Index

Introduction

• Welcome

• Introduction

1. What is the Color Spin?

• (1.1) Color Spin Product Description

• (1.2) Color Spin Background Information

• Significant Events in Mattel's History

2. Why Redesign?

• (2.1) Mattel 2000

• (2.2) Choosing Color Spin for Redesign

• Meet Fred Schwager

• Meet Isaak Volynsky

3. Design Goals

• (3.1) Goals for Color Spin Redesign

4. Development Team

• (4.1) The Multifunctional Development Team

5. Concurrent Engineering

• (5.1) Concurrent Engineering at Mattel

• (5.2) Computer Aided Modeling

• Linear vs. Concurrent Development

6. Design for Manufacture

• (6.1) Design for Manufacturability Goals

• (6.2) Minimizing Fasteners

• Sonic Welding and Mechanical Snap Fits

• Combining Parts Using Ultrasonic Welding

• (6.3) Standardizing Parts and Processes

• (6.4) Unidirectional Assembly

• (6.5) Minimizing the Parts Count

• (6.6) Considering Alternate Concepts

• (6.7) Considering Alternate Materials

• (6.8) Considering Alternate Processes

• (6.9) General Design Advice

7. Design for Environment

• (7.1) Environmental Impact of Industrial Activities

8. Old vs. New Design

• (8.1) Improved Design

• (8.2) Improved Design Details - Reduction in Parts

• (8.21) Improved Design Details - Roller Drive

• (8.22) Improved Design Details - Idler Gear

• (8.23) Improved Design Details - Housing

• (8.24) Improved Design Details - Drive Train

9. Assembly and Manufacturing

• (9.1) Mabamex

• (9.2) Making the Molds for Injection Molding

• Making Molds Using Electrical Discharge Machining

• (9.3) Just In Time System

• (9.4) Pull System

• (9.5) Color Spin Assembly Line

10. Product Packaging

• (10.1) Product Packaging

11. Product Success

• (11.1) Product Success