Apparatus, system and method for modular manufacture of cooking appliances
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Solution Overview
Problem
Current manufacturing processes for complex devices like appliances are inefficient due to the manual installation of numerous components and wiring harnesses, leading to increased production costs, workplace injuries, and storage challenges, as well as limitations in manufacturing throughput and yield.
Innovation Solution
The implementation of a modular manufacturing system where devices are assembled using prefabricated snap-in, screw-in, or clip-in modules that can be easily integrated into a generic device shell, allowing for automation and reducing the complexity of assembly, thereby decreasing assembly time and improving manufacturing efficiency and logistics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual installation of wiring harnesses and components is used, then device functionality and features can be implemented, but assembly time increases and productivity decreases
Solution Approach 1:
The device is divided into modular components (cabinet, cooking module, oven module) that can be manufactured separately and assembled quickly. Each module contains pre-organized wiring harnesses and components that connect through standardized interfaces, reducing assembly time while maintaining full device functionality.
Solution Approach 2:
Wiring harnesses and components are pre-assembled and pre-positioned within modules during manufacturing. The cabinet is prepared with pre-installed mounting structures and electrical interfaces before modules are attached, eliminating the need for complex on-site wiring and component installation.
2Adaptability or versatility
If numerous components and wiring harnesses are installed manually, then complete device functionality is achieved, but workplace injuries increase due to repetitive tasks
Solution Approach 1:
By segmenting the device into pre-assembled modules with integrated wiring harnesses, the number of repetitive manual installation tasks is dramatically reduced. Workers assemble complete functional modules rather than installing individual components, reducing repetitive strain injuries while maintaining full device functionality.
3Ease of manufacture
If traditional manufacturing processes are used, then device assembly is completed, but storage and floor space requirements increase due to in-process inventory
Solution Approach 1:
The manufacturing process is segmented into independent module production lines that can operate in parallel. Modules are manufactured separately and stored in compact configurations, then quickly assembled in the field. This eliminates the need for large in-process inventory storage areas while maintaining manufacturing flexibility.
Solution Approach 2:
Modules are designed to fold or collapse into compact configurations for storage and transport. The cooking module and oven module can be folded flat or stacked vertically, dramatically reducing the floor space required for inventory storage while maintaining ease of assembly through the folding mechanisms.
4Device complexity
If manual component installation is performed, then device complexity is managed, but manufacturing throughput decreases
Solution Approach 1:
The complex device is segmented into standardized modules with pre-organized components and wiring. This modular approach simplifies the assembly process while maintaining device complexity, enabling parallel production and significantly increasing manufacturing throughput.
Solution Approach 2:
Standardized module interfaces and mounting structures allow the same cabinet to accommodate different cooking modules and oven modules. This universality simplifies the assembly process and enables flexible production scheduling, increasing manufacturing throughput while managing device complexity.
Data Source
AI summary
An apparatus, system and method for a manufactured cooking appliance. The apparatus, system and method may include: a generic device shell comprising at least a power supplying wire harness and a plurality of female latching points on a top and a front thereof; a folding module comprising a cooktop and, hinged to the cooktop, an oven front comprising at least an oven door fittedly associated with a frame and having a door hinge connected to the over door and passing through the frame; and a plurality of male latches associated with the folding module, including at least one male latch associated with the portion of the door hinge that passes through the frame, each capable of latching into a corresponded one of the plurality of female latching points so as to, upon the latching, form a completed one of the manufactured stove.