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Grinder
Executive Summary
The report details the reverse engineering project of a Vomach Manual Coffee Grinder
and how the product’s design has come to be. This includes the design analysis of the
unraveling the creator’s design intent and hopefully improve the product with three potential
design changes. Therefore, the engineering team sought to understand the design of each
individual component, why they are in a specific manner, the reasoning behind the material
choice, and the current manufacture and assembly process of the coffee grinder. Once the team
disassembled the product, 3D modeled parts as well as engineering drawings were completed for
each part. After conducting DFA analysis on the product, the team categorized the product into
three sub-assemblies each consisting a potential design change. Three part reductions made lied
within the Upper Body and Grinder Assembly, the Handle, and the Collection Receptacle. The
design changes improved from a DFA perspective at the expense of increasing the
Table of Contents
Executive Summary 2
Gantt Chart 8
Fishbone Diagram 10
Product Decomposition 11
DFA Analysis 17
Material Analysis 24
Grinder Core - Ceramic 24
Top Lid Cover - Rubber 27
Handle - Brown Oak 30
Body - Stainless Steel 33
Threaded milled rod - Stainless Steel 36
Manufacturing Analysis 39
Coffee Grinder - Body 39
Coffee Grinder - Grinding Mechanism 42
Economic Analysis 44
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Assembled View 50
Conclusion 52
References 54
Appendices 55
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Table of Figures
Figure 1: Gantt Chart…………………………………………………………………………...8
Figure 2: Black Box Diagram…………………………………………………………………...9
Figure 3: Fishbone Diagram…...………………………………………………………………10
Figure 4: Upper Body Diagram………………………………………………………………..18
Figure 5: Redesign of Upper Body…………………………………………………………….19
Figure 6: Handle Diagram……………………………………………………………………..19
Figure 7: Redesigned Handle…………………………………………………………………..20
Figure 8: Collection Receptacle Diagram……………………………………………………..21
Figure 9: Collection Receptacle Diagram……………………………………………………..21
Figure 10: Grinder Core…………………………………………………………..…………..24
Figure 11: Possible materials for the grinder with a line of best
fit to show which materials meet the max strength 1 …………………………...25
Figure 12: A plot of the average cost of different materials…………………………………26
Figure 13: A plot of wear rate vs hardness of different materials ………………………….26
Figure 14: Rubber Lid………………………………………………………………………….27
Figure 15: Possible materials for the rubber cover with a line of
best fit to show which materials meet the necessary max strength……………..28
Figure 16: A plot of the average cost of different materials…...…………………………….29
Figure 17: Handle Piece………………………………………………………………………...30
Figure 18: Possible materials for the handle with a line to show
which materials meet the max tension loading using……………………………31
Figure 19: A plot of the average cost of different materials……………..………………….32
Figure 20: Collection Receptacle (Body)………………………………………………………33
Figure 21: Possible materials for the body with a line of best fit for
materials that meet the max load for a cylinder under internal pressure……...34
Figure 22: A plot of the average cost of different materials………………..……………….35
Figure 23: Threaded Rod………………………………………………………………………35
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Table of Tables
Table 1: Product Decomposition of Manual Coffee Grinder………………………………...11
Table 2: DFA metrics of Original Design………………………..…………………………...17
Table 3: DFA metrics comparison of Original and Redesign………………………………..22
Table 4: Process Rejection Chart…………………..…………..……………………………..41
Table 5: Process Decision Matrix…………………..…………..……………………………..41
Table 6: Grinding Mechanism Process Rejection Chart……………………………………..42
Table 7: Grinding Mechanism Process Decision Matrix……………………………………..43
Table 8: Unit Cost Comparison - Original…………..…………………..…………………...46
Table 9: Unit Cost Comparison - Redesign………………………………..………………….46
Table 10: OME cost of Original Design………………………………..……………………...47
Table 11: OME cost of Remodeled Design……..…………………………………………….47
Table 12: CustomPart.net Quote Estimate of Original……………………………………....48
Table 13: CustomPart.net Quote Estimate of Remodeled Design…………..……………….48
Table 14: Break-Even Analysis of 5,000 Units of the Original and Remodeled Design…....49
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Gantt Chart
In order to complete the project on time while keeping events organized, a Gantt Chart
was used to update the team with deliverables. Time periods for each task were created during
the initial phase of the project and were updated each week. The chart was found to be especially
helpful with updating other team members with individual progress. Overall, the Gantt Chart
ensured the task was completed to the proper standards and at the proper time. The complete
Gantt chart can be seen below.
Fishbone Diagram
The fishbone diagram breaks down the coffee grinder into its subassemblies and
individual components. As the main centered horizontal line illustrates, all sub-assemblies
connect to the threaded rod of the grinder. Each angled vertical line delineates a sub-assembly,
while the small horizontal lines that stem off of each subassembly represent an individual part.
By connecting each part this way, it is easy to understand how the coffee grinder is assembled on
a surface level. The full fishbone diagram can be found below.
Product Decomposition
To better understand the product, the team documented the disassembly of the product
and the individual component during the process. It is essential to understand how the parts
interfere and mate with each other. The material and manufacturing process was also determined
during this process. While decomposing the product, the team to identified potential redesigns to
the product. The following table (Table 1) depicts the decomposition of the manual coffee
grinder. It should be noted that some of the parts were not able to be disassembled (Parts 1003,
1007, 1008, 1009, 1011, 1013, 1015, 1017, and 1019) due to the manufacturing method
implemented by the designer, therefore Solidwork models of these parts were illustrated:
Product Decomposition
Design Organization:Coffee Inc. Date: 2/26/18
Product Decomposed:Vomach Manual Coffee Grinder
Description A stainless steel mechanical coffee grinder with an adjustable coarseness level
mechanism.
How it works: Pour coffee beans in the cavity. Use the handle and rotate counter clockwise to
grind the coffee beans. Adjust the gear in the threaded rod to adjust coarseness level. After
grinding the coffee, twist the upper body to open base and use the grinded coffee for your
beverage.
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Parts:
Part # Part Name # Req’d Material Mfg Process Image
1001 Grinder Cap 1 Stainless Steel Die Casting
Disassembly:
Step # Procedure Part #s Image
removed
1 Remove Rubber Cover 1005
DFA Analysis
Upon disassembling the product, the team immediately realized room for improvement in
the assembly process. Overall, the design has self aligning features such as the mating of the
coffee base to the coffee cover (Parts No. 1008 and 1014). The product has minimal chance of
error proofing with the exception of the center blade (Part No. 1009), this is because the part
has distinctive features on faces of the blade which may affect the performance of the grinding of
the beans if placed incorrectly. The coffee grinder core, bolt connector, coffee grinder upper and
mid body, as well as the coffee grinder cover (Parts No. 1002, 1012, 1010, 1006, and 1014)
have difficulty during insertion. This is because the holes on these parts should be aligned in
order to insert fasteners. The following table is the DFA analysis of the manual coffee grinder:
connects the two assemblies together is comprised of two parts (Part No. 1014 and Part No.
1006). The team could not definitively find a reason for the component being separate pieces.
2. Handle
Current Design Description
In the original design, the handle engages with the threaded rod by a square hole. And it
acts as a crank to grind the coffee beans. It is currently comprised of three pieces: the crank, grip,
and a rivet. The head piece does not spin when rotated. The head piece is made of wood, and
seems to be pure aesthetic.
Redesign
Again, this assembly can be made into one piece. The head piece does not spin when
rotated, so having a piece that combines all three components does not change function. The
piece would be slightly more complex, but would be an advantage to make from a design for
assembly point of view. Below is the redesign for the handle:
3. Collection Receptacle
Current Design Description
The coffee grounds fall from the grinder to the collection receptacle. This assembly is
currently comprised of three components. The bottom cap and O-ring attach to the main body. At
first glance the team assumed these were one piece. The O-ring was assumed to be used for a
tighter fit, or to prevent coffee grounds from escaping the receptacle. The bottom cap could be a
separate piece for ease of cleaning.
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The team found that reducing the part count ultimately reduced the DFA metrics, while
maintaining an increase to both theoretical and practical efficiency. Implementing the previously
mentioned design changes reduced the complexity factor from 34.58 to 15.16. The following
table depicts the comparison of the DFA metrics of the Original and Redesign of the manual
coffee grinder. The full DFA table can be found in the Appendix:
Error Proofing
The goal for error proofing is preventing errors in assembly. The lower the statistical
number, the better. As seen in Table 3, the error proofing in the coffee grinder shows to be in a
safe zone. Most of the parts are large or unique enough that misassembly can be prevented. The
designers created the product with disassembly in mind. The threaded rod (Part No. 1017)
allows for the grinding components to easily fasten to each other, and the parts are unique
enough to identify the order of assembly. The redesign did not better or worsen this category, as
the threaded parts were not changed. The error proofing shows that the grinder was designed
well enough to prevent any confusion during use.
Handling
Most of the handling issues were from the Upper Body and Grinder Assembly (Parts No.
1006, 1012, 1014) and the Collection Receptacle (Parts No. 1008, 1011, and 1015). The Upper
Body and Grinder Assembly consisted of individual components prone to nesting and had sharp
edges, while the collection receptacle only had sharp edges. When fully assembled, the coffee
grinder can be taken apart to access the coffee grounds. This movement is done by twisting the
bottom apparatus counter clockwise. Besides this functionality, the fasteners are the only other
piece that interact with other components. The two nuts that fasten the grinder core to the upper
body are relatively difficult to access. The space is tight and is hard to use any tools to tighten.
However, the bolt-nut interactions are most likely meant to be hand tight. The redesign
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eliminates the nuts and bolts and therefore prevents any handling issues. This design improves
the handling greatly from (1.08) to (0.56). This leaves one fastening component that connects the
entire grinding assembly together. This piece is essential for the grinder to change grinding
effectiveness (how fine the grounds are.) Without this fastening piece the grinder loses
functionality and therefore was not redesigned.
Insertion
The grinder core assembly must be attached to the upper body. This requires the user to
hold the upper body, grinder core, and fasteners in place while the nuts are tightened. This
operation relates to handling issues when accessing the nuts discussed in the handling section.
The assembly of the components do not require any additional tools. The parts are all hand held
and can be assembled with hand tight fits. The redesign reduces the number of interactions and
parts needed to be held to assemble the grinder.
Secondary Operations
Secondary operations include re-orienting the workspace or using an additional tool or
material to assemble parts correctly. The product itself is purely mechanical, and almost no
secondary operations are needed to assemble the parts. A wrench may be used to tighten the
bolts, but hand tight fits are sufficient enough for this product.
Based of the metrics, the redesign from a DFA perspective has been a success, with an
increase to both theoretical (90%) and practical (100%) efficiencies to the product.
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Material Analysis
Grinder Core - Ceramic
Function: The grinder core grinds the coffee beans into powder with the inner blade. This
allows for the coffee to be used in brewing of coffee itself.
Material Index: For a cylindrical vessel with internal pressure, to maximize strength:
M ax Strength = σ f /ρ
For steel with ρ = 8.05 M g/m3 and σ = 350 M P a the max strength is 43.48 MPa/(Mg/m^3)
Constraints/Requirements:
● Cannot deform while grinding
● Must be wear resistant
● Must be food safe
● Must be able to make complex geometry
● Minimize cost
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Figure 11: Possible materials for the grinder with a line of best fit to show which materials
meet the max strength 1
3. Screen Using Constraints:
Based upon the line of materials that meet the design requirements, it is possible to use
wood, ceramic, steel, or other metal alloys. All of these materials meet the necessary design
requirements for this component and could be used for different reasons.
Function: The top lid cover prevents the coffee beans from splitting while grinding.
Additionally while in storage the cover protects the grinder from collecting dust within the main
body.
Material Index: For a plate in bending the max strength is given as:
M ax Strength = E 1/3 /ρ
For rubber with ρ = 1.1 M g/m3 and E = 55.0 M P a the max strength is 3.457 MPa/(Mg/m^3)
Constraints/Requirements:
● Need to be soft and provides good sealing
● Must be wear resistant
● Must be food safe
● Must be able to make complex geometry
● Minimize cost
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Figure 15: Possible materials for the rubber cover with a line of best fit to show which
materials meet the necessary max strength
Function: Provide easy access to use rotational motion to grind coffee beans using the grinder
core. Additionally, be able to easily fit in the hand of the user.
Material Index: For a bar in tension the max strength is given as:
M ax Strength = σf /ρ
For oak with ρ = 0.72 M g/m3 and σ = 5.50 M P a the max strength is 7.62 MPa/(Mg/m^3)
Constraints/Requirements:
● Does not break under loading
● Easy to produce/cheap
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Figure 18: Possible materials for the handle with a line to show which materials meet
the max tension loading using
Function: Be able to hold all components of the coffee grinder structure. Additionally, support
the other components with a rigid body to allow for other components to be attached onto and
contain all coffee beans and grounds within the system.
Material Index: For a cylindrical vessel with internal pressure the max strength is:
M ax Strength = σf /ρ
For steel with ρ = 8.05 M g/m3 and σ = 350 M P a the max strength is 43.48 MPa/(Mg/m^3)
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Constraints/Requirements:
● Strong enough to support other components
● Rust resistant
● Easy to produce
● Easy to form
Figure 21: Possible materials for the body with a line of best fit for materials that meet
the max load for a cylinder under internal pressure
provide the longest lifetime of the product and protect it from corrosion and rust it is best to use
either steel or some other form of metal alloy to protect the components and allow for the easiest
forming of the components.
Function: Allow for multiple different pieces to be attached onto the shaft and transfer rotational
motion from the handle to the grinder core. Additionally, it must fit different components with
different finished onto the central component.
Material Index: For a bar in tension the max strength is given as:
M ax Strength = σf /ρ
For steel with ρ = 8.05 M g/m3 and σ = 350 M P a the max strength is 43.48 MPa/(Mg/m^3) and
for a bar in torsion the max strength is given as:
M ax Strength = σ f2/3 /ρ
For steel with ρ = 8.05 M g/m3 and σ = 350 M P a the max strength is 6.17 MPa/(Mg/m^3)
Constraints/Requirements:
● Easy to form
● Easy to produce
● High strength
● Rust resistant
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Manufacturing Analysis
For the manufacturing and assembly of this product there are multiple different methods
that can be used. Each method provides different capabilities on the process itself and allows for
different finishes and properties of the pieces produced. While some components are
standardized and could be bought off the shelf, most of the pieces need to be machined or
manufactured. For the primary parts to this product however, the body and grinder, they were put
through the process selection to determine what method would be most appropriate for the
manufacturing of these parts.
Figure 26: Possible shapes for different stock materials and desired shapes
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From here, the possible processes that could produce this shape geometry were
scrutinized to determine which methods were feasible for the production of this part. Based upon
the geometry restrictions the possible methods determined were centrifugal casting, die casting,
investment casting, permanent mold, sand casting, powder injection molding, injection molding,
blanking, and deep drawing
2
Figure 27: Possible machined shapes for different processes
From the possible processes available to make this component, these processes were then
analyzed to determine their capability to produce this specific piece. Despite all methods being
able to produce parts of component it was important to find a method that could be standardized
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to be able to produce all pieces. This would overall reduce cost and need for more tooling to
produce other parts.
Table 4: Process Rejection Chart
From the final available processes that meet all design requirements, they were
scrutinized based upon the specifics of the method to determine which method to use.
Table 5: Process Decision Matrix
For the final body pieces the best method to produce these pieces was chosen as die
casting. This method has very short cycling time of parts, and thus allows pieces to be produced
in a line process maximizing production time. It also has a small material cost reducing the cost
of raw materials needed for the part. While it does have high tooling cost and low process
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flexibility, for the mass production of parts this method is the best option. After the large initial
investment cost in tooling, parts will be able to be produced on a much faster scale at lower
costs, which in turn will provide a larger return to the manufacturer than other methods.
Based upon the possible processes available that meet the necessary requirements, these
methods were analyzed to determine which process provide the best conditions for this part. For
this component it was important it could be produced in a similar manner to the body to allow for
a similar production time and assembly process of all components.
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The final method chosen for this piece was sand casting, while not as fast as the die
casting method, it is the cheapest method to produce parts considerably. Additionally, it allows
for a high amount of customization of the part for possible different iterations of the component,
allowing for the piece to be made through many iterations and overall reduce the cost.
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Economic Analysis
The market is driven cost, therefore the team performed an extensive cost analysis to
determine the cost of the product before and after the redesign. Several cost estimates were made
(Unit cost, OME, quote estimates, and breakeven point) to assure the cost analysis was
justifiable.
Unit cost is an in depth cost analysis of the product. The calculations involves the
material cost C M , labor cost C L , tooling cost C T , equipment cost C E , and overhead cost.
C OH , where
3
Material Cost CM :
Labor Cost C L :
Tooling Cost C T :
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Equipment Cost C E :
Overhead Cost. C OH :
C U = C M + C L + C T + C E + C OH
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The following tables depict the cost comparison of the original and Remodeled Design:
Table 8 & 9: Unit Cost Comparison Between Original and Redesign
Simply reducing the parts dropped the cost by $2.30, even though the three redesigned
parts were more complicated relative to the other components.
The next cost estimate implemented was the Order of Magnitude Estimate (OME). The
OME is usually used to ballpark the cost of materials, manufacture, and the sales price. The
following equation is used to predict such estimates:
OM E material = (1 + f raction of waste) * material cost * material weight
The following tables depicts the OME cost comparison of the original and remodeled design:
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The total OME cost of the original and remodeled design were $21.187 and $22.72
respectively, this estimator is simply another form of verification to the team’s cost analysis of
the product. Moreover, CustomPart.net, an online quoting source, was used to provide the
estimated manufacturing cost of the both original and remodeled design and is displayed in the
following table:
Table 12 & 13: CustomPart.net quote estimate of Original and Remodeled Design
The remodel design reduced the cost by $0.632. Even though this change is small, the difference
becomes noticeable over a large product run.Finally, a break-even point analysis was created, the
team sought to determine the break-even sales price at 5,000 units. The break-even is given by
the following equation:
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The following table is the break-even analysis comparison of the original and remodeled design:
Table 14: Break-even analysis of 5,000 units of the original and remodeled design
A 33% reduction of the sales price was found with the remodeled design. The team is
confident with the cost analysis, since all cost estimates used proved the remodeled design would
reduce the cost with the proposed design changes.
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Assembled View
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Conclusion
The Vomach Manual Coffee Grinder is the simplest of kitchen appliances that requires
inserting coffee beans in a cup plus a twisting motion that results in the ultimate output of coffee
grounds which are used to brew coffee. The design of the coffee grinder is simple and was found
to be effective for its use. The grinder can adjust the fineness of the grounds desired. Having this
flexibility is positive for user marketability. The product was assessed through the reverse
engineering process with exceptional attention to detail. The simplicity of the product plus the
effectiveness of its use brought a drive for knowledge and research. These reasons made the
product a prime candidate for design for manufacturability (DFM) and design for assembly
(DFM) analysis.
During the disassembly process, it was obvious the coffee grinder was originally built
with aspects of DFA in mind. The center core was found to hold almost all the components
together. The process took the team only about 10 minutes, showing the products intent; ease of
disassembly. Coffee grounds are small particles that can get into hard to reach areas. Being able
to easily disassemble the product to clean away coffee powder is a clear user accessibility intent.
Coffee grounds do not necessarily get ‘dirty,’ but a change in coffee beans with leftover grounds
from the previous bean would result in a mix of flavors, most likely undesirable for the user.
An analysis of component material was made, resulting in the conclusion of mostly die
casted parts. The components which are tapped and fastened to the threaded rod are unique in
shape and the process of die casting was determined to be the most economical process. The
majority of the body is made of a stainless steel (most likely 300 series.) This specific series of
stainless steel most notably resists corrosion well. The components which grind the coffee beans
into powder were undetermined in material, but were identified to be of either a ceramic material
or Alumina. However, it was determined that the process to create the grinders was sand casting.
Sand casting provides greater dimensional accuracy, so it would create the profiles of the sharp
edges well.
The reassembly plus consumer use of the product saw three possible redesigns. The team
found a design that improves the number of parts for assembly greatly. Two fasteners are used to
attach five components together. A design where all five components are as one was created. The
part, however, is very complex and would be expensive to manufacture. The design also
combines what was two different materials, so a new material must be chosen that will have the
hardness of the blades with the structural and weight properties of the outer body. This may
increase the manufacture cost, but was shown to greatly decrease the number of parts, improving
DFA categories. The handle consists of three components of three different materials. A redesign
for easier assembly processes was made by creating a more complex part with the same
functionality of the current design. The last redesign follows the pattern of reducing parts by
combining three components from the collection receptacle subassembly. With the three
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redesigns combined, the DFA categories drastically improved and the unit cost reduced for the
product.
The reverse engineering process is advantageous for any product. Flaws as well as
strengths in design are found that original designers could have missed. It is impossible to know
the exact intent of the owner, but reverse engineering allows a team to gain knowledge and
experience of a product without any interaction of an original designer. The coffee grinder
showed the team that designs should be kept simple. The biggest drive in the marketplace is
price. The lower the price of a product can be without sacrificing usability creates a marketable
and successful product.
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References
1.Riffell, Dan. “Lecture 12.” MCEN 5045 Spring 2018. Boulder, CO. February 2018. Lecture.
2.Riffell, Dan. “Lecture 13.” MCEN 5045 Spring 2018. Boulder, CO. February 2018. Lecture.
3.Riffell, Dan. “Lecture 11.” MCEN 5045 Spring 2018. Boulder, CO. February 2018. Lecture.
4.Fernau, Karen. “Coffee grinds fuel for the nation.” The Arizona Republic. USA Today. March 2018.
Website. URL:
https://www.usatoday.com/story/money/business/2013/04/09/coffee-mania/2069335/
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Appendices
Appendix A
Orthographic Drawings
6 5 4 3 2 1
REV. DESCRIPTION DATE
A INITIAL RELEASE 2/27/2018
NOTES:
1. ITEM NUMBER 1 AND 9 ARE SUB ASSEMBLIES
QTY.
ITEM NO. PART NUMBER
15
A A
9
1 2001 1
2 1004 1
3 1016 1
4 1012 1
5 1019 1
6 1007 1 5
7 1003 1
8 1001 1 6
9 2002 1
B 10 1008 1
B
11 1015 1
12 1011 1
7
13 HFBOLT 0.25-28x0.875x0.875-N 2
14 HNUT 0.2500-28-D-N 2
15 1005 1 2 8
4 3
13
12 1
C C
10 14
11
UNIVERSITY OF COLORADO
COFFEE GRINDER
1111 ENGINEERING DRIVE
D BOULDER, CO 80309-0427 D
DESCRIPTION
COFFEE GRINDER ASSEMBLY
PN REV SHEET
2000 A 1 of 1
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE
PROPERTY OF UNIVERSITY OF COLORADO. ANY REPRODUCTION IN
PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION IS
PROHIBITED.
6 5 4 3 2 1
6 5 4 3 2 1
REV. DESCRIPTION DATE
A INITIAL RELEASE 2/27/2018
QTY.
ITEM NO. PART NUMBER
A A
1 1017 1
2 1013 1
3 1009 1 1
4 1002 1
5 HHNUT 0.3125-18-D-N 1
B B
C C
UNIVERSITY OF COLORADO
GRINDING CORE
1111 ENGINEERING DRIVE
D BOULDER, CO 80309-0427 D
DESCRIPTION
GRINDING CORE
PN REV SHEET
2001 A 1 of 1
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE
PROPERTY OF UNIVERSITY OF COLORADO. ANY REPRODUCTION IN
PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION IS
PROHIBITED.
6 5 4 3 2 1
6 5 4 3 2 1
REV. DESCRIPTION DATE
A INITIAL RELEASE 2/27/2018
QTY.
ITEM NO. PART NUMBER
A A
1 1006 1
2 1014 1
3 1010 1
B B
3
C C
UNIVERSITY OF COLORADO
UPPER BODY
1111 ENGINEERING DRIVE
D BOULDER, CO 80309-0427 D
DESCRIPTION
UPPER BODY
PN REV SHEET
2002 A 1 of 1
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE
PROPERTY OF UNIVERSITY OF COLORADO. ANY REPRODUCTION IN
PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION IS
PROHIBITED.
6 5 4 3 2 1
REV. DESCRIPTION DATE
A INITIAL RELEASE 1/29/2018
2.214
.134
.664
1.428
R.519 THRU
.214 THRU
.203
.024
.060
B
DETAIL B
SCALE 8 : 1
.238
SECTION A-A
UNIVERSITY OF COLORADO
.053
.219
C
DETAIL C
SCALE 4 : 1
UNIVERSITY OF COLORADO
A. X16 LARGE GRINDER TEETH EQUALLY SPACED APART AND ALL OF THE SAME DIMENSIONS COFFEE GRINDER OUTER CORE
PN REV SHEET
B. TEETH ARE ROTATED BY 22.5 DEGREES FROM THE BOTTOM TO MID IN A CCW DIRECTION
1002 A 3 of 3
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE
PROPERTY OF UNIVERSITY OF COLORADO. ANY REPRODUCTION IN
PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION IS
PROHIBITED.
REV. DESCRIPTION DATE
A INITIAL RELEASE 3/2/18
NOTES:
1.REFER TO CAD FOR COMPLEX GEOMETRY
5X R.22
.25
.65
.29
69°
A R.52
3X .400
.75
5X 60°
TOLERANCES X.X 0.050 UNIVERSITY OF COLORADO
UNLESS X.XX 0.010 MCEN 5045
NOTED:
X.XXX 0.005 1111 ENGINEERING DRIVE
UNITS: INCHES X.X 1 BOULDER, CO 80309-0427
MATERIAL DESCRIPTION
.05 .10
R.25
3X R.50
.275 THRU
3X 60°
2X R.108
.275
2X .15
.50
3.00
5/16" 7/64"
PART
NUMBER 90480A006
http://www.mcmaster.com Hex
© 2015 McMaster-Carr Supply Company
Information in this drawing is provided for reference only.
Nut
REV. DESCRIPTION DATE
A INITAL RELEASE 1/31/2018
B UPDATED DIMENSIONS AND GD&T 3/4/2018
A
.143
.136 .497
A
.035 TYP SECTION A-A
.214 THRU
1.335 THRU
.214 THRU
2.938 NOTES:
A. THE THICKNESS OF THIS PART IS 0.070
INCHES
1.248 THRU
B. NO HARD EDGES ON ANY CUTS OR
FEATURES
C. TOP LIP IS ROLLED OVER ONTO THE
.005 B OUTER WALL OF THE PART
.005 D. PART SHOULD MATE WITH PART NUMBER
1006
4.059
R2.00
1.45
.01 A
.493
2.36
.209 R.05 [TYP]
102°
.659
.53 .46
1.777
2X .214
A A NOTES:
1. BREAK ALL EDGES
2. UNIFORM THICKNESS OF 0.05
3. USE CAD FOR REFERENCE OF COMPLEX GEOMETRIES
3.35
4. DEPTH OF THE EXTRUSIONS ARE 0.040''
1.40
TOLERANCES X.X 0.05 UNIVERSITY OF COLORADO
UNLESS X.XX 0.01
NOTED:
X.XXX 0.005 1111 ENGINEERING DRIVE
2X .89 UNITS: INCHES X.X 1 BOULDER, CO 80309-0427
MATERIAL DESCRIPTION
.120
.020
DETAIL A
8X .03 SCALE 4 : 1
4X 19°
8X .07
UNIVERSITY OF COLORADO
.581
R.11
R.17
.09
3.200
DETAIL A
SCALE 2 : 1
A
3.00
3.303
1.58
NOTES:
1.UNIFORM THICKNESS OF 0.010"
3.790
R.10 [TYP]
TOLERANCES X.X 0.050 UNIVERSITY OF COLORADO
R.17 UNLESS X.XX 0.010 Coffee Grinder Base
NOTED:
X.XXX 0.005 1111 ENGINEERING DRIVE
UNITS: INCHES X.X 1 BOULDER, CO 80309-0427
MATERIAL DESCRIPTION
1.177
.114
.414
.022
.108
DETAIL AR
SCALE 1 : 1
DETAIL AL
SCALE 2 : 1
AR
AK
AL
AK UNIVERSITY OF COLORADO
Coffee Grinder Base
SECTION AK-AK 1111 ENGINEERING DRIVE
BOULDER, CO 80309-0427
DESCRIPTION
COFFEE GRINDER BASE
PN REV SHEET
1008 A 2 of 2
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE
PROPERTY OF UNIVERSITY OF COLORADO. ANY REPRODUCTION IN
PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION IS
PROHIBITED.
REV. DESCRIPTION DATE
1 INITIAL RELEASE 1/29/18
R.26
30X R.04
30X .05
R.67
A .20
.20 .19
.53 B .55
.33 R.16
.15
.28
TOLERANCES X.X 0.050 UNIVERSITY OF COLORADO
UNLESS X.XX 0.010 MCEN 5045
NOTED:
.49 X.XXX 0.005 1111 ENGINEERING DRIVE
UNITS: INCHES X.X 1 BOULDER, CO 80309-0427
MATERIAL DESCRIPTION
4.1
3.75
3.23 .15 R.3
A
.18
1.3
R.13 DETAIL A
R.30 SCALE 1 : 1
4.72
.200 R5.4 5.09
R4.5
3.7
2.9
R.4
.12 TYP
.26
THRU ALL
.10 2X R.73
.20 2X .22
2X R.400
2X .25
.96
2X .10
2X 1.15
.09±.01
.21±.050
7X .15±.050
6X .09±.010
+.005
.04 - .000
1.70±.050
6x 60°
6X R1.00±.050
R2.03±.050
6X R1.70±.010
SECTION A-A
SCALE 1 : 1
A
TOLERANCES X.X 0.050 UNIVERSITY OF COLORADO
UNLESS X.XX 0.010 MCEN 5045
+.000 NOTED:
R1.85 - .050 X.XXX 0.005 1111 ENGINEERING DRIVE
UNITS: INCHES X.X 1 BOULDER, CO 80309-0427
MATERIAL DESCRIPTION
R.600 R.300
.43
.09
.12
1.4
R.200
.34 .02
R.220
.20 THRU
.64
.66
UNIVERSITY OF COLORADO
.80
1111 ENGINEERING DRIVE
BOULDER, CO 80309-0427
DESCRIPTION
WOODEN CRANK HANDLE
PN REV SHEET
1007 A 2 of 2
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE
PROPERTY OF UNIVERSITY OF COLORADO. ANY REPRODUCTION IN
PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION IS
PROHIBITED.
REV. DESCRIPTION DATE
A INITIAL RELEASE 2/5/2018
.008 TYP
2.7
3.0
C 2X .60
2X .89 2X .30
.21
2.20
.001 2X .05
R.05 [TYP] 2X .766
.001 C
2X .289
+.01
.01 - .00
2X .05
2X 1.028
2X 1.48
B
.05
.33
.10
B
C
6X 30°
R.400
5X 30°
R.025 [TYP]
1.563
.060 .155
7/16" 7/32"
PART
NUMBER 90490A205
http://www.mcmaster.com Hex
© 2015 McMaster-Carr Supply Company
Information in this drawing is provided for reference only.
Nut
7/16" 11/64" 7/8"
Hex
0.25"
1/4"-28 Thread
PART
NUMBER 92620A565
http://www.mcmaster.com High-Strength Steel
© 2014 McMaster-Carr Supply Company
Information in this drawing is provided for reference only.
Cap Screw-Grade 8
6 5 4 3 2 1
REV. DESCRIPTION DATE
ITEM NO. PART NUMBER DESCRIPTION QTY. A INITIAL RELEASE 3/5/2018
1 1004 U-CONNECTOR 1
2 1016 GEAR 1
3 1001 Cap of Grinder Assembly 1
A 4 1014R GRINDER AND UPPER BODY REDESIGN 1 A
5 1003R REDESIGNED CRANK & HANDLE 1
6 1008R COLLECTION RECEPTICLE 1
7 1009 CENTER BLADE 1 11
B B
4
C C
7
10
UNIVERSITY OF COLORADO
6 5 4 3 2 1
REV. DESCRIPTION DATE
A INITIAL RELEASE 3/4/2018
B B UP 100° 0.03
7.5
C DOWN 60° 0.03
4.7
C
D
1.2
.8
A
.18
R.13
.58
R.11 .09
3.19
DETAIL B
SCALE 2 : 1
3.41
1.68
3.79
R.10 [TYP]
TOLERANCES X.X 0.050 UNIVERSITY OF COLORADO
2X R.17 UNLESS X.XX 0.010
NOTED:
X.XXX 0.005 1111 ENGINEERING DRIVE
UNITS: INCHES X.X 1 BOULDER, CO 80309-0427
MATERIAL DESCRIPTION
.108
.025 DETAIL F
EXTRUSION SHALL BE PLACED AT EVERY 90 SCALE 1 : 1
DETAIL E
SCALE 2 : 1
C F
E
.325
60X .024
60X 70°
.050
.908 R.519 THRU
102°
78°
2.407
1.408
.070 60X .060
R2.001 DETAIL F
76°
.960 SCALE 8 : 1
SECTION C-C
.240 SCALE 1 : 1
1.428 1.248
1.280
.175 .600
1.428
3.350 R.400 F .500
.320 THRU
4.059
3.919
2.938
4° .449 .564
C C
DETAIL D
SCALE 2 : 1
D
1.280
TOLERANCES X.X 0.050 UNIVERSITY OF COLORADO
UNLESS X.XX 0.010 MCEN 5045
NOTED:
X.XXX 0.005 1111 ENGINEERING DRIVE
UNITS: INCHES X.X 1 BOULDER, CO 80309-0427
MATERIAL DESCRIPTION
.467
8X .069
8X .069
DETAIL P
16X .140
SCALE 2 : 1
16X.043
Cost (Low/Medium/High)
Number of Interfaces (Ni)
Resistance to Insertion
Assemble Wrong Part/
Pliers, Tweezers, or
Number of Parts (Np)
Re-orient Workpiece
Bend, or Crimp
Obstructed Access/
Liquid or Gas
Around
Slippery
Omit Part
Together
Visibility
Part Number Part Name
Sub Assem 1 Grinding Core
1017 Threaded Rod 1 7 1 1 M 1 0 0 0 0 0 0 0 0 0 0 1 0 0 0
1009 Center Blade 1 1 0 0 H 1 0 1 1 1 0 0 0 0 0 0 0 0 0 0
1013 Inner Blade Piece 1 3 1 0 H 1 0 0 0 0 0 0 0 0 0 0 1 0 0 0
1002 Coffee Grinder- Core 1 4 1 0 H 1 0 0 0 1 0 1 1 0 0 0 0 0 0 0
Sub Assem 2 Upper Body
1014 Coffee Grinder - Cover 1 3 1 0 M 1 0 0 0 1 0 0 0 0 0 0 1 0 0 0
1006 Coffee Grinder - Mid 1 2 0 0 H 0 0 0 1 1 0 1 1 0 0 0 1 0 0 0
1010 Coffee Grinder - Upper 1 3 0 0 H 1 0 0 1 1 0 1 1 0 0 0 1 0 0 0
Sub Assemb 3 Manual Crank System
1012 Bolt Connector 1 4 0 0 L 1 0 0 0 0 0 1 1 0 0 0 0 0 0 0
1016 Gear 1 3 0 1 L 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0
1004 U- connector 1 2 1 0 M 1 0 0 1 0 0 0 0 0 0 0 0 0 0 0
1003 Crank 1 4 0 0 M 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0
1018 Rivet 1 2 0 1 L 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0
1007 Handle 1 2 0 0 M 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
1001 Grinder Cap 1 2 1 1 L 1 0 0 0 0 0 0 0 0 0 0 1 0 0 0
Sub Assemb 4 Collection Recepticle
1011 O-ring 1 1 1 0 L 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0
1008 Coffee Grinder-Base 1 3 0 0 H 1 0 0 0 1 0 0 0 0 0 0 1 1 0 0
1015 Bottom Cap 1 1 0 0 L 0 0 0 0 1 0 0 0 0 0 0 0 1 0 0
1005 Rubber Cover 1 1 0 0 M 1 0 0 0 1 0 0 0 0 0 0 0 0 0 0
1020 Fasteners 2 2 2 1 L 2 0 0 0 0 0 1 1 0 0 1 0 0 0 0
1019 Nuts 3 2 3 1 L 3 0 0 0 0 0 0 0 0 1 0 1 0 0 0
Totals 23 52 12 6 0 18 0 1 4 9 0 5 5 0 1 1 9 2 0 0
←Theor. Effy.
Design for Assembly Metrics 34.58323293 52.2% Pract. Effy.→ 78.3% 0.08 1.08 0.92 1.00
Targets 60.0%
Appendix C
DFA Analysis - Redesign
DFA Analysis Worksheet
Assembly Name: Mechanical Coffee Grinder Team: Coffee Date: 2/28/2018
If the answer is Yes to any of the metrics or questions enter a 1. If the answer is No then enter 0. Each cell must have a number.
DFA Functional Analysis / Error
Part Complexity Redesign Opportunity Proofing Handling Insertion Secondary Operations
Cost (Low/Medium/High)
Number of Interfaces (Ni)
Resistance to Insertion
Assemble Wrong Part/
Pliers, Tweezers, or
Number of Parts (Np)
Re-orient Workpiece
Bend, or Crimp
Obstructed Access/
Liquid or Gas
Around
Slippery
Omit Part
Together
Visibility
Part Number Part Name
1001 Grinder Cap 1 2 1 1 L 1 0 0 0 0 0 0 0 0 0 0 1 0 0 0
1017 Threaded Rod 1 5 1 1 M 1 0 0 0 0 0 0 0 0 0 0 1 0 0 0
1009 Center Blade 1 1 0 0 H 1 0 1 1 1 0 0 0 0 0 0 0 0 0 0
1013 Inner Blade Piece 1 3 1 0 H 1 0 0 0 0 0 0 0 0 0 0 1 0 0 0
1014R Coffee Grinder - Upper Body 1 3 1 0 H 1 0 0 0 1 0 0 0 0 0 0 1 0 0 0
1016 Gear 1 3 1 1 L 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0
1004 U- connector 1 2 1 0 M 1 0 0 1 0 0 0 0 0 0 0 0 0 0 0
1003R Handle 1 2 1 0 H 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0
1008R Collection Recepticle 1 1 1 0 H 1 0 0 0 1 0 0 0 0 0 0 1 1 0 0
1018 Nuts 1 1 1 1 L 1 0 0 0 0 0 0 0 0 1 0 1 0 0 0
Totals 10 23 9 4 0 10 0 1 2 3 0 0 0 0 1 0 6 1 0 0
←Theor. Effy.
Design for Assembly Metrics 15.16575089 90.0% Pract. Effy.→ 100.0% 0.11 0.56 0.11 0.78
Targets 60.0%
Appendix D
DFA Cost Analysis - Original
Design
Parameters Grinder Cap Coffee Grinder-Core Crank U-connector Rubber Cover
Part: 1001 1002 1003 1004 1005
Cm $0.03 $0.10 $0.10 $0.05 $0.07
m (weight) 0.02 0.044 0.07 0.03 0.024
cm (cost) 1.29 1.83 1.29 1.29 2.18
f ( fraction of waste) 0.1 0.2 0.1 0.2 0.2
Total Cu $13.71
Coffee Grinder-Cover Bottom Cap Gear Threaded Rod Nuts Semi-Tubular Rivet Fasteners
1014 1015 1016 1017 1018 1019 1020
$0.35 $0.16 $0.03 $0.07
0.19 0.111 0.02 0.046
1.29 1.29 1.29 1.29
0.3 0.1 0.1 0.1
Total Cu $10.41
Nuts Fasteners
1018 1020
0.0171 0.6296