Manufacturing Systems and Production for Toilet Seat Peddle - Coursework Example

Name Institution Subject Instructor Date Manufacturing Systems and Production for Toilet Seat Peddle Introduction Toilet seat pedal is a mechanical device that is useful in lifting lids and seats of toilets by the use of toilet mechanisms. Levers are used to connect the toilet mechanism to a cylindrical lifting device that is found in the shaft. The lifting device is connected to the lead and seat by means of clasps that are screwed, bolted, riveted or glued to the toilet lid and seat. Floor braces are used to attach the apparatus to the floor with the use of screws and nuts or by being cemented in based on the nature of materials to be fixed to. An adjusting material coming from the lifting device and fixed to the pedal component by a lever is adjusted so that the lid and seat are maintained in upright position when the foot is taken away from the pedal. It is possible to action one or both pedals at the same time with one foot. The pedals are cup shaped. This allows lifting of the lid and seat by pressing down with the help of sole of the shoe. Lowering of the seat or lid can be done by making contact between the shoe and inside top of the pedal stirrup pressing upwards on the pedal resulting in lowering of the lid or seat It is possible to make the entire apparatus using synthetic materials and or non-corrosive metal with except when mounting shaft o the floor braces. It is best to use no corrosive metals for the mounting shaft and the floor braces due to strain produced when mounting the apparatus in its location to ensure security of the place 1. Product Structure The pedal is composed of two pedals that are located in a position where they are aligned with the foot of the user. For the case of male users, it will be located in a place where the foot can be raised and the toilet seat will be raised upon placing the foot on the pedal and in a similar manner to trash bin lid. This allows easy use of the toilet. On releasing the pedal, by removing the foot from the pedal the seat will be ale to roll back to the resting position while the flushing mechanism is activated. When it is being used by sitting users, the pedal will enable activation of the flushing mechanism only. The main component of the device are self-supported movable base where a foot pedal is mounted and an upright rod is hinged on one end to the foot pedal while on the 2. Bills of materials (quantity, materials, where is the part manufacture The pedal will be composed of a number of parts. There will be the need to use two plastic pedals coupled to the toilet seat in addition to the flushing handle by the use of pulley and belts. These materials are easily available. The pedal will be composed of four pulleys numbered BD155RS.They will be one inch in radius and grove diameter of 0.8 inch. The other components of these pulleys will be a belt of 4.76 millimeters that will be around one and half meters long. The belts will be numbered CDB-1-MTR. There will be a coil on the pedal lever to enable its pressing and releasing functionality. The springs will be bought from a local hardware and suppliers. The outer casing of the pedal will be fabricated based on the specification of pedal design. 3. Manufacturing and Outsourcing During the manufacturing process for the pedal, there are some materials that will be made while others will be outsourced. Complex materials that are not available in the shops or are too complex to manufacture will be obtained from other areas. The design of the pedal will enable easy incorporation into the design of the flushing unit of the toilet. The first step in during the manufacture will involve incorporation of a number of processes that will be embraced. The process will involve collection of the required materials such as the pulleys and the rod and then these materials will be passed on to the quality measuring process. The purpose of quality measurement is to make sure the belts and pulleys are of the required size based on the specifications of the design (Grewal 18). The parts quality checking process is also focused on ensuring compatibility of the pulleys and that they are in the right working conditions. The component quality check is followed by taking the parts to assembly process. The assembly process involves coming up with the finished product that resembles the pedal. The finished pedal will be taken for quality check where it will be tested to determine whether it has the right qualities to function properly. The quality check process will b followed by various amendments that will be made on the flaws detected and improvements such as oiling of the pulleys and providing the right alignment of the pulley and aesthetic value checks. The major processes involved in the production process are summarized n the chart below: 4. Product Component Documentation This is the process where the data relating to products will be kept in documents stored within the manufacturing firm. The documentation process will involve providing descriptive information relating to a product component and assisting the users in the right direction for using the component. The following information il be used for product documentation: Basic information: In this case, the main information relating to a product will be provided such as functionality, quality attributes general information and constraints. Detailed Information: This includes technical information such as restrictions for use methods of implementation of instructions for use, methods of delivery of the product and technical information. Acceptance information: This will involve methods of testing the component, testing environment and test support. Support information: This will include a guide for customers while using the component, tailoring support and method of installation. 5. Manufacturing processes The main manufacturing process for the components will be based on the types of components to be manufactured. For instance, in the manufacture of the plastic rod, plastic forming process of injection blow molding will be used. In the case of aluminum components, casting methods will be used. This includes die casting where the molten aluminum will be poured into molds of the shape of component to be manufactures (Grewal 25). Components such as screws will be produced by machining processes such as green machining and milling processes. 6. Production Systems and various equipment Production systems for the components will consist of a shop floor where several machines will be installed to serve the needs of the production processes. The machines will be operated by experienced employees who are able to produce the required components according to specifications. Raw materials for production of metallic components will be located in casting areas and furnaces where metal parts will be cast and molded to the required shapes. Plastic components will be taken to plastic melting and forming places. In these places, the components will be cast into the right components using injection molding process. Parts that are to be machined will be taken to machining centers for machining. 7. Equipment Flexibility and Reconfigurability This refers to a condition where it will be possible to use another alternative to produce the product that is required. It will also involve the possibility of using different approaches to produce a similar component. For instance, the plastic rod can be produced through extrusion casting or injection molding. In addition it can be produced by machining of a plastic material. The same process will apply in the manufacture of other components of the pedal. 8. Estimated Cost of Equipment and Facility Cost estimation will involves estimation of costs from the time product raw material is purchased until it is assembled. The following table shows the cost estimates for various components of the pedal. Component Raw material cost ($) Casting costs ($) Machining costs ($) Assembly costs ($) Total Costs $ Movable base 20 24 10 10 64 Foot Pedal 30 - - 10 40 Upright rod 20 20 10 10 60 Hinges 45 - - 10 55 Total 115 44 20 40 219 References Grewal, Simmey. Manufacturing Process Design and Costing: An Integrated Approach. London: Springer, 2011. Print. Read More