Production Manual FINAL .pdf

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COASTLINE
KEEPER
Production Binder

Neal Gorris, Tyler Ubenhand, Ben Lakes, Cade Vallejo, Brydon Clark Kendra
Berning, Sergio Cois, Andrew Dieterle, Jordan Cook, Tyler Corell, Jake Smith,
Pedrom Mashaw, Vip Bhatnagar











Table of Contents
Team Mission & Vision Statement ……………………………………………………………..4
Production Plan ………………………………………………………………………………….5
Bill of Materials…………………………………………………………………………………5
Callout Diagram ………………………………………………………………………………..6
Solidworks Renderings …………………………………………………………………………7
Solidworks Drawings …………………………………………………………………………10
Production Gantt Chart ………………………………………………………………………23
Value Stream Map …………………………………………………………………………….24
Workflow Diagram ……………………………………………………………………………25
Time Studies …………………………………………………………………………………..26
Lists………………………………………………………………………………………………30
Equipment & Machinery……………………………………………………………………….30
Consumable Tooling…………………………………………………………………………....31
Nonconsumable Tooling ………………………………………………………………………32
Jigs, Fixtures, & Gauges………………………………………………………………………...34
Safety & PPE…………………………………………………………………………………...35
Work Instructions………………………...……………………………………………………...36
Waterjet Steel…………………………………………………………………………………..36
Deburring Steel Coastline & Vertical cutout …………………………………………………...43
Bending Vertical Steel Backplate ………………………………………………………………45
Bending Vertical Steel Backplate Tabs …………………………………………………………47
Welding Front Plate to Side Plate ……………………………………………………………....50
Sandblasting Coastline ………………………………………………………………………....54
Die Grinding Sandblasted Coastline……………………………………………………………58
Clear Coat of Sandblasted Coastline …………………………………………………………....60
J-B Welding the Magnets ………………………………………………………………………62
WaterJet Wooden Backplate & Shelves ………………………………………………………...65
Routing Wooden Shelves ……………………………………………………………………....72
Drilling for Wire Inlay …………………………………………………………………………75
Beveling Wooden Shelves with Chop Saw ……………………………………………………..77
Sanding Wooden Backplate & Shelves ………………………………………………………....79
Staining Wooden Backplate & Shelves …………………………………………………………81
Bending Trim …………………………………………………………………………………..85
Trim Attachment ………………………………………………………………………………87
Nailing Shelves to Wooden Backplate ………………………………………………………….89
Screwing Vertical Side Plate to Wooden Backplate ……………………………………………..91
Clear Coat of Coastline Keeper ………………………………………………………………...93
CNC Lathe of Keychains ………………………………………………………………………95
CNC Mill Engraving of Keychains ……………………………………………………………105
© 2017 Coastline Keeper



www.coastlinekeeper.com

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Tumbling of Keychains ……………………………………………………………………….116
Keychain Assembly …………………………………………………………………………...118
Coastline Keeper Packaging Assembly ………………………………………………………..120
Team Documentation ………………………………………………………………………....123
Cross Training Matrix ………………………………………………………………………123
Hours Worked ……………………………………………………………………………...124
Testing & Analysis …………………………………………………………………………….125
MVB Analysis ………………………………………………………………………………125
Failure Modes & Effects Analysis (FMEA) …………………………………………………129
Break Even Analysis ……………………………………………………………………….. 131
Gauge Calibration & Validation ……………………………………………………………..133
Product Life Cycle & Destructive Testing …….……………………………………………..139
Lessons Learned …………………………………………………………………………….142
Art & Marketing ……………………………………………………………………………….147
Marketing and Sales Strategy ………………………………………………………………..147
Market Testing Data ………………………………………………………………………..150
Logo Designs ………………………………………………………………………………159
Keychain Designs …………………………………………………………………………..160
Engraving Designs …………………………………………………………………………161
Retail Packaging Design .…………………………………………………………………....162
Website Pages & Online Presence ………………………………………………....………..163
Glossary of Terms ……………………………………………………………………………..165
Misc. Assets ……………………………………………………………………………………168
Supplier Contingency Plan …………………………………………………………………..168
Process Contingency Plan …………………………………………………………………...170
Material Safety Data Sheets ………………………………………………………………….172









© 2017 Coastline Keeper



www.coastlinekeeper.com

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Mission Statement:
Coastline Keeper exists to deliver high quality, attractive, decor-level storage solutions
that allow you to never lose your personal items inside your own home again.


Vision Statement:
Providing seamless convenience in a cluttered world.


















© 2017 Coastline Keeper



www.coastlinekeeper.com

P a g e | 4










Production Plan
Bill of Materials



















© 2017 Coastline Keeper



www.coastlinekeeper.com

P a g e | 5










Callout Diagram






















© 2017 Coastline Keeper



www.coastlinekeeper.com

P a g e | 6










Solidworks Renderings
Rendering 1



























© 2017 Coastline Keeper



www.coastlinekeeper.com

P a g e | 7










Rendering 2




























© 2017 Coastline Keeper



www.coastlinekeeper.com

P a g e | 8










Rendering 3
























© 2017 Coastline Keeper



www.coastlinekeeper.com

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