• Created SolidWorks 2D and 3D part drawings for the bottle opener (Part No. 4)

• Developed a manufacturing process plan including stamping, punching, finishing, and inspection

• Selected appropriate production equipment (e.g., stamping press, punching press, polishing tank)

• Estimated cycle times and batch quantities to support high-volume output (550,000 units/year)

• Defined quality assurance strategy: 1-in-50 part inspection for dimensional accuracy and finish

• Assigned Part: Bottle Opener (Part No. 4)

• Material: Sheet metal (stainless steel)

• Processes Used:

  • Stamping to shape the part profile

  • Punching to cut out the functional bottle opening

  • Finishing through mechanical polishing and protective electroplating

  • Manual inspection for dimensional and surface quality control

• Key Feature: Process plan optimized for high-speed, low-cost production at 550,000 units/year

• No CAD-based simulation was required; instead, cycle time estimates and tolerancing decisions were made through manual analysis and standard assumptions.

• Chosen processes: stamping, punching, and mechanical polishing, were selected for their high throughput, automation compatibility, and cost efficiency.

• Inspection frequency (1 in 50 parts) was set to balance quality assurance with production rate, based on typical tolerance acceptance in mass manufacturing.

• Selected cost-effective manufacturing methods (e.g., stamping over forging) to meet production scale while minimizing tooling complexity.

• Ensured dimensional tolerances were met without requiring excessive inspection time or specialized metrology tools.

• Balanced high-volume production goals with realistic cycle times and manual inspection ratios (1 in 50) to maintain quality without slowing throughput.

• Created the 2D technical drawing and detailed manufacturing traveler sheet for the bottle opener (Part No. 4).

• Selected and justified stamping, punching, and polishing processes aligned with high-speed, high-volume production.

• Defined tooling, cycle time, and inspection steps to meet the 550,000 units/year production goal under the $2/unit cost constraint.

• Contributed to the team’s final report by documenting manufacturing logic, process flow, and quality control measures for the assigned part.

Process Planning · Sheet Metal Design · SolidWorks 2D Drafting · Manufacturing Cost Estimation · Traveler Sheet Documentation · Cycle Time & Production Rate Analysis · Team-Based Engineering Collaboration

This project provided valuable experience in manufacturing planning and documentation. I gained a deeper understanding of how part geometry, materials, and process selection must align for efficient high-volume production. Writing the traveler sheet and estimating cycle times helped me connect design intent to practical constraints like cost targets and inspection loads. Overall, this work broadened my skills in manufacturability analysis, industrial process planning, and collaborative engineering workflows.