Group 10 - Kodak Flash Camera

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Executive Summary

Our group was assigned to analyze the Kodak zoom disposable camera. Aspects of the camera that we were asked to examine include overall design concept, specific components and their respective functions and features, materials and manufacturing processes used, and develop possible design improvements. Before disassembly began, our group identified the purpose of the camera and made assumptions of how it works. We then tested the camera to see if it worked, predicted how many components make up the complete device, and how many different materials were used. During the disassembly every removed piece and tool used was recorded. The internal pieces of the camera were already numbered- we assumed they were used for assembling the camera at the manufacturing factory. Disassembly of the camera took approximately one hour, while reassembly took only about half an hour. The camera was primarily composed of plastic- with a few small metal and electronic components. Plastic is an excellent material to be used for a one-time use camera because it is inexpensive and can be easily recycled and reused.

Introduction

The purpose of the Kodak disposable camera is to capture photographs in a cheap, convenient, and affordable way. The camera has a flash feature so photographs can be taken in low light situations, and zoom for pictures taken at a distance.

Research Group Members

Before Disassembly

Chemical energy from battery- into electrical

Mechanical energy for the user- (pushing buttons, turning knobs)

Chemical reaction- film with light exposure

Flash capacitor- charge it so it will work

Product worked properly.

Initial assumption- product is made up of at least 25 parts.

Multiple types of plastic- clear, black, gray

Disassembly Procedure

1. First, the stickers located on the back cover were removed using our fingernails.

2. The back cover was then pried off with a small screwdriver and a pocket knife.

3. The battery was next component removed.

4. The rolled up film and winding spool were next to be taken out.

5. We then began working on the front of the camera. The front cover was pried off with the small screwdriver.

6. The next piece removed was the flat metal spring that holds in the double lens toggle (part 5). The double lens toggle was then removed.

7. We then popped off the little coil spring that hooks the plate that the double lens toggle mounts on (part 9), to a black connecting piece (part 1).

8. Once the spring was off the black connecting piece (part 1) and a connecting rod (part 12) fell off.

9. The tiny copper spring that connects the shutter to a fixed point on the circuit board was then taken off.

10. Dissection then began on the top of the camera. We took off a clear plastic piece (part 9), and then took off a gray plastic part (part 16).

11. Then we took the "number of pictures remaining" wheel off, the winding wheel, the winding cam, and part 32- the piece that connects the cam to the winding wheel.

12. Next we took the copper brace that holds the viewing lens in place (part 4). The viewing lens was then removed.

13. We then took off a blue plastic piece (part 9), which was located below the viewing lens.

14. We then went back to the front of the camera and pried off the toggle zoom plate (also labeled part 9) using a small screwdriver and pocket knife.

15. Then the large gray zoom lever arm (part 2) was removed and the shutter simply fell off.

16. We then removed the shutter lever (part 1) which is composed of blue plastic, as well as the spring that holds it in place.

17. Part 101, the small winding gear then fell out. This piece is simply held in place by the winding cam.

18. The circuit board was then pried off using again, the small screwdriver and pocket knife.

19. The plastic insert in the back of the camera, which is responsible for holding many of the camera’s inner components, was then removed.

20. Next, a small metal lever located in the front was removed.

21. The only component remaining was the plastic shell of the camera. The camera is completely disassembled.

Group 10 met in Furnas 621 at 11:00 AM on Friday, October 12, 2007.

The only tools used were our hands, a small screw driver, and a pocket knife. The tools were only used when a component had to be pried off.

The complete disassembly process took approximately one hour. We took extra time to study the internal components and observe how the parts fit together because the process didn't require much force. Disassembly was very simple because many of the components were simply held together by gravity and the compression of the camera's shell; most of the time components were simply falling off.

Post Disassembly- Component Analysis

Part #	Part Name	# Required	Material	Manufacturing Process	Estimated Manufacturing Cost	Function	Image
1	Front Shell	1	ABS Plastic	Injection Molding	$0.05	Front piece of protective housing for internal camera components.
2	Back Shell	1	ABS Plastic	Injection Molding	$0.05	Rear piece of protective housing for internal camera components.
3	Inner Shell	1	ABS Plastic	Injection Molding	$0.04	Internal frame for small camera components.
4	Face Plate	1	ABS Plastic	Injection Molding	$0.04	Protective lens housing.
5	Zoom Toggle Switch	1	ABS Plastic	Injection Molding	$0.02	Allows zoom feature to be enabled or disabled.
6	Photobox Frame	1	ABS Plastic	Injection Molding	$0.03	Guides film.
7	Zoom Mechanism Brace	1	ABS Plastic	Injection Molding	$0.02	Stablizes components of zoom feature.
8	Zoom Lever Arm	1	ABS Plastic	Injection Molding	$0.03	Connects the zoom switch with lenses.
9	Zoom Toggle Connecting Piece	1	ABS Plastic	Injection Molding	$0.02	Connects zoom switch to zoom lever arm.
10	Zoom Lever Connecting Rod	1	ABS Plastic	Injection Molding	$0.04	Aids in the placement of the zoom lenses.
11	Zoom Toggle Spring	1	Steel Wire	Formed and Extruded	$0.04	Aids in an easy transition between zoom and standard lenses.
12	Standard 1X lens	1	ABS Plastic	Injection Molding, Polishing	$0.05	Transparent plastic, standard non-zoom photo lens.
13	Zoom Lens Unit (Inner Lens)	1	ABS Plastic	Injection Molding, Polishing	$0.06	Transparent plastic, magnifying inner zoom lens.
14	Zoom Lens Unit (Outer Lens)	1	ABS Plastic	Injection Molding, Polishing	$0.05	Transparent plastic, magnifying outer zoom lens.
15	Zoom Lens Unit (Shell)	1	ABS Plastic	Injection Molding	$0.02	Houses inner and outer zoom lenses.
16	Lens Toggle Face Plate	1	ABS Plastic	Injection Molding	$0.05	Secures standard and zoom lenses to lens toggle frame.
17	Lens Toggle Frame	1	ABS Plastic	Injection Molding	$0.10	Housing for standard and zooom lenses.
18	Shutter	1	Steel	Formed and Shaped	$0.10	Allows light to enter camera and exposure of film.
19	Shutter Spring	1	Copper Wire	Formed and Extruded	$0.05	Allows rapid movement of shutter.
20	View Finder Lens	1	ABS Plastic	Injection Molding, Polished	$0.02	Allows camera operator to accurately see what will be captured on the film.
21	View finder Lens Brace	1	Copper	Heated and Formed	$0.02	Secures the view finer lens inside the camera.
22	View finder Lens Toggle Switch	1	ABS Plastic	Injection Molding	$0.02	Zooms view finder lens. Allows camera operator to accurately see what will be captures on the film using the zoom feature.
23	Pictures Remaining Window/View Finder Cover	1	ABS Plastic	Injection Molding, Polished	$0.05	A protective transparent plastic cover for the picture remaining wheel and the view finder lens.
24	Shutter Button	1	ABS Plastic	Injection Molding	$0.07	When button is pressed the shutter opens; how the camera operator takes a picture.
25	Film Advance Wheel*	1	ABS Plastic	Injection Molding	$0.05	Camera operator manually rotates wheel with thumb to advance film.
26	Pictures Remaining Wheel*	1	ABS Plastic	Injection Molding, Painted	$0.08	Visually displays the approximate remaning number of photographs left on the camera.
27	Film Advance Gear*	1	ABS Plastic	Injection Molding	$0.05	Guides film using holes that are manufactured onto the edges of the film.
28	Winding Cam*	1	ABS Plastic	Injection Molding	$0.05	Aids in proper winding of film.
29	Shutter Arm	1	ABS Plastic	Injection Molding	$0.05	Component that allows the shutter to move.
30	Shutter Arm Spring	1	Steel Wire	Formed and Extruded	$0.03	Aids in quick movement of shutter arm.
31	Advance Arm*	1	ABS Plastic	Injection Molding	$0.05	Allows film to advance only one frame at a time.
32	Advance Arm brace	1	Steel	Formed and Molded	$0.03	Reinforces the advance arm to limit film advancement.
33	Flash Unit	1	Steel, ABS Plastic, Flash Bulb	Formed and Bent, Injection Molded, Blow Molded with Assembly	$0.35	Once charged through the capacitor, the flash can illuminate dark environments for clearer pictures.
34	Flash Circuit Board	1	Silicon, Solder, and various metals and plastics	Machined and soldered	$0.60	Electronic component responsible for coordinating the flash bulb and capacitor.
35	Capacitor	1	Metal and Plastic	Formed and Soldered	$0.30	Creates increased charge to illuminate flash bulb.
36	Film Spindle	1	ABS Plastic	Injection Molding	$.08	Film is stored and rolled around the spindle.
37	KODAK 800 Speed Film*	1 roll @ 27 exposures	Varies	Chemical Bonded	$0.45	After exposure to light by the shutter, images are stored on the film.
38	1.5V Alkaline AA battery	1	Steel and various Chemicals	Formed and Shaped	$0.15	Source of power to charge capacitor and illuminate flash bulb.

Our group estimated the approximate cost to manufacture the Kodak one time use flash camera to be $3.36.

The prices of each component were calculated based on the size, complexity, manufacturing process, and material used. We assumed that the most expensive parts were the film and electronic components- such as the flash, circuit board, battery, and capacitor. Using plastics as the major material is a wise choice for a one time use camera because it is a cheap but sturdy material and the majority of the camera can be easily recycled and reused to create new one time use cameras.