Design for Manufacture & Assembly – Coin sorter

Product

Red 5 Electronic coin sorter
Red 5 Electronic coin sorter

Aim

Investigate and propose improvements for an existing product to reduce costs attributed to manufacturing and assembly requirements.

Method

The following was carried out using the DFA method for manual assembly theorised by Geoff Boothroyd.

The product was disassembled to review the assembly sequence and identify each component and its function.  From this point I identified two specific functions that could be improved to reduce components count (therefore tooling) and assembly time.

The Lid contained 29 components, however, with a redesign this was reduced to 6. The result is an assembly time of 26.47 seconds compared to the original 174.49 seconds and a design efficiency of 45%.

Lid

Each Arm contained 7 components, however, with a redesign this was reduced to 1. The result is an assembly time of 5.45 seconds compared to the original 42.23 seconds and a design efficiency of 75.9%.

Arms

The product fully modelled in UGS NX 7.5

An electronic coin sorter reversed engineered, recreated and exploded in CAD.
An electronic coin sorter reversed engineered, recreated and exploded in CAD.

Published by Jason Scupham

I am a First Class Honours graduate in Product Design Engineering (MEng) from Loughborough University. I have attained the highest grade in my class gaining a prestigious Carlton Laser Scholarship. In the future I hope to run my own design house creating products that will have a positive impact on the world we live in, focusing on consumer and healthcare applications. This blog is designed to exhibit my current and past work detailing the design process and decision points along the way.

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