design challenge 4: happy meals! 1.0 background egr corp has been contacted by fluke toy corp (“if...
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Design Challenge 4: Happy Meals!
1.0 BackgroundEGR Corp has been contacted by Fluke Toy Corp (“If it’s fun – It must be a Fluke!TM”), to engage EGR20 teams on an exciting opportunity: providing a new toy design to be placed in McDonald’s Happy Meals in late 2014.
In particular, they wish to have a new and creative toy that is fun, low-cost, and most importantly, safe for children to use. Fluke is therefore seeking design team proposals and a verbal marketing presentation to be submitted at the prestigious upcoming “Duke Toy Fair” event.
Assigned: Tuesday Sept 17th
Due: Tuesday Oct 21st
Grade Weight: 25%
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2.0 Design Challenge Overview:
This challenge is divided into two parts:
1) Toy Concept Development 2) ‘Duke Toy Fair’ Marketing Presentation
2.1 Toy Concept DevelopmentWorking in teams, your design challenge is to create and document a McDonald’sHappy Meal toy that is fun, economical, and safe.
Development requirements include:• Toys must include at least three plastic pieces• Parts must be designed to accommodate standard injection-molding principles• Team must show evidence that toy is designed for efficient mass-production
through 3D CAD modeling and basic tolerance analyses methods• To prevent a choking hazard, each easily-separable part must be large enough to not
fully fit within a 1.25” internal diameter cylinder which has a slanted bottom varying in depth between 1.00 and 2.25 inches. (A “test cylinder” meeting these specifications will be available in lab for your inspection; also see attached drawing)
• All unassembled parts together must be able to fit within a ~5” x 5” x 5” cube• Each team-member is expected to fully design and document at least one part each• Other parts may be added so long as any separate pieces meet choking hazard rqmt
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2.2 ‘Duke Toy Fair’ Marketing Presentation
Toy design concepts must be presented at the ‘Duke Toy Fair’ scheduled for Monday October 21st
• Each team is expected to create and display their toy concept at their individual Toy Fair booth
• Each team will sign up for a five-minute presentation slot where the teaching team will visit their booth – all team-members are expected to be in attendance for this presentation
• At least one team-member must staff the team Toy Fair booth throughout the fair
• Team-members not staffing the team booth are encouraged to circulate to view other toys at the fair
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3.0 Deliverables3.1 Written Documentation (Memo Format):
1. Executive Summary
2. Approach Description- Ideation techniques used and why- Idea refinement and selection techniques used and why
3. Toy Description and Documentation- Overview discussion of toy features- Identify Critical-to-Fit/Function (CTF) dimensions- Three-view layout drawing of each part showing basic and CTF dimensions- Cross-section view of each part- 3D Exploded view of toy assembly- Part material specification(s)- Estimated production costs and volume (parts/year)- Complete Tolerance analysis of part fit for all CTF dimensions- Discussion of basic design-for-manufacturability features- One-page “Marketing Sheet” handout showing toy sketch and illustrating key features
4. Marketing Analysis- target customer/demographics: age/gender/ethnicity (US only? World-wide)- production volume and duration- any parent-friendly features?
5. Conclusion
6. Appendix
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3.2 Toy Fair Presentation
1. Toy Fair Marketing Display Materials (to be determined by team)
2. Toy Fair Verbal Presentation- 5-minute duration (max.)- Marketing Sheet handout
3.3 3D Toy Model- Teams will have the opportunity to download CAD files to “3D printer” to
render rapid plastic prototypes of their toy concepts- 3D Printer dimensional accuracy = ±0.004 inches- Pat McGuire and TAs will coordinate CAD file submission and 3D printer process- Note: plastic proto parts are produced on a best-effort basis and are not
guaranteed.please prepare a backup plan just in case there are production
difficulties.
4.0 Design Challenge Key DatesDC Start Tuesday September 17thCAD file submission-I Friday October 11thToy Fair Presentation Monday October 21st
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5.0 Grading Criteria
5.1 Written Documentation (50%) - Complete?- Sound and well-documented approach and results?- Does design methodology draw from all the skills presented in class?
- Clear and concise?- Key points conveyed in a logical manner?
5.2 Toy Design and Toy Fair Presentation (50%)- Is toy fun and safe?- Is toy displayed in a compelling fashion?- is presentation clear, concise, entertaining and cohesive?
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2.25 in.
1.0 in.
1.25 in.
Choke Requirement Test Cylinder