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Toys are an essential product in modern society. Every aspect of engineering – safety, functionality, reliability, mass production, education, usability, etc. – is represented in toys.
You should buy (or acquire!) a “cheap” plastic toy (about £5.00), dissect it to understand how it works, and then re-design it for easier and more efficient manufacturing.
Project Phases
Take the toy apart. [Hint: many assembly screws are hidden under labels.]
Since you do not have to re-assemble the toy, you can break off snap-tabs and the like. A good utility knife or even a Dremel-type tool (if you have one) can be very helpful.
Reverse engineer the parts, by drawing them (with any CAD package: [Hint – many are downloadable as ‘trial’ versions from the internet]) and try to work out how they were
manufactured (injection moulding, stamping, etc.)
Fully dimensioned drawings are expected. Dimensions may be approximate. [Hint: to facilitate measuring dimensions, photocopy the parts – this creates a relatively accurate 2D
rendering of a part – then measure distances on the photocopy.]
For the report, you should submit:
Introduction, giving a brief description of the selected toy, the goals of the project (in your own words), and any special background information that you feel is necessary.
An assembly drawing of the toy, a drawing for each part, and a description of how you think each part was made and why you think that. This is essentially a ‘reverse engineering’ report.
For the final report, you will discuss your re-designed toy. Original parts may be included; variations on existing parts and entirely new parts are also acceptable. Refer to the online
notes regarding the nature of written reports.
The final report must include the following sections:
1. Abstract
2. Table of Contents
3. Introduction
4. Sketch of the existing toy as a whole
5. A product architecture schematic showing the major parts/components of the toy as you bought it, and how the parts/components interact
6. Sketch of your re-designed toy as a whole
7. A product architecture schematic showing the major parts/components of your re-designed toy, and how the parts/components interact Module Leader: Alan Edgar 2
Room: A74
8. Dimensioned drawings of your new design including parts list/BoM
9. A pairwise comparison table showing how you ranked and weighted the main product characteristics of your design. i.e.:
? functionality
? durability
? quality
? affordability
? producibilty
? usability
? maintainability
? safety
? marketability
10. Predicted life cycle of the new product, including descriptions of how the parts are to be made, and the assembly process (including diagrams). This MAY
include a Boothroyd-Dewhurst analysis of the design efficiency, if you choose.
11. Cost analysis of the old product and the new product, analysis of recyclability Environmental issues.
12. Summary and conclusions
Assessment Criteria:
The assessment will require you to spend some time on the exercise and keep details of the works completed in your logbook. The marking for this section will be
solely on the report you write and the material there in.
The assessment will be marked as follows:
Presentation of Report 15%
Sketch/Drawings of Original Item 10%
Sketch/Drawings of Modified Item 30%
Comparison and Predicted Lifecycle 20%
Summary and Conclusions 10%
The report should remain relevant to the exercise. There will be no reward for material which is included simply to fill space. All arguments should be clearly
justified and all drawings etc. should be properly documented.
Module Leader: Alan Edgar 3
Room: A74
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Assessment Type: Coursework
Final Module Mark Weighting: 25%
Assessment Limits: 2000 words
Submission Date: 06 September 2010
Submission Method: Via School of Engineering Office, E33
Turnitin Unlimited Attempts
Tutor with Direct Responsibility: Ken Benjamin
Standard Instructions to Students:
1. Your work must be submitted with the appropriate cover sheet which must confirm that the assignment work is your own.
2. You are advised to keep a copy of your assessment solutions.
3. Late submissions will be penalised following the University guidelines as follows:
a. Up to 5 working days late maximum mark 40% or P1
b. After 5 working days no mark will be awarded or F5.
4. Extensions to the submission date may only be given by the Module Leader for exceptional circumstances.
5. The University rules on Plagiarism will apply to all submissions.
6. Work will normally be returned within THREE WEEKS from the date of submission.
Special Instructions:
Material to support this self- learning exercise is available on WebCT under the module name. You are also expected to carry out researches of your own into the
topics which are covered by this exercise.
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