product should be able to crack nuts of a varying types, sizes and shape so it can have as wide an application as possibleb. The product should try and reduce the mess created by the nutcracking process as people don’t want an excessive fa� when cracking nutsc. The nutcracker should be something that can be depended on so should always perform at the necessary level as if it couldn’t, the product wouldn’t be desirable as it wasn’t reliabled. It should be able to crack a maximum of one nut at a time as any more would be putting to much stress on any nutcrackere. Users should be able to crack between 6 and 10 nuts every minute because any longer and the product would be considered ine�ective and ine�cientf. The product should make the nutcracking process undemanding, uncomplicated and smooth as otherwise people would �nd an alternative product to use and buy

2. Ergonomics:a. The handle of the nutcracker should be designed so that it is easy to use by any user regardless of their age or the size/mobility of their hand so it can be suitable for as many users as possibleb. The product should not weigh more than 1kg so any user can hold it and carry it a short distance (5m > ) across the roomc. The thread of the product should be accurate so the turning on the handle is easy for anyoned. The base of the product should be comfortable to hold as it’s where the product will be supported when it’s in use

3. Performance/Quality: a. The product should be durable enough to last at least 10 years as this will allow a large usage before its design becomes out-of-date and so it will be replacedb. The product should be able to be used repeatedly with no maintennance as this would be too much work for some users so they could be put o� the productc. The product must be able to be used by anyone without excessive amounts of strength being required as this means it can be used a range of di�erent usersd. The product should be smooth to the touch and should have no sharp edges (apart from the crushing part) so that the chance of injuring the user is kept to an absolute minimume. The �nish should be such that it represents the colour scheme of my designated supermarket - Lidl

4. Materials: a. The product should be made from steel as it is strong enough to cope with the stresses of cracking nuts and is resistant to corrosion once the product has been paintedb. All the materials should be safe to be in contact with food that may not be cooked or cleaned in between use and consumptionc. Materials used should be high quality as this will give the user an impression of the calibre of the product

5. Environment: a. The product should be made from materials that can be recycled at the end of their usable lifeb. Materials used should have been sourced from the most e�cient and environmentally friendly meansc. In the manufacturing process, waste should be kept to a minimum so that the process is as e�cient as possible

6. Scale of Production:

a. The product’s design should be appropriate for batch production as nutcrackers are not a staple piece of equipment in every kitchen but is used in lot of households

7. Costs:a. The product should have a retail price that is no more than £10.00

FIGURE 1: A nutcracker, that’s currently on the market, in use cracking an almond

FIGURE 2: The Lidl logo which shows the colour scheme that should be used in the finish of the product

FIGURE 3: All the materials used should be recyclable

Page No:

Name: Ewan Harris



Manufacture PlanThis is how I plan to manufacture my nutcracker. It includes all the processes, equipment, timings and safety that I will have to consider as I progress through my project:

Page No:

Name: Ewan Harris



Manufacture Plan Part 2

This is how I plan to manufacture my nutcracker. It includes all the processes, equipment, timings and safety that I will have to consider as I progress through my project:

Page No:

Name: Ewan Harris





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Name: Ewan Harris





This stacked chart shows the division of time between each of the six parts:

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Name: Ewan Harris



Gantt ChartThis is a graphical represntation of my time will be spent carrying out the di�erent tasks that are required to manufacture my nutcracker:NB: The task numbers correspond to my manufacture plan

0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00

1.11.21.31.41.51.61.71.81.9

1.101.11

2.12.22.32.42.52.6

3.13.23.33.43.5

4.14.24.34.44.54.64.74.84.9

5.15.25.35.45.55.65.75.85.9

5.105.115.125.135.14

6.16.26.3

Time (hours)

Task

Num

ber

Gantt Chart for Manufacture Project

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Name: Ewan Harris



Flow ChartThis page shows the process that I will go through to manufacture components 1-3. It includes quality management, details of the check, safety and the required equipment:

Top Handle

Select stock materialCalliper

Is the material straight, free from dents and

20mm diameter? N

Select new stock materialCalliper

Mark out 32mmRule and Scriber

Cut to lengthHacksaw

Is the material 32mm long?

N

Face o� both ends

LatheCheck the lathe is in the correct gear, the piece is held securely and wear goggles and an apron

Are the ends smooth?

N

Y

Chamfer one endLathe

Continue the safety procedures from the facing o�

Centre drill and drill hole in the bottom

Lathe, centre drill and 8.5mm drill bit

Continue the safety procedures from the facing o�

A

A

Tap hole in the bottomPlug tap, taper tap, wrench

and cutting compound

Is the thread straight?

Re-tap hole in the bottomPlug tap, taper tap, wrench and

cutting compound

N

Y

Y

Round o� the topCNC Lathe

Use the protective screen to stop any debris

Is the exterior smooth?

N

Y

Smooth out the exteriorLathe, varying grades of emery

cloth

FINISH

Top Bar


Is the material straight, free from dents and 10mm

diameter? N





N

Y

B

Round o� one end

CNC LatheEnsure the protective

screen is in place before starting the program

B

Y

Y

Face o� both ends



N

Is there a lip on the surface?

N

Y

Y Smooth out the exteriorLathe, varying grades of emery

cloth

FINISH

Threaded Bar



diameter? N




Y

C

C


N

Return to “Threaded Bar”

Y

Face o� both ends



N

Cut spherical endLathe, Specially milled

cutterCheck the lathe is in the correct gear, the piece is held securely and wear goggles and an apron

Is the end perfectly spherical?

N

Continue to cut/wet and dry as appropriate

Lathe, Specially milled cutter, varying grades of wet and dry

paperEnforce the same safety procedures as when the

original cut was being made

FINISH

Y

Y

Is the material too long?

Y N

Measure the product using a micrometer or

ruler


ruler


Y N

“Mark out 62mm”


NY


ruler

Conduct a visual

inspection and measure with micrometer

Conduct a visual


Run �nger over surface to check for bumps etc.


Conduct a visual



Run �nger over surface to check

for a lip


Conduct a visual

inspection

Page No:

Name: Ewan Harris



Flow Chart Part 2This page shows the process that I will go through to manufacture components 4-6. Once again it includes quality management, details of the check, safety and the required equipment:

Sca�old Pole



diameter? N




N

De-burr

De-burring tool

Y

D

D

Chamfer both endsLathe

Y

Cut to lengthChopsaw

Ensure the material is held securely and you’re wearing an apron and

goggles for protection from debris

Sandblast the exteriorSandblaster

The guard show be secured, there should be

no holes in the gloves and the extractor should be on

Face o� both ends



N

Y

Check the lathe is in the correct gear, the piece is held securely

and wear goggles and an apron

Are the chamfers the

same depth and at 45 degrees?

N

Y

Continue to chamferLathe

Keep the same procedures as before

Centre drill and drill 8.5mm hole in the top

Drill, Centre Drill, 8.5mm drill bit, vice

Make the sure the drill bit is in straight and the material

is held tightly in the vice

Tap the holePlug tap, taper tap, wrench

and cutting compound

Is the thread straight?

Re-tap the holePlug tap, taper tap, wrench and

cutting compound

N

Y

FINISH

Whole Product

Braise the top handle, top bar and screw thread togetherOxyacetylene torch, �ux, braising rod, vice

Wear tinted-goggles and apron to protect from the light/debris. Lay the torch in the bracket when not in use,

leave the material in the sink after braising to cool

Are the materials joined securely and are

they straight?

N

Y

Continue to braise and adjust as you go

Oxyacetylene torch, Flux, braising rod, viceKeep the same safety

procedures

E

E

Clean o� any excess braising rod from the exterior

Various grades of �le or wet and dry paper

N

Y

Is the exterior smooth and clear from any excess

material?

Apply layer of grey primer to both components (excluding

the thread)Primer, wire stand

Wear an apron to protect your clothes and turn the extractor

on to remove any fumes

Y

Is the product dry?

Leave the product for longerWire stand

N

Wet and dry the exterior to smooth the layer downWet and dry paper, tap

Repeat the process two more time

Apply coat of blue paint to both components (excluding

the thread)Spray paint, wire stand



Y

Is the product dry?

Leave the product for longerWire stand

N

F

F

Do the materials need a top up coat

of paint?

Apply coat of blue paint to both components (excluding

the thread) as necessarySpray paint, wire stand



N

Y

Wet and dry the exterior to smooth the layer downWet and dry paper, tap

Select the vinyls for the supermarket coloured �nish

Cut the vinyl stripsMarking knife, ruler, cutting mat

Are the strips straight?

Y

N

Apply the vinyl strips

FINISH

Display Stand

Peel the protective wrapper o� all 3 components

Glue base to side 1

FINISH

Ensure there’s adequate ventilation to remove any fumes

Tensol Cement

Glue base to side 2

Ensure there’s adequate ventilation to remove any fumes

Tensol Cement


Y

N


ruler

Conduct a visual



Use a tri-square to check that all

the parts line up

Twist the handle mimicking use to

test

Use a protractor to see that they

match

Touch the paint to see if any

comes o�

Touch the paint to see if any

comes o�

Use a tri-square to check that all

the parts line up

Visually inspect if the colour is

even

Page No:

Name: Ewan Harris



Manufacture

Part Number 1

1.1 - Select the stock material 1.2 - Mark out 32mm (allows for material to be lost in �nishing before the �nished product)

1.4 - Face o� both edges1.3 - Cut to length 1.5 - Chamfer one end

1.6 - Centre drill the bottom1.7 - Drill hole in the bottom1.8 - Tap hole in the bottom1.9 - Round o� the top1.10 - Round o� the top

1.11 - Smooth the exterior

Part Number 2

2.1 - Select the stock material 2.2 - Mark out 22mm 2.3 - Cut to length

A

These following pages show the design process as outlined on the plan and �ow chart. It documents each process with accompanying images of myself carrying out the tasks:

Page No:

Name: Ewan Harris



Manufacture Part 2

2.4 - Face o� both edges 2.5 - Round o� one end 2.6 - Smooth the exterior 3.1 - Select the stock material

APart Number

3

3.2 - Mark out 62mm (allows for material to be lost before

the �nished product)

4.1 - Select the stock material3.3 - Cut to length3.4 - Face o� both ends3.5 - Cut spherical end

Part Number 4

4.2 - Mark out 52mm (allows for material to be lost before

the �nished product)

4.3 - Cut to length 4.4 - Deburr 4.5 - Sand blast the exterior 4.6 - Face o� both ends

B

4.7 - Chamfer both ends 4.8 - Drill 8.5mm hole in the top

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Name: Ewan Harris



Manufacture Part 3

4.9 - Tap the hole with a plug tap and a taper tap

BPart Number

5

5.1 - Braise the top handle, top bar and screw thread

together

5.2 - Clean o� an excess braising rod from the

exterior

5.3 - Apply layer of grey primer

5.4 - Wet and dry the exterior to smooth the layer

down

5.9 - Apply coat of blue paint to both components

(excluding the thread)

5.10 - Select vinyls5.11 - Cut the vinyl strips5.12 - Apply the vinyl strips

Part Number 6

6.1 - Peel the protective wrapper o� all 3

components

6.2 - Glue base to side 1 6.3 - Glue base to side 2

FINISH

FINISHED PRODUCT

Page No:

Name: Ewan Harris



QualityThis page showcases all the processes and materials that went into my product. It also justi�es why these processes or materials were used:

Component Materials Used Processes/Techniques Covered Justi�cation

Top Handle Mild SteelLathe (facing o�, chamfering and drilling)

Taping holesCNC lathe

Mild Steel = used for the whole product so it has some uniformity. It’s also appropriate because it’s tough and is easily joined Lathe = the lathe was used for facing o� because the process means that we will achieve a perfectly �at end without applying excessive force. It also meant we could set the cutter at exactly a 45° angle and it would use this angle the whole way round the handle’s base. Drilling using the lathe was necessary as it meant we could be sure we were drilling right in the centre of the part and that the drill bit wouldn’t slip. Taping = I tapped the hole as it allows the threaded bar to be easily joined to the top handle. CNC lathe = I used the CNC lathe because I knew that it would give me a perfectly equal rounded finish which would have been impossible to achieve by hand on the normal lathe.

Top Bar Mild SteelLathe (facing o�, sanding)

CNC lathe

Mild Steel = used for the whole product so it has some uniformity. It’s also appropriate because it’s malleable which allowed us to shape it Lathe = the lathe was used for facing o� because the process means that we will achieve a perfectly �at end without applying excessive force. We also smoothed the exterior of the bar using the lathe. The speed of the rotations meant the sanding process was a lot more e�cient and time saving as we took more material o� compared to doing all the sanding purely by hand CNC lathe = I used the CNC lathe for the same reason as the handle because I knew that it would give me a perfectly equal rounded finish which would have been impossible to achieve by hand on the normal lathe.

Screw Lathe (facing o�, rounding o� an end)

Mild Steel = used for the whole product so it has some uniformity. The malleability of the material meant it was right for this component as we needed to work the part on the lathe. Lathe = the lathe was used for facing o� as the process allows us to achieve a smooth �nish at both ends. The specially cut piece that we used with the lathe meant that one end could be given a spherical �nish that didn’t di�er as it would if we’d had to use the initial cutter by hand.

Mild Steel

Cracker Body

ChopsawSand blaster

Lathe (facing o�, chamfering)Tapping (plug tap, taper tap)

Mild Steel = used for the whole product so it has some uniformity. The mild steel is used here because it’s tough and as the base of the nutcracker, this component will have top contend with lots of wear and tear as it’s used. Chopsaw = this was used as it meant I would accurately cut the pole at 90 degrees and it required a lot less force and time than cutting by hand with a saw. Sand blaster = used as it’s a very e�cient way to remove all the corrosion and dirt from the exterior of the pole. This leaves the pole with a very clean and standard �nish across all the pole before I carried out any further processes. Lathe = was once again used to �atten the ends because it’s incredibly accurate and e�cient. The chamfering was also done on the lathe as I could �x the cutter at 45 degrees so the �nish would be the same the whole way round and on both ends. Taping = this was used to provide a temporary join between the threaded bar and the nutcracker body. It’s also adjustable so this means all di�erent sizes of nut will be able to �t under the cutter when the product is in use.

Mild Steel Sca�old Pole

WholeBrazing

Painting (primer, exterior colour)Vinyl

Brazing (oxyacetylene) = this was used as it’s very strong way of joining the various components that make up the handle and cutter together. It’s strong enough not to come loose when under any strain as the handle is being turned. The other advantages is that if the join is done well and clean down, it’s almost invisible on the outside. Paint = this was used as it can produce an equal �nish across all the faces. The primer was applied to get the exterior to a base level that’s the same all over the product so when the main colour is applied, the colour isn’t patchy. The exterior blue was used as it’s the base colour of my designated supermarket, Lidl. Vinyl = vinyl was used as it means I can add the highlights colours of my brand in vivid and equal odds without a�ecting the quality of the blue paint’s �nish.

-

Stand - Acrylic = it was used as it can come in translucent form so the stand’s design doesn’t clash or detract from the nutcracker’s �nishAcrylic

Page No:

Name: Ewan Harris



TestingThis page shows how I tested my nutcracker against my speci�cation to gauge the level of its performance. I selected the most important and relevant points of my speci�cation to test:NB: The analysis is broken down into speci�cation point, relevant test and results

FUN

CTI

ON

a - The product should be able to crack nuts of varrying types, shapes and sizes I would test the nutcracker using nuts of

increasing size

The photo shows me cracking brazil nuts, chesnuts and walnuts. The biggest nut I could crack was 21mm x 27 x 47. It was

segment-shaped (similiar to that of a chocolate orange piece). This is an above

averagely large nut so it proves my nutcracker is capable of cracking a

variety of di�erently sized and shaped nuts.

b - The product should try and reduce the mess created by the

nutcracking processI would visually inspect how far the shell spreads after the nut has been

crackedAs you can see from the photo, all

the shell was contained in the body of the cracker. This means that the nutcracker removes all the mess

from the process as the shell doesn’t go all over the �oor.

e - Users should be able to crack between 6 and 10 nuts every minute

I would time how long it took to crack one nut and extrapolate this

up to represent one minute

The picture shows that it 8.93 seconds to successfully crack the

nut. Over a minute, this means I’d be able to crack 6.7 nuts - which falls in

the stated window

ERG

ON

OM

ICS

a - The handle of the nutcracker should be designed so that it is easy to use by any user regardlessn of their age or the

size/nobility of their handI would give the nutcracker to students or teachers in the design schools to use,

testing a variety of ages and strength

No user I tested had any problem using the cracker and so it’s a product that can be used by lots of people regardless of their age or the size/mobility of their

hands

b - The product should not weigh more than 1kg so any user can hold

it and carry it a short distance (5m>) across the room

I will measure the weight of the completed nutcracker

Even with its display stand to support it, the nutcracker only

weighed 0.36kg - well below the maximum weight I set out

c - The thread of the product should be accurate so the turning of the

handle is easy for anyone.I would get a number of people to use the nutcracker so see whether

the thread was easily turnedNo-one had any problem using the thread. Some even only needed the

one hand (see the photo) which suggests the handle can be easily turned by any user that wishes to

use the product

a - The product should be durable enough to last 10 years as this will allow a large usage before its design becomes

out-ofdate and so it will be replacedI will review the manufacturing processes

to ensure they’re reliable

The photo shows some of the solidi�ed braising material on the join to the

thread. This is an example of how I used strong permanent processes on my

product and I carried them out at a high quality so the nutcracker is durable.

PERF

ORM

AN

CE/Q

UA

LITY c - The product should be smooth to

the touch and should have no sharp edges (apart from the cutting part) so that the chance of injuring the user is

kept to an aobsolute minimumI would feel some of the

more prominent edges to check they were safe

This shows the handle which is one of the examples of how the edges have

been smoothed for safety. This lowers the risk of any injury.

d - The �nish should be such that it represents the colour scheme of my

designated supermakret - LidlI would compare the colours of my

nutcracker to that of the logo found on my speci�cation page

This pictures displays my �nished nutcracker on its stand. It is obvious that the colours are the same as the ones that are a part of the Lidl brand

identity.

Page No:

Name: Ewan Harris



Testing Part 2

This page contines to show how I tested my nutcracker against my speci�cation to gauge the level of its performance. I selected the most important and relevant points of my speci�cation to test:NB: The analysis is broken down into speci�cation point, relevant test and results

ENVI

RON

MEN

T

b - Materials used should have been sourced from the most e�cient and

environmentally friendly means

I would research the source of my materials to check they’re appropriate and e�cient

My steel was sourced from the UK (which contributes £2.9 billion to

the Uk balance of trade) which won’t have travelled as far as

international steel so is the most environmentally friendly source

c - In the manufacturing process, waste should be kept to a minimum so that the process is as e�cient as possible

I would review my manufacturing process to see how I’ve reduced waste

When I was cutting pieces to length, I tried to cut them so I would have to

remove as little as possible. This means the manufacturing processes I carried

out were as economical as could be

a - The product should be made from materials that can be recycled at the

ends of their usable life

I would �nd out whether the materials used are recyclable

Steel is the most recycled metal in the UK and the world. This means

that my product will be easily recycled at the end of its life

a - The product’s design should be appropriate for batch production...

I would see whether the production of my nutcracker is conduisive for

batch production

Most of this product can be constructed individually before

being brought together which is a characteristic of batch production. As is the fact that the most of the parts can be made using similiar

processesSCA

LE O

F PR

OD

UC

TIO

N a - The product should have retail price that is no more than £10.00I will consider all the parts of the

nutcracker and what their price is, estimating how much this would

retail atThe steel in my product is

approximately £5 worth. Adding the paint �nish etc, I estimate this would have a cost value of £7 and

so would retail under £10

a - The product should be made from steel...

I would review the materials used in the manufacturing of my

product

Every component that went into this product was made of steel

(predominately mild steel)

MAT

ERIA

LS

b - All the materials used should be safe to be in contact with food that

may not be cooked or cleaned in between use and consumption

I will research if any of the materials used have any health

e�ectsOnce the product has been

cleaned, the steel which makes up the body or any other part will have no negative health e�ects if left in

contact with the food

Conclusion - As you can see, my product peforms very well against the speci�cation. This means I can be sure that my nutcracker will carry out its role in the kitchen and in generalat a high level.

I have checked that it is an accessory that can be used by an array of di�erent users as it doesn’t require excessive amounts of strength so anyone who wanted to, could use my nutcracker.

It’s also been checked that the materials and processes are as environmentall friendly as possible so that the product’s e�ect on the environment is minimal.

Page No:

Name: Ewan Harris



Third Party TestingThe �nal tests I put my nutcracker through were third party testing. I asked 10 people various questions about my product and asked them to answer once they’d had a chance to use my product:NB: When the question gives answers from 0-5: 0 is equivalent to not at all or low and 5 is equivalent to very or high.

How easy it to use my nutcracker?

0 1 2 3 4 5

Conclusion:The responses to question 1 indicate that people found my product very easy to use. The majority being 4/5 for ease of con�rms speci�cation point 1f that its use is “undemanding, uncomplicated and smooth”.

Conclusion:This category was a resounding success. All the interviewees found the product was comfortable to hold so speci�cation point 2d is de�nitely satis�ed.

Conclusion:It is clear that this category was a bit more split than the rest of the categories. The brand isn’t as recgonisable as I would have liked but most still recognised it. This could be perhaps because the colours are quite generic or because Lidl is one of the most well known supermarkets.

Conclusion:This section was also very successful. People clearly felt that my product was of a high quality, the majority rated it 5/5. This de�nitely means that my product covers spec point 4c.

Conclusion:This question was very encouraging. The fact that people would be comfortable to pay over the intended retail price speaks volumes for its quality and ease of use. However, it does raise concerns that it may not be viable to sell this product at £10 or less as stipulated in the speci�cation.

Conclusion - The �ve questions I asked all recieved positive feedback on the whole. This shows that users were impressed by the quality of the product and how easy it was to use.

It also helped secure the �nal few speci�cation points which shows that my product has clearly satis�ed all the constraints I set at the start of the product.

How recognisable is the supermarket brand from the colour scheme?

0 1 2 3 4 5

How comfortable is the product to hold?

0 1 2 3 4 5

What kind of quality is the product?

0 1 2 3 4 5

How much would you pay for this product?

£0 £2 £4 £6 £8 £10 £15 £20

nutcracker manufacture - compressed

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