Thomas Doyle MSc.
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Design Evaluation (DE)
Design Evaluations:
Examples of Design Evaluations Before, During and After Production:
Background :"Boots on the ground " QA Director meets directly with "Skin in the Game" Factory Owner to execute research testing and validate packaging design to meet transit and drop testing (i.e. no third party services).
Requirement: Luxury 5th Ave Retailer features promotional offers for a "Pre-Gift-Wrapped Mother's Day Gift with Purchase".
White Color MDF Tray with Design Artwork featured on surface, co-pack with matching white ceramic vase with matching artwork. Both items are sold as "gift wrapped" product. It is critical the "gift wrapped" package design will protect the wood tray and ceramic vase from damage from extreme transport conditions. The Factory owner (boss) with his project engineers worked closely with the buyer's QA director based in Hong Kong to verify the package design could withstand extreme drop and transit testing.
Action Items: DfM research test package design to withstand transit testing.
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Lesson Learned: "Boots on the ground" buyer QA Director with "Skin in the Game" Factory owner
Background: DE sculpture review for tool start custom toy premiums for licensed cartoon character (animation studio based in Southern California).
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Action Items: DfM
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Background: DE for die cut tooling pattern to puzzle on product character ().
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Action Items: Benchmarking
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Background: Design Evaluation (DE) for tool start custom premiums for (Packaged Food Company based in Lausanne, Switzerland).
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Background: DE for tool start custom toy premiums for licensed character (US Movie Ranch headquarter based in Northern California ).
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Background: DE for tool start custom toy premiums for licensed character (British Claymation studio based in Bristol, UK).
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Background: DE for tool start custom toy premiums for licensed character (US Movie Studio Theme Park based in Osaka Japan).
Requirement: Design and manufacture custom product for theme ride gift stores.
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Background: DE to tool start on balancing toy design.
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Background: Composite Wood (CARB) Products ATCM.
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Background: Excessive Use of Material Regrind that creates hazards from material degradation (i.e. substrate color).
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Background: .Battery compartments
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Background: .Instruction sheets and warning statements
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Background: Injection molding short shots. Dimensional Stability, Material Weight Verification
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Background: Material selection (properties for decoration, mechanical, performance properties),
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Background: .Reasonable foreseeable uses and abuse (misuse).
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Background: .Marketing claim verification and validation.
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Background: Product design and package design evaluation for: Transit and Drop Test
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Background: White-label
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Background: Multiple sourced design variance risk
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Background: Wall-Clock designs -material and processes.
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Background: Playing card container with Cute Cartoon eyes and ears.
Requirement: Small parts risk assessment.
Action Items: Legacy staff requested a design evaluation assessment on the risk hazard for small parts (i.e. cartoon shaped animal ears).
Results: The owner refused comments by claiming it was not a toy. However the container's smooth capsule shape, bright colors, cartoon eyes and ears could create risk of unintended use as an infants pacifier. Additionally, the product had been feature "for all kids" in a retailer's advertisement.
Lesson Learned: It is prudent to consider the worst case scenario in terms of reasonable and foreseeable use and abuse by intended or unintended consumer age grade. It is the mindset of firms that value proactive product safety design evaluations including research test to failure (TTF).
Background: Product design Protocols from US and International retailers and big box stores (i.e. Avon, COSTCO, RadioShack, JC Pennies, Toys R Us).
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Background: Benchmarking
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Background: Performance Metric
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Background: Verification and Validation
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Background: Analysis of Variance (ANOVA)
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Background: Measurement System Analysis
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Background: First Article Inspection (FAI) for Physical and Mechanical (P&M) Force Diagrams
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