Fall 2012- Design for Manufacturing

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Redesign of a canopy chair- Design, material, manufacturing process, assembly and robustness

Transcript of Fall 2012- Design for Manufacturing

  • 1. REDESIGNING A CANOPY CHAIRTeam 2: Mengshi Gao, Vibin Ilango, Tianshu Li, Shengyu Lou , Aniruddha Srinath University of Michigan, Ann Arbor

2. 12/13/2012Product to be ImprovedREDESIGNING ACANOPY CHAIR 2 3. 12/13/2012REDESIGNING ACANOPY CHAIR 3 4. 12/13/2012REDESIGNING ACANOPY CHAIRLOOK HOW FRUSTRATED 4HE IS 5. 12/13/2012Problems & ImprovementsREDESIGNING ACANOPY CHAIRCustomer ComplaintsMobilityPersonali-To design zation a comfortable, sturdy and economic canopy chairwhich is attractive across a wide range of customers (20~75 Sturdiness &years old) for allDurability outdoor recreations. kinds ofComfortDelighting FeaturesPresence Of Cup HolderWeight Of ChairPresence Of Canopy Presence Of PhoneStorageSturdiness Of Chair Seat Back Angle 5Adjustment 6. 12/13/2012Target GroupsREDESIGNING ACANOPY CHAIRPRIMARY CUSTOMERS SECONDARY CUSTOMERS 20-50 Age51-75 Sturdiness &High GoodDurability GoodMobilityGood Basic Comfort High Good PersonalizationGood Perform at BASIC Level Perform at GOOD Level 6 Perform at HIGH Level 7. 12/13/2012ConceptsREDESIGNING ACANOPY CHAIR 7 8. 12/13/2012Functional Improvements - CanopyREDESIGNING ACANOPY CHAIR A Flipping Extension can provide wider range to safeguard the customersfrom rain and sunlight.Kelsyus OriginalUmich NEW Canopy ChairCanopy Chair 8 9. 12/13/2012Also, it can be swiveled...!REDESIGNING ACANOPY CHAIR 25% Shadow Area Increase 50% Side Area Increase 9 360 Swivel Angle 10. 12/13/2012Functional Improvements Seat MaterialREDESIGNING ACANOPY CHAIR Nylon fabric is highly durable, and easy to wash and care for.Kelsyus Original Umich NEW Canopy Chair Canopy Chair 10 11. 12/13/2012For elderly customers group, cushion is availableREDESIGNING ACANOPY CHAIRInserted withPolyurethane Foamcushion 11 12. 12/13/2012Functional Improvements - StorageREDESIGNING ACANOPY CHAIR The lightweight, easy-folding material in bellow mechanism contributesmuch to the functionality and styling of this practical widget.Kelsyus OriginalUmich NEW Canopy ChairCanopy Chair 12 13. 12/13/2012PP Retractable Below Cup-holderREDESIGNING ACANOPY CHAIR 13 14. 12/13/2012Functional Improvements - SturdinessREDESIGNING ACANOPY CHAIR The tilting and holding brackets would both reduce stress and increasedurability.Kelsyus Original Umich NEW Canopy Chair Canopy ChairTilting BracketHolding Bracket 14 15. 12/13/2012Hybrid concept Tube Position Reinforcement BlockREDESIGNING ACANOPY CHAIR Also, features an extended storage room. 15 16. 12/13/2012Functional Improvements Seat Back AdjustmentREDESIGNING ACANOPY CHAIR The Slot Mechanism does everything possible to achieve the tradeoffbetween functionality and reliability.Kelsyus OriginalUmich NEW Canopy ChairCanopy Chair 16 17. 12/13/2012Pin-Slot MechanismREDESIGNING ACANOPY CHAIR 17 18. 12/13/2012FoldingREDESIGNING ACANOPY CHAIR 18 19. 12/13/2012FoldingREDESIGNING ACANOPY CHAIR 19 20. 12/13/2012FoldingREDESIGNING ACANOPY CHAIR 20 21. 12/13/2012FoldingREDESIGNING ACANOPY CHAIR 21 22. 12/13/2012FoldingREDESIGNING ACANOPY CHAIR 22 23. 12/13/2012Further Functional ImprovementsREDESIGNING ACANOPY CHAIR 23 24. 12/13/2012Material Improvements Primary RedesignREDESIGNING ACANOPY CHAIR Tube FrameStainless SteelGasket ABS Plastic Oval-section Tube Frame Reinforcement Blocks 24Low Alloy SteelHigh Strength Polyamides 25. 12/13/2012Material Improvements - Secondary RedesignREDESIGNING ACANOPY CHAIR Seat Cushion Pad Single Layer Fabric BellowNylon Mesh Seat Cushion PadBellow Polyurethane Foam PP Homopolymer 25 26. 12/13/2012Process ImprovementsREDESIGNING ACANOPY CHAIR Assembly Efficiency Improved: From 25% to 42% Simplified mechanism Reduced Manual Steps Self-positioning Reinforcement Block Manufacturing Tooling Cost Reduced by: $20,000 per 100,000units Better formability due to material change from Stainless Steel to Low Alloy Steel (AISI 1070/4130) 26 27. 12/13/2012 Cost Improvements (BOM and BOP) C anopy CanopyREDESIGNING A BO I DM Canopy C ot h l C ryarSt r apsH di ng ol C i pslCanopyf r ameLegsuppor tCanopyCanopyext ensi on suppor t i ng sw vel ij oi nt - sw veli j oi nt s - Ar m r est - Ar m r est -m le obi dr i nkEnd l eg pl ast i cs mSl otechani sm C rhaiSeat i ng C r M nhaiFr am ai eFi nal - assy C - FA- 01 CCANOPY CHAIRpl ast i cs f l apsar mst op bot t om hol di nghol di ngcl ot hFast ener s- Cover - chai r Set s of bol t s, Par t Name C - C - 02 C O C - C - 08C O C - C - 09 C O C - C - 01C O C - C - 06 C HC - C - 03 C OC - C - 06 C OC - C - 05 C O C - C - 04C O C - C - 03 C H C - C - 04C HC - C - 05C HC - C - 06C H C - C - 02 C HC - C - 01 C H assy nut s and washer s Number of11211 2 2 2 1 11 1 44 214 Del et ed Par t s Par t s M er i al at $0. 30 $0. 75 $0. 50$0. 43$0. 50$0. 60$0. 34 $1. 08$1. 08 $0. 38 $0. 38$0. 50$0. 09$2. 00$1. 70 $0. 00 $2. 00 ( $/ uni t )Manuf act ur i ng Pr ocess $0. 20$0. 10 $0. 08$0. 20$0. 20$0. 08 $0. 10$0. 10 $0. 05 $0. 05$0. 10$0. 10$0. 40$0. 08$0. 20( $/ uni t ) Assem y Ti m bl e10. 67. 9 7. 92. 6316 34 3. 95 3. 9527. 8 17. 910. 6 12. 6 16 ( $0. 01/ s) C - C - 01C O Cover C ot h l 1 $0. 30 $0. 4010. 6$0. 20 C - C - 02C OC r y St r apsar 2 $0. 757. 9 $0. 00 C - C - 03C OH di ng C i psoll2 $0. 40 $0. 20 7. 9$0. 00 U pper Bar C - C - 04C O2 $0. 15 10. 72 $0. 26 H di ng C ot hol l Upper ar m t o C - C - 05C O l ow ar m l i nk- er2 $1. 00 $0. 08 9. 4$0. 41 1 Upper ar m t o C - C - 06C O l ow ar m l i nk- er2 $1. 00 $0. 08 9. 4$1. 17 2 Upper ar m t o C - C - 07C O l ow ar m l i nk- er2 $1. 00 $0. 08 9. 4$1. 17 3 U pper Bar C - C - 08C O2 $0. 20 $0. 089. 02( $0. 16) H di ng C i pol lAr m r est - m l eobi C - C - 01C H1 $0. 30 $0. 103. 95 ( $0. 03) hol di ngAr m r est - dr i nk C - C - 02C H1 $0. 30 $0. 103. 95( $0. 03)hol di ng Rear suppor t C - C - 03C H2 $1. 25 $0. 08 7. 9$1. 41 l i nk C r Seat i nghai C - C - 04C H1 $1. 13 $0. 4010. 6 ( $0. 88)cl ot h C r M nhaiai C - C - 05C H1 $5. 00 $0. 0812. 6$3. 30Fr ameCover - chai rFi nal - assy1 $0. 0018 $0. 02assyFast ener s- Set s C - FA- 01Cof bol t s, nut s 6 $3. 00 $0. 20 $1. 00 and w asher s New Par t s( $0. 86) ( $0. 80) ( $1. 18)( $1. 18) ( $0. 88) ( $0. 36)$2. 60 OriginalRedesigned ProductProductCostCost 27$18.97$16.37 28. 12/13/2012Architecture Strategy MUST-BEDI High DELIGHTERSI HighREDESIGNING ASI LowDI LowCANOPY CHAIR PRIMARY CUSTOMERSSECONDARY CUSTOMERSORIGINAL PRODUCTPricePhone Storage Weight PayloadLight-weighted SturdinessAdditional StorageDurability Effectiveness of Canopy W/ Seat Cushion Storage Oval-Section Tubes ComfortSeat Folding Angle Easy to Use 28 29. 12/13/2012ModularityREDESIGNING ACANOPY CHAIR 29 30. 12/13/2012ModularityREDESIGNING ACANOPY CHAIR 30 31. 12/13/2012And Color!REDESIGNING ACANOPY CHAIR 31 32. 12/13/2012And of coursePriceREDESIGNING ACANOPY CHAIR Kelsyus OriginalUmich NEWCanopy ChairCanopy Chair $59.99 $30.00 $28.97 32 33. ORIGINAL REDESIGN12/13/2012REDESIGNING ACANOPY CHAIR COMPETITOR$30.00 $59.99$39.99 $28.97 33 34. ORIGINAL REDESIGN12/13/2012REDESIGNING ACANOPY CHAIRCOMPETITOR 34 35. ORIGINAL REDESIGN12/13/2012REDESIGNING ACANOPY CHAIRCOMPETITORWhich of these were your motivationof buying our product? (Check all that apply) 35 36. 12/13/2012REDESIGNING ACANOPY CHAIRQ&A 36 37. 12/13/2012REDESIGNING ACANOPY CHAIRThank You! 37