CHAPTER 6

PROTOTYPING, TESTING AND REFINEMENT

6.1

Product prototyping

A prototype is an early sample, model, or a first full-scale and usually functional form of a
new type or design of a construction. A prototype is designed to test and try a new design to
enhance precision by system analysts and users. Prototyping serves to provide specifications for
a real, working system rather than a theoretical one. In some workflow models, creating a
prototype is the step between the formalization and the evaluation of an idea.
6.1.1

Process Involved

All of the process involved in this project is by applying the knowledge of the mechanical
engineering. The safety factor is considered during all of the process, to make sure there are no
error or damage happened. The damage may affect the material, environment and health. The
process involved is as follows.
Table 6.1: Process Involved
No.

Process Involved
Tungsten Inert Gas

Figure
(TIG)

welding.
Used to join the stainless steel
metal
1

Grinding Stainless steel surface.

Using grinder to make the welding
surface smooth.
2

Joining (bolt and nut).

Bolt and nut are used to join some
of the component.

Cutting.
Stainless steel iron are cut using
steel cutter.
4

Spray painting
To make stainless steel more
attractive.

6.1.2

Prototyping Process Time

The process to complete or manufactured the prototype is divided into two major parts, which
are fabrication process and assembly process. The fabricating process of the prototype takes
around 2 weeks to complete. Effective time management is highly demand in this stages to make
sure that prototype of the project can be done in time. All of the material are then assembled to
form a complete prototype.
i.

Fabrication process

Fabrication process was conducted by building two main parts of the prototype; Main body and
the conveyor system which the conveyor system was made only using chain to show the
mechanism. Processes involved in fabrication process consist of cutting process, grinding
process, and welding process.
ii.

Assembly process

Assembly process takes place as the last stage of the manufacturing process by combining all
manufactured part together as one final product. Manufactured parts of the project such as main
body, curry-puff mold and filler container.
Table 6.2: Process Duration

Process
Measuring process, cutting

Duration (hours)

Percentage (%)

grinding

20.83

process.
Welding process
Spray painting process
Main
parts
assemble

8
4

33.33
16.67

20.83

8.33

process,

and

process
Final assemble process
6.1.3

Prototype Product

Creating prototype cost us a lot money. Our prototype was done using a low-cost budget as it
could the process of fabricating uses a lot of money. But developing a prototype gives us the
opportunity to really tap into creativity, using those skills that inspired the invention idea in the
first place. And whether making the prototype at home or hiring the services of an engineer,
seamstress or machinist, it is truly exciting to see the idea transformed into something tangible
and real.

Figure 6.1: Prototype of curry-puff machine

6.2

Testing Requirement and Checklist

Product testing is a process of measuring the properties or performance of our designed product.
In other words, product testing objective is to confirm that consumers would able to understand
what our products will do for them and which products are the best values. Testing process was
proceeded by measuring the properties as well as performance after our designed product has
been completely assembled. Through testing process, we would able to observe and identify
whether our designed products have meet it specification or not. If necessary, improvement on
the designed machine will be consider by improving the efficiency of the designed product.
Testing of prototype can be divided into three major parts as shown below:

i.

Form test

In term of form test, the conceptual design for the machine was carried out with actual size but
lighter weight. Besides that, simple operational procedure of the designed machine and required
less maintenances allowed it to be more user friendly.
ii.

Fit test

Low operating height machine was designed mainly due to lower body height characteristic of
Asian population. With suitable operating height, workers would able to operate machine in well
condition.

iii.

Function test

For testing of functionality, the machine was designed only to show the mechanism of the real
machine but not all mechanism can be operated, only a few as it was designed based on the lowcost budget.
6.2.1

Testing Requirement

Three general testing processes were introduced in order to make sure that our manufactured
prototype has met the qualification. These three testing process are functional test, stress test and
reliability test as shown in Table 6.3.

Table 6.3: Testing Requirement

No.
1

Testing Method
Functional Test

Descriptions
To ensure that our designed
product could reach the

Stress test

required output.
To make sure that designed
portable rack could
withstand the overall weight

Reliability test

of the machine.
To ensure that our
designed product could
operate long period of
time without failure.

6.2.2

Checklist

A checklist is a type of informational job aid used to reduce failure by compensating for potential
limits of human memory and attention. It helps to ensure consistency and completeness in
carrying out a task. In this project, several checklists were introduced by ensuring that our
designed machine has met the customer requirement. Components checklist was conducted as
shown in Table 6.4 by confirming that every component of the designed machine could function

as we expected. But some of the important components cannot be installed because of the budget
problems.
Table 6.4: Checklist
No.
1
2
3

Component
Conveyor
Clamper
Filler container

Function
To transport mold
To clamp mold
To store curry-puff filling

Action
Run
Run
Run

Next, functional checklist was introduced as shown in Table 6.5 in order to ensure that our
designed product has met the qualification of the product.

Table 6.5: Functional Checklist

No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14

Item
Stable operation
Reliable system
Occupy less space
Safe operation
Easy to used
Required less maintenance
Low man power
Low operating cost
Low maintenance cost
Ergonomics
Sustainability system
Eco-friendly product
Suitable materials
Low vibration

Checklist (X)
X
X
X
X
X
X
X
X
X
X
X
X
X
X

In term of product failure, possibility of failure in every single parts of the machine was collected
as shown in Table 6.6. Possibility of failure were categorized in to 3 major parts; Low, Medium
and High possibility of failure. With assisting of possible failure checklist, we are able to focus
more on critical failure components by allowing maintenance process takes place before
component failure occurred.

Table 6.6: Possible Failure Checklist

No.
1
2
3

Component
Conveyor
Clamper
Filler container

Possible failure
Wear and break
Bend due to load
overload

Possibility
Low
High
Low

6.3 Testing and Refinement

6.3.1

Testing

In term of prototype testing, our designed machine will be tested in order to make sure that it will
fit the customers and purpose.
Observation on the performance of the machine will take place by make sure that our
designed product works well. If there are any errors or problems, improvement on the designed
prototype will be taken and tested again. This goes until the product is considered to be fully
functional and suitable. The process is known as prototyping and testing and is illustrated in
Figure 6.2.

Figure 6.2: Prototyping and Testing

Through testing process, performance of our designed machine will be evaluated through
Failure Modes and Effects Analysis (FMEA). Failure Modes and Effects Analysis (FMEA) is a
systematic, proactive method for evaluating a process to identify where and how our designed
product might fail and to assess the relative impact of different failures, in order to identify the
parts of the process that are most in need of change. FMEA includes review of the following:

Steps in the whole design process

Failure modes

Failure causes

Failure effects

In fact, Failure Modes and Effects Analysis (FMEA) will be introduced in our project as the
evaluate processes for possible failures and to prevent these failures by correcting the processes
proactively rather than reacting to adverse events after failures have occurred. This emphasis on
prevention may reduce risk of harm to our customers. FMEA is particularly useful in evaluating
a new process prior to implementation and in assessing the impact of a proposed change to an
existing process.

Basic terms involved in Failure Modes and Effects Analysis (FMEA) are probability, severity
and detection. In term of probability, it is necessary for us to look at the cause of a failure mode
and the likelihood of occurrence. A failure cause is looked upon as a design weakness that
existing in our project. All the potential causes for a failure mode involved in our study will be
identified and documented. This should be in technical terms.

Table 6.7: Rating of Probability

Rating
A

Meaning
Extremely Unlikely (Virtually impossible or No known occurrences on

B
C
D
E

similar products or processes, with many running hours)

Remote (relatively few failures)
Occasional (occasional failures)
Reasonably Possible (repeated failures)
Frequent (failure is almost inevitable)

For severity, it enables us to determine the worst-case scenario adverse end effect which has
involved in our product. It is convenient for us to write these effects down in terms of what our
customer might see or experience in terms of functional failures.

Table 6.8: Rating of Severity

Rating
I
II
III

Meaning
No relevant effect on reliability or safety.
Very minor, no damage, no injuries, only results in a maintenance action (only
noticed by discriminating customers).
Minor, low damage, light injuries (affects very little of the system, noticed by
average customer).

Moderate, moderate damage, injuries possible (most customers are annoyed,

IV

mostly financial damage).

Critical (causes a loss of primary function; Loss of all safety Margins, 1

failure away from a catastrophe, severe damage, severe injuries, max 1

possible death).
Catastrophic (product becomes inoperative; the failure may result in complete

VI

unsafe operation and possible multiple deaths).

Detection was defined at which failure of our designed machine is detected. In this stage, it
should be made clear how the failure mode or cause of our designed product can be discovered
by operator under normal system operation.
Table 6.9: Rating of Detection.
Rating
1
2
3
4
5
6
6.3.2

Meaning
Certain - fault will be caught on test
Almost certain
High
Moderate
Low
Fault is undetected by Operators or Maintainers

Refinement
In term of refinement process, improvement on the overall design of the curry-puff

prototype machine will be conducted after testing process of the product has completed. Besides
that, spraying the prototype with spray color is considered by producing more simple and
professional look as a final manufactured product.