DESIGN OF A CURRY PUFF MAKING
MACHINE
IMRAN BIN IBRAHIM
A thesis submitted in fulfillment of the
requirements for the award of the degree of
Master of Engineering (Mechanical – Advanced Manufacturing
Technology)
Faculty of Mechanical Engineering
Universiti Teknologi Malaysia
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DEDICATION
iv
ACKNOWLEDGEMENT
In preparing this thesis, I was in contact with many people, researchers, academicians, and practitioners. They have contributed towards my understanding and thoughts. In particular, I wish to express my sincere appreciation to my main thesis supervisor, Associate Professor Zainal Abidin bin Ahmad, for encouragement, guidance, critics and friendship. Also to my industrial contact who had expense their time for me to explain and share their valuable knowledge in progressing my project namely En. Mazlan bin Ahmad and En. Ahmad Fakhruddin bin Jusoh. Without them the idea of designing this current project would not be initiated and completed within the allocated time frame.
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ABSTRACT
Most of the processes of curry puff making in small scale industry are well known as handmade product where curry puffs are made by using human manpower completely. This certainly needs many human power and skilled operators to increase their production rate at high competitive level. In another side, experienced curry puff maker use the machine that imported from out of our country. This can be a burden for small scale industry player that want to start and continue their small business.
This project is to design a curry puff making machine that will help industry player to start their business at low cost. To realize the model of the machine, a systematic approach called product design and development is implemented to ensure the proper design is completed. It is covers the concept development, concept scoring, selection and preliminary final design. Consequently a conceptual model of curry puff machine complete is created. For further step, this conceptual model will be designed in detail and model analysis will be performed to distinguish any design related issues.
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ABSTRAK
Kebanyakan proses pembuatan karipap dalam industri berkala kecil lebih menjurus kepada produk pembuatan tangan di mana karipap dibuat dengan menggunakan tenaga manusia sepenuhnya. Ini sudah tentu memerlukan tenaga manusia yang ramai serta berpengalaman untuk meningkatkan kadar penghasilan produk di peringkat berdaya saing. Di satu bahagian yang lain, pengusaha yang berpengalaman menggunakan mesin pembuat karipap yang diimport dari luar negara di mana kebergantungan kepada mesin luar adalah tinggi. Ini membebankan bagi pengusaha industri berskala kecil ini yang memulakan dan menjalankan perniagaan mereka secara kecil-kecilan.
Projek ini merekabentuk mesin pembuat karipap yang bakal membantu pengusaha memulakan perniagaan pada kos yang rendah. Dalam merealisasikan rekabentuk model mesin tersebut, kaedah merekabentuk yang sistematik dipanggil pembangunan dan rekabentuk produk diserapkan bagi memastikan sebuah rekabentuk yang tersusun dipatuhi. Ini merangkumi pembangunan konsep, penilaian, pemilihan konsep, dan permulaan kepada rekabentuk akhir.
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TABLE OF CONTENTS
CHAPTER TITLE PAGE
DECLARATION ... ii
DEDICATION ... iii
ACKNOWLEDGEMENT ... iv
ABSTRACT ... v
ABSTRAK ... vi
LIST OF TABLES ... x
LIST OF FIGURES ... xii
LIST OF ABBREVIATIONS ... xiii
LIST OF APPENDICES ... xiv
1.0 INTRODUCTION ... 1
1.1 Project Background ... 1
1.2 Product Description ... 2
1.3 Product Objective ... 3
1.4 Problem Statement ... 3
1.5 Scope Of Work ... 3
2.0 LITERATURE REVIEW ... 5
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2.2 Curry Puff and Its Making Process ... 6
2.3 Concept Development Phase ... 9
2.4 Concept Generation ... 11
2.4.1 Pattern Search ... 11
3.0 RESEARCH METHODOLOGY... 15
3.1 Research Planning ... 17
3.2 Concept Development ... 20
3.2.1 Proposed Design ... 20
3.3 Identifying Customer Needs ... 22
3.4 Product Spesification ... 24
3.5 List of Metrics ... 26
3.6 Product Concept ... 30
3.7 Concept Screening ... 33
3.8 Concept Scoring ... 37
3.9 Set Final Spesifications ... 39
4.0 RESULT & DISCUSSION ... 41
4.1 Detail Design ... 41
4.2 Design Analysis ... 49
4.3 Material & Process Selection ... 61
4.4 Estimating the Cost of Components ... 71
4.5 Detail Drawing ... 73
4.6 Bill of Materials ... 74
4.7 Schematic Diagram ... 76
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x
LIST OF TABLES
TABLE NO. TITLE PAGE
Table 3.1 Customer statement and interpreted needs ... 23
Table 3.2 Customer need for curry puff making machine and their relative importance ... 25
Table 3.3 List of metrics for curry puff making machine ... 27
Table 3.4 The needs-metrics matrix. ... 28
Table 3.5 Design Screening Matrix ... 35
Table 3.6 Design Scoring Matrix ... 38
Table 3.7 Set final specification ... 40
Table 4.1 Main structure of curry puff making machine ... 42
Table 4.2 Curry puff mould ... 43
Table 4.3 Linear motor ... 44
Table 4.4 Switch button ... 45
Table 4.5 Emergency switch button ... 45
Table 4.6 Push button switch ... 46
Table 4.7 Motor and motor drive... 47
Table 4.8 Controller or frequency inverter ... 48
Table 4.9 L angle bracket ... 62
Table 4.10 Clamp plate ... 63
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Table 4.12 Side Plate 2 ... 65
Table 4.13 Mounting Plate ... 66
Table 4.14 Front panel support ... 67
Table 4.15 Side panel ... 68
Table 4.16 Shaft ... 68
Table 4.17 Slide mounting plate ... 69
Table 4.18 Shim plate ... 70
Table 4.19 Bill of Material for curry puff machine ... 74
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LIST OF FIGURES
Figure 1.1 Overview of a typical curry puff making process ... 4
Figure 2.1 Basic methodology of curry puff making ... 7
Figure 2.2 Manual process of curry puff making ... 8
Figure 2.3 (a) Continuous dough feeder (b) Dough extruding feeder ... 13
Figure 2.4 (a) Apparatus for producing corrugated pasta sheet (b) Dumpling making machine... 14
Figure 3.1 Project methodology of design and development of curry puff making machine... 16
Figure 3.2 Schedule plan for project 1 ... 18
Figure 3.3 Schedule plan for project 2 ... 19
Figure 3.4 Flow of curry puff making machine processes... 21
Figure 4.1 Stress analysis ... 52
Figure 4.2 Displacement analysis ... 53
Figure 4.3 L Angle-Study 1-Stress-Stress1 ... 56
Figure 4.4 L Angle-Study 1-Displacement-Displacement1... 56
Figure 4.5 Slide mounting plate -Study 1-Stress-Stress1 ... 60
Figure 4.6 Slide mounting plate-Study 1-Displacement-Displacement1 ... 60
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LIST OF ABBREVIATIONS
ABS
Acrylonitrile butadiene styrene
BOM
Bill of material
FEA
Finite Element Analysis
PDS
Product Design Specification
PBT
Polybutylene Terephthalate
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LIST OF APPENDICES
APPENDIX TITTLE PAGE
A-1 Linear Guide 87
A-2 Hexagon socket head cap screw 88
A-3 Stainless steel socket head cap screw Parallel keys
89
A-4 Flanged nuts
Hexagon socket flat head cap screw
90
A-5 Spur gear : Pressure Angle 20˚ Module 0.8 Screw plug
91
A-6 Screw plug 92
A-7 Stepping motor 93
A-8 Driver dimension 94
A-9 Controller 95
A-10 Rack gears: Pressure Angle 20° L Dimension Fixed/L Dimension Specified Type
96
B-1 Curry Puff Machine Assembly Drawing 97
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APPENDIX TITTLE PAGE
B-3 L angle bracket 99
B-4 Clamp plate 100
B-5 Bar clamp 1 & 2 Shaft
101
B-6 Side plate 1 102
B-7 Mounting plate 103
B-8 Front panel 104
B-9 Front panel support 105
B-10 Shim plate 106
B-11 Side mounting plate 107
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CHAPTER 1
1.0
INTRODUCTION
1.1 PROJECT BACKGROUND
The industry of frozen food is believed to have high chances of expansion especially in the export market. Every time and everywhere, locally, we saw curry puff is sold from food stalls near the main road until the big shopping complex. Therefore it is not to surprise if this curry puff making industry was selected by most local entrepreneurs with good understanding its potential to be commercialized so that it can getting into the local and foreign markets massively.
Curry puff cake is traditionally made manually. Most of the manufacturers (in SMI) are also producing the curry puff manually with extra workers. Manual production refers to the process of folding or crimping dough into curry puff shape. They use variety of machines to prepare the raw materials until up to preparing the dough sheets. From business point of view, this is time consuming therefore becomes the bottleneck in responds to the market demands. Besides the manual production, this traditional process requiring numerous skilled workers that contributes to the high labour cost.
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1.2 PRODUCT DESCRIPTION
This project is focusing on the design of curry puff making machine, in particular the automatic crimping mould assembly.
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1.3 PRODUCT OBJECTIVE
To produce a detailed product design specifications of a curry puff making machine capable of performing dough sheet stamping and crimping processes.
1.4 PROBLEM STATEMENT
Figure 1.1 shown is the overview of curry puff making process which was identified as problem statement of this project. This manual method shows how the processing steps which is time consuming thus making curry puff production is not competitive enough in term of business. This project intends to solve the problem of crimping method where the manual crimping technique is not suitable for large quantity production.
1.5 SCOPE OF WORK
1. Identify the manual methods of producing curry puff and analyze the possibility for production improvement using a machine.
2. Product design and development technique is implemented.
3. Design a few concepts of curry puff making machine and perform the best design selection.
4. Design a curry puff machine in 3D models.
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PROCESS CONSTRAINT
Rolling dough Rolled by piece
Time consuming
Fill stuffing
Manual crimping
Time consuming High manpower
Mould crimping OR
Low production rate
High manpower
Job constraints
Need for skilled
Low competitiveness Product varies
Time consuming