Design & Manufacture - Trek pro™ 350s
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Transcript of Design & Manufacture - Trek pro™ 350s
TrekPro™ 350SDesign & Manufacture 3N Project 2013
By: Uvarajan M Velayutham; Tong Jing Kai; Benjamin Quek; Shaiful
Contents of Presentation
▪ Introduction
▪ Design Process
▪ Consumer Needs
▪ QFD
▪ Final Specifications
▪ Concepts Generations & Selection
▪ Concept Exploration
▪ Human Factors
▪ Psychology
▪ Physiology
▪ Product Differentiation
▪ Product Architecture
▪ Functional Charts & FTA
▪ Product Marketing Potential
▪ Product Material Selection
▪ Design for Environment
▪ CAD Model
▪ CAD analysis
▪ Conclusion
Introduction
▪ Sport Engineering
▪ Trekking
Generic Design Process
• Manufacturing product
Production ramp-up
• CAD Analysis
• Design for Environment
• Product testing
Testing and Refinement
• Design for manufacture
• Materials selection
• CAD Modelling
Detail Design
• Concept exploration
• Human factors
• Physiology
• Psychology
• Product architecture
• Concept testing
System level design
• Rapid concepts generation
• TRIZ Principles
• Concept screening and scoring
• Concept evaluation
Concept Development
• Market research
• Consumer needs
• QFD
• Final Specifications
Planning
Trekking▪ Trek Bag
▪ Items you carry for trekking trip includes:
▪ Clothing
▪ Sleeping Bag
▪ Medical Kit with ointments
▪ Water container
▪ Field chair
▪ Trekking pole
▪ Nesting equips
▪ Survival kits
Different item has a different function. If we can cut down items, we can make a more productive bag.
Realised Trekkers require multifunction bag.
Mission Statement
Mission Statement: Trekking Survival Bag
Product Description Storage bag for trekking equipment and trip survival necessities
Benefit Proposition Multiple functions in one bag
Bag allows trekkers to trek independently without much aid
Primary Market Mountain trekkers
Military rangers
Adventurous people venturing into inaccessible areas
Secondary Market Casual users
Assumption and
Constraints
Able to provide medical needs
Aids during emergencies and evacuation
Able to provide optimum performance in all weather
Stakeholders User
Retailer
Production team
Consumer needs
Question/Prompt Customer Statement Interpreted Need
Typical uses I need to store my personal equipment easily into the bag. The bag can store equipment easily.
I store medical equipment needed for the trip. The bag can store medical equipment.
Bag has to be comfortable and safe to use. The bag is comfortable and safe to use.
I use the same bag for trips in dangerous trails other than in
mountains.
The bag can be used in all terrains.
Likes – Existing Bag The usage of the bag is simple. The bag is easy to use.
The bag is large enough to place most of my necessities. The bag has a lot of storage space.
The bag is light and easy to carry. The bag is lightweight.
The bag has cool design. The bag has an attractive design.
Dislikes – Existing Bag Other equipment like tents are carried by porters has no space in
the bag.
The bag can be used to carry larger items.
Not comfortable when resting with bag on. The bag can be used to rest comfortably.
It has little splashproof properties. The bag is splashproof.
The bag buckles when dropped on the ground. The bag is rigid enough to hold its shape.
Internal material if the bag tends to peel off. The bag has internal material with good properties.
The zip of the bag will open itself when overloading the storage. The bag allows storage overload.
Suggested Improvements It would be good to have heating on bag. The bag can warm the user.
Incase fall into running water, good to have a lifebuoy on bag. The bag allows the user to be buoyant in water.
No easy way to signal for help, in an emergency. The bag can signal for help in an emergency.
It is good to have water filtration in bag. The bag can filter water.
Instructions on bag for beginner trekkers will be useful. The bag will have markers on it to aid user.
The shoulder straps can have more cushions. The bag will have cushions on the shoulder straps.
The price of the bag must be cheap.The bag is cheap.
The bag is easy to manufacture.
Consumer needs No. Primary Need Secondary Need
1 The bag is easy to use
The bag can store equipment easily.
The bag will have markers on it to aid user.
The bag is easy to use.
2 The bag has a lot of storage space
The bag has a lot of storage space.
The bag can be used to carry larger items.
The bag can store medical equipment.
3 The bag is comfortable to use
The bag is comfortable and safe to use.
The bag is lightweight.
The bag can be used to rest comfortably.
The bag will have cushions on the shoulder straps.
4 The bag is easy to maintain The bag is splashproof.
5 The bag is durable
The bag is rigid enough to hold its shape.
The bag has internal material with good properties.
The bag allows storage overload.
The bag can be used in all terrains.
6 The bag is lightweight The bag is lightweight.
7 The bag is multifunctional
The bag can warm the user.
The bag allows the user to be buoyant in water.
The bag can signal for help in an emergency.
The bag can filter water.
8 The bag is easy to manufacture The bag is easy to manufacture.
9 The bag is cheap The bag is cheap.
10 The bag has an attractive design The bag has an attractive design.
Hierarchy listing of Primary needs from Secondary needs
QFD –TrekPro™ 350S
Competitor Products
North Face –Patrol 24
Berghaus –Jalan II
Black Diamond –Mercury 75
Deuter –Quantum 55
Boblbee -Megalopolis
Final Specifications
Metric No. Metric Units Value
1 Time to store all equipment into bag min < 1.5
2 No. of equipment that could fit in bag No. > 15
3 Fluid volume of storage in bag L > 35
4 No. of compartments in bag No. > 2
5 Thickness of padded cushions in bag mm > 10
6 Thermal conductivity of material Wm-1K-1 < 0.33
7 Elastic modulus GPa > 100
8 Mass of bag kg < 3.0
9 Material strength MPa > 30
10 No. of functions in bag No. > 2
11 Buoyancy of bag (Weight of displaced fluid L < 3
12 Cost of manufacture S$ < 100
13 No. of colour schemes available No. > 2
Rapid Concept Generation
Rapid Concept Generation
Concept ScreeningConcept
Selection Criteria
A
Buoyant Filter
Bag
B
Air-Bag
C
Trekking Duffel Bag
D
Stretcher Bag
E
Sleeping Trek Bag
F
Boblbee Megalopolis
Bag
(REF)
Ease of Use 0 0 - - 0 0
Storage 0 - + + 0 0
Comfort + 0 0 0 + 0
Maintenance - - + - 0 0
Durability + - + + 0 0
Portability 0 - + - 0 0
Functions + + - + 0 0
Ease of manufacture 0 - + - + 0
Cost - - + - 0 0
Design + - - - 0 0
Sum +’s 4 1 6 3 2 0
Sum 0’s 4 2 1 1 8 10
Sum –‘s 2 7 3 6 0 0
Net Score 2 -6 3 -3 2 0
Rank 2 5 1 4 2 3
Continue? Combine No Combine Revise No No
TRIZ Principles
Principle 6 – UniversalityCombining a Buoyancy tube, field chair, water filter and storage functions into 1 product
Principle 11 – Beforehand CushioningBy having a buoyancy tube to aid trekker incase of water emergency situations
Principle 30 – Flexible shells and thin filmsSolid internal structure will become hollow to reduce weight
Principle 5 – Merging/ ConsolidationCombining a wardrobe door concept onto bag design
Concept ScoringConcept
C
Trekking Duffel Bag
(REF)
AC
TrekPro
D+
Fold-a-Trek
Selection Criteria
Weight (%) Rating
Weighted
Score Rating
Weighted
Score Rating
Weighted
Score
Ease of Use 14.7 2 0.294 3 0.441 3 0.441
Storage 8.8 3 0.264 3 0.264 4 0.352
Comfort 14.7 3 0.441 4 0.588 2 0.294
Maintenance 5.9 3 0.177 2 0.118 3 0.177
Durability 11.8 3 0.354 5 0.590 4 0.472
Portability 11.8 3 0.354 4 0.472 2 0.236
Functions 11.8 2 0.236 5 0.590 3 0.354
Ease of manufacture 2.9 3 0.087 2 0.058 4 0.118
Cost 8.8 3 0.264 2 0.176 4 0.352
Design 8.8 3 0.264 5 0.440 2 0.176
Total Score 2.735 3.737 2.972
Rank 3 1 2
Continue? No Develop No
Final Concept Evaluation
Mechanisms within concepts requires further exploration
Exploration will be helpful for detail designing later part of the process
Combination of Scuba Buoyancy Compensator, Field Chair, Water filter and a Backpack
Concept Exploration
Human Factors
▪ Ergonomic design considerations taken into account
▪ To make design simple so that users can use the product safely without any guidance
Anthropometrics
Male Female
Measurement
Type
(inch) 5 Percentile 50 Percentile 95 Percentile 5 Percentile 50 Percentile 95 Percentile
Measurement
Used
Mid Shoulder
Height 23.9 25.7 27.5 20.4 22.1 23.8 23.9
Hip Breadth 13.6 15.1 16.6 12.0 13.3 14.6 14.2
Shoulder 17.6 19.3 20.9 14.0 15.3 16.6 17.3
Popliteal
Height 16.0 17.5 19.0 13.6 15.1 16.5 19.0
Thigh
Clearance 5.7 6.6 7.5 4.4 5.1 5.7 5.8
5.8”
17.3” 23.9”
14.2”
Utility The human interfaces such as zipping the backpack, pumping water
to the storage tank of the backpack, folding and unfolding the chair
is easy to use and intuitive. Also these interfaces are relatively safe to
use.
Appearance The TrekPro 350S has good form, line and proportion.
Orange: it’s the color tied to fun times, happy and energetic day’s
warmth and organic product. It is also associated with ambition and a
new dawn with attitude
Green: it’s the color of balance and growth. It is also very calming and
soothes the viewers
Ease of
maintenance
Hand pump can be easily maintain as the pump assembly is snap fit
The whole backpack can be wash with water and quickly dry as the
material selected is water resistance.
Low costs As the backpack outer body shell is made from Ripstop Polyamide,
the material can be easily cut and form into the shape of the frame.
The cost of sewing into the material on the frame is relatively cheap.
Psychological
Communication The color of orange sends strong image of ambition for the trekkers.
The whole design of the backpack communicate a sense of adventure
for the user. From the shape and the contour of the backpack the
design sends a strong message of ruggedness and durability
Water Ability for backpack to pump and filter clean water
Fatigue Excellent weight distribution ensuring that the user of the TrekPro
350s will not easily suffer from fatigue and exhaustion.
Heat Air filled cushion ensure that the user will get maximum air circulation
on his back.
Physiological
Product DifferentiationLight weight With a weight of 2.5 kg it’s among the lightest trekking backpack on the market
Performance features The TrekPro 350S features an integrated filter and water pump. A foldable chair for
the user to sit on
Superior ergonomics The design allows the user to carry the backpack with maximum comfort and guaranteeing no back injury will occur. The design allows the user easy access to the items inside the bag.
Durability The TrekPro 350S was design to meet rigorous specification. It is design to be used on all-weather outdoor condition. The TrekPro 350S can also withstand temperatures extreme and humidity.
Materials The TrekPro 350S utilized several advanced materials to enhance both performance and appearance. These include CFRP frame and neoprene for maximum comfort on the shoulders.
Appearance The sleek design gave the TrekPro 350S a futuristic look associated with innovation. Because of its aesthetic appeal and highly recognizable appearance, the TrekPro 350S is expected to be a status symbol for early adopters and creates a strong feelings of pride among adopters.
Product Architecture
1. The functional elements of a product are the individual operations and transformations that contribute to the overall performance of the product
2. The physical elements of a product are the parts, components and subassemblies that ultimately implement the products functions. The physical element becomes more defined as development progresses.
3. Perhaps the most important characteristic of products architecture is its modularity.
Modularity of TrekPro 350S
In a sectional modular architecture, all interfaces are of the same type, but there is no single element to which all the other chunks attach. The assembly is built up by connecting the chunks to each other via identical interfaces
In slot modular architecture each interfaces between chunks in a slot modular architecture is of a different type from the others.
Product Architecture
Physical ElementFunctional
Element
Storage of items
Pumping of
clean filtered
water
Chair for user to
sit on
Foldable Chair
compartment
Water pump
Sternum Strap
Zippers
Bag Cushion
Area
Buoyant
Tube
Buoyancy force
Functional Flow Chart - Water PumpPlaced filter onto
water source
Used hand to
generate pressure
on Squeezer
Water will flow
through hose by
the pressure loss
generated by the
squeezer
Water will flow
into the hydration
pack
Turn knob
clockwise
Used hand to
generate pressure
on Squeezer
Dirt will flow out
through release
valve
Filter
Squeezer
Water flow to storage
Release valve
Knob
Dirt Cleaning
Functional Flow Chart - Foldable Chair
Foldable Chair in closed position Foldable Chair in open position
Placed backpack
firmly on flat
ground
Used hand to
open chair
Secure foldable
chair at 90
degree position
Function-Storage
Primary Storage
compartment,
opened and closed
by Zipper
23L
Secondary Storage
compartment,
opened and closed
by Zipper
5L Side storage
compartment,
opened and closed
by Heavy Duty
Velcro
1.5L x 2
Top storage
compartment, Quick
Access opened and closed
by Heavy Duty Velcro
5L
Bottom Storage
compartment, opened
and closed by Heavy
Duty Velcro
4L
Function-Buoyant Tube
Bouyant Tube
Implications of design on architecture
Product change Since the outer body of the bag is made of fabric, the styling of the backpack can
be easily modified for different target market segments
Product variety Different variety can be manufactured without increasing the cost of production
as the outer body shell is made soft fabric.
Component standardization Zipper, sternum straps, heavy duty velcro
Product performance -ability to hold 40kg of load
-ability to pump and store clean filtered water
-integrated foldable chair for the user to sit on
Manufacturability -internal frame of the bag made from CFRP can be easily manufactured
- the body of the bag made from RipStop Polyamide can be easily shaped and
sewed to the bag
Platform Planning (Differentiation plan)
Differentiating
Attributes
Trek Pro Trek Pro
Lite
Trek Pro
Student
Chair
Water Pump
- -
-
Fault Tree Analysis (FTA)
Material Specifications and Selection
Promotional poster of Product
TrekPro™ 350S Layout
•Fabric Covering
•Buoyant Tube
•Bag Strap
•Air Cushion
•Seat
•Internal Frames
Selected materials for TrekPro™ 350S
Fabric Covering
▪ Ripstop Polyamide 210DHD
(Outer and inner Material Fabric)
Bag Strap
▪ Ripstop Polyamide 210DHD With Neoprene
Buoyant tube
▪ Air Inflated
▪ (Outer Layer 1680 Denier Ballistic Nylon) Fused with (Inner Layer 420 Denier Nylon)
Selected materials for TrekPro™ 350S
Convertible Seat
▪ Polybutylene Terephtalate infused with 30% Carbon Fibre (PBT 30% Carbon Fibre)
Internal Structural Frames
▪ Carbon Fibre Reinforced Plastic CFRP
Lumber Pad Cushion
▪ (Outer Layer 1680 Denier Ballistic Nylon) Fused with (Inner Layer 420 Denier Nylon)
▪ Neoprene
Material Selection for Frame
CFRP vs. Aluminum Silicon Carbide
Properties to be weighted between CFRP and Aluminum Silicon Carbide:•Weight •Fracture toughness •Cost•Tensile strength •Machinability
CFRP vs. Aluminum Silicon Carbide
•Table shows that CFRP is better than Aluminum Silicon Carbide •Hence CFRP was chosen
Material Properties
CFRP (FRAME)
▪ Extremely strong and lightweight
▪ High strength and rigidity
▪ Corrosion resistance
▪ Eco friendly
▪ High damage tolerance
Material Properties
Polybutylene Terephtalate, PBT (30% carbon Fibre) (SEAT)
▪ Widely available
▪ High strength and stiffness
▪ Good creep durability under thermal stress
▪ Corrosion resistance
▪ High heat deflection temperature
▪ Eco friendly
Material Properties
Ripstop Polyamide 210DHD
▪ Recycled waste material (Eco friendly)
▪ Extremely lightweight
▪ UV radiation resistance and water resistance
▪ High resistance to ware and tear
▪ Cheap
▪ Readily available in the market
Material Properties
Sternum Strap
▪ Fast release
▪ Cheap
▪ Lightweight
▪ Readily available in the market
Material Properties
Neoprene
▪ Lightweight
▪ Excellent good impact absorber
▪ Weather and Water resistance
▪ Low friction
▪ Elastic and form-fitting
Material Properties
Brass
▪ Used for zippers
▪ Corrosion resistance
▪ Appealing
▪ High strength
Material Properties
1680 Denier Ballistic Nylon and 420 Denier Nylon
▪ Abrasion and corrosion resistance
▪ Bullet proof (Being extremely high strength)
▪ Water resistance
▪ Able to stretch
▪ Durable
▪ Eco friendly
Material Properties
Heavy Duty Velcro Tape
▪ High adhesive strength
▪ High adhesion
▪ High tensile strength
▪ Weather and temperature resistance
▪ Cheap
▪ Eco friendly
TrekPro™ 350S Layout with material
Front View
TrekPro™ 350S Layout with material
Back View
Material Pricing
Material Cost Volume Total Unit Cost
CFRP
SGD 6 – 80 / piece
Min 300 Pieces
250
500
1000
$50
$20
$12
PBT (30% Carbon Fibre)
SGD 2.30 - 4 / Kg
Min 1000Kg
250
500
1000
$4
$3
$2.50
Ripstop Polyamide 210DHD
SGD 1 – 2 / Meters
Minimum 500 Meters
250
500
1000
$2
$1.50
$1
Sternum Straps
SGD 1 – 6 / Piece
Minimum 500 pieces
250
500
1000
$8
$6
$1.50
Neoprene
SGD 6.62 – 7.28 / Kg
Minimum 250Kg
250
500
1000
$9
$7.50
$6
Material Pricing
Brass Zippers
SGD 0.01 – 1 / Piece
Minimum 100 Pieces
250
500
1000
$0.50
$0.25
$0.10
Ballistic Nylon
SGD 1.2 – 4 / Meters
Minimum 500 Meters
250
500
1000
$6
$4
$2
Denier Nylon
SGD 1 – 3 / Meters
Minimum 500 Meters
250
500
1000
$4
$3
$1.50
Self Adhesive Velcro Tape
SGD 0.01 – 1 / Meters
Min 3000 Meters
250
500
1000
$0.80
$0.50
$0.30
Brief summary of financial analysis
•Total cost of materials: $22875•Total operating expenses: $9900•Total manufacturing cost (500 units): $32775
•Cost per unit: $65.55•Expected profit margin estimated to be 200%•Expected cost per unit: SGD$199.90
Drafting for TrekPro™ 350S
Frame Draft SolidWorks Surface Modelling CATIA
CAD Drafting Frame (Close)
CAD Drafting Frame (Open)
CAD Drafting Surface
Assess energy/CO2 Over
lifespan of
Material
• Minimize raw material usage.
• Raise material recycle awareness
Manufacture
Minimize• Process energy
by selecting the correct manufacturing process for the material.
• Energy/CO2
Usage
• Material Wastage
Transport
Minimize• Distance travel
• Transportation method
Disposal
Select• Non-Toxic
materials.
• Recycle material.
Manufacture Energy Eco-Audit for Material
Component Material Process Amount processed Energy (MJ) %
Seat PBT (30% carbon fiber) Polymer molding 2.8 kg 54 48.9
SeatABS (20% carbon fiber, EMI
shielding, conductive)Polymer molding 2.8 kg 56 51.1
Total 1.1e+02 100
Component Material Process Amount processed Energy (MJ) %
FrameCFRP, epoxy matrix
(isotropic)Resin spray-up 1.8 kg 27 59.2
Frame Aluminum/Silicon carbide
compositeCasting 1.8 kg 18 40.8
Total 45 100
CO2 Eco-Audit for Material
Component Material Process Amount processedCO2
footprint (kg)
%
Seat PBT (30% carbon fiber) Polymer molding 2.8 kg 4 48.9
SeatABS (20% carbon fiber, EMI shielding,
conductive)Polymer molding 2.8 kg 4.2 51.1
Total 8.3 100
Component Material Process Amount processed Energy (MJ) %
FrameCFRP, epoxy matrix
(isotropic)Resin spray-up 1.8kg 27 59.2
Frame Aluminum/Silicon carbide composite
Casting 1.8kg 18 40.8
Total 45 100
Why TrekPro™ 350S is a Eco Design?
Drop Test Analysis (Stress)
Drop Test Analysis (Displacement)
Drop Test Analysis (Strain)
Sitting Analysis@1000N (Stress)
Video of the Sitting Analysis@1000N (Stress)
Sitting Analysis@1000N (Displacement)
Sitting Analysis@1000N (Strain)
Original LifeStraw®
Modification on LifeStraw®.
1
2
3
45
Air Traps
Volumetric Shrinkage
Weld lines
Sink Marks Shaded
Deflection, All Effect
How good is TrekPro™ 350S?
Metric No. Metric Units Target Value Actual Value Fulfilled?
1 Time to store all equipment into bag min < 1.5 Nil
2 No. of equipment that could fit in bag No. > 15 Nil
3 Fluid volume of storage in bag L > 35 40
4 No. of compartments in bag No. > 2 6
5 Thickness of padded cushions in bag mm > 10 15
6 Thermal conductivity of material Wm-1K-1 < 0.33 0.24
7 Elastic modulus GPa > 100 150
8 Mass of bag kg < 3.0 2.5
9 Material strength MPa > 30 35
10 No. of functions in bag No. > 2 4
11 Buoyancy of bag (Weight of displaced fluid) L < 3 Nil
12 Cost of manufacture S$ < 100 65.55
13 No. of colour schemes available No. > 2 5
TrekPro™ 350S has met 77% of the targeted final specifications set for it