Final Report For Loaf Slicer

iMechanisch
LOAF SLICER MACHINE
FINAL REPORT
ENGINEERING DESIGN
BDA40203/SEMESTER I/SESSION 2014-2015/SECTION 3
MOHAMMAD SYAKIR BIN SURANI DD110038

MUHAMMAD SHALIHIN BIN MD YUSOF CD110393
MOHD SAFA RUDDIN BIN MD JUNOH DD110027
SHAHRUL AZNI BIN HADISON DD110004
REEHANA BINTI MOHAMED RILWAN DD110031
UNIVERSITI TUN HUSSEIN ONN MALAYSIA
CONTENTS
ACKNOWLEDGEMENT...I
ABSTRACT.....II
CHAPTER 1. INTRODUCTION...........1
1.1
Product Background ........1
1.2
Problem for Existing Product.1
1.3
Project Scope1
1.4
Project Significance...2
1.5
Team Members.2
1.6
Design Process...7
1.7
General Task Delegation8
1.8
Project Planning and Scheduling..9
CHAPTER 2. DEFINE TASK...10

2.1
Product Background of Loaf Slicer .10
2.1.1
Patent Search ......11
2.1.2
Catalogue Search.17
2.1.3
Commercial Product Search....19
2.1.4
Website Search.....21
2.2
Comparison Of Products From Patent Search.22
2.3
Benchmarking Of Product Specification from Commercial Product .23
2.3.1
Problem for existing product.25
2.4
Identifying Market Needs (Market Survey) and Customer Satisfaction....25
2.4.1
Questionnaire...26
2.4.2
Analysis Questionnaire.......28
2.5
Objective Clarification ....31
2.6
Weighting of Objective Tree........32
2.8
Quality Function Deployment (QFD) House Of Quality ..33
2.9
Requirement List (Rl)/Engineering Design Specification (EDS)....34
CHAPTER 3. CONCEPTUAL DESIGN.....37

3.1
Introduction..37
3.2
Clarifying Function..38
3.2.1
Activity analysis...38
3.2.2
Component decomposition analysis.39
3.2.3
Function decomposition analysis.40
3.2.4
Function structure.41
3.3
Concept Generation..43
3.3.1
Brainstorming concept generation...43
3.3.2
Morphological chart.44
3.4
Concept Evaluation..47
3.4.1
Evaluation matrix-weighted rating method.47
3.4.2
Concept Selection.47
3.4.2
Product sketching.....49
CHAPTER 4. EMBODIMENT DESIGN AND ANALYSIS.50

4.1
Product Architecture50
4.1.1
Schematic diagram of the product50
4.1.2
Element cluster of schematic...51
4.1.3
Rough geometric layout...52
4.1.4
Incidental interaction...53
4.2
Configuration Design...53
4.2.1
Standard Main Parts ....54
4.2.2
Standard of Modules....54
4.2.1
Special Purposes Parts......54
4.3.
Parametric Design....55
4.3.1
Parametric Design Problem..55
4.3.1.1 Component Analysis and Selection.55

4.3.1.2 Failures Analysis..63
4.3.1.3 Material Selection....71
4.3.1.4 Material Used...76
4.3.2
Consideration of Design for X....78
4.3.2.1 Design for Safety......78

4.3.2.2 Design for Function..78
4.3.3
Ergonomic Consideration....79
CHAPTER 5. DETAIL DESIGN AND PRODUCT SIMULATION....81

5.1
Introduction..81
5.2
Final Product Design Specification......81
5.3
Detail Drawings....82
5.3.1 Parts .....82

5.3.2 Assembly .....83
5.3.3 Complete Drawing...83
5.4
Product Analysis and Simulation by Solidworks Simulation..84
5.4.1
Static Analysis..84
5.4.2
Fatigue Failure ....85
5.4.3
Other Analysis ....85
5.5
Bill of Material (BOM)....87
5.6
Manufacturing Process ....87
5.7
Final Product Design Specification .....88
5.8
Complete Design Checklist .....89
CHAPTER 6. PROTOTYPING, TESTING AND REFINEMENT..90

6.1
Product Prototyping ....90
6.1.1
Process Involved....90
6.1.2
Prototype Product..92
6.2
Testing Requirement and Checklist...95
6.3
Testing & Refinement.95
6.4
Final Prototype Product ....................97
6.4.1
Overview Product ....................98
CHAPTER 7. SUSTAINABILITY AND ENVIRONMENTAL CONSIDERATION IN

ENGINEERING DESIGN..........................99
7.1
Introduction..99
7.1.1
Design for minimal use of materials ...99
7.1.2
Element of sustainability.100
7.1.3
Design for recyclability 101
7.2
Environmental Consideration101
7.2.1
Life Cycle Assessment (LCA)...101
7.3
Social and Economic Issues ..101
CHAPTER 8. ECONOMIC AND COSTING...103

8.1
Introduction103
8.2
Cost Evaluation..104
8.3
Business Plan.106
8.3.1
Executive Summary106
8.3.2
Mission and Vision ....108
8.3.3
Key to Success............1 08
8.3.4
Company Background110
8.3.5
Product Description111
8.3.6
C o mp e t i t or s 1 12
8.3.7
SWOT Analysis..113
8.3.8
Market Analysis114
8.3.9
Marketing Strategy116
8.3.10 Sales Forecast..118
CHAPTER 9. SUMMARY..................121
9.1
Product Development Process121
9.2
Product Significant..122
REFERENCES
APPENDIX A
APPENDIX B
APPENDIX C
ABSTRACT
Loaf slicer machine is a new project that designed to helping SME to improve productivity. The loaf slicer
is the way to easier the workers to cut loaves into pieces. In this project, loaf slicer machine is designed to
improving the current loaf slicer machine in the market. This machine were able to cut loaves into 8 pieces
per loaf. The machine is able to help the owner of Kacang Pool Haji to cut their loaves into 8 pieces that
current not available in the market. For the current market only enable to cut loaves into 24 pieces which is
not required for the francais of kacang pool haji. The thickness required is 3.75cm per bread. New design
of frame to cut loaves is created to helping SME. The current frame of loaf machine is used casting to
build. This make the cost is too high and price in the market also will high. Then, make SME unaffordable
to buy the machine. New mechanism is created that new frame used is angle hollow bar. These processes
not take too much time to build. The angle bar will weld for each connection. The shape of frame is
rectangle. Each edge is welded that make the frame strong. The cutter is measured depend on desired
thickness. The holder of cutter is placed the spring to avoid the cutter to bends. The motor for HP used
to move the pulley and then move the shaft to cut the loaves vertically. By Using the Engineering Design
process, this project required analysis to make sure the strength of the product to ensure the safety for the
user indeed of publishing.
ACKNOWLEDGEMENT
Firstly, praise to God Almighty for His blessing and guidance in lending us the strength and determination
to successfully accomplished this design project; Loaf Slicer Machine, that assigned to us who partake the
course of Mechanical Engineering Design 2, BDA40203. Only with his blessing we were able to carry out
this project successfully.
We would like to express our fully appreciation for the support of our lecture, Dr Mohd Fahrul
Bin Hassan for all his supports, ideas, encouragement and guidances for this project. His vast amount of
experience combined with advanced knowledge in this course provided us a great deal of assistances. We
truly grateful for his help in accomplishing this project which is one of the condition in completion of
Mechanical Engineering Design course. In addition, a lot of thanks for Haji Makpol Bin Saimon from
Kacang Pool Larkin as our SMEs partner because give a good cooperation and share idea to ensure this
project become successful.
Beside that, not forgotten the appreciation for every group members who gave their best and
cooperate with full commitment during this project. There are several setbacks occurred during this
project, but with the support of each member, we were able to overcome it. From brainstorming until the
completion of this report, we are grateful for the cooperation given. In addition, big thanks for the support
of family members, friends and our significant one for their help, directly or indirectly.
The bottom line is we can draw the conclusion here that this project covered every aspects of
theories and concept in Mechanical Engineering Design 2 course. The exposure this project provided gave
immense boosts in our knowledge of designing a product. This knowledge will be useful in future.
Thank you
II
CHAPTER 1.
INTRODUCTION
1.1 Product Background.
Haji Makpol Bin Saimon is a founder of Kacang Pool Haji, the famous food in Johor Bahru. This food
was inspired from Arabic dishes. The menu is prepared to meet the taste of Malaysian citizen especially
Malays [1]. The delicious menu makes it famous among the people included VIPs and Singaporean. The
ingredient used very simple and easy to dishes [2]. It is only uses kacang parang and cooked with minced
meeat and mixed rempah ratus that produced by Haji Makpol and then prepared with Key Lime (limau
purut), egg halved cooks and homemade bread.
The bread that produced for a whole day is about 2400 pieces. There are too many bread to be
produced. This machine is gravity fed by the inclined delivery of bread through its blades into the
receiving tray for bagging. This machine is able to cut loaves bread into 8 pieces with thickness 3.75 cm
per bread. There are no machines is produced to meet the requirement of these breads. These breads are
homemade especially for Kacang Pool Haji for his menus.
1.2 Problem for Existing Product

The problem statements based on the manual procedures are:
1. The manual procedures required more time in production.
2. The manual process wasting human energy and time.
3. The manual process cannot produce large amount of bread with the fast and accurate.
4. The existing machine cannot meet the requirement of bread size.
1.3 Project Objective

The main objective of this project is to design a new loaf slicer that can increase the productivity of
cutting breads and to make sure that the size of breads to be cut must be accurate.
i. To ease the workers to cuts bread into pieces.
ii. To ensure that the size of breads that to be cut is accurate.
iii.
To save time and energy consumption in serving the dishes.
1.4 Project Scope

The scopes of our project are:
1. To make 3-dimension (3D) modeling and simulation of the design by using Solid Work software.
2. To related engineering analysis and engineering fundamental for the project design.
3. Using three mechanical elements that are gears, shaft and bearing.
4. To save time and man power cost in process of serves food.
1.5 Product Significance

This part of study will provide brief description on the significance of the project to the community
general. Such as:
1. This project participates in helping the Small and Medium Enterprise (SME) to enhance the
productivity of product and competes to the others in the food marketing.
Lot of support from the government in term of training, capital, and advice contributes to the
successful to the small dealer in business. Be part of the effort from the government, we contribute in
help to increase the production of the product. Loaf Slicer Machine is our group effort to give various
advantages in other to upgrade the manual process to the automatic process. The high demand from
the market with the limited facilities will waste more time and energy of workers.
2. From this project, the owner will take the advantages to cuts bread in large amount.
These problems occur when more orders to serve in period time. When the breads finish, the workers
need to take some time to cut the breads before they toast the breads. Consider to the problem, the
machine created to maximize the quantity output of the breads to be cut. The reasonable machines
price for large output is worth for the SME entrepreneur to buy where it will give more profit the
entrepreneur.
1.6 Team Member Introduction
1.6.1 Group Name

iMECHANISCH Corporation was established in August 2014 and Mohammad Syakir bin Surani
was appointed as a Project Leader. The company consists by five experience engineer with good individual
skill. This company will grow and become one of the trusted companies in UTHM and the local area. It is
good to have all graduated engineer from UTHM because mechanical engineering graduated from UTHM
have been trained well to solve the problem in real situation.
The name of iMECHANISCH is a translation from Dutch language which means of mechanical. i
representing to our company where all members are certified in Mechanical Engineering and having a lot
of experience that related to the mechanical field.
1.6.2 Group logo and description
Above is the iMECHANISCH logo that has been inspired by members. The logo has designed by
combination of two colours which is black and white. The logo is simple and looks like exclusive that we
can see in the logo. The bolt and nut symbol shows that we focused on sturdiness design and involve
installation works. The words since 2014 that we placed in the logo means the years of our company
establishment. Below is the meaning of the colour on the logo:
i. Black
The colour of black contains the energy of the threatening unknown. It is also mysterious, providing a
sense of potential and responsible. So, it is mean that we really have a high potential and responsible to
perform well in our work.
ii. White
White is a reflection of all the colors. It enhances the presence of all other different colors. White means
peace, personified and purity. It is show that we emphasize cleanliness in works
1.6.3 Motto
Think Simple, Act Ordinary
1.6.4 Organizational Chart Of iMechanisch

MANAGER
MOHAMMAD SYAKIR BIN SURANI

VICE MANAGER
MUHAMMAD SHALIHIN BIN MD YUSOF
PROJECT ENGINEER I
MOHD SAFA RUDDIN BIN

MD JUNOH
PROJECT ENGINEER II
SHAHRUL AZNI BIN HADISON
R & D ENGINEER
REEHANA BINTI
MOHAMED RILWAN
1.6.5 Members profile

NAME:
MOHAMMAD SYAKIR BIN SURANI
MATRIC NO: DD110038

AGE:
24 YEARS OLD
EDUCATION: DIPLOMA IN MECHANICAL ENGINEERING

BACHELOR IN MECHANICAL ENGINEERING
POSITION:
DEPUTY MANAGER
FACULTY:
FACULTY OF MECHANICAL ENGINEERING

AND MANUFACTURING
NAME:
MUHAMMAD SHALIHIN BIN MD YUSOF
MATRIC NO: CD110393

AGE:
24 YEARS OLD

POSITION:
VICE MANAGER
FACULTY:

AND MANUFACTURING
NAME:
MOHD SAFA RUDDIN BIN MD JUNOH
MATRIC NO: DD110027

AGE:
25 YEARS OLD

POSITION:
PROJECT ENGINEER 1
FACULTY:

AND MANUFACTURING
NAME:
SHAHRUL AZNI BIN HADISON
MATRIC NO: DD110004

AGE:
24 YEARS OLD

POSITION:
PROJECT ENGINEER 2
FACULTY:

AND MANUFACTURING
NAME:
REEHANA BINTI MOHAMED RILWAN
MATRIC NO: DD110031

AGE:
24 YEARS OLD

POSITION:
RESEARCH AND DEVELOPMENT ENGINEER
FACULTY:

AND MANUFACTURING
1.7 Design Process

Embody the steps required to take an idea from concept to realization of the inal system and are
problem-solving methodologies that aim to develop a system that best meets the customers need within
given constraints[3].
1.7.1 Design
The design process are sometimes viewed as common sense and thus ignored, resulting in failed
products. Basically, design in the context of engineering usually implies that knowledge is combined with
specialized skills to create a device, machine, circuit, building, mechanism, structure, software program,
manufacturing process, or other system that meets a set of desired specifications. In other word, design is
the arrangement of parts, details, from, color and other so as to produce an artistic or skillful invention.
The engineering design process is the set of decision making and steps that engineer should think and
identifying all the solution to develop something [4].
1.7.2 Design Process

The design processes are including:
Fig. 1-1 Design process based on Pahl and Beitzs model
1.8 General Task delegation

Table 1-1 Task delegation
No.
Item
Remarks
Project Planning and Scheduling
Syakir
Phase 1 - Define Task:

Product Background
Syakir
Information Collection Literatures, Patent Search, Catalogue,

Commercial Product, Website
Comparison of Products from Patent Search
Shahrul
Benchmarking of Product Specification from Commercial Product

Problem for Existing Product
Reehana
Identification of Market Needs (Market Survey) and Customer

Satisfaction Questionnaire; Construct, Distribute, Analysis
Clarifying Objectives Objective Tree
Shalihin
Weighting of Objective Tree

Quality Function Deployment (QFD)
Reehana
Requirement List (RL)/Engineering Design Specification (EDS)
Safa Rudin
Phase 2 - Conceptual Design
3.1
Clarifying Function:
Activity Analysis
Syakir
Component Decomposition Analysis
Shahrul
Function Decomposition Analysis

Function Structure
3.2
Safa Rudin
Concept Generation:
Brainstorming
Shahrul
Morphological Chart Combine and firm up into concept variants
3.3
Product Sketching
Shalihin
Concept Evaluation:
Safa Ruddin
Evaluation Matrix Weighted Rating Method

Concept Selection
4
Phase 3 Summary
Reehana
Reference
Shalihin
1.9 Project Planning and Scheduling

Planning chart is an action plan or sometime called Gantt chart is a graphic representation of a
projects schedule, showing the sequence of tasks, which tasks can be performed simultaneously, and the
most critical tasks to monitor. The planning chart can be used for an entire project or for a key phase of a
project. The planning chart allows a team to avoid unrealistic timetables and schedule expectations, to help
identify and shorten tasks that are bottlenecks, and to focus attention on most critical tasks.
Because they are primarily project-management tools, Gantt charts are most useful for planning and
tracking entire projects or for scheduling and tracking the implementation phase of a planning or
improvement effort. In addition, we also create a planning chart to cleaning up our progress work
** For Gantt Chart, Please refer to APPENDIX A
CHAPTER 2.
DEFINE TASK
2.1 Product Background Loaf Slicer Machine
Define task is the initial stage to briefly define the product purpose and task involved in the product
design. In this study, we have conduct investigation and research to improve our design of the product.
Loaves slicer is used to slice the big amount of any kind of breads. This machine also designed to
produced large amount of product in once. Some research have been done due to overcome the problem
existed. By using this newly invention, customer can minimize their time to slice or cut large quantity of
bread. The quantity of product that produced by semi-automatic method is more than manual method in a
short time. This project has been named as the Loaf Slicer Machine.
It is designed to alleviate or minimize the use of manpower to produce in large quantities in one time
and this process is faster and easier without using much manpower. In addition this machine is more
economical use of time. This product and the system have been designed to facilitate the users especially
for the small industry which is easy use product and easy to handle it. Finally, the introduced of this
invention could help the people in the industries especially in IKS food industries and night market hawker.
In this chapter, we will show a few patents that can help our progress to develop the product. Patent
search is a mechanism and method that already patented in the past and nowadays. The purpose of finding
patent search is to find the related mechanism that will used in producing the product
10
2.1.1 Patent
Patent 1[5,461,956]
11
General Information
Title:
Variable thickness bread slicer
Inventor:
Bernard L. Petersen, Alan M. Ledford, Gary L. Kruse
Patent Number:
5,461,956
Date of Patent:
Oct 31, 1995
Patent Source:
Google Patent
https://www.google.com/patents/US5461956?dq=bread+loaf+slicer&hl=en&sa=
Address:
X&ei=AhkpVLy1GYSc8QX5rYDwCA&ved=0CCMQ6AEwATgK
Description
Capable of slicing successive loaves of bread to varying selected slice thicknesses.
A variable thickness bread slicing machine that is capable of slicing both crusty and soft breads.
The bread loaf is advanced by a pusher, step-by-step, to be fed to a rotating or pivotally reciprocating
cutting knife.
Each step is of selected thickness. The knife may be a revolving circular knife which rotates through a
slicing stroke and a return stroke, after each feed step, until the pusher is adjacent the knife, at which
time the knife remains retracted while the pusher advances the cut loaf to a discharge position past the
knife, and returns to the first side of the knife.
The slicer works effectively on crusty breads such as garlic breads or French breads, as well as on
soft, somewhat wet breads, such as conventional American bread.
12
Patent 2[20,060,075,859]
General Information
Title:
Bread slicer
Inventor:
Paul Willett
Patent Number:
20,060,075,859
Date of Patent:
Apr 13, 2006
Patent Source:
Google Patent
https://www.google.com/patents/US20060075859?dq=method+for+loaf+slicer&hl
Address:
=en&sa=X&ei=EhcpVN_eMYXX8gXc64KYBw&ved=0CFUQ6AEwCA
Description
This invention relates to bread slices and more particularly to bread slices in which the bread is sliced
with a reciprocating blade and it is mounted within the casing.
An angled table for the movement of loaves towards the reciprocating cutting blade assembly and a
means for feeding loaves along the angled table to the cutting blade assembly.
The housing having an opening for the introduction of loaves on the angled table and a gate for
restricting access to the cutting blade assembly through the opening.
The gate is controlled by the position of the loaf feeder and has a locked mode and an unlocked mode
with the locking and unlocking of the gate being controlled by a locking mechanism interacting with
the loaf feeder.
The loaf feeder operates between a position where the last loaf in a procession of loaves is pushed
into the reciprocating cutting assembly and a retracted position
When the loaves have all been sliced the loaf feeder is retracted, locking the gate in the closed
position and the reloading cycle is commenced.
13
Patent 3[458,197]
General Information
Title:
Automatic roll and bread top slicer
Inventor:
Lloyd S. Hickman, Andrew G. Quinzani
Patent Number:
458,197
Date of Patent:
Apr 15, 1986
Patent Source:
Google Patent
https://www.google.com/patents/US4581971?dq=bread+loaf+slicer&hl=en&sa=
Address:
X&ei=AhkpVLy1GYSc8QX5rYDwCA&ved=0CD8Q6AEwBTgK
Description
The present invention is an automatic roll and bread top slicer for forming vertical slits to a
predetermined depth along the top length of various sized.
The invention includes tracks for moving the slicer, a shuttle, and shuttle drive for moving the shuttle
across the sections of dough.
Mounted on the shuttle are cutters which simultaneously slit a plurality of dough sections. The slicer
operates automatically while the dough sections are in trays moving to the oven for baking.
14
Patent 4[4,662,257]
General Information
Title:
Countertop bread slicer
Inventor:
Bernard L. Petersen, Gary L. Kruse
Patent Number:
4,662,257
Date of Patent:
May 5, 1987
Patent Source:
Google Patent
https://www.google.com/patents/US4662257?dq=bread+loaf+slicer+machine&hl
Address:
=en&sa=X&ei=WiwsVIjcG9GSuATi8YHYCw&ved=0CDgQ6AEwBDhG
Description
The present invention relates to bread slices, and more particularly to compact bread slicers suitable
for countertop use.
A countertop bread slicer is provided having a compact size and a simplified construction, while still
providing the requisite performance.
The slicer includes a horizontal blade assembly, an in feed table, and a vertically shift able cradle for
carrying a loaf upwardly against the in feed table and through the blade assembly.
The cradle movement mechanism includes a gas spring to carry the loaf upwardly through the blade
assembly at a relatively uniform rate.
15
Patent 5[458,197]
General Information
Title:
Inventor:
Bread slicer with knives arranged in a wave- or V-shape

Marcus Aloysius Petrus Theodorus Breugelmans, Den Hamsvoort Petrus Wilhelmus
Johannes Van
Patent Number:
1,574,304
Date of Patent:
Sep 13, 2006
Patent Source:
Google Patent
Address:
https://www.google.com/patents/EP1574304B1?cl=en&dq=loaf+slicer&hl=en&sa
=X&ei=AhkpVLy1GYSc8QX5rYDwCA&ved=0CD8Q6AEwBTg
16
Description
A cutting head consists of multiple laterals, at a distance placed knives in parallel planes, in which at
one side the knives are connected to a crankshaft and at the other side are tensioned with draw springs
in a rimmed stretcher, which must be constructed rather heavily due to the many springs.
The drawing springs on the top side of the knives are suspended in a blunt V-shape, through which
the knives start cutting the bread practically at the same time, but first the outer knives and then step
by step inwardly the next pairs of knives are used, through which the bread is not pulled apart.
The thin knives will start vibrating sooner and due to the tension of the springs of a large quantity of
drawing springs a lot of energy is necessary to keep the device going to cut through the loaf or bread.
Further, the exerted pressure of the pusher cannot be too high because the knives almost
simultaneously cut into the loaf of bread, through which the resistance is large due to the cutting and
the slices are crushed together.
2.1.2 Catalogue
Catalogue is a list of goods or services on sale with their description and prices published as a printed
document, or as an electronic document (e-catalog) on internet or on a diskette, CD, DVD, etc. Catalogue
is used to make some research regarding the existing product in market and to get information for the
product development.
Fig. 2-1 Catalogue 1
17
Fig. 2-2 Catalogue 2
Fig 2-3 Catalogue 3
18
Fig 2-4 Catalogue 4
Fig 2-5 Catalogue 5
2.1.3 Commercial Product Search

Commercial product search is a product list with their specification. This is used to gain information
regarding the existing product in the market and improvement for the new product and find some ideas for
product development of the new product.
19
Table 2-1 Commercial Product Search for Bread Slicer Machine

PRODUCT
SPECIFICATION
Company : Redberry Equipment Pvt. Ltd
Brand Name : GRT
Type : Cutter
Material : Stainless Steel
Weight : 80kg
Bre
ad
Slic
er
For slicing various breads
Sharp and durable blade
High grade motor, high torque and high

efficiency
Professional design, uniform slicing force, flat

slice action
http://www.souptodessert.com/Suppliers/View
ProductDetail.aspx?ProductId=528
Company : Yong Kang Tiange Electric Co., Ltd
Brand Name : FMA
Type : Cutter &Slicer
Material : Stainless Steel and Aluminum
Weight : 23kg
Bread slicer.
Fast and Convenient
Fit for various types of breads
Loaves are fed through the slicer by weight

assisted gravity chute.
Automatic Bread Slicer
20
http://www.archiexpo.com/prod/fernetosa/slicers-commercial-automatic-bread-62172251707.html
Company : Kuhn Machines, (Pty) Ltd

Brand Name : ANKO
Type : Cutter &Slicer
Material : Stainless Steel
Weight : 140kg
KB Bread Slicer
Bread slicer.
Fast and Convenient
Fit for various types of breads
http://www.archiexpo.com/prod/fernetosa/slicers-commercial-automatic-bread-62172251707.html
2.1.4 Website
Website is electronic searches that are used to gain information regarding the existing product.
a) Commercial product
Table 2-2 Commercial product references
No
1
Product
Website
http://www.archiexpo.com/prod/ferneto-sa/slicers-
Bread Slicer (GRT-BC300)
commercial-automatic-bread-62172-251707.html
Automatic Bread Slicer
(FMA SM30212)
KB Bread Slicer
(KB-800)
21
b) Patent
Table 2-3 Patent references
No
Patent
Variable Thickness bread
slicer
Website
https://www.google.com/patents/US5461956?dq=bread+loaf+slic
er&hl=en&sa=X&ei=AhkpVLy1GYSc8QX5rYDwCA&ved=0C
CMQ6AEwATgK
https://www.google.com/patents/US20060075859?dq=method+f
Bread Slicer
or+loaf+slicer&hl=en&sa=X&ei=EhcpVN_eMYXX8gXc64KY
Bw&ved=0CFUQ6AEwCA
Automatic roll and bread top

slicer
er&hl=en&sa=X&ei=AhkpVLy1GYSc8QX5rYDwCA&ved=0C
D8Q6AEwBTgK
Countertop bread slicer
er+machine&hl=en&sa=X&ei=WiwsVIjcG9GSuATi8YHYCw&
ved=0CDgQ6AEwBDhG
Bread slicer with knives
https://www.google.com/patents/EP1574304B1?cl=en&dq=loaf+
arranged in a wave or V-
slicer&hl=en&sa=X&ei=2BYpVK2rNoKB8gXkuYGIBw&ved=
shape
0CCoQ6AEwAjge
2.2 Comparison of Products from Patent Search

This comparison is made to take account in the advantages and disadvantages of previously design
product in terms of their design, process, material and function. In which, the advantages can be made as
an idea and disadvantages can made as a key point for the improvement of new product.
22
Table 2-4 Comparison between Patterns

COMPARISON BETWEEN PATENTS
PATENT
ADVANTAGE
Various blades.
Small components.
Can slice variety of breads
DISADVANTAGE
Dangerous to the user.
Uncovered blade.
Can slice variety of breads
Dangerous to the user.
Easy to use.
Uncovered blade.
3.0 Automatic roll and bread top
Large amount of output.
Limited movement for the
slicer
Less idle time.
Many blade
Produced constant thickness
1.0 Variable thickness bread slicer
2.0 Bread slicer
4.0 Countertop bread slicer
of output.
machine.
Noisy.
Manual use only
Too many step to use it
5.0 Bread slicer with knives
Simple component
Need lot of force to use it.
arranged in a wave- or V-shape
Large amount of output.
Mess the component.
We can see clearly the advantages and disadvantages of the patent search from previous product
(existing product) of a loaf bread slicer. Most of the patent search describes that the machine lack in aspect
of safety such as uncovered blade and mess the component. Besides, loaf slicer involved a cutting process
which using blade, it is sharp and might risk the users. So from here, besides the function, we take in
account the safety aspect. The advantages of the machine, we keep it as an ideas.
2.3 Benchmarking of Product Specification from Commercial Product

Benchmarking is a comparison between existing products in market and can be simply defined as a
continuous process to find and implement best practices that will lead to superior performance. As the
definition implies, benchmarking is a process that will improve quality and productivity.
23
Table 2.5 Benchmarking between products

No
Specification
Product A
Product B
Product C
Manufacturing
Redberry Equipment
Yong Kang Tiange
Kuhn Machines, (Pty)
Pvt. Ltd
Electric Co., Ltd
Ltd
Bread slicer
Automatic Bread
KB Bread Slicer
Name of Product
Slicer
4
Photo
Material
Stainless steel
Stainless steel
Stainless Steel
Machine Size
680x780x780 mm
750x660x750mm
490x1800x1840mm
Motor rating
230V/60Hz
110
380V, 3 Phase
Power Supply
0.25kW
0.75kW
0.55kW
Operation
Manual
Automatic
Automatic
10
Capacity
31pcs/Batch
40pcs/Batch
28pcs/Batch
11
Model No
GRT-BC300
FMA SM30212
KB-800
12
No. of operator
13
Covering Body
Yes
Yes
Yes
14
Screw
No
Yes
Yes
15
Bearing
Yes
Yes
Yes
16
Shaft
Yes
Yes
Yes
17
Switch
Yes
Yes
Yes
18
Blades
Yes
Yes
Yes
19
Disc
Yes
No
Yes
24
2.3.1 Problem for Existing Product

Table 2.6 Problem of existing product
No.
Product
Problems
1.
Bread
Vibration and noise occurred.
Small amount of output.
No output reservoir.
Vibration and noise occurred.
Not stable
High maintenance
Limited sizes of product.
Expensive price.
Need power supply
High maintenance
Low production or small amount of
Slicer
2.
Automatic Bread Slicer Dicer
3.
KB
Bread
Slicer
output
2.4 Identification of Market Needs and Customer Satisfaction

For research from questionnaire, we decide to take 15 people which is the worker at the industry to
answer our questionnaire. From this questionnaire, we supposedly been able to construct the overview
about the machine that we want to developed from the data that we get.
We chose this method because from what we observe, people a lot easier when answering a question
rather been interview, so this method good for both parties. A market is defined as all people who share
similar needs and wants and who have the ability to purchase given products.
The industrial, or business-to-business, market includes businesses that buy products and services for
use in their operations. Market share is a firm's percentage of the total sales in a given market.
A target market is the group of people identified for a specific marketing program. Below is example of
our questionnaire form:
25
2.4.1 Questionnaire
We are UTHM student which are taken DESIGN II subject. Our group is doing the research about
Toast Loaf Slicer Machine. We really appreciate your help on answering those questions below to make us
easier to design a product that can satisfy customers.
Part A (Personal Details)
Please tick your answer in the box given below:
1.
What is your gender?
Male
2.
Female
Your age
Less than 20
3.
20- 30 year
Your occupation
Catering
31-40 year
Small industries
41 above
Housewife
Other
Part B (Respondent View)

Please tick [] your answer in the box given by referring the rate of number below:
1- Strongly Disagree
2- Disagree
3- Moderate
4- Agree
5- Strongly Agree
Question
4. How often you use bread in your food menu?

5. In 5 minutes, can you slicing the bread in 20 pieces?
6. Do you prefer to use a knife to do question 5 tasks?
7. According to question no. 5, are you satisfied with your answer?
Question
8. Do you think that the way in cut and slice this bread need to be
26
improved with portable conditions?

9. Do you like a safety product that cannot dangerous our self or not?
10. Do you like a machine that can be produce large amount of output at
once?
11. Do you like the machine that produces without mess up your
kitchen?
12. Do you like the machine that also can fit into your kitchen?
13. Do you like the machines that build up with a high-quality material?
14. Do you like the machine that easy and low cost in maintenance?
15. In your opinion, do you think RM 800 is the suitable price of this
Toast Loaf Slicer Machine?
16. Is it 500mm x 800mm x 1000mm is the suit size for the machine?
17. If there is an advance loaf slicer in the market, do you want to have it?
18. Is it anti-corrosion is the safety characteristic that must have in this

machine?
Thank you very much for spent your times to answer this questionnaire.
27
2.4.2 Analysis of the Questionnaire
a) Part A (personal detail)
3
15%
12
[PERCENTA
GE]
Fig. 2-6 Number of respondent by gender
Chart 1 shows the gender of the respondent who answers the questionnaire distributed. The chart
clearly shows that there are 3 male residents and 17 female residents answered the questionnaire regarding
this study. The gender of the respondents can affect the result of this study because their opinion regarding
technical matter is different.
<20
21-29
31-39
41-49
50>
1, 5% 1, 5%
2, 10%
3, 15%
8;
[PERCENTAGE]
Fig. 2-7 Number of respondent by group of age
28
Chart 2 shows the different of age from below 20 ages to above 50 ages in term of group of age. It
includes the manager and the worker on this field of food business. 65% of the respondent between 41-49
ages mostly the villagers resident who work part time in the food factory. Less than quarter of the
respondent between 31-39 ages work in this field of industries and also the owner of the business. The type
of age effect the process of making, where depend on their strength and willing to do the job.
5
25%
10
[PERCENTA
GE]
IKS
Penjaja
Fig. 2-8 Number of respondent by type of trade
Chart 2 shows the type of trade of the 15 respondents. Most of them work in the factory. The least
work is housewife and labor while the others represent the businessman, contractor and government officer.
Their type of job is taken into account since it can affect their awareness to the cleanliness of the system
and also their knowledge in technical aspect.
b) Part B (respondent view)
25
No of Person
20
5
15
4
10
0
4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Question
Fig. 2-9 Number of respondent for the part B
29
So, from the analysis for the questionnaires above, it shows that the customers or users need a new
products, machines or methods that can use to slice breads or loaves. Here some customer requirements
that customer or user need:
Prefer to use loaf slice machine to slice the product in a larger amounts.
Need in form of machine.
Safety for user.
Can produce large amount of output.
Machine that without mess up and fit to the kitchen.
High quality material of machine.
Easy and low cost in maintenance.
Limited price around RM 800.

So, from here, we need to create or produce machine that suitable and relate to the requirement state at
above so that it will satisfy the customer or user needs. We can determine the important user requirement
for our product. The important user requirement such as:
i.
Function
ii.
Design
iii.
Maintenance
iv.
Safety
v.
Environment
vi.
Price
FUNCTION
MAINTENA
NCE
PRICE
USER
REQUIREME
NT
SAFETY
DESIGN
ENVIRONME
NT
Fig. 2-10 Customer requirement of the product
30
2.5 Clarifying Objective Objective Tree

Objective tree are used to model the hierarchical nature of the requirement or objectives of a design problem. This tool is used primarily in early stages of design
in problem definition and clarification.
LOAF SLICER MACHINE
FUNCTION
User
friendly
High
material
quality
Less
production
time
Heavy
duty
MAINTENANCE
Reliability
All in one
process
Easy
maintenance
Easy to
clean
Part
easily
found
Easy to
service
DESIGN
Low
cost
Ergonomic
Long
lifetime
Attractive
Appearance
Easy to
operate
Clean
workspace
No
gases
produce
Compact
No
pollution
No
water
pollution
Simple
Easy to
dismantle
Fig. 2-11 Objective Tree
31
Cheap
in
price
No
noise
No air
pollution
Non
corrosion
High
mechanical
Easy to
assemble
PRICE
SAFETY
ENVIRONMENT
No
sharp
edge
Emergency
stop button
2.6 Weighing of Objective Tree

It is a weight importance refers to the previous objective tree. It shows how importance those objective for the product as a purpose for product development.
O1
1.0 | 1.0
O13
O14
O15
O16
0.2 | 0.2
0.1 | 0.1
0.1 | 0.1
0.1 | 0.1
O12
O11
0.3 | 0.3
0.2 | 0.2
O111
O112
O113
0.4 |0.1
0.3 |0.09
0.3 |0.09
O121
O122
O123
0.5 | 0.09
0.4 | 0.07
0.2 | 0.04
O131
0.7 | 0.14
O1311
0.4 |0.049
O1131
O1132
O1133
O1211
O1212
0.3 | 0.027
0.2 | 0.018
0.5 |0.045
0.5 | 0.045
0.5 | 0.045
O132
0.3 | 0.06
O141
O142
O143
O161
0.4 | 0.04
0.4 | 0.04
0.2 | 0.02
1 | 0.1
O1421
O1422
0.2 | 0.008
0.5 | 0.02
O1312
0.7 | 0.091
O1321
0.2 |0.012
O1322
0.3 | 0.018
O13231
0.5|0.015
O1323
0.5| 0.03
O13232
0.5| 0.015
Fig 2-12 Weighing Objective Tree
32
O1423
0.3 | 0.012
O151
O152
O153
O154
0.4 | 0.04
0.3 | 0.03
0.1 |0.01
0.2 | 0.02
2.7 Quality Function Deployment (QFD)

Quality function deployment is as an approach to design the design concept. Quality function deployment is provided specific method for ensuring quality
throughout each stage of the product development process, starting with design.
Table 2-7 QFD
33
2.8 Engineering Design Specification (EDS)

This design specification sets out the minimum submission requirements of design for development
consents. This specification aims to set standards and document requirements for the execution and
recording of design processes in order that the infrastructure associated with any development is designed
to be fit for service and where applicable, be of a standard reasonably maintainable. These qualities be
readily demonstrable by clear records of key design processes and that data relevant to the upkeep of the
assets is available
Engineering Design Specifications
Title: Loaf Slicer Machine

Introduction
Design problem: IKS Loaf slicer machine
Intended purpose or use: Making loaf slicer machine for cutting breads
Unintended purpose or use: The slice blade usable for variety type of breads.
Special features:
Can slice or cut mass quantity of breads/loaves per hour
Customer Requirements
D or W
Functional performance
Improve the number of slicer to save time and increase production
Customer want an user friendly plug
The size of cutter plate is capable for the size of the breads
Automatic features to help operator
34
Operating environment
Less noise pollution
Dont want water get staining
Dont want to mess the workspace
Can operate using green energy
Appearance
Easy to operate with less operator
Operator less work directly with the position of breads
Maintenance, repair, retirement
Easy to clean and service due the moderate dimension
Motor have a safety features such as emergency stop button
Have a good factor of safety
Body that doesnt have dangerous part such as sharp edge
Material that cannot corrode
Safety
35
Company Requirements
Marketing
Retail price should be less than RM800
Manufacturing
Scale for IKS industry
A prototype machine must be done before November
Components must be form smoothly to make the machine look nicer
Financial
Development costs using grants
36
CHAPTER 3.
CONCEPTUAL DESIGN
3.1 Introduction
A design concept is an idea for a design. For instance a design concept for a website might sounds like
"It will be mostly dark muted colors with some orange highlights, and use the theme of circles that will be
repeated throughout the site". It is usually accompanied with a design mock up, which is a representation
of the idea that isn't fully finished or implemented the way the final product will be. For instance a mock
up for a web design might be a screen shot instead of a rendered webpage. A mock up for a business card
might be a few versions of the design idea printed out on a sheet of paper instead of the final run of printed
cards. It is a general idea for the drawing. it help to know and identify all the process under taken in the
design process.
The three principal elements of the conceptual design are:
i. Information Input
Information from the market and specification phases, the design team and other sources used to facilitate
concept generation, evaluation and development.
ii. Concept Generation

The generation and development of concepts such like total product, sub-system, or component to meet the
requirement
iii. Concept Evaluation

The process of evaluation and refinement of concepts generated in relation to the requirement.
There is no distinct conclusion to the conceptual design activity as the preferred concept is gradually
defined with ever increasing detail throughout conceptual design and into detail design. By the end of the
activity, however, effort will be concentrated on a single preferred solution. This will normally be
presented in the form of a set of layout drawings and diagrams. In this chapter, we create an idea of activity
analysis, function and decomposition analysis, function structures and brainstorming.
3.2 Clarifying Function

Activity analysis is used to learn how the customer will and ultimately retire our product. It will help
the customers to understand all required functions, not just those during daily use and how product
interacts with the environment. Activity analysis is to let customer know detail about our product. We
make an activity analysis based on using of the product and to retire the product. Table below shows how
customer activities relating to use and retire a products.
Table 3-1: Activity analysis list for loaf toast slicer machine
Activity Analysis List for Loaf Toast Slicer Machine
Use
Setup
1. Open package
2. Examine machine, tool cutter and socket for power
3. Read instruction booklet given
4. Fill out warranty card
5. Plug in the power source and test run
6. Test run
Place the machine in the production line process
Daily use
7. Check the tool cutter

8. Switch on the power supply
9. Put the bread at the loaves loader
10. Press the start button for cutting process
11. Clean the loaf storage and tool cutter
12. Repeat steps 7-11 until bread process finish
13. Shut down the machine
Adding Bread
14. Add the bread at the loaves loader

15. Cutting process
Daily use
Service
16. Repeat steps 7-12 until bread finish

17. Change cutter tool
18. Check all bearing condition
Daily use
Retire
Dispose of machine
19. Repeat steps 7-12 until machine un-repairable

20. Dismantle all part
21. Throw out machine and auxiliaries
38
source
3.2.1 Component Decomposition Analysis

Component decomposition is a block diagram of the parts and subassemblies that make
up the product in the form of hierarchical structure of component forms. In our project, we
have five main of components which are switch, roller, motor, frame and also cutter.
ON/OFF
Switch
Emergency stop button
Shaft
Roller
Bearing
Loaf Toast
Slicer
Motor
Gearbox
Body cover
Frame
Mounting
Loaves loader
Switch
Fig. 3-1 Component decomposition of product
39
Cutter
3.2.2 Function Decomposition Analysis

Functional Decomposition is a fundamental analysis technique. It breaks a complex problem into
successive layers of more manageable and comprehensive pieces, resulting in a hierarchically
structured that describes the problem and/or solution in levels of increasing detail. In Functional
Decomposition, the lower level functions/processes completely describe the parent. A function/process at
a lower level cannot exist unless it is included within its parent function/process.
Loaf Toast Slicer

Machine
Convert
electrical to
mechanical
movement
-When turn ON,

machine will be
running and when
switch turn OFF,
machine will be
stop.
Cutter Tool
Loaves Loader
-Tool cutter cut

the bread.
-Put bread at
loaves loader
before cutting.
-Bread divided
with eight pieces.
-When turn ON
emergency stop
button, the
machine will be
stop.
Fig. 3-2 Function decomposition of product
40
Easy to Use
-Accurate shape
bread produced in
once time
-No need many
operator to
handle it.
3.2.3
Function Structure
a) Black box of Loaf Toast Slicer Machine
Put bread at loaves loader
Bread finish cutting

Loaf Toast Slicer
Input
Output
Machine
Functio
n
Fig. 3-3 Black box function
b) Transparent Box
Switch on
Convert electrical to
mechanical movement
system
Input
Transfer Loaf Toast

Slicer
Output
Put the bread
Move to cut the bread

Clean loaf storage
Remove waste
Move to output
Function
Fig. 3-4 Transparent box function of the product
41
c) Analysis of principle function structure for Loaf Toast Slicer Machine.
Move the bread to

loaf storage
Cutting process
Loaves collecting
Convert electrical to
mechanical movement
system
Switch
ON/OFF
Remove
waste
Human
energy
Waste
bread
Switch on
Put at loaves
loader
Move to output
Shape
bread
Bread
System Boundary
Main function
Input
Fig. 3-5 Analysis of principle function structure for Loaf Toast Slicer Machine
42
Output
3.3 Concept Generation
3.3.1 Brainstorming
Brainstorming is a process for generating creative ideas and solutions through intensive and
freewheeling group discussion. Every participant is encouraged to think aloud and suggest as many ideas
as possible, no matter seemingly how outlandish or bizarre. Analysis, discussion, or criticism of the aired
ideas is allowed only when the brainstorming session is over and evaluation session begins. This is
important to let we know how to produce an effective product and the process of making the product will
be clearly without any problem. Below is the brainstorming of our project:
Machine Casing
Turn On Machine
Push button
Twist switch
Toggle switch
Aluminum
Plastic
Stainless steel
Alloy
Power source
Direct Current
Alternative Current
Solar
Loaf Storage
Loaf collecting
process
Container
Bucket
Tray
Scraper
Hand
Decline surface
Cutting process
Cutting
Slicing
Punch stamping
Chopping
Movement
system
Roller
Conveyor
Hand
Robotic arm
Mechanism
Frame
Electrical
Pneumatic
Hydraulic
Loaves loader
Conveyor
Hand
Decline Surface
Tool
Fig. 3-6 Brainstorming
43
Motor
3.3.2 Morphological Chart

Morphological chart is the tools that represent a large qualitative design space. These charts list the
function identified for the design problem, and the means that can perform each function [23] of the
product.
Table 3-2 Morphological Chart
Suggestion 1
Suggestion 2
Suggestion 3
Suggestion 4
Switch
Push Button
Toggle Switch
Twist Switch
Loaves Loader
Conveyor
Hand
Decline Surface
Loaf Storage
Bucket
Container
Tray
Mechanism
Electrical Motor
Hydraulic
Pneumatic
Loaves Collecting
Scrapper
Decline Surface
Hand
Movement System
Conveyor
Hand
Decline Surface
Robotic Arm
Cutting Process
Cutting
Chopping
Slicing
Punch Stamping
Machine Casing
Stainless Steel
Plastic
Aluminium
Alloy
Power Source
Direct Current
Alternative Current
Solar
Transmission
Belt and pulley
Chain and Sprocket
Rotational
Straight
Mechanical
Movement
Both
After have a brainstorm with all group members, we have come out with five combinations to evaluate in
concept evaluation stage. Table below shows the each of combination.
Table 3-3 Combination 1

Part to assembly
Selection component
Switch
Push button
Loaves Loader
Hand
Loaf Storage
Container
Mechanism
Electrical motor
Loaves Collecting
Hand
Movement System
Hand
Cutting Process
Cutting
Machine Casing
Stainless Steel
Power Source
Direct Current
Transmission
Belt and Pulley
44

Part to assembly
Selection component
Switch
Toggle
Loaves Loader
Decline surface
Loaf Storage
Bucket
Mechanism
Electrical motor
Loaves Collecting
Decline surface
Movement System
Decline surface
Cutting Process
Slicing
Machine Casing
Stainless Steel
Power Source
Direct Current
Transmission
Belt and Pulley
Mechanical Movement
Both

Part to assembly
Selection component
Switch
Push button
Loaves Loader
Hand
Loaf Storage
Tray
Mechanism
Electrical motor
Loaves Collecting
Hand
Movement System
Decline surface
Cutting Process
Slicing
Machine Casing
Plastic
Power Source
Direct Current
Transmission
Belt and Pulley
Mechanical Movement
Both
45

Part to assembly
Selection component
Switch
Toggle
Loaves Loader
Hand
Loaf Storage
Tray
Mechanism
Electrical motor
Loaves Collecting
Decline surface
Movement System
Decline surface
Cutting Process
Slicing
Machine Casing
Stainless Steel
Power Source
Direct Current
Transmission
Belt and Pulley
Mechanical Movement
Both

Part to assembly
Selection component
Switch
Toggle
Loaves Loader
Hand
Loaf Storage
Tray
Mechanism
Electrical motor
Loaves Collecting
Decline surface
Movement System
Decline surface
Cutting Process
Slicing
Machine Casing
Stainless Steel
Power Source
Direct Current
Transmission
Belt and Pulley
Mechanical Movement
Both
46
3.4 Concept Evaluation

The evaluation of design concepts implies and involves both comparison and decision making.
Evaluation techniques require a comparison between the concepts developed and the requirements they
must meet along with decisions regarding how well they meet those requirements.
3.4.1 Evaluation Matrix Weighted Rating Method

Table 3-8 Evaluation matrixes weighted rating method
Design Criteria
Weight
Combination
Combination
Combination
Combination
Combination
m s
1. Material
m s
m s
m s
m s
0.2
1.1 Suitability
0.075
0.6
0.6
0.38
0.6
0.6
1.2 Durability
0.03
0.24
0.24
0.15
0.24
0.24
1.3 Cost
0.075
0.3
0.3
0.53
0.3
0.3
1.4 Weight
0.02
0.08
0.08
0.16
0.08
0.08
2. Maintenance
0.15
2.1 Cost
0.05
0.3
0.35
0.35
0.25
0.25
2.2 Easy to maintain
0.04
0.28
0.2
0.24
0.24
0.24
2.3 Easy to Service
0.04
0.28
0.2
0.2
0.2
0.2
2.4 Easy to Clean
0.02
0.16
0.12
0.12
0.14
0.14
3. Cutting Efficiency
0.2
3.1 Loaf shape after cut
0.15
0.6
1.35
1.35
1.35
1.35
3.2 Loaf waste
0.05
0.4
0.2
0.2
0.2
0.2
4. Design
0.15
4.1 Aesthetic
0.02
0.1
0.14
0.12
0.1
0.1
4.2 Safety
0.06
0.24
0.48
0.36
0.42
0.42
4.3 Appearance
0.02
0.14
0.1
0.12
0.12
0.12
4.4 Portable
0.05
0.35
0.25
0.3
0.25
0.25
5. Environment
0.1
5.1 Noise
0.07
0.49
0.49
0.49
0.49
0.49
5.2 Loaf Chips after cut
0.03
0.24
0.18
0.18
0.18
0.18
0.1
0.4
0.8
0.5
0.7
0.7
6.2 Easy to use the machine0.1
0.4
0.7
0.5
0.6
0.6
6. Function ability
6.1 Machine Efficiency
TOTAL
0.2
5.6
6.78
47
6.25
6.46
6.46
3.4.2 Concept Selection

Concepts are the basic building blocks of scientific knowledge or theoretical frameworks for any
discipline. The strength of the theories that guide a discipline is dependent on the quality of the concept
analysis. During the concept design phase, there are no any specific information about sizes, material
properties, configuration, and manufacturing processes. In addition, we need to analysis the criteria and
the important physical principle and also we need to abstract embodiment. As known, conceptual design is
an iterative process consisting of a series of generative and evaluative stages that gradually converge on a
preferred conceptual solution. At the each iteration concepts are defined in increasing detail, thereby
permitting ever more accurate evaluation. Context of Total Design the development process is:
1. Market Requirements
2. Product Specification
3. Concept Design
4. Detailed Design
5. Manufacture
6. Sell
After done concept evaluation by using weighted rating method for five different combinations, we
have selected the highest rating of component to proceed the next stage. The high rating component is
combination 2.
Table 3-8 Concept selection

Part Assembly
Switch
Loaves Loader
Loaf Storage
Mechanism
Loaves Collecting
Movement System
Cutting Process
Machine Casing
Power Source
Transmission
Mechanical Movement
Component
Toggle
Decline surface
Bucket
Electrical motor
Decline surface
Decline surface
Slicing
Stainless Steel
Direct Current
Belt and Pulley
Rotational and straight
48
3.4.3 Product Sketching

Sketches that are created by designers while developing an idea of a product. Mainly roughly made
and without details. The combination is sketch to figure out the possible product.
i. Combination 4.
Fig. 3-7 Combination 4
ii. Combination 5

iii. Combination 2 (choice)
49
CHAPTER 4.
EMBODIMENT DESIGN AND ANALYSIS
4.1 Product Architecture

Product architecture is the scheme by which the function of a product is allocated to physical
components. It also to raise awareness of the far-reaching implications of the architecture of the product, to
create a vocabulary for discussing and addressing the decisions and issues that are linked to product
architecture, and to identify and discuss specific trade-offs associated with the choice of a product
architecture.
4.1.1 Schematic Diagram of the Product

Bread feeder
Cutting Mechanism
Bread Deliver
Connecting Rod
Frame
Switch
Loaf Slicer
Machine
Emergency Stop Button
Supply AC Power
Motor
Belting
Pulley
Flow of force and energy
Bearing
Flow of materials
Fig. 4-1 Schematic diagram of product
50
4.1.2 Elements Cluster of Schematic
Output
Chassis
Bread feeder
Cutting Mechanism
Bread Deliver
Connecting Rod
Frame
Switch
Loaf Slicer
Machine
Supply AC Power
Power Source
Safety
Emergency Stop Button
Motor
Belting
Pulley
Flow of force and energy
Bearing
Flow of materials
Fig. 4-2 Elements cluster of schematic
51
4.1.3 Rough Geometric Layout
Frame
Bread Deliver
Bread feeder
Belting
Connecting
Pulley
Motor
Fig. 4-3 Loaf slicer sketch
52
4.1.4 Incidental Interaction
Loaf Insert
Slide
Torque
Slicing
Table Outfeed
Cutting
Mechanism
Output
Motor
Host
Procedure
Power supply
Casing
On/Off
Vibration/Sound
Emergency
button
Cut-off
power supply
Fig 4-4 Incidental interaction diagram
4.2 Configuration Design

Configuration design is a kind of design where set of predefined components that can be interfaced
(connected) in predefined ways is given, and an assembly of components selected.
53
4.2.1 Standard Main Parts

Table 4-1 Standard main part
No.
Name
Quantity
Motor
Switch button
Connecting Shaft
Emergency button
Bearing
Bolt & Nut
12
Screw
14
4.2.2 Standard Modules

Table 4-2 Standard modules
No.
Name
Quantity
Frame
Cutter
4.2.3
Special Purpose Parts
Table 4-3 Special purpose part

No.
Name
Quantity
Cover
Connecting Rod
Table Out feed
Guide Side
Bread Deliver
Pulley and Belt
54
4.3 Parametric Design

Greater refinement takes place to set critical design variables to enhance the robustness (toughness) of
the design. This involves optimizing critical dimension and the setting of tolerances.
4.3.1 Parametric Design Problem

4.3.1.1 Component Analysis and Selection
1. Analysis of motor specification with experiment
From the experiment that we have done, we find the result of the slicer need to rotates 38 times in
order to slice the bread at 40s. If it is targeted to design a slicer machine which capable to slice the
bread in 25s . From that, we know that our speed is 57 rpm based on the formula below:
So the speed required is :
So, from the speed we can get power output :

(
(
)
)
From calculation above, we get the power output is 24 Watt. This value we use to compare with power of
motor for others slicer machine because we know that selected specification of motor and we can select
types of motor to use. We know the principal this selected its power at motor must be higher than power
output.
Table 4-4 Standard Motor Selection
Model
XDS120
XDS135
XDS150
XDC 180
Rating
Voltage
(V)
220
220
220
220
Rating
Rating
Frequency(Hz) Power(KW)
50
50
50
50
0.01-0.050
0.055-0.10
0.10-0.150
2.0
55
Rating
Current(A) Speed(rpm) Capacity(uF)
0.80
1.25
1.36
1.54
1200
1400
1800
2000
10
10
10
10
We assuming the motor specification are:

Volt = 220V
Speed = 1400 rpm

Power = 550W
Current = 1.25A
Assume that the value of torque input and torque output:
2. Bearing Analysis
Bearing Number 1
At shaft 1, 2 bearing are the same.
Bearing Load at the Rated Reliability
56
To calculate dimensionless desired life,

Desired Lifetime, LD
We estimate that user use the loaf slicer 1day = 5 hours.
We estimate that the loaf slicer can use for 3 years.
So,
Dimensionless Desired Life, XD
Our group choose the NTN companys bearing, so it category as most bearing manufacturer.
226.025 = 0.226kN
57
We choose bearing NO. 6202 because our load is 3.406kN and the load ratings of this bearing is the
nearest to our load value in NTN bearing with 15mm bore.
Bearing Number 2
At shaft 2, 1 bearing is used.
Bearing Load at the Rated Reliability
58
Dimensionless Desired Life, XD
Our group choose the NTN companys bearing, so it category as most bearing manufacturer.
The bearing Bore diameter = 5mm
59
We choose bearing NO. 6902 because our load is only 1.647kN and the load ratings of this bearing is 2kN
and it is the nearest basic load ratings in NTN bearing with 15mm bore.
3. Welding Analysis
Statically load and with a 10mm fillet weld
From table below:
Sy = 345 MPa, Sut = 427 MPa

From Bending Properties of Fillet Welds table, (3rd pattern):
60
A = 1414hb
Iu =
(second moment of area)
b = 10mm
d = 30mm
A = 1.41hd = 1.414(10)(30)
= 424.2mm2
Iu =
I = 0.707hIu = 0.707(10)(4500) = 31815
Primary shear
=
Where A = 1.414(10)(30) = 424.2mm2
=
Second shear
=
The shear magnitude is the Pythagorean combination

= (2 + 2)1/2 = 6.938 MPa
The factor of safety based on minimum strength
61
n=
4. Screw and Fasteners Analysis

Clamping load and tightening of bolted joints
For example, 3 set of bolts is to be used to provide a clamping force of the load on each screw is to be
39.228 N
SAE Grade 5 Steel
Proof Strength = 586.054 MPa
We know that, 1psi=6894.757 Pa
So, allowable stress is:

a = 0.75(586.054 MPa) = 439.54 MPa
Tensile stress area for the bolt is then
At =
From American Standard thread dimension table below,
The required tightening torque will be:

T = KPD = 0.15(15)(39.228N)
= 88.263Nm
Refer to as T1 , is the torque required to develop the tensile load in the bolt, Pt using inclined plane nature
of the thread
T1 =
62
Where is the load of the bolt thread and = P =

The second component of the torque, T2 is that required to overcome friction between the mating threads,
computed from
T2 =
Where,
The third component of torque, Ta is the friction between the underside of the head of the bolt or nut and
clamped surface
Ta =
Where,
Total Torque,
Ttotal = T1 + T2 + T3
4.3.1.2 Failure Analysis

Failure analysis is the process of collecting and analyzing data to determine the cause of a failure.
Where it is a vital tool used in the development of new products and for the improvement of existing
products. It relies on collecting failed components for subsequent examination of the cause or causes of
failure using a wide array of methods.
63
Static Failure Analysis
Tresca Criterian
Ductile
Von-Mises Theory
STATIC
FAILURE
THEORIES
Moh-Coloumb
Theory
Brittle
Maximum Normal
Stress Theory
Fig. 4-5 Static failure theories
Fatigue Failure Analysis

Fatigue failure is a significant problem because it can occur due to repeated loads below the static
yield strength. This can result in an unexpected and catastrophic failure in use. It is because most
engineering materials contain discontinuities most metal fatigue cracks initiate from discontinuities in
highly stressed regions of the component. The failure may be due the discontinuity design, improper
maintenance or other causes. A failure analysis can determine the cause of the failure.
Fatigue failure is caused by repeated cycling of the load. It is a progressive localized damage due to
fluctuating stresses and strains on the material. Metal fatigue cracks initiate and propagate in regions where
the strain is most severe.
The process of fatigue consists of three stages:
Initial crack initiation
Progressive crack growth across the part
Final sudden fracture of the remaining cross section
Fatigue Failure in Analysis and Design
The methods of fatigue failure analysis represent a combination of engineering and science. Often
science fails to provide the complete answers that are needed. But the airplane must still be made to fly
safely. And the automobile must be manufactured with a reliability that will ensure a long and trouble-free
life and at the same time produce profits for the stockholders of the industry. Thus, while science has not
yet completely explained the complete mechanism of fatigue, the engineer must still design things that will
not fail. In a sense this is a classic example of the true meaning of engineering as contrasted with science.
Engineers use science to solve their problems if the science is available. But available or not, the problem
must be solved, and whatever form the solution takes under these conditions is called engineering.
64
In this chapter, we will take a structured approach in the design against fatigue failure. As with static
failure, we will attempt to relate to test results performed on simply loaded specimens. However, because
of the complex nature of fatigue, there is much more to account for. From this point, we will proceed
methodically, and in stages.
In an attempt to provide some insight as to what follows in this chapter, a brief description of the
remaining sections will be given here.
a) Fatigue failure is characterized by three stages:

i.
Initial crack initiation
ii.
Progressive crack growth across the part
iii.
Final sudden fracture of the remaining cross section
Fig. 4-6 Schematic of S-N Curve, showing increase in fatigue life with decreasing stresses.
b) Stress Ratio
The most commonly used stress ratio is R, the ratio of the minimum stress to the maximum stress (S min
/ Smax).
If the stresses are fully reversed, then R = -1.
If the stresses are partially reversed, R = a negative number less than 1.
If the stress is cycled between a maximum stress and no load, R = zero.
If the stress is cycled between two tensile stresses, R = a positive number less than 1.
65
Variations in the stress ratios can significantly affect fatigue life. The presence of a mean stress
component has a substantial effect on fatigue failure. When a tensile mean stress is added to the alternating
stresses, a component will fail at lower alternating stress than it does under a fully reversed stress.
Fig. 4-7 Fatigue failure; types of fluctuating stress
c) Preventing Fatigue Failure

The most effective method of improving fatigue performance is improvements in design:
Improve the details of fabrication and fastening procedures
Avoid sharp surface tears resulting from punching, stamping, shearing, or other processes
Reduce or eliminate tensile residual stresses caused by manufacturing
Eliminate or reduce stress raisers by streamlining the part
Prevent the development of surface discontinuities during processing
d) Fatigue Failure Analysis

Metal fatigue is a significant problem because it can occur due to repeated loads below the static yield
strength. This can result in an unexpected and catastrophic failure in use. Because most engineering
materials contain discontinuities most metal fatigue cracks initiate from discontinuities in highly stressed
regions of the component. The failure may be due the discontinuity, design, improper maintenance or other
causes. A failure analysis can determine the cause of the failure.
66
e) Calculation of Fatigue Failure

AISI 1020 cold drawn
1 x 1 square hollow
In reversed axial loading for 70,000 cycles to failure in an operating environment of 50
. Estimate the
endurance limit and fatigue strength at 70,000 cycle

From Table A-20 Shigleys:
We determine the ultimate strength at the elevated temperature first, using Table 6-4 (Shigley) (page 291)
= 1.010
The ultimate strength at 50
The rotating beam specimen endurance limit at 50
is then estimated
Marine Factor, from Table 6-2 gives (page 288)
=0.881
i. For axial loading

A reliability since we accounted for the temperature in modifying from Table 6-5 (page 293). Finally,
since no other conditions were given, the miscellaneous factor is the endurance limit for the part is
estimated.
67
(ref: Shigleys Mechanical Engineering Design, ninth edition, pg:293,Table 6-5)
= 0.881(0.9)(1)(1)(0.814)(1)(237.35) = 153.2 MPa
For the fatigue strength at 70,000 cycles, we need to construct the S-N equation. From page 285, since
Then
Finally, for the fatigue strength at 70,000 cycles
ii. Fluctuating Stress
This part is to withstand a fluctuating tensile load varying from 0 to 1.1kN.

Assume that a fatigue stress concentration factor
. To find
and
and the factor of safety
guarding against fatigue and first cycle yielding using Gerber fatigue line and ASME elliptic fatigue line.
Assume
Solution:
We know that
68
= 237.35 MPa
The main factor,

=
= 0.881
=
The nominal axial stress component
Applying to both component
and
and
are
constitutes a prescription of no notch yielding
iii. Factor Safety

The factor safety for fatigue is:
= 7.31(0.25)
= 1.83
The factor of safety guarding against first cycle yield is :
The fatigue will occur first and the factor of safety is 1.83. This can be seen where the load line intersects
the Gerber fatigue curve first at point B.
From table 6-7, r =
= 1,
= 633.9(0.25) =158.5 MPA
69
= 158.5 MPa
Check on the previous result,
= OB/OA =
= 158.5/86.7 = 1.83
We could detected that fatigue failure will occur first without drawing by calculating
. From the third
row third column panel of Table 6-7, the intersection point between fatigue and first cycle yield is
= 633.9(0.43) = 270 MPa

= 380 270 = 110 Mpa
The critical slope is thus

=
= 0.407
which is less than the actual load line of r = 1. This indicates that fatigue occurs before first-cycle-yield.
For the ASME-elliptic line, the same procedure are repeated, for fatigue
= 1.87
* Again, this is less than = 2.25 and fatigue is predicted to occur first.
70
4.3.1.3 Material Selection

Materials selection plays an essential role in the product design process (Doordan, 2003). Product
materials determine the range of function, durability, certain costs, user feedback, and user experience.
When users interact with products, their senses are in contact with the materials of those products. Users
see the colors of materials, feel the texture and weight, and hear the sounds that the materials make when
the object is moved. These sensory perceptions contribute to product usability and use experiences
(Hekkert, 2006). Product designers use materials to create these sensory perceptions (Ashby & Johnson,
2002, 2003). In addition, product designers select materials for products to elicit the right associations.
Hodgson and Harper (2004) stated that materials considerations are pervasive in design as the substance
through which product designers' intentions are embodied. Likewise, Gant (2005) emphasized that the
strategic use of materials is one of the most influential ways through which product designers engender
deeper, more emotive connections between their products and their users. The materials that a product is
made of thus influence how users interact with the product.
The different aspects of materials can be for the most part categorized in two groups, namely the
technical aspects and the user-interaction aspects. The technical aspects of materials define how the
product will be manufactured and how it will function. The user-interaction aspects are those that influence
the usability and personality of a product. For example, shininess can influence how well users can read
from a display (use aspects) and colors are a very strong aspect to create a personality that influences user
experience. For high quality products, product designers should select materials that are optimal or
compromise in both aspects.
There are many type of chart, we can consider, when we are dealing with Material Selection.
These charts contain most available:
Young's modulus - Density
Young's Modulus - Cost
Strength - Density
Strength - Toughness
Strength - Elongation
Strength - Cost
Strength - Max service temperature
Specific stiffness - Specific strength
71
Graph below show comparison between different materials Young Modulus and density.
Fig 4-8 (ref: Shigleys Mechanical Engineering Design, ninth edition, pg64:,Figure 2-16)
Youngs Modulus measures the stiffness of a material. The stiffer it is, the more strain it can bear before it
reaches its yield strength. The Youngs Modulus can also be thought of the slope of the line on the Stress
& Strain graph before the yield point.
a. Material Performance Requirements

First and foremost we need to analysis of material Performance Requirements.
i. Analysis of material Performance Requirements

The material performance requirements can be divided into five board categories, namely functional
requirement, process ability requirements, cost, reliability and resistance to service conditions.
ii. Functional Requirements

Functional requirements are directly related to the required characteristics of the part or the product. For
example, in our project we needs to consider about the load that act on the axial shaft, the yield strength of
the material can be directly related to the load-carrying capacity of the product. However, some
characteristics of the part or product may not have simple correspondence with measurable material
properties, as in the case of thermal shock resistance, wear resistance and reliability. Under these
conditions, the evaluation process can be quite complex and may depend on the load and other physical of
product.
72
iii. Processability Requirements

The processability of a material is a measure of its ability to be worked and shaped into a finished part.
With reference to a specific manufacturing method, processability can be defined as castability, weldability,
machinability, etc. Ductility and hardenability can be relevant to processability if the material is to be
deformed or hardened by heat treatment, respectively. The closeness of the stock form to the required
product form can be taken as a measure of processability in some cases. It is important because the
processing operations will always affect the material properties so that processability considerations are
closely related to functional requirements.
iv. Cost
Cost is usually an important factor in evaluating materials because in many applications there is a cost
limit for a material intended to meet the application requirements. When the cost limit is exceeded, the
design may have to be changed to allow for the use of a less expensive material. The cost of processing
often exceeds the cost of the stock material. In some cases, a relatively more expensive material may
eventually yield a less expensive product than a low priced material that is more expensive to process. In
our project we selected a low priced of material to build our prototype.
v. Reliability Requirements
Reliability of a material can be defined as the probability that it will perform the intended function for
the expected life without failure. Material reliability is difficult to measure because it is not only dependent
upon the materials inherent properties, but it is also greatly affected by its production and processing
history. Generally, new and nonstandard materials will tend to have lower reliability than established,
standard materials. Despite difficulties of evaluating reliability, it is often an important selection factor that
must be taken into account. Failure analysis techniques are usually used to predict the different ways in
which a product can fail and can be considered as a systematic approach to reliability evaluation. The
causes of failure of a part in service can usually be traced back to defects in materials and processing, to
faulty design, unexpected service conditions, or misuse of the product.
vi. Resistance to Service Conditions

The environment in which the product or part will operate plays an important role in determining the
material performance requirements. Corrosive environments, as well as high or low temperatures, can
adversely affect the performance of most materials in service. Whenever more than one material is
involved in an application, compatibility becomes a selection consideration. For example, in our project we
used aluminum to avoid the corrosion happen to the material.
73
b. Screening methods:
Screening method is the process we screen out the materials that which is not satisfy the functional
requirements of the part. We need to compare the application information from the engineering design
specification to the mechanical and physical properties of material classes. We typically include criteria
regarding the nature of applied loads and the operating environment. This screening will eliminate a
number of infeasible material classes. Those remaining will be compatible with some manufacturing
process.
Stage of Material Selection
Stage of Design
Preliminary and Conceptual Design
1.
2.
3.
Initial Screening
Translate marketing ideas into industrial

design leading to board description of the
product.
Decompose the product into
subassemblies and identify the different
parts of each subassembly.
Specifying the main function of each part
identify their critical requirements.
1.
Configuration (Embodiment) Design

1.
Use the critical requirements of each part to

define the performance requirements of the
material. Start with all materials available and
narrow down the choices on the basis of the
rigid properties.
Comparing Alternative Solutions
Develop a qualitative sketch of each part

giving only the order of magnitude of the
main dimensions but showing the main
features.
1.
Use soft material or the existing material that

on the market. It will save time to build the
product.
Detail (Parametric) Design
Selection of the Optimum Solution
1.
1.
2.
Determine the dimensions of the parts based

on a specific material and manufacturing
process taking into the account the design
limitations, the manufacturing process,
weight concerns, space limitations. The cost
must be considered in detail.
Generation of an alternative detail design,
which requires selecting a design based on
the alternative materials and evaluation
against requirements.
2.
3.
Use the optimum materials and matching

manufacturing process to make detail designs.
Compare alternative combination taking into
account the elements of cost.
Select optimum combination of design material
manufacturing process.
Fig 4-9 Stages of design and the related stages of materials selection
74
Material
Plastics
Process
Molding
Stainless
Steel
Machining
Mild Steel
Cast Iron
Wood
Aluminium
Machining
Machining
Woodworker
Machining
Screening Process
The highlighted column is the eliminated materials
due to the machining we have in FKMP.
Material
Stainless Steel
Mild Steel
Cast Iron
Aluminium
Process
Machining
Machining
Machining
Machining
Rating
Material
Stainless Steel
Mild Steel
Cast Iron
Aluminium
Process
Machining
Machining
Machining
Machining
Rating
5/5
3/5
4/5
4/5
Best Material Selected

Material
Stainless Steel
Process
Machining
Rating
5/5
Fig 4-10 Screening and evaluation of material
75
4.3.1.4 Materials used

Stainless steels resistance to corrosion and staining, low maintenance and familiar mineral make it
an ideal material for many applications. There are over 150 grades of stainless steel, of which fifteen are
most commonly used. The alloy is milled into coils, sheets, plates, bars, wire, and tubing to be used in
cookware, cutlery, hardware, surgical instruments, major appliances, industrial equipment (for example, in
sugar refineries) and as an automotive and aerospace structural alloy and construction material in large
buildings.
Storage tanks and tankers used to transport orange juice and other food are often made of stainless
steel, because of its corrosion resistance and antibacterial properties. This also influences its use in
commercial kitchens and food processing plants, as it can be steam-cleaned and sterilized and does not
need paint or other surface finishes.
The advantages of stainless steel appliances is stainless steel can withstand very hot and very cold
temperatures. This makes the material ideal for appliances. Unlike plastic or ceramic, stainless steel does
not break easily, even if dropped. Stainless steel may dent, but it will not shatter or chip the way other
materials will. Cleaning stainless steel appliances is very easy. Wiping the surface down with liquid soap
and water is usually all that is required. Do not use abrasive cleaners or scrubbers (such as steel wool). For
fingerprints or similar smudges, use glass cleaner and a polishing cloth. Stainless steel, as it is a neutral
colour, is easy to match with just about any modern kitchen decor. These appliances usually come in a
high-shine, mirror finish or a less bright, but still beautiful, brushed stainless steel finish. The price of a
stainless steel appliance is comparable to or cheaper than appliances made of other materials. Also,
although wiring and mechanical functions in appliances may malfunction, stainless steel itself will last a
long time, which may save money in the long run.
i. Mechanical Properties
The following table shows mechanical properties of stainless steel.
Table 4-5 Mechanical properties for grade 304
Grade
304
Tensile
Yield strength
Elongation (%
Strength (MPa)
0.2% Proof
in 50mm) min
min
(MPa) min
515
205
40
76
Hardness
Rockwell B
Brinell (HB)
(HR B) max
max
92
201
ii. Physical Properties

The following table shows mechanical properties of stainless steel.
Table 4-6 Physical properties for grade 304
Grade
Density
3
(kg/m )
Elastic
Mean Coefficient of Thermal

o
Modulus
Expansion (m/m/ C)
(GPa)
0-100oC
304
8000
193
17.2
0-315oC
17.8
0-538oC
18.4
Thermal
Specific
Electrical
Conductivity
Heat 0-
Resistivity
(W/m.K)
100oC
(n.m)
at
at
100oC
500oC
16.2
21.5
(J/kg.K)
500
720
iii. Principal Design Features

One of the most widely used and oldest is the stainless steels. This was originally called 18-8 which stood
for its chromium and nickel content. It possesses an excellent combination of strength, corrosion resistance
and fabric ability. It is available in the widest variety of forms and sizes of any stainless steel
iv. Corrosion Resistance

Excellent in a wide range of atmospheric environments and many corrosive media. Subject to pitting and
crevice corrosion in warm chloride environments, and to stress corrosion cracking above about 60C.
Considered resistant to potable water with up to about 200mg/L chlorides at ambient temperatures,
reducing to about 150mg/L at 60C.
v. Machinability
Slow speeds and heavy feeds will minimize this alloys tendency to work harden. Due to long stringy chips,
the use of chip breakers is advisable.
vi. Hardening
This alloy does not respond to heat treatment. Cold work will cause an increase in both hardness and
strength.
vii. Welding
All fusion and resistance processes have been successfully employed in welding 304. AWS E/ER308 or
312 filler metal is recommended. For cleaner, stronger welds, may users choose 304L which has a
controlled low carbon content designed to reduce carbide precipitation at the weld boundaries.
77
viii. Heat Resistance

Grade 304H has higher strength at elevated temperatures so is often used for structural and pressurecontaining applications at temperatures above about 500C and up to about 800C. 304H will become
sensitised in the temperature range of 425-860C; this is not a problem for high temperature applications,
but will result in reduced aqueous corrosion resistance
4.3.2 Consideration of Design for X.

When analyzing configuration alternatives, we consider the likelihood that the parts will function as
expected, that the parts can be assembled and that they can be manufactured. We develop a configuration
checklist using two criterion categories like design for safety and design for function.
4.3.2.1 Design for Safety

Safety and design are the principal focus of human factors psychologists. These product and
design that take into account human or system interaction and the relevant performance capacities and
limitations of the people who use them. The goal is to be improving efficiency or increase reliability this
design in function to slice the loaves. They may want to enhance safety and reduce accidents. In this
product with a lot of safety that can improve customers acceptance of a product.
Safe design is the integration of hazard identification and risk assessment methods, early in the
design process to climate or minimized the risks of injury, throughout the life of the product being
designed. In our machine we use transparent blocker to avoid output short away from blade disc. Beside
that our machine have an emergency stop button, when have any problem with machine we can push this
button immediately and machine will stop automatically. After that we also use pusher and funnel to avoid
risks of injury to users when handling input material before it slice by blade disc. Lastly we apply to do not
have sharp edges by file it at every angle of sharp edges.
4.3.2.2 Design for Function

The device has been used in ancient times longer with the manual method by using the knife or by
manual slicer. The development of technology nowadays, the method of slicing has been changed from
manual to automatic used.
The modern food slicer is a large, heavy piece of equipment most commonly found in restaurants.
Early versions were difficult to use and dangerous. Newer models are easier to operate and produce even
results, but they can still be dangerous.
Manual and hand-cranked slicers introduce a feeding shoot for the food to rest in while a handle
moves the blade from a safe distance. The distance from the blade was a good theory, but as the product
was sliced and lost mass, it lost the weight to cut evenly, eventually turning into uneven or too-thin slices.
This invention relates generally to any kind of loaf slicers, and more specifically to this particular
company which used arabs breads slicer for domestic use or for catering establishments, restaurant,in
small industries and has for its object the provision of an appliance which will permit for instance one or
78
more loaves to be sliced into pieces of suitable size for a contemplated culinary purpose without causing
the user to be inconvenienced by the sharp or biting smell of the breads.
Table 4-7 Design for Function Checklist Item

1. Strong
2. Economic
3. Safe
4. Easy to use
5. Maintainable
6. Repairable
7. Stable
8. Human factor/ Ergonomics
9. Fast and efficient
10. Quite/noise
4.3.3 Ergonomic Consideration

Ergonomics is the study of designing equipment and devices that fit the human body, its movements,
and its cognitive abilities. Ergonomics is employed to fulfil the two goals of health and productivity. It is
relevant in the design of such things as safe furniture and easy to use interfaces to machines and equipment.
Proper ergonomic design is necessary to prevent repetitive strain injuries, which can develop over time and
can lead to long-term disability.
When one considers the term ergonomics, perhaps an initial thought focuses on the safety, wellbeing, and comfort of the operator. Although the rate of injury and illness among waste-collection workers
is slowly inching downward, the industry still has one of the highest injury rates in the country. To assess
the fit between a person and the used technology, ergonomists consider the job (activity) being done and
the demands on the user; the equipment used (its size, shape, and how appropriate it is for the task), and
the information used (how it is presented, accessed, and changed).
Ergonomics should be part of the design and development of a new machine or equipment where
there is engagement between the product and its potential User. In other words, a machine design requires
appropriate interaction with the practice of ergonomics. The fulfillment of the requirements helps to
increase ergonomic comfort and ensure the correct use of the product, while ensuring the security of User.
The use of ergonomics also helps to minimize constraints and human costs, optimizing the performance of
the task, the performance of work and productivity of the man-machine task
Most machines, especially the most complex, have attributes that make it difficult to use. These
attributes must be systematically identified and measured, where possible, in terms of requirements for
human performance. And the results of such monitoring should be incorporated into the product design.
Thus, ergonomics help reduce the element of conjecture and increases the level of reliability in design
79
decisions regarding the consideration of important factors in terms of satisfaction, safety and welfare of
users.
The ergonomics must be considered because ergonomics was another name for Human Factors.
Today, Ergonomics commonly refers to designing work environments for maximizing safety and
efficiency. Biometrics and Anthropometrics play a key role in this use of the word Ergonomics.
Engineering Psychology often has a specialty dealing with Workplace or Occupational Ergonomics. In our
project we consider ergonomics as the priority. The customer will feel comfortable while used it because it
provide easyness (doesnt required so much of energy) and it also safe because all of the sharp device have
been protect by a cover. Finally, the introduced of this invention could help the people in the culinary field.
The automatic process is faster and easier without using manpower. The quantity of product that
produced by automatic method is more than manual method in a short time. This project has
been named as the Loaf Slicer Machine. It is designed to alleviate or minimize the use of manpower
to slice in large quantities. In addition this machine is more economical use of time. This product and the
system has been designed to facilitate the users especially for the small industry which is easy use product
and easy to handle it.
Worker
Workplace
Job
Design
Fig. 4-11 Interaction between worker job design (machine) and workplace
4.3.4 Published Standards

This invention relates generally to loaves slicers, and more specifically to Arab breads slicer for
domestic use or for catering establishments, restaurant or in small industries and has for its object the
provision of an appliance which will permit for instance one or more breads or loaves to be sliced into
pieces of suitable size for a contemplated culinary purpose without causing the user to be inconvenienced
by the sharp.
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CHAPTER 5.
DETAIL DESIGN AND PRODUCT SIMULATION
5.1 Introduction
This chapter will show you a product that is produced in the form of early drawings. In addition, this
chapter will also explain products and components used in which components of electrical and mechanical
components. Other explanations include the use of materials used in the production of this product.
Experiment study will show analysis of material will be performed to determine the strength of products
will produced. Besides that, this chapter will also show the simulation of products is used. This analysis is
done to see the strength of the products in terms of static, properties and situations load.
5.2 Final Product Design Specification

Table 5-1 Product specification
Specification
Loaves Slicer Machine
Picture
Retail List Price
RM 1800
Weight
70 kg
Dimension Machine
Square (680mm x 610mm x 685mm)
Machine Capability
150 Kg/h
Motor Power
220V,50Hz, 1.5kW
Material (Core)
Stainless Steel
Type of input
Bread
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Operator
Emergency button
No
5.3 Detail Drawings

5.3.1 Parts
Table 5-2 Drawing number of each part
No.
Part
Drawing No.
LSM-01-01
Connector
Collar
LSM-01-02
Frame
LSM-01-03
Key lock
LSM-01-04
Knife holder
LSM-01-05
Knife
LSM-01-06
Shaft holder upper
LSM-01-07
Shaft frame holder at piston
LSM-01-08
Shaft frame holder
LSM-01-09
10
Upper frame holder
11
Upper shaft holder
12
Frame housing left
13
Frame housing right
14
Shaft frame housing
15
Connecting rod
16
Pulley
17
Pulley motor
18
Table out feed
19
Bread deliver
LSM-01-10
LSM-01-11
LSM-01-12
LSM-01-13
LSM-01-14
LSM-01-15
LSM-01-16
LSM-01-17
LSM-01-18
LSM-01-19
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20
Motor
21
Guide side
22
Ring retaining
23
Stud
24
Stud wing
LSM-01-20
LSM-01-21
LSM-01-22
LSM-01-23
LSM-01-24
* For drawing number, please refer to attachment
5.3.2 Assembly
Table 5-3 Drawing number for each part
No.
1
Part
Drawing No.
Full Assembly
LSM-01-25
5.3.3 Complete Drawing

Table 5-4 The assembly drawing for the overall part.
No.
Part
Drawing No.
1.0
Full Assembly Isometric View
LSM-01-26
2.0
Full Assembly Exploded View
LSM-01-27
83
5.4 Product Analysis And Simulation By Solidworks Simulation

SOLIDWORKS Simulation uses the displacement formulation of the finite element method to
calculate component displacements, strains, and stresses under internal and external loads. The geometry
under analysis is discretized using tetrahedral (3D), triangular (2D), and beam elements, and solved by
either a direct sparse or iterative solver. SOLIDWORKS Simulation also offers the 2D simplification
assumption for plane stress, plane strain, extruded, or axisymmetric options [15].
5.4.1 Static Failure

This type of analysis had been done on several main parts which are waste area, loading area and
container. All of the figures below are the results of the analysis. For all of them, the red zone is the
maximum value for each of the analysis and the blue zone is the minimum value. The value of this zone
can be observed at the right side of the part.
Fig. 5-1 Deformation (von misses)
Fig. 5-2 Displacement (von misses)
84
Fig. 5-3 Strain for shaft of frame (von mises)
5.4.2 Fatigue Failure

Fatigue analysis examines how repeated or random load cycles can cause structural failure which
is called metal fatigue. SOLIDWORKS Simulation enables designers to take two, complementary
approaches to design analysis [16]
Fig. 5-4 Total life for shaft
5.4.3 Other Analyses

i.
Buckling analysis
Investigate the buckling strength of a design with and without environmental loads to ensure that it
meets product requirements for strength, performance, and safety.
85
Fig. 5-5 Buckling analysis for body of machine
5.5 Bill Of Materials (BOM)
Loaves Slicer Machine
Chasis
Outer part
Frame
Bearing
Side guide
Motor
Belting
Belting guide
pulley
Bread receiver
Fig. 5-6 Bill of material for loaf slicer machine
86
Table 5-5 Bill of material

Item No.
Part No.
Quantity
Frame Housing Left
Frame Housing Right
Top Cover
10
Back Cover
16
Motor
17
Shaft Piston
19
Pulley
20
Sub Assembly Knives Frame
32
Pulley Motor
35
Belt
36
Holder
37
Driver Pulley
38
Pulley
39
Machine Stand
42
Bread Deliver
45
Shaft Connector
5.6 Manufacturing Processes

In order to complete all the component assembly for this Multi slice machine, there was a various
manufacturing process depends on the component purpose. The following is the manufacturing process for
overall component and parts.
Frame This is a major and most important part in this assembly. Since the material for this part is
based on steel, it been designed and fabricated using arc welding process in order to join a piece of
steel plate with other same material.
Shaft Considering it is function as a medium to transmit the rotational force from the motor, the
dimension of the shaft need to be considered. This shaft has undergone a lathe machining process until
it achieved the target dimension.
Bread receiver The bread receiver was done using wire cut and drilling process.
Hole for nut and bolt The overall hole in this machine been produce by using drilling process and it
depend to the size of bolt that required.
87
5.7 Final Product Design Specification

Based on design briefing, the analysis of the participatory design project, customer requirement and
benchmark of product, we drawn our final product design. This purpose is to design new frame of loaf
slicer that able to cut loaves bread into 8 pieces. These machines are usually we seen in market but some of
them are not in customer and user requirement.
Customer requirements:
Low Power Consumption
Low Maintenance Cost
Environmental Friendly
No Noise
Small Vibration
Good Performance
Machine Stability
Safety
Reduce Man Power
Save Time Work
Easy to Used
Design requirements:
1. Physical and Operational Characteristics
a.
Performance requirements: The speed production of cutting dough follows the suitable of operator
production.
b. Safety: This machine is providing a body that covers all the operation part and dangerous part
(closed structure).
c.
Accuracy and Reliability: The product produces a high quality and reliable operation.
d. Life in Service: The product should withstand normal daily use for many years.
e.
Ergonomics: The machine is easy to use, save time work, and reduce man power to operate by using
1 button to on the machine.
f.
Size: The size of the machine is very suitable for user comfort to operate the machine. Small sizes of
machine ease to lift up the machine.
g. Materials: The materials should all be stainless steel.
88
5.8 Complete Design Checklist

Table 5-6 Checklists for design
No.
Title
Sub Section
Item
Checklist
Heading
1
Product specification
1.1
Full Assembly
Drawing
2.1
Parts
2.2
Assembly
2.3
Complete Drawing
3.1
Product Analysis
3.2
Solid Works Simulation
3.3
Static Failure
3.4
Fatigue Failure
4.1
Full Assembly
4.2
Outer part explode
4.3
Chassis Explode
4.4
Roller Explode
Simulation
Bill of Materials
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CHAPTER 6.
PROTOTYPING, TESTING AND REFINEMENT
.
6.1 Product Prototyping

Product prototyping is important as a basic knowledge before produced a real product. Prototype may
be reduced scale, expanded scale, or full scale representing the part. In addition, prototypes may be made
of materials similar to or exactly like the intended product. For our project, we reduced the scale, part and
also material used of the actual project.
The process are involved the process of lathe, wire cuts, grinding process, welding process, cutting,
drilling, rivets, polishing, painting and lastly in the wiring process. Few of the process are done by using
the equipment in the Universiti Tun Hussein Onn Malaysia Laboratory.
6.1.1 Processes Involved

The process involved in our product prototyping such as the follow. All of the process is using by the
mechanical engineering knowledge. During the process, all of the safety factor important thing to make
sure there are no error and damage happen during the process. The damage mention is including for the
material, environment and human health.
i. Lathe
To reduce the shaft diameter based on the bearing hole.
Fig. 6-1 Lathe process
90
ii. Wire cuts

Cut the metal plate for loaves receiver.
Fig. 6-2 Wire cuts process
iii. Grinding
To cleaned the metal surface.
Fig. 6-3 Grindings process
iv. Welding process

Using electrode for arc welding to weld the body.
Fig. 6-4 Welding process
91
v. Cutting
Cut the metal to make body and frame by using the saw machine.
Fig. 6-5 Cutting process
vi. Drilling
Make hole for screw place by using the hand drills.
Fig. 6-6 Drilling process
vii. Polishing
Used grinding machine to clean the surface of the metal sheets and frame body.
Fig. 6-7 Polishing Process
92
viii. Painting
To improving the appearance and prevent corrosion.
Fig. 6-8 Painting process
ix. Wiring
Provide wiring to connect the power supply to the electric motor.
Fig. 6-9 Wiring process
6.1.2 Prototype product

As mention before, prototype is the sample built to test a concept or process to act as a thing to be
replicated or learned from. In semantics, prototype instances combine the representative attributes of a
category. In addition, prototype is typical instances of a category that serve as benchmarks against which
the surrounding, less representative.
93
Besides that, there is great uncertainly as to whether a new will actually do what is desired. New
design often have unexpected problems. A prototype is often used as part of the product design process to
allow engineers and designers the ability to explore design alternatives, test theories and confirm
performance prior to starting production of a new product. Figure 6.13 shows the product prototype of our
project based on 3D view, top view, side view and front view.
3D View
Top View
Side View
Front View
Fig. 6-10 3D view, top view, side view and front view of the project
94
6.2 Testing requirement and checklist

After the product prototype is created, we need to make sure all the part of the product prototype is
function properly. Other than that, safety testing is important to make sure the product is not inherently
dangerous for the user. If there is any risk associated with the product, we must to determine how high the
odds are and how serious the outcome would be. Prototype evaluations often include specific tests for
mechanical modes of failure, manufacturability, operation/maintenance, safety, and environmental
protection. Below is the checklist result after we conducted a testing for our product prototype.
Table 6-1: Testing checklist results

Excellent
Good
Average
No.
Criteria
Grades
Sound test (Noise)
Portable
Vibration
Strong and toughness
Energy efficient
Stability
Reliability
Ergonomics
Safety
10
User friendly
11
Easy to maintenance
12
Repairable
13
Durability
14
Pollution
6.3 Testing and refinement

Some clients, instead of briefing us to design entirely new products, ask us to improve existing ones.
Generally this happens when competitors start to catch up and a product begins to lose sales and market
share. From the clients point of view it is less risky to enhance or refresh an existing product than it is to
design an entirely new one.
95
In these cases we then use our wealth of manufacturing experience and engineering intelligence to
determine how costs can be stripped out and where functionality, performance or aesthetics can be
improved. We will identify aspects that may be over engineered, look at reducing the part count, see where
we can utilize less expensive materials and explore ways to simplify the manufacturing process.
After we did the testing to our prototype product, we faced several problems of the product. In order to
overcome such problems, we must to do the refinement. In refinement process, we provide process such as:
i. Testing process
Product testing is, perhaps, the single most important type of research any company ever conducts.
Achieving clear-cut product superiority in a category is the surest way to build brand share, engender
customer loyalty, and boost profitability. Better products tend to command higher prices and be more
responsive to advertising investments. Product testing methods vary by product category. For consumer
packaged goods, in-home usage testing is typically the recommended method. For durable goods, however,
product clinics are generally the preferred method. For services, some type of mystery shopping is
recommended. Regardless of product category, the following principles generally apply. In this case, we
tested the product with dough due to the function of the machine.
ii. Product decoration

The quality of decoration and graphics is what gives products shelf appeal and catches the attention of
the consumer. We designed and decorate product for good and attract the customer to use it. We also
provided brochure, description and manual to the user.
iii. Finishing process

The last step is the finishing process. Finishing process is including the job to polishing and cleaning
process of the machine from any unneeded stuff. Finishing process is important to make sure the machine
always in good condition of surfaces.
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6.4 Final Prototype Product
Fig. 6-11 Final project
Fig. 6-12 Isometric view
97
6.4.1 Overall View

Input
Output
Fig. 6-13 Overall projects
98
CHAPTER 7.
SUSTAINABILITY AND ENVIRONMENTAL CONSIDERATION IN
ENGINEERING DESIGN
7.1 Introduction
The awareness regarding the environmental consciousness showed an incremental pattern nowadays
in many industrial countries. Many designers included the factor of environmental friendly in their design
of product. The result produced design that put higher priority in reducing the cost in development,
assembly and service.
Environmental sustainability is defined based on Brundtland Report titled Our Common Future as
development that meets the needs of the present without compromising the ability of future generation to
meet their own needs. Sustainable Development contained two major concepts. The first concept is the
concept of needs, where overriding priority should be attends first. The second concept is the idea of
limitation. This idea imposed by the state of technology and social on the environment ability to meet
present and future needs.
In order to achieve global sustainability, we need to design the product that we produced with
consideration of the two concept discuss earlier. This can help us in our cost of producing and
commercializing our product. For our Loaf Slicer Machine, we had design it to be sustainable and
environmental friendly.
7.1.1 Design for minimal use of materials

Material is not only important to produce a good performance, but it also plays vital part in
maintaining the sustainability of a product. The lesser number of, the more sustainable a product will be. In
our design project, we tried to use as less variety of material as possible. For the fabrication of our Loaf
Slicer Machine, we use three types of materials which consist of stainless steel , steel and plastic. Minimal
use of materials can be defined as the less usage of a material in a product.
There are several advantages of using stainless steel in our product such as it malleable enough to
bend as we wish, it is a recyclable material, has a high durability property, easy to be clean and suitable for
food processing. Some plastic is to be used on the machine casing in order to reducing cost. This is
because machined plastic parts do not require expensive manufacturing tools, the cost per part for
machined components stays relatively uniform and economical at volumes down to even a few pieces.
99
7.1.2 Elements of Sustainability

One of the characteristic needed in process of sustainability development is it must always be
flexible. There are different backgrounds for each community out there, therefore there is no such thing as
fixed action and decision. There are three major elements in sustainable development which provide the
foundation to guide us in sustainable activities which are:
i. Environment
Being a steward of the natural environment and reducing the impact of human activities on natural
resources and systems that support the community achieve environmental sustainability.
ii. Economy
A sustainable economy is one that is strong and resilient. It is achieved by supporting education, jobs,
businesses, green industries, innovation, and economic development.
iii. Community
A sustainable community is one that is accessible, healthy, safe, and diverse and promotes well being.
It is achieved by supporting public participation, healthy living, access to social services, cultural diversity,
historic preservation, and the arts.
Fig. 7-1 The elements in Sustainable Development
100
7.1.3 Design for recyclability

Recyclability is an ability of a material to be captured and separated from a waste stream for
conversion or reuse. Recycle is one of the best ways to have a positive impact on the world we live which
include environment and living things. So, in concern of that we design our product to used recyclable
materials.
Most of the components in the loaf slicer machine can be recycled again so that it can be used in
other manufacturing process. For example the shaft for the frame support is made of steel. These parts can
be used again in other products or can be machined for other purpose. It that shows us the design of our
product considered the design for recyclability.
7.2 Environmental Consideration

7.2.1 Life Cycle Assessment (LCA)
As environmental awareness increases, industries and businesses are assessing how their activities
affect the environment. Society has become concerned about the issues of natural resource depletion and
environmental degradation. Many businesses have responded to this awareness by providing greener
products and using greener processes. The environmental performance of products and processes has
become a key issue. Many companies have found it advantageous to explore ways of moving beyond
compliance using pollution prevention strategies and environmental management systems to improve their
environmental performance. One such tool is LCA. This concept considers the entire life cycle of a product.
Specifically, LCA is a technique to assess the environmental aspects and potential impacts associated with
a product, process, or service, by:
Compiling an inventory of relevant energy and material inputs and environmental releases.
Evaluating the potential environmental impacts associated with identified inputs and releases.
Interpreting the results to help decision-makers make a more informed decision
7.3 Social and Economic Issues
i. Social
Social issue or social problem is an issue, which related to societys perception of peoples personal lives.
In designing product, we need to consider the entire customer needed because the produce product wills
depends or following their requirements. We need to interact with people in many ways to ask them for
their requirements such as interviewing and survey. The purpose of collecting customer requirements is to
produce better product. If the requirements been ignored, it will cause problems to the user. Moreover, the
design of the product must be ergonomic for the social to accept it.
101
ii. Economical
Economical issue is a problem that based on the market needs of the product. If the market needs for
the certain product is relatively low, then there is no need to design it. In economic issue, it is also based
on the requirements from the customer. This is important for designing the product so it will not contain
excessive functions that are not needed at all. Due to that, the expenses can be save and waste can be
evaded thus will stabilize the economical.
102
CHAPTER 8.
ECONOMIC, COSTING AND BUSINESS PLAN
8.1 Introduction
Economics is the social science that analyses the production, distribution and consumption of goods
and services. In microeconomics, production is the conversion of inputs into outputs. It is an economic
process that uses inputs to create a commodity for exchanger direct use. Production is a flow and thus a
rate of output per period of time.
Product costing is the process of tracking and studying all the various expenses that are accrued in the
production and sale of a product, from raw materials purchases to expenses associated with transporting
the final product to retail establishments. It is widely regarded as an extremely important component in
evaluating and planning overall business strategies. Now, production of a product's various components is
often so synchronized on highly automated production lines that there is little or no need to maintain
component inventories. Further complicating the costing equation is the trend in manufacturing to focus
more attention on quality, flexibility and responsiveness, to meet customer needs. This makes productionline cost analysis more difficult because each line requires small, but significant, changes in production
techniques.
Product costing is a methodology associated with managerial accounting. More specifically product
costing is intended accurately to determine the cost of a unit of production or of a service delivered by
study of every resource used in its creation. The activity is only in part motivated by obtaining an accurate
final cost that incorporates all contributing streams. In part it is a way of identifying cost components that
can be addressed specifically in order to take cost out of the product by purchasing, redesign, reengineering,
retooling, packaging, and other interventions by management at whatever stage. Product costing evolved in
an environment of mass production in the second half of the 20th century as ever more managerial
attention was focused on optimizing the production function.
Some might require more or less strength and hence heavier forgings; these in turn might need more
or less additional machining. Some components could be attached mechanically, others had to be welded.
These operations could be measured in time, time in dollars. A systematic analysis of how a product came
to be, the inputs costing as received and then the operations performed on them individually estimated,
produced the final cost of production from which receipts from sale of scrap would be deducted to get a net
cost. Product costing evolved further from this point by assigning an appropriate percentage of totals
overhead and also measuring additional costs upstream such as packaging, warehousing, and delivery to
the ultimate buyer.
The analytical resources made available by such detailed information have made product costing a
routine aspect of most significantly-sized manufacturing operations. Product costing data act as feedback
to designers, are used in manufacturing management to identify ideal workflow, influence the purchase of
tooling, and are used in precise pricing of goods. Product costing is used in most routine production
activities, including service occupations, although the level of detail sought is variable and usually
103
determined by the size of the operation. Even in quite small businesses, some level of product costing is
practiced in that managements usually know the costs associated with important functions identified with
different products.
In production, research, retail, and accounting, a cost is the value of money that has been used up to
produce something, and hence is not available for use anymore. In business, the cost may be one of
acquisition, in which case the amount of money expended to acquire it is counted as cost. In this case,
money is the input that is gone in order to acquire the thing. This acquisition cost may be the sum of the
cost of production as incurred by the original producer, and further costs of transaction as incurred by the
acquirer over and above the price paid to the producer. Usually, the price also includes a mark-up for profit
over the cost of production. More generalized in the field of economics, cost is a metric that is totaling up
as a result of a process or as a differential for the result of a decision. Hence cost is the metric used in the
standard modeling paradigm applied to economic processes.
Cost accounting is a process of collecting, analyzing, summarizing and evaluating various alternative
courses of action. Its goal is to advise the management on the most appropriate course of action based on
the cost efficiency and capability. Cost accounting provides the detailed cost information that management
needs to control current operations and plan for the future. Since managers are making decisions only for
their own organization, there is no need for the information to be comparable to similar information from
other organizations. Instead, information must be relevant for a particular environment.
8.2 Cost Evaluation

Any project or organization that uses financial or other resources to operate uses cost evaluation. In
general terms, cost evaluation is the process of determining how resources are used. It can be on any scale,
from as focused as one single project or unit of an organization, to broad, comparative studies of resource
allocation in a whole network of organizations. Generally, a cost evaluation is only one part of a broader
cost-benefit analysis, with the goal of determining whether resources are being used efficiently.
i. Electrical Part
Table 8-1 Electrical part

No
Part
Cost (RM)
Quantity
Total Cost (RM)
Electric Motor
150.00
ON/OFF Switch
4.00
Wire
2m
7.00
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ii. Raw Material
Table 8-2 Raw material

No
Part
Cost (RM)
Quantity
Total Cost (RM)
Steel L shape
12.00 x 1pcs
24.00
Stainless Steel Plate
45.00 x 1pcs
90.00
Transparent prospect
30.00 x 1pcs
30.00
V Belt
10.00 x 1ft
5 ft
50.00
Plastic
40.00 x 1pcs
40.00
Mild Steel Rod
10.00
10.00
iii. Mechanical Part
Table 8-3 Mechanical part

No
Part
Cost (RM)
Quantity
Total Cost (RM)
Bearing
9.00
54.00
Bearing with cover
13.00
52.00
Handle
6.00
12.00
Knife
15.00
135.00
Shaft frame holder
25.00
50.00
Frame
50
50.00
Bolt (10mm)
0.40
0.80
Nut (10mm)
0.20
0.40
Bolt (13mm)
0.80
3.20
10
Nut (13mm)
0.40
1.60
11
Screw
0.20
20
4.00
12
Knife holder
3.00
18
54.00
13
Bread deliver
30.00
30.00
14
Guide side
25.00
100.00
15
Table out feed
25.00
25.00
16
Pulley and belt
100.00
100.00
17
Connecting rod
5.00
5.00
18
Top cover
20.00
20.00
19
Shaft pulley receiver
5.00
5.00
20
Shaft frame housing
10.00
20.00
105
21
Holder
5.00
20.00
22
Frame housing left/right
42.50
85.00
23
Back cover
20.00
20.00
24
Upper shaft holder
20.00
20.00
25
Upper frame holder
15.00
5.00
26
Shaft piston
5.00
5.00
iv. Others
Table 8-4 Others cost evaluation

No
Cost For
Total Cost (RM)
Transportation
50.00
Utility
60.00
Salary
200.00
8.3 Business Plan

8.3.1 Executive Summary
A business plan is a formal statement of a set of business goals, the reasons they are believed
attainable, and the plan for reaching those goals. It may also contain background information about the
organization or team attempting to reach those goals. Business plans may also target changes in perception
and branding by the customer, client, taxpayer, or larger community. Business plans are decision-making
tools. There is no fixed content for a business plan. Rather, the content and format of the business plan is
determined by the goals and audience. A business plan represents all aspects of business planning process
declaring vision and strategy alongside sub-plans to cover marketing, finance, operations, human resources
as well as a legal plan, when required. A business plan is a summary of those disciplinary plans.
As we can see, nowadays the traditional food industries grow and become one of a major industry
which is involving in producing several of food products. Due to this rapid growth, it just gives
opportunities to the beginner to getting involved in this sector especially in manufacturing fields. For
example, as we known, Parit Raja is one of the important areas of Batu Pahat, Johor for the production of
small and medium industries. It requires the machine to help alleviate and reduce human labour as well as
to reduce labour costs and increase productivity of a company or factory.
When viewed with a widespread, according to the current market of traditional food industries in
Malaysia, it is very important to us to design a good business plan in order to be a newbie participant in
this field or sector. As a new comer in this industry, the competitors need to be considered which is to
ensure that there have spaces to the new participant. Our business plan are considering of various level in
strategy that provide goods to the food industries.
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Out target is to supply products that useful for small industries users with a minimum cost. It is
providing a good functional and helps the supplier to slice the loaves easily and with the high production.
So, the product that will be increase the production no of loaves slicesc and saving time compare to the
manual process. The machine applied cutting process. As we know the process for cutting loaves or breads
by manual method really wasting time because only a low production can be made in once time based on
the human work and energy.
The planning process, by the way, is part of what makes putting together a business plan so
important. As we know, a business plan is a written description of businesses future, a document that tells
what we plan to do and how we plan to do it. The business goals may be defined both for non-profit or forprofit organizations. For-profit business plans typically focus on financial goals, such as profit or creation
of wealth. Non-profit, as well as government agency business plans tend to focus on the "organizational
mission" which is the basis for their governmental status or their non-profit, tax-exempt status, respectively,
although non-profits may also focus on optimizing revenue. The primary difference between profit and
non-profit organizations is that "for-profit" organizations look to maximize wealth versus non-profit
organizations, which look to provide a greater good to society. In non-profit organizations, creative
tensions may develop in the effort to balance mission with margin. Our business plans is :
Identify area/region target where more traditional food industries located.
Identify the usage/function of product
Market survey and analysis via questionnaire/interview.
Promote the product via website, template, newspaper, etc.
Customer feedback
Product sales
Fig 8-1 Business Plan
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8.3.2 Mission and Vision

As we know, a business motto or slogan descriptive phrase about our company. It represents a set of
beliefs, ideals or ethical stance that the company takes as a business entity. So, to make sure all members
in Precision Design work perfectly and constantly, we use a motto that could become part of our mission
and focus. Our motto is:
Think simple, Act ordinary
Based on the motto, we believe that there is no possible to making something new. We also have
no reason why we cannot be the best among the best. If we cannot believe in our strength, we try to
discover what is the possible. For sure, we can perform better than before. We do not want to complicate
the process. Our group plan to elaborate the simple plan to become ordinary. Our vision is to design a
product that can help people as possible because that is our responsibility. Our product is actually can carry
out the highest production and also reduce the time operation for the traditional food industrial or supplier.
We also will discover anything that impossible in this world to help increasing of the economy in Malaysia
with our engineering knowledge.
Our mission is:

Being a global family, that has matured over a years, we are committed to providing a world-class
mechanical product to people across the world in cost-effective and environmentally friendly machine.
Going green is our mantra as we believe that proper machine can sustain our atmosphere.
8.3.3 Key to Success

Success is known to be the key to any developing business. When we are able to show that our
business is helpful for our clients that is where we are gain than half of our success. There are a various
keys that guide us to being a successful entrepreneur. These keys are simple yet very effective.
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Passion : The first key to starting and maintaining a business is the

passion of our work.
Goal and vision : The next key to success is a vision or a goal of

raching a certain level in a particular duration of time.
Purpose : The business plan is designed to provide our business to

the clients.
Teamwork : Work in a team is key to the success of an organization
to continue to grow and excel to reach the target and the objectives
set.
Strategy : Coming up with a few strategies is necessary for the

business to work and reach people.
Professionalisme : Being professional with people aroud us and

guiding them with our knowledge.
Adaptability : Doing the research about the market could us to make

desicion.
Fig. 8-2 Key to success
Besides that, we also used the 5S concept to make sure our company always in good environment and save
situation. The 5S is the habit that all workers must always remind and implement in their work. The 5S
concept such like below:
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Sorting: Eliminate
all unnecessary
tools, parts.
Straightening
Flow:Arranging
the work, workers,
etc and instructions
in such a way that
the work flows free
of waste.
Systematic
Cleaning (Shine):
Clean the
workspace and all
equipment,keep it
clean, tidy and
organized.
Standardize:
Ensure uniform
procedures and
setups throughout
the operation to
promote
interchangeability.
Service (Sustain):
Ensure disciplined
adherence to rules
and procedures to
prevent
backsliding.
Fig. 8-3 5S concept
8.3.4 Company background

iMechanisch Sdn.Bhd is a company founded in 2014 which consists of five mechanical
engineering students of Universiti Tun Hussein Onn Malaysia (UTHM). This company is located in the
town ditch, where the strategic and competitive area for all residents in the area generally Parit Raja. The
first product we created is Loaf Slicer Machine. Our vision is to design a product that can help people as
possible because that is our responsibility. Our product is actually can carry out the highest production and
also reduce the time operation for the traditional food industrial or supplier.
Other than that, our company provides services to consumers who purchase products from our
company in the area of strategic and accessible to residents and the surrounding area. iMechanisch Sdn.
Bhd. is an innovative machine services and development that provider dedicated to quality and our
customers, while specializing in Food Industrial Machining. We offer a full line of services from tool
design and prototype machining through close tolerance, high volume production runs.
iMechanisch Sdn.Bhd is committed to providing exceptional value through competitive pricing,
superior quality, dependable on-time deliveries, and outstanding customer service. Whether the machining
service order is simple or complex, a short run or high volume production, Precise guarantees turn-key
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mechanical assembly solutions tailored to your requirements. We ensure exact tolerance and precise
positioning, supplying you with consistent quality machined parts on time, every time.
We also specialize in the high precision machining of instruments and component assemblies. We
have the experience, expertise and capability to provide turn-key mechanical assembly solutions for your
manufacturing needs, as well as, competitive pricing and delivery for all your production runs. From
concept to prototype to production, we ensure exact tolerance and precise results on all size components
whether simple or complex, supplying you with consistent quality machined parts, on time, every time.
8.3.5 Product Description

A product description in project management is a structured format of presenting information about
a project product. Product description is usually created by the project manager and approved by the
project board.
Table 8.5 Product Description
PRODUCT DESCRIPTION
NAME
Loaf Slicer Machine
ASSEMBLED
iMechanisch Sdn.Bhd
MOTOR POWER
220V, 1/4HP
MATERIAL
Stainless Steel
NET WEIGHT
70kg
DIMENSION
Square (680 x 610 x 685 )
TYPE OF INPUT
Large loaves that had not been cut into slices
OPERATOR
PRICE
RM 1500.00
MACHINE CAPABILITY
240 Loaves per hour

Easy to use
Less Idle time
FEATURES
Easy to clean
Easy to Maintenance
Non Corrosion
Protection Equipment
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8.3.6 Competitors
Competitor analysis in marketing and strategic management is an assessment of the strengths and
weaknesses of current and potential competitors. This analysis provides both an offensive and defensive
strategic context to identify opportunities and threats. Profiling coalesces all of the relevant sources of
competitor analysis into one framework in the support of efficient and effective strategy formulation,
implementation, monitoring and adjustment.
Competitor analysis is an essential component of corporate strategy. It is argued that most firms do
not conduct this type of analysis systematically enough. Instead, many enterprises operate on what is called
informal impressions, conjectures, and intuition gained through the bits of information about competitors
every manager continually receives. As a result, traditional environmental scanning places many firms at
risk of dangerous competitive blind spots due to a lack of robust competitor analysis. For our company,
there are few competitors in our region. There are:
Table 8-6 Competitors of iMechanisch Sdn.Bhd

Lee Manufacturing
ANALYSIS
Sdn.Bhd
Price
Capacity
Operation
Functions
Location
Excellent
Good
Average
Metal Works Sdn.Bhd
Power Steel Sdn.Bhd
Mega Jaya Sdn.Bhd
8.3.7 SWOT Analysis

SWOT analysis is a tool for auditing an organization and its environment. SWOT analysis is the
first stage of planning and helps marketers to focus on key issues. SWOT stands for strengths, weaknesses,
opportunities, and threats. Strengths and weaknesses are internal SWOT factors. Opportunities and threats
are external SWOT factors. The strength is a positive internal factor. A weakness is a negative internal
factor. An opportunity is a positive external factor. A threat is a negative external factor. The main purpose
of SWOT analysis has to be to add value to our products and services so that we can recruit new customers,
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retain loyal customers, and extend products and services to customer segments over the long-term. If
undertaken successfully, we can then increase our Return on Investment (ROI).
Fig. 8-4 SWOT Analysis

A process generates information that is helpful in matching an organization or groups goals, programs,
and capacities to the social environment in which it operates. The analysis such like below:
i. Strengths
Strength is a characteristic of the business or project that gives it an advantage over others. Our
company offers a product or a high quality machine suitable for all levels of users and ages. Other than that,
we offer affordable prices as well as friendly service using a minimum of maintenance products. To
complete effective and productive services, the company provides maintenance services for free and
warranty for three month.
ii. Opportunities
Opportunity is the elements that the project could exploit to its advantage. Our company also able a
spare part that can be and are easily available in large supermarkets and related stores in the surrounding
area near the user. Also, our company location also strategic to make sure has a good competitive
marketing with company at surrounding.
iii. Weaknesses
Weakness is characteristics that place the team at a disadvantage relative to others. There are certain
limitations we faced included the designated capacity of our products are only suitable for personal use,
small and medium industries which are not able to support production and large-scale operations. We
especially focused on small industries with a low production of machine in a certain time.
iv. Threats
Threat is the elements in the environment that could cause trouble for the business or project. There are
several threats facing such competition from several other companies involved rival product prices and
production functions of similar products will cause customers to make the selection and purchase of
products based on lower price is cheaper than the quality of products and services offered. Our company
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also took the risk to offer a cheap product prices to attract customers to the products offered. For
improvements in products, the company is still conducting research to improve processes and increase the
function of the product so much longer lifespan and more economical.
8.3.8 Market Analysis

A market analysis studies the attractiveness and the dynamics of a special market within a special
industry. It is part of the industry analysis and this in turn of the global environmental analysis. Through all
of these analyses the opportunities, strengths, weaknesses and threats of a company can be identified.
Finally, with the help of a SWOT analysis, adequate business strategies of a company will be defined. The
market analysis is also known as a documented investigation of a market that is used to inform a firm's
planning activities, particularly around decisions of inventory, purchase, work force expansion/contraction,
facility expansion, purchases of capital equipment, promotional activities, and many other aspects of a
company.
Although the terms "marketing" and "marketing analysis" can both be described as games of
information, they are not to be confused. Marketing encompasses all of the activities that go into
promoting a product or service. A marketing analysis is the actual assessment of the target population,
competition and needs for marketing that product or service.
The marketing analysis process can be broken down into six steps:
1. Defining the problem

2. Analysis of the situation
3. Obtaining data that is specific to the problem
4. Analysis and interpreting the data
5. Fostering ideas and problem solving
6. Designing a plan
In market analysis, we have set some criteria included the analysis of the effectiveness of the
product to be marketed, customer satisfaction with the products we use, and customer demand and
improvement. Analysis is in several ways, such as surveys and response from customer, booth sales, and
comparison between other competitors. In our market analysis, we provide some activities and analysis
that provide and evaluates of our machines to the consumers.
Below the analysis that used:
i. Survey and response from customer

Results of analysis conducted the analysis most users were encouraging comments and respond well to
the effectiveness of the products we produce. Besides that, result of consumer response and reaction, most
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are satisfied with the products we produce even if it is limited to personal use, and small and medium
industries.
ii. Booth sales

We also hold frequent demonstrations at a nearby booth to provide an introduction and explains the use
of machines that we produce as well as closing the gap, the difference between the seller and the buyer and
either the proportion at the same time, promote our products to consumers.
iii. Comparison between other competitor

Comparison of the products produced by existing products on the market at times is one method to
improve and upgrade the functionality of a product in order to generate higher production. Healthy
competition will give progress to a company for the production of high quality products. However, there
must be balance in the competition to avoid any discrepancy.
iv. Size of the primary target market

In addition to the size of our market, we are prepared what data can we include about the annual
purchases of our market in the industry. We also determine the forecasted market growth for our company
and so on.
8.3.9 Marketing Strategy

Marketing strategy is defined as a process that can allow an organization to concentrate its resources
on the optimal opportunities with the goals of increasing sales and achieving a sustainable competitive
advantage. Marketing strategy includes all basic and long-term activities in the field of marketing that deal
with the analysis of the strategic initial situation of a company and the formulation, evaluation and
selection of market-oriented strategies. Therefore contribute to the goals of the company and its marketing
objectives.
Marketing strategies serve as the fundamental underpinning of marketing plans designed to fill
market needs and reach marketing objectives. Plans and objectives are generally tested for measurable
results. Commonly, marketing strategies are developed as multi-year plans, with a tactical plan detailing
specific actions to be accomplished in the current year. Time horizons covered by the marketing plan vary
by company, by industry, and by nation, however, time horizons are becoming shorter as the speed of
change in the environment increases. Marketing strategies are dynamic and interactive. They are partially
planned and partially unplanned. See strategy dynamics. Marketing strategy needs to take a long term view,
and tools such as customer lifetime value models can be very powerful in helping to simulate the effects of
strategy on acquisition, revenue per customer and churn rate.
Marketing strategy is a process that can allow an organization to concentrate its limited resources on
the greatest opportunities to increase sales and achieve a sustainable competitive advantage. Our marketing
strategies are:
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1. Market scope strategy

Scope of the marketing strategy is a method conducive to be implemented to ensure that marketing
strategies can run smoothly and according to plans that have been made. Our marketing strategy is on
target to do the buyers. We offer quality products and friendly user where it can accelerate the work of man,
whether for use in small industrial or personal use at home. This project participates in helping to enhance
competitiveness among the Small Medium Enterprise (SME) to compete in the food marketing. Then, the
product also help the owner also needs to limit the production due to the limitation of the factory area and
the product also valuable for the hawker especially for the sales in night market with small production.
2. Product strategy
The products we offer are the machines Loaves Slicer Machine in which it can operate with a
maximum capacity according to the needs of consumers. This product is also able to help and ease the user
in addition to reducing labor costs on small and medium industries. In addition, it is a product more
affordable for all groups including the medium. The machine that will be increase the production of cutting
loaves and saving time compare to the manual process.
3. Promotion strategy
In marketing strategy, marketing channel selection to be accurate and systematic and that the message
conveyed in accordance with the product to be promoted. Advertising is one of the
promotion
strategy.
Our company has selected a number of printed medium channels such as advertising in posters,
newspapers, magazines and pamphlets as pamphlets are distributed to consumers. Other than that, a few
other channels in term of electronics medium such as advertising media such as blogs and social sites to
reach the target and set specifications.
Fig. 8-5 Example of poster
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4. Pricing strategy
Pricing strategies for products or services encompass three main ways to improve profits. These are that
the business owner can cut costs or sell more, or find more profit with a better pricing strategy. When costs
are already at their lowest and sales are hard to find, adopting a better pricing strategy is a key option to
stay viable. Merely raising prices is not always the answer, especially in a poor economy. Many businesses
have been lost because they priced themselves out of the marketplace. On the other hand, many business
and sales staff leave "money on the table". One strategy does not fit all, so adopting a pricing strategy is a
learning curve when studying the needs and behaviors of customers and clients. Most users are more than
price and quality specifications of the products offered. At the beginning, our company offers a price
appropriate and timely in accordance with specifications, quality, life expectancy, functionality, and userfriendly.
5. Service strategy
Once a service has been used and a contract between a service provider and a client has been
terminated, it likely ends up being phased out by the service provider. Retiring a service is a normal event
in a service lifecycle. Retired service is not available for use by present customers, but if they provide a
strong and special business case, the service providers can reinstate and revamp the phased out service.
Although these services are fully terminated, the information and data accumulated while it was under
operation might prove valuable as they are stored in the knowledge base of the company. Strategy is the
inclusion of a package of services offered by an enterprise of products will be marketed to attract further
users are satisfied with the product produced. Strategy service we offer is the maintenance and quality
assurance of products. So, our service strategy is provide quality assurance that we offer are for three
month and any damages caused certain related matters can be referred back to us for the good of the
products purchased by consumers.
8.3.10 Sales Forecast

Sales forecast can be define as an estimate of a company's future sales based on the historical
patterns, macroeconomic factors, and expected future trends. The sales forecast is important when a
company is making financial plans sales that fall short of the forecast may cause the company to be unable
to meet the obligations it has assumed based on those financial plans. Sales forecasting is the art of
estimating future demand by anticipating what buyers are likely to do under a given set of future
conditions. A sales forecasting is a projection into the future of expected demand given a stated set of
environmental conditions. It includes the financial, marketing, production, purchasing, and research and
development.
Forecasting is the process of making statements about events whose actual outcomes (typically)
have not yet been observed. A commonplace example might be estimation of some variable of interest at
some specified future date. Prediction is a similar, but more general term. Both might refer to formal
statistical methods employing time series, cross-sectional or longitudinal data, or alternatively to less
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formal judgemental methods. Usage can differ between areas of application, for example, in hydrology, the
terms "forecast" and "forecasting" are sometimes reserved for estimates of values at certain specific future
times, while the term "prediction" is used for more general estimates, such as the number of times floods
will occur over a long period. Risk and uncertainty are central to forecasting and prediction; it is generally
considered good practice to indicate the degree of uncertainty attaching to forecasts. In any case, the data
must be up to date in order for the forecast to be as accurate as possible.
Sales forecasting is one important element in a business plan to ensure that the proceeds raised
will provide the maximum benefits and profits to the company to reverse the process of further capital
increases the production of a product. Sales forecasting is a continuation of the total cost to be incurred and
the profit to be obtained. Sales forecast helps to plan a companys investment, launch new products, and
decide when to closer or withdraw production and so. The diagram below shows the step of sales
forecasting process.
Fig. 8-6 Component of integrated planning
Below is the step to conduct a sales forecasting:
Setting goal
for sales
forecasting
Gathering
data
Choose the best

model for sales
forecasting
Analysis of
data
Sales
forecasting
Evaluation of
forecasting
outcomes
Fig. 8-7 Steps of sales forecasting process

To discuss operational planning, lets take a look at sales and operational planning (S&OP), which
embodies the best set of concepts for this discussion. S&OP is typically applied to manufacturing
organizations but all companies are involved in some method of S&OP planning:
i.
Manufacturing needs to optimize the production facility while harmonizing it with customer
demand/sales, resource/raw material availability, production process, and inventory levels.
ii.
Retailers need to optimize shelf space utilization by merging/balancing sales with customer, market,
promotional demand, and shipping/distribution capacities to the stores as well as related financial
impact to gross margin.
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iii.
Services companies need to coordinate sales against available human resources to deliver the
services. Some services organizations hire first and sell to the resources they have, others sell first
and hire resources to deliver the services to the desired level of utilization.
Sales and operational planning (S&OP) is a process for matching demand and supply within a consensus
management framework. It is typically defined in terms of operational units and is a common sense
approach to ensure that organizations have a structured framework for matching demand exposure to
supply capabilities through the harmonization of various functional areas.
i. Sales Forecasting
The first step is to create a monthly rolling sales forecast that contains projections for the
coming
18
to 24 months. This process includes both a sales forecast from the field (typically optimistic), tempered
with analysis from the Marketing department of previous years data, market trends and marketing
programs.
The sales forecast is typically planned based on how the product/service is sold, i.e.
customer/product/channel.
ii. Demand Planning

Demand planning validates the sales forecast and tempers it with an understanding of the sources of
sales as well as current inventory levels and customer service policies. The initial demand planning steps
include converting the sales forecast into units, then separating by
customer/product/channel and how the
product is manufactured or delivered.
iii. Supply Planning

Supply planning is typically performed by an operations group on the production planning side who
analyses the ability to achieve the demand plan by reviewing availability of resources and production
capacity (in the case of services this would be headcount).
iv. S&OP Reconciliation of the Plans

This step merges/reconciles the demand and supply plans with constraints to create an optimal plan. It
is important this process has the ability to chase both demand and supply constraints and opportunities
equally. Many implementations only focus on the demand side of the plan which hides revenue
opportunities created by excess supply capacities or key customer opportunities.
v. Finalize S&OP and Move to Production

The final step in the monthly S&OP process is to finalize the plan and release it to production. This is
typically done in the monthly S&OP meeting and includes representatives from Marketing and Sales with
the demand side plan, and Operations and Supply Chain management with the supply side plan, and
Finance. This meeting helps to foster a single version of the truth for this months production cycle.
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CHAPTER 9.
SUMMARY
9.1 Product Development Process
As mention before, the objective of our project is to to find the solution to help the supplier to
produce loaf slicer easily and with the high production. As we know, the procedures really make the
person tired because the loaves or breads need to slice by manual using human energy. In other hand, the
project is the way to make sure that will be increase the production of number of loaf slicer and saving
time compare to the manual process. This is because the machine applied the cutting process. As we know
the process for cutting loaf by manual method really wasting time because only a low production can be
made in once time based on the human work and energy. So, that is why we are design a machine that we
call as Loaf Slicer Machine.
We expect that the product that has developed from our group is the new invention in today market
which is the product can help to increasing the production of loaf slicer especially for Small Medium
Enterprise (SME). By using the knowledge of Engineering Design (BDA 40203), the product successfully
developed as we are considering the detail design step and procedures. As we know, the design process is a
sequence of events and a set of guidelines that helps define a clear starting point that takes the designer
from visualizing a product in human imagination to realizing it in real life in a systematic manner.
Basically, design in the context of engineering usually implies that knowledge is combined with
specialized skills to create the new product. After we are considered all of the design needed based on the
archival collection which is from the questionnaire, the collected data is analysed and lastly we can
conclude the factors that will be give the influence for our project. The main factors are the function,
design, maintenances, safety, environment and price.
From the engineering design process is a formulation of a plan or scheme to assist an engineer in
creating a product. The engineering design is defined as component, or process to meet desired needs. It is
a decision making process in which the basic sciences, mathematics, and engineering sciences are applied
to convert resources optimally to meet a stated objective. Among the fundamental elements of the design
process are the establishment of objectives and criteria, synthesis, analysis, construction, testing and
evaluation. That is why we also focused on the calculation and the analysis of the product to make sure
there are no failures during or after the product are developed. In situations where a component failure can
cause damage to people, property or the environment it is important to do a Failure Mode and Effect
Analysis. These aids in assessing the potential risk of various failure modes, and may point the way to
improving design toward fail safe modes. There are always unknown or overlooked aspects in any large
project, and verification is an important step in any solution. Testing should start with the collection of data
as to make small changes in the existing system and measure their effects.
Generally, the engineering design process is a multi-step process including the research,
conceptualization, feasibility assessment, establishing design requirements, preliminary design, detailed
120
design, production planning and tool design, and finally production. For example, in the research section
where we need to compile all of the data that we are got from our research and also by distribute the
questionnaires. By the data, we did the benchmarking and objectives tree to known the first or main
function that we should to make as the importance things to develop our product.
Lastly, we can conclude that the mechanical engineering design is a part of the overall domain of
mechanical engineering. The advent of mechanical engineering and the intrusion of equipment have
largely redefined human lifestyles. In mechanical engineering, the development of any product involves
some broad steps as mentioned before. The basic step also is discussed in the Engineering Design subject.
As known, the step are including the process of identify idea and concept, define the requirement for
realizing the concept, gather relevant information on similar product, the design phase and lastly is the
prototype product.
For the overall processes to develop the product, we can state that the most important before make the
product is we can understand in detail all of the engineering knowledge. Without the knowledge we cannot
make the product as well as we are expected. Besides that, the additional knowledge also must to be
practice in self. Without the skill to welding well, machining, lathe and others, we cannot make the
product in good quality. As mechanical student, everybody should know the skill whether the basic
knowledge. In other hand, team works also really to be more important to making the perfect job. Without
cooperation to each other, the way to develop the product will be hard and unsuccessful.
For the conclusion, engineering design knowledge really gave a lot of advantages to people especially
for the engineer. With the knowledge, there are no impossible job cannot be done. We must to know that
the engineering design process is the set of decision making and steps that engineer should think and
identifying all the solution to develop something to make sure the entire engineering job can be done
successfully.
9.2 Product Significance

From the research and data collection, we are decided to develop the new product called as Loaves
Slicer Machine. As discuss before, the product significant is mostly is to helping and enhance
competitiveness among the Small Medium Enterprise (SME) to compete in the loaves food marketing.
With the lot of support from the government in term of training, capital, advice and so on contributes to the
successful to the small dealer in business.
Besides that, the owner also needs to limit the production due to the limitation of the factory area. The
problem occur from the observation from the certain small factory that process of the loaf slicer shows
that the cutting process need to do manual which demands more human energy and workers. Consider to
the problem, the machine created to maximize the quantity output of the product. The reasonable machines
price for large output worth for the SME entrepreneur to buy it for large production.
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9.3 Product Features

The following able 9-1 is the features of the loaf slicer machine
Table 9-1 Product description

NAME
Loaf Slicer Machine
ASSEMBLED
iMechanisch Sdn.Bhd
MOTOR POWER
220V, 1/4HP
MATERIAL
Stainless Steel
NET WEIGHT
70kg
DIMENSION
Square (680 x 610 x 685)
TYPE OF INPUT
Large loaves that had not been cut into slices
OPERATOR
PRICE
RM 1500.00
MACHINE
CAPABILITY
FEATURES
240 Loaves per hour

Easy to use
Less Idle time
Easy to clean
Easy to Maintenance
Non Corrosion
Protection Equipment
122
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medium,
United
States
Patent
(5173313),
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2013
from
http://www.freepatentsonline.com/5173313.html
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APPENDIX A
APPENDIX B
MINUTE OF MEETING 1
DATE
25 September 2014
TIME
8.30 PM 10.00 PM
VENUE
LIBRARY UTHM
ATTENDANCE
1) MOHAMMAD SYAKIR BIN SURANI
2) MUHAMMAD SHALIHIN BIN MD YUSOF
3) MOHD SAFA RUDDIN BIN MD JUNOH
4) SHAHRUL AZNI BIN HADISON
5) REEHANA BINTI MOHAMED RILWAN
AGENDA
TIME
PARTICULARS
ACTION
8.30 - 8.35
Group member arrival
8.35 - 9.00
a) Selecting group leader
Mohammad Syakir
b) Selecting group secretary
Reehana
c) Discussion about the design project.
All group member
- Group Name
- Organization Chart
- Group Logo
- Motto/Vision of group
9.00 - 9.45
Task distibution
Mohammad Syakir
a) Decription of the design project :
All group member
- How about the system?

- The system function?
9.45 10.00
10.00
Meeting conclusion
Mohammad Syakir
Meeting dismissal
*All contents discussed in the meeting is written in the report.
Prepared by :
Checked by :
(Reehana binti Mohamed Rilwan)
(Mohammad Syakir bin Surani)
Secretary
Leader
MINUTE OF MEETING 2
DATE
16 October 2014
TIME
9.00 11.00 PM
VENUE
LIBRARY UTHM
ATTENDANCE
AGENDA
TIME
PARTICULARS
ACTION
9.00 9.05
9.05 9.20
a) Parts distribution
Mohammad Syakir
b) Presentation about the Loaves Slicer Machine:
All group member
Description of the project :

Machine that used for cutting process.
- Badget?
-
Scope and project background.
Main component in Machine?
Using the second hand machine or

fabricate a new one?
10.20 10.45
Discussion on project preparation.
10.45 10.50
Next meeting determination
10.50 11.00
Meeting dismissal
All group member
Prepared by :
Checked by :
Secretary
Leader
MINUTE OF MEETING 3
DATE
6 November 2014
TIME
9.00 11.00 PM
VENUE
LIBRARY UTHM
ATTENDANCE
AGENDA
TIME
PARTICULARS
ACTION
9.00 9.05
9.05 9.20
a) Parts distribution regarding the drawing
Mohammad Syakir
of Solid Work
All group member
b) Idea and opinion regarding the location

for the project fabrication.
10.20 10.45
10.45 10.50
10.50 11.00
Meeting dismissal
All group member
Prepared by:
Checked by :
Secretary
Leader
MINUTE OF MEETING 4
DATE
20 November 2014
TIME
9.00 11.00 PM
VENUE
LIBRARY UTHM
ATTENDANCE
AGENDA
TIME
PARTICULARS
9.00 9.05
9.05 9.20
a) Discussion about concept
ACTION
Mohammad Syakir
development.
-
All group member
How to make the fundamental
analysis, gear analysis, gear failure

analysis, shaft analysis, bearing
analysisand housing analysis.
10.20 10.45
Distribution of work process.

-
All group member
Discuss about the detail about the analysis. How much

gear we need to use? What material should we use?
10.45 10.50
10.50 11.00
Meeting dismissal
Prepared by :
Checked by :
Secretary
Leader
MINUTE OF MEETING 5
DATE
30 November 2014
TIME
4.00 5.00 PM
VENUE
LIBRARY UTHM
ATTENDANCE
AGENDA
TIME
PARTICULARS
ACTION
4.00 4.05
4.05 4.45
a) Discussion about the preparation of
Mohammad Syakir
booth for the UTHM Innovators 2014 on 2
All group member
December 2014
b) Rehearsel on preparation for the

presentation infront of the panel.
4.50 5.00
Meeting dismissal
Prepared by :
Checked by :
Secretary
Leader
APPENDIX C

Final Report For Loaf Slicer

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iMechanisch

LOAF SLICER MACHINE

MOHAMMAD SYAKIR BIN SURANI DD110038

UNIVERSITI TUN HUSSEIN ONN MALAYSIA

Product Background ........1

Problem for Existing Product.1

General Task Delegation8

Project Planning and Scheduling..9

CHAPTER 2. DEFINE TASK...10

Product Background of Loaf Slicer .10

Patent Search ......11

Commercial Product Search....19

Comparison Of Products From Patent Search.22

Benchmarking Of Product Specification from Commercial Product .23

Problem for existing product.25

Identifying Market Needs (Market Survey) and Customer Satisfaction....25

Objective Clarification ....31

Weighting of Objective Tree........32

Quality Function Deployment (QFD) House Of Quality ..33

Requirement List (Rl)/Engineering Design Specification (EDS)....34

CHAPTER 3. CONCEPTUAL DESIGN.....37

Component decomposition analysis.39

Function decomposition analysis.40

Brainstorming concept generation...43

Evaluation matrix-weighted rating method.47

CHAPTER 4. EMBODIMENT DESIGN AND ANALYSIS.50

Schematic diagram of the product50

Element cluster of schematic...51

Rough geometric layout...52

Standard Main Parts ....54

Special Purposes Parts......54

Parametric Design Problem..55

4.3.1.1 Component Analysis and Selection.55

Consideration of Design for X....78

4.3.2.1 Design for Safety......78

CHAPTER 5. DETAIL DESIGN AND PRODUCT SIMULATION....81

Final Product Design Specification......81

5.3.1 Parts .....82

Product Analysis and Simulation by Solidworks Simulation..84

Fatigue Failure ....85

Other Analysis ....85

Bill of Material (BOM)....87

Manufacturing Process ....87

Final Product Design Specification .....88

Complete Design Checklist .....89

CHAPTER 6. PROTOTYPING, TESTING AND REFINEMENT..90

Product Prototyping ....90

Testing Requirement and Checklist...95

Testing & Refinement.95

Final Prototype Product ....................97

Overview Product ....................98

CHAPTER 7. SUSTAINABILITY AND ENVIRONMENTAL CONSIDERATION IN

Design for minimal use of materials ...99

Design for recyclability 101

Life Cycle Assessment (LCA)...101

Social and Economic Issues ..101

CHAPTER 8. ECONOMIC AND COSTING...103

Mission and Vision ....108

8.3.10 Sales Forecast..118

Product Development Process121

1.2 Problem for Existing Product

1.3 Project Objective

To save time and energy consumption in serving the dishes.