Manufacturing

Torchlight specification Brand: SONCA Cost: $3.20 Power: 2 x AA Battery Description (From Manufacturer): Av Krypton, a general purpose portable battery operated handlight torchlight made with super heavy duty rubber case. Grease and oil resistant and rugged deisgn for firm grip. Length: 140mm Body Diameter: 22mm Head Diameter: 30mm Operation: 3 modes: Beacon (Low / High) and off. Switch On: Rotate the head clockwise to switch the flashlight on; Switch Off: Turn the head counter-clockwise until the brightness fades out completely. Part (Description) Head Reflector Bulb holder Bulb (From supplier) Battery (Qty: 02) Head Spring Plastic 0-Ring Rubber 0-Ring Bottom Spring Conducting Strip Main Housing Lanyard with metal clip Total (exclude battery) Total Torchlight Assembly – Requirements • • • • Main components must be fully enclosed for aesthetic and functional reasons Have a removable cover to provide access to replacement of battery and bulb. Bulb and battery should have a complete circuit connecting to the switch Head must be able to rotate (degree of freedom) for flashlight to switch on / off. Material Plastic body with Plastic Len Polished Aluminum Aluminum Tungsten filament Lithium-ion Copper Plastic Rubber Copper Aluminum Plastic for housing Aluminum and nylon Weight (grams) 8 2 2 1 55 0.2 0.5 0.5 0.5 0.3 28 2 55 100

Torchlight Assembly (Assembly sequence) Operator does not require any fixture to re-orientation, as parts are light and within reach. 1. Place Head (1) upside down as illustrated in figure 3. Parts is assumed to be picked up from a bin and then re-orientate to correct orientation as illustrated.

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A0073477W . ME3263 Design for Manufacturing and Assembly . DFA Term Project

2. Apply adhesive around the circumference of Plastic Len (2). This part of operation is slow because care has to be taken to apply the adhesive to the circumference of