Fall 2012- Design for Manufacturing

REDESIGNING A CANOPY CHAIR

Team 2: Mengshi Gao, Vibin Ilango, Tianshu Li,

Shengyu Lou , Aniruddha Srinath

University of Michigan, Ann Arbor

Product to be Improved04/12/2023


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LOOK HOW FRUSTRATED HE IS……

Problems & Improvements04/12/2023


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Personali-zation

Mobility

Sturdiness & Durability

Comfort

Sturdiness Of Chair Seat Back Angle Adjustment

Presence Of Phone Storage

Presence Of Cup Holder

Weight Of ChairPresence Of Canopy

Delighting Features

Customer Complaints

To design a comfortable, sturdy and economic canopy chair

which is attractive across a wide range of customers (20~75

years old) for all kinds of outdoor recreations.

Target Groups

20-50 Age 51-75

HighSturdiness &

DurabilityGood

Good Mobility Good

Basic Comfort High

Good Personalization Good

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PRIMARY CUSTOMERS SECONDARY CUSTOMERS

Perform at BASIC Level

Perform at GOOD Level

Perform at HIGH Level

Concepts04/12/2023


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Functional Improvements - Canopy

• A Flipping Extension can provide wider range to safeguard the customers

from rain and sunlight.

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Kelsyus Original Canopy Chair

Umich NEW Canopy Chair

Also, it can be swiveled...!04/12/2023


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25% Shadow Area Increase

50% Side Area Increase

360° Swivel Angle

Functional Improvements – Seat Material

• Nylon fabric is highly durable, and easy to wash and care for.

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For elderly customers group, cushion is available04/12/2023


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Inserted with Polyurethane Foam cushion

Functional Improvements - Storage

• The lightweight, easy-folding material in bellow mechanism contributes

much to the functionality and styling of this practical widget.

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PP Retractable Below Cup-holder04/12/2023


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Functional Improvements - Sturdiness

• The tilting and holding brackets would both reduce stress and increase

durability.

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14Tilting Bracket Holding Bracket



Hybrid concept – Tube Position Reinforcement Block04/12/2023


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Also, features an extended storage room.

Functional Improvements – Seat Back Adjustment

• The Slot Mechanism does everything possible to achieve the tradeoff

between functionality and reliability.

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Pin-Slot Mechanism04/12/2023


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Folding

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Folding

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Folding

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Folding

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Folding

Further Functional Improvements04/12/2023


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Material Improvements – Primary Redesign04/12/2023


24 Low Alloy Steel High Strength Polyamides

Oval-section Tube Frame Reinforcement Blocks

Tube FrameStainless Steel

ABS Plastic Gasket

Material Improvements - Secondary Redesign04/12/2023


25Polyurethane Foam PP HomopolymerSeat Cushion Pad Bellow

Seat Cushion PadSingle Layer Fabric

Nylon MeshBellow

Process Improvements

• Assembly Efficiency Improved: From 25% to 42%

– Simplified mechanism

– Reduced Manual Steps

– Self-positioning Reinforcement Block

• Manufacturing Tooling Cost Reduced by: $20,000 per 100,000

units

– Better formability due to

material change from Stainless

Steel to Low Alloy Steel

(AISI 1070/4130)

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Cost Improvements (BOM and BOP)04/12/2023


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BOM I DCanopyCl oth

CarryStraps

Hol di ngCl i ps

Canopyf rame

Legsupportpl ast i cs

Canopyextensi on

fl aps

Canopysupport i ng

arms

Canopyswi velj oi nt -

top

Canopyswi vel

j oi nts -bottom

Arm rest -mobi l ehol di ng

Arm rest -dr i nk

hol di ng

End l egpl ast i cs

Sl otmechani sm

Chai rSeat i ngcl oth

Chai r Mai nFrame

Fi nal - assy CC- FA- 01

Part Name CC- CO- 02 CC- CO- 08 CC- CO- 09 CC- CO- 01 CC- CH- 06 CC- CO- 03 CC- CO- 06 CC- CO- 05 CC- CO- 04 CC- CH- 03 CC- CH- 04 CC- CH- 05 CC- CH- 06 CC- CH- 02 CC- CH- 01Cover- chai r

assy

Fasteners-Sets of bol ts,

nuts andwashers

Number ofParts

1 1 2 1 1 2 2 2 1 1 1 1 4 4 2 1 4

Materi al($/ uni t)

$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

Manufacturi ng Process($/ uni t)

$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

Assembl y Ti me($0. 01/ s)

10. 6 7. 9 7. 9 2. 63 16 34 3. 95 3. 95 27. 8 17. 9 10. 6 12. 6 16

CC- CO- 01 Cover Cl oth 1 $0. 30 $0. 40 10. 6 $0. 20

CC- CO- 02 Carry Straps 2 $0. 75 7. 9 $0. 00

CC- CO- 03 Hol di ng Cl i ps 2 $0. 40 $0. 20 7. 9 $0. 00

CC- CO- 04Upper Bar

Hol di ng Cl oth2 $0. 15 10. 72 $0. 26

CC- CO- 05Upper arm to

l ower arm l i nk-1

2 $1. 00 $0. 08 9. 4 $0. 41


l ower arm l i nk-2

2 $1. 00 $0. 08 9. 4 $1. 17


l ower arm l i nk-3

2 $1. 00 $0. 08 9. 4 $1. 17

CC- CO- 08Upper Bar

Hol di ng Cl i p2 $0. 20 $0. 08 9. 02 ($0. 16)

CC- CH- 01Arm rest - mobi l e

hol di ng1 $0. 30 $0. 10 3. 95 ($0. 03)

CC- CH- 02Arm rest - dri nk

hol di ng1 $0. 30 $0. 10 3. 95 ($0. 03)

CC- CH- 03Rear support

l i nk2 $1. 25 $0. 08 7. 9 $1. 41

CC- CH- 04Chai r Seat i ng

cl oth1 $1. 13 $0. 40 10. 6 ($0. 88)

CC- CH- 05Chai r Mai n

Frame1 $5. 00 $0. 08 12. 6 $3. 30

Fi nal - assyCover- chai r

assy1 $0. 00 18 $0. 02

CC- FA- 01Fasteners- Setsof bol ts, nuts

and washers6 $3. 00 $0. 20 $1. 00

($0. 86) ($0. 80) ($1. 18) ($1. 18) ($0. 88) ($0. 36)New Parts

Del etedParts

$2.60

Original Product

Cost$18.97

Redesigned Product

Cost$16.37

Architecture Strategy04/12/2023


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PRIMARY CUSTOMERS SECONDARY CUSTOMERS

Price

Weight

Payload

Sturdiness

Durability

Effectiveness of Canopy

Storage

Comfort

Seat Folding Angle

Easy to Use

ORIGINAL PRODUCT

√ √ ×

MUST-BEDI HighSI Low

DELIGHTERSI HighDI Low

Phone Storage

Additional Storage

Oval-Section Tubes

W/ Seat Cushion

Light-weighted

Modularity04/12/2023


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Modularity04/12/2023


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And… Color!04/12/2023


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MEET OUR PRODUCT FAMILY!

And of course……Price！04/12/2023


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$59.99$28.97

$30.00

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ORIGINAL REDESIGN

COMPETITOR

$39.99$30.00

$59.99$28.97

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ORIGINAL REDESIGN

COMPETITOR

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ORIGINAL REDESIGN

COMPETITOR

Which of these were your motivation of buying our product?

(Check all that apply)

Q&A

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Thank You!

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Fall 2012- Design for Manufacturing

Education

Transcript of Fall 2012- Design for Manufacturing