Report on Toothbrush

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    Product design and

    development of an

    electronic toothbrush

    Submitted by-

    DHIRAJ KUMAR 623/MP/10PIYUSH GUPTA 637/MP/10

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    ACKNOWLEDGEMENT

    There are many people without the support of whom

    this report could not have been completed. We

    gracefully thank Mr. Sanjay Gupta sir for his proper

    guidance and feedback. He was there whenever we

    needed his help and gave us opportunity to learn about

    this topic. I would also like to thank sir for providing us

    the opportunity to explore the product designing and

    development concepts.

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    CONTENTS

    1. Mission statement

    2. Concept development

    2.1Identification of need

    2.2Market research

    a. Customer needs analysis

    2.3 Target specification

    2.4Concept generation

    a. Literature and patent search

    b. Benchmarking

    c.

    Morphology table2.5Concept selection

    a. Concept screening

    b. Concept scoring

    2.6Final specifications

    3. System level designs

    3.1 design 1

    3.2 design 2

    3.3 design 3

    3.4 design 4

    3.5design 5

    4.

    Detailed designs of various parts

    5. Selection of material and processes

    6. Testing and refinement

    6.2Nonintrusive

    6.2 Intrusive

    7. Manufacturing processes

    8. Packaging

    9. Marketing

    9.1Targeted market

    9.2Advertisement and promotions

    9.3 Distribution

    9.4Growth estimation

    10. Disposing or recycling at end of product life

    11. References

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    MISSION STATEMENTOur goal for this project is to develop a better understanding of an electric powered

    toothbrush and to launch a new electric toothbrush that could cater to all needs of oral

    health. It should be able to perform complete functions of a brush in true sense and the

    brand should surpass all the competitors. To do this we will do research on the toothbrush.We will also look at alternative solutions and designs for the toothbrush and come up with a

    comprehensive designing and to make improvements if necessary.

    CONCEPT DEVELOPMENT

    IDENTIFICATION OF NEED

    The history of the toothbrush extends back to 3000 BC, but the modern day brush as we

    know it was designed in 1938 with the addition of nylon bristles instead of boar bristles. The

    first electric toothbrush, the Broxodent, was introduced in 1960. Interestingly enough, the

    only functional difference between the Broxodent and the toothbrush from 1938 was that

    the Broxodent vibrated. To this day, most mass produced toothbrushes all have the same

    single headed brush design, with minimal functional differences.

    Typically in the Indian market the percentage of toothbrush users has slowly inched

    upwards. As it has always been associated by the non-users as a non-essential item more so

    because of their fierce loyalty to the margosa twigg (Datun) and the index finger. The

    market of late has been the entry of several foreign players and the marketing game has

    assumed a totally new dimension. Companies are trying to shift to PULL strategy of long

    term returns and the inclination of consumers to shell out a few rupees extra to ensure a

    more wholesome care of their teeth and gum. This has resulted in rapid growth in valueterms. Added to this is the initiative of the companies to focus on expanding the market by

    bringing over 65% non-users in their consumer fold. With such vast potential to be

    exploited, the entry of several new players with their innovative ideas and experience in

    similar developing markets, the industry is likely to see a lot of action in the immediate

    future.

    The overall response reflects a gradual move in the direction of the premium to super

    premium segment as it is once in three months/four months purchase, thus being successfulin luring all customers (except the rural user who are a small minority of the Market) to try

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    out the ones that are places at a higher price on account of their trendy looks and overall

    appeal of style and splendour. The present day brushing habits of the Indian society as a

    whole leaves a lot to be desired - 41 toothbrushes are sold for every 100 persons per year!

    Total units sold add u to a little over 400 million, growing at the rate of 10% p.a. in volume

    terms and 25% in value terms. This implies not much inroad has been made into the rural

    and semi-urban market.

    The need to maintain oral health is greater than ever since recent research has shown a

    connection between periodontal disease and diabetes, cardiovascular disease, and preterm

    low birth weight. The exact cause and effect relationships are still being investigated, but

    more and more data emphasize that having a healthy mouth is important to preserving

    systemic health.

    Opportunity lies in existing and emerging markets by using an interchangeable technology

    whereby a manufacturer can produce a product line to reach entry level markets to high

    end markets.

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    MARKET RESEARCH

    The purpose of the research was to find out details about the existing product and how tomake it function better and to help the toothbrush better suit the needs of the customers.

    CUSTOMER NEED ANALYSIS

    The data for our customer needs statements was compiled after taking interviews. Consumers

    were asked questions about the quality, comfort and aesthetics of the product. Then

    customer needs statements were developed based on the data gathered during interviews.

    An importance rating was given to each statement to decide which aspects of the

    toothbrush were most important. The needs that were considered as the most important

    were long lasting bristles and a quiet motor.

    Questionnaire used for market research

    How often do you brush your teeth, on average?

    A- 3+ times per day

    B- 2 times per day

    C- 1 time per day

    D- Less than 1 time per day

    What type of toothbrush do you currently use?

    A- Manual toothbrush

    B- Manual toothbrush with replaceable heads

    C- Electric toothbrush

    How do you rate Cleaning effectiveness of your current brush?

    A- Maximum

    B-Minimum

    C-Average

    How satisfied are you with Design (handle comfort, colors) of your current brush.

    A-Maximum

    B-Minimum

    C-Average

    What you think about Brand name while going for buying brush?A-Maximum

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    B-Minimum

    C-Average

    Which is the crucial functions of a toothbrush that you would consider are important(max 3 options)?

    A- Improve gum healthiness

    B- Sensitive teeth protection

    C- Tongue cleaning

    D-360 degree cleaning: easy access to every surfaceof the teeth

    E- Prevent bad breath

    F- Plaque/ debris removal/ prevention

    G- Dental beauty

    What is the source of opinion that affects your purchase decision?

    A- Expert opinions like from dentist

    B- Medical testimonials claimed by manufacturersC- Message communicated from TV commercial

    D- Opinions from users

    what kind of head shape you want for your toothbrush?

    A- Round

    B- Square

    C- Diamond

    What do you think about Handle design

    A- Straight

    B- Curved

    C- Flexible handle

    D- Slip prevention

    How long will you replace your toothbrush?

    A- on average 1 month

    B- on average 1.5 month

    C- on average 2-3 month

    D- replace until the bristle worn out

    Reasons of replacing the current toothbrush?

    A- General oral health advice

    B- Bristle worn out

    C- Oral/ tooth problems

    D- Travelling

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    The findings of the market research are tabulated below-

    TARGET SPECIFICATION

    We found it imperative to increase the appeal of toothbrush by setting higher expectations

    for aspects of the brush. Sound, physical appeal, and excitability are the categories that are

    to be primarily focused. Some sacrifices need to be made for the effectiveness of othercategories such as price. Incidentally, by increasing the performance in other categories of

    the brush, we are to expect a lower performance in the price area. To keep the price from

    increasing by too large of a margin, we have found it in our best interest to increase

    performance in other categories, but not by a tremendous amount or by relatively

    inexpensive means.

    Target specifications-

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    CONCEPT GENERATIONThis is where different ideas to solve each individual need of the customers are developed.

    They are first sorted in a morphology table, then different ideas are generated by taking

    different paths through the table, combining individual ideas together to develop

    complete concepts. Once several concepts have been developed, they are sorted in a

    concept selection matrix, where each is scored and are selected to develop further.

    Selected concepts are moderately developed, they are compared to the values obtained

    from the benchmarking process, and the final design is selected based on the scores

    awarded.

    Literature and Patent Search

    Literature and patent search were done to find out which patents the toothbrush had, cost

    ranges in different stores, and reviews from customers about the product. There were three

    patents found for the Crest Spin Brush Swirl. Patent 1 described the overall toothbrush,

    stating An electric toothbrush with a head that has a static portion of bristles and a circular

    portion that reciprocates. And the body is angled. (Patent number: 6178579, Issue date:

    Jan 30, 2001) Patent 2 described the head of the toothbrush saying A design for the head

    of the toothbrush, allowing multi-level bristles. (Patent number: 5392483, Issue date: Feb

    28, 1995) Patent 3 described the grip saying Grip for the handle of the toothbrush. (Patent

    number: D357121, Issue date: Apr 11, 1995)

    Benchmarking

    Benchmarking was done to compare the product to other products on the market and to

    see how to make the product better or more competitive. To complete the benchmarking

    portion of the design process, it was necessary to gather the results of various tests that

    were performed on various toothbrush available in market. A variety of trials were used to

    test such criteria as sound, battery life, cost, etc. A decibel meter was used to test theoverall loudness of the toothbrush, a multimeter was used to discover the life of the battery

    in the toothbrush while under assorted loads, and a sandpaper test was used to find the

    bristle life. These three values and the additional value of price were the most important

    factors for us to consider during the design process.

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    Morphology Table

    The concepts developed in this Morphology table were developed out of ideas from

    Customer Survey and Needs Analysis and were selected to meet the ideal specifications

    from the Target Specifications table.

    NOTES:

    Insulation The addition of Styrofoam around the motor inside the body of the

    toothbrush to reduce the amount of noise created by vibrations.

    Reduced Size

    The size of the handle is reduced to be more suitable tochildrens hands.

    Generator A crank drives a generator that converts mechanical energy into

    electrical energy, which will be stored in a capacitor and returned

    to the motor by flipping a switch. Current will be controlled by a

    resistor; the crank will be stored inside of the toothbrush body.

    Alternator A magnet housed inside of the toothbrush body will pass through a

    copper coil, creating a current which will be stored and released in

    a manner identical to the generator.

    Single-Button Operation A single button will open and close the circuit to take

    power from the source and deliver it to the motor.

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    The following concepts were developed from the morphology table above and inserted into

    the concept selection

    SYSTEM LEVEL DESIGN FOR CONCEPTS

    Concept #1 was designed with a color scheme on the body of the toothbrush, a quieter

    motor, and a replaceable battery.

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    Concept #2 was designed with a plain body, less expensive, and all plastic.

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    Concept #3 was designed only to be more appealing to the eye of the customer.

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    Concept #4 was designed with a jelly grip for comfort, and various sports designs on the

    body.

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    Concept #5 was designed with a quieter motor,with sporty design.

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    CONCEPT SELECTIONThe criteria for selecting concepts came down to using metrics. The most important criteria

    had to do with sound and life. A replaceable battery would add value to the product. The

    aesthetics were also important because many other products had very intricate designs. Inthe selection, some aspects of various concepts were used to yield a final product. New

    features include a full rubber grip on the handle, colorful design, a door for a replaceable

    battery and foam insulation around the motor to decrease sound. After screening all 5 of

    our concept variants, we decided that concept 1 and concept 4 were best to continue

    screening.

    Concept Screening

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    Concept Scoring

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    FINAL SPECIFICATIONS

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    DETAILED DESIGNS OF VARIOUS PARTS

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    SELECTION OF MATERIAL AND PROCESSESThe materials used in the process of creation are: acetal, polypropylene and

    nylon 66. These materials have been chosen because they are the typically used in

    such applications.

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    The acetal is a thermoplastic product for the mechanics industry in general. It has a high

    hardness and good dimensional stability. It is a thermoplastic with high molecular weight

    that is characterized by high mechanical resistance, almost zero water absorption and good

    friction properties. The acetal is also called POM or polyoxymethylene.

    The polypropylene is a commercial thermoplastic polymer, semi-crystalline, white, semi-

    opaque and currently it is produced in a wide variety of grades and modifications. It is a rigid

    and hard material which excellent impact resistance, to chemist corrosive products and

    dielectric. The nylon 66 is a polyamide with excellent qualities: durability, toughness, high

    elongation, excellent abrasion resistance, highly resilient the ability of shock absorption,

    noise and vibration. It is moisture resistant since it is dried completely and thus, it avoids thebacterial growth.

    TESTING AND REFINEMENTNonintrusive Testing

    For the nonintrusive testing, students were asked to:

    1. Record all external features, observe safety features and identify potential hazards.

    2. Comment on the ergonomics and aesthetics of the design.

    3. Record external dimensions, make a list of parts and understand the function of the

    various parts.

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    4. Do AUTOCAD drawings of the entire toothbrush and the various parts with proper

    labelling and dimensioning.

    5. Note all intellectual property rights (like trademark, patent numbers and registration).

    6. Do a patent search of related patents on the World Wide Web.

    7. Estimate the cost of the product.

    8. Check environmental feasibility in terms of recyclability and packaging.

    9. Understand the operating instructions and operate the product.

    10. Devise and perform an experiment to see how the electric toothbrush compares with a

    manual toothbrush in removing stains. Is the cost of the electric toothbrush justified in

    terms of its cleaning capability?

    11. Recommend any improvements in terms of cost, manufacturing, aesthetics, safety and

    environmental issues.

    12. Do a literature survey of electric toothbrushes available in the market

    Intrusive TestingFor the intrusive testing, two main experiments are conducted as follows:

    1. Charging the toothbrush is done by electromagnetic induction. The coil in the toothbrush

    is evaluated in terms of the number of turns and the voltage across it. The number of turns

    are then varied to study its relationship to voltage induced. From these data points, least-

    squares curve fitting is taught and a curve is estimated to derive a mathematical

    relationship. The magnetic flux density is also measured using a Gauss meter for varying

    numbers of coil turns. Again, a least-squares fit is determined.

    2. The energy stored in the nickel cadmium battery is measured. The voltage across the

    battery as a function of time is measured by building a simple resistive circuit through which

    the battery discharges. From the voltage and resistance, the power of the battery as afunction of time is determined. Since the integral of the power is the energy, numerical

    integration is used to find the energy from the power curve.

    MANUFACTURING PROCESSESInjection Modeling:

    At first they put PP powder (Polypropylene powder) in the Injection Modeling Machine

    which is almost like a small plastic ball. These plastic balls are of crystal color. According to

    the design of the brush they add different color to make the body of the toothbrush. The

    pressurization of the Machine of plastic balls in 40 degree Celsius is used to shape the body

    of the brush. Within 20 to 40 second these machine produce the shape of the body of atooth brush. It can produce 8 toothbrushes at a time. In the injection modeling machine

    there is some dice which help to design the brush. They have five injection Modeling

    machine in their factory.

    Particle Machine:

    In the Particle machine they set a logo on the dice and later the logo of that particular brand

    is added to the body of the brush. It also adds rubber to design the toothbrush. After that,

    the particle machine helps to add different colors of logo according to their choice. At first

    they put eight brushes at the middle of the machine and the brushes are held for 5 seconds

    to put color and logo on the brush. That means whatever work is remaining in the stage of

    injection modelling machine, is been completed in this particle machine. Moreover, in total

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    it needs approximately 20 seconds to add a logo. They have 3 particle machines to make

    their production faster.

    Taffting Machine:

    After the completion of the job of particle machine, next step is done by Taffting Machine.

    Main job of Taffting machine is to adjoin bushels on the head of tooth brush. They use the

    silver ware to weave the brushels at the head of the brush which help to attach the brushels

    strongly with the brush. The machine takes one minute to attach brushels on the five

    brushes. Whatever the color or design they want to add on the brushels they set on the

    machine, which is controlled by the PRM-850 programming system. For each design they

    have particular software to command the machine. They have 5 Taffting Machines in their

    factory. In one minute they can adjoined 25 pieces of brushes. In this production section

    one people control each machine. According to them this machine holds the highest price

    among the entire machineries they have. These machines are kept in the air conditioned

    room as this task is controlled by computer programming.

    Finishing Machine:Taffting machine has some limitation like brushels of toothbrush may not be in same size or

    may be brushels are not in same line. For that reason to ensure the quality, finishing

    machine do the final touch. They have two finishing machines for that purpose and each

    machine sizing the brushels. These machines are able to size 100 brushels within one

    minute. However if machines do defect for any reasons they continue their production by

    manually. They have 6 workers for this department.

    PVC (polyvinyl chloride) forming machine:

    For the packaging purpose at first they prepare plastic cover. Previously they collected

    plastic

    cover from their supplier which incurred huge cost and ultimately reduced profit. To solvethis problem, recently they start to produce plastic cover by themselves. Tri-Star purchases

    the bundle of the plastic paper. At first they put the plastic paper into the PVC forming

    machine in 24 degree Celsius and after the 20 second it divides the paper into 8 brush

    shapes plastic cover. They have only one PVC forming machine.

    Blister Packaging Machine:

    After the tasks of finishing machine here comes the packaging part. For that purpose, they

    use two Blister Packaging Machines, which help to package the toothbrush. To packages the

    brush they first lay down the plastic cover page. Then keep eight brushes on that shaped

    plastic paper and upon those brushes they put a paper which is labeled by their company

    name and logo. Then through the system, they send those brushes to the middle of themachine. In this process the upper side of the machine put pressure on that. And after that

    a package of 8 brushes comes out through the Blister packaging machine. In total it takes

    nearly 5 seconds to package 8 brushes. They let us know that, the logo papers are

    outsourced from different computer and graphic shop. They have not any fixed suppliers for

    that, rather they go for bargaining option to reduce cost. They let us know that if any

    packaging machines run out of operation or for load shedding they go for manual

    production. For that packaging department they have 20 workers.

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    PACKAGING

    Cardboard cartons, transparent blisters, hanger shaped hooks, coffin packing (storing whennot in use). In a blister pack, packaging makes up to 40% of cost. Transparent blister pack

    with a hanger shape hook should be used.

    MARKETINGToothbrush industry is one of the broadest sectors whose market consists of the entire

    world. No matter how different the cultures of different countries or which race they belong

    to, toothbrushes have customers all around the world. Additionally, with the increasing

    education level, people are getting more aware of oral health care and that is also a reason

    for toothbrush industry to enlarge.Therefore, if we want to give a number for the size of targeted customers of toothbrush

    industry, we say the size of around 6 billion people which is the population of the World.

    However, it is very difficult to operate so much globally even for the most advanced

    companies. Careful plans and reasonable analysis need to be done to select most

    advantages countries that fit the company's capacity.

    Targeted market

    Although all the people using any kind of toothbrushes are our candidate customers, users

    of current electrical toothbrushes best fit to our targeted market.Providing medically the best brushing style, our product can take over the current market

    share of electrical toothbrushes. To guarantee our goal, we need to carefully analyze the

    reasons of people for using and not using current electrical toothbrushes. Then avoiding

    disadvantages and improving the advantages will not only lead us to top of the electrical

    toothbrush market but also increase the market share of electrical toothbrushes among

    total toothbrush industry.

    Advertisement and Promotions

    We have a new type of product and people are not aware of it. Putting it on shelves doesn'tsell it since people don't know about it, they must hear about our product first.

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    TV advertisements are the most effective but expensive advertisement way however it will

    definitely compensate its cost.

    The pricing of TV commercials changes very much depending on the time, the length and

    popularity of the channel. To get the best value of advertisement, careful research must be

    done to select the advertisement strategy.Instead of expensive prime time commercials, we think that the morning period is more

    efficient for our product. Firstly, commercials in morning time are cheaper than the evening.

    Secondly, morning programmers are watched by women, especially by housewives who

    usually decide what to buy and shop for home. Women are also careful to their health than

    men. Therefore, showing the advertisements in morning will be cheaper and more effective.

    Besides TV commercials, Internet media is another place which is much more cheaper than

    TV and still effective enough to be considered. Google advertisements are the first option.

    There are several pricing for Google advertisements such as per-click or per-showing.

    Apart from Google advertisements, the advertisements in Internet shopping web sites must

    also be utilized. Campaigns for famous shopping sites will also work as advertisements since

    the web site will announce it at several sections of the site.

    In addition to the digital advertisements, promotions in shopping malls will also bring us a

    quick entrance to the market. Selling with very small revenue for the first month can help us

    to make use of word-of-mouth. People buying our product for the first time, will definitely

    tell their friends about it since it is new in the market.

    Including an explanatory brochure with our product can also convince people to buy it.

    Distribution

    The main sale channels for any kind of toothbrushes today is shops with any size from

    groceries to gross markets; and Internet especially for comparatively expensive products.

    We also plan to utilize these two channels to deliver our product to customers. Since the

    Internet doesn't require much attention, we only need to focus on the delivery system for

    shops.

    There are different delivery mechanisms for different kind of products. If you have to deliver

    your product to shops each day, then it could be better you establish your own distribution

    system. However, if you only need to deliver your product few times in month, and if your

    product doesn't expire in short time, you may relay on third party distribution networks.

    Our product is best delivered by established distribution networks in each country. Usually,

    those distribution channels specialized for the category they operate. Personal care

    products such as shampoos, soaps and toothbrushes are delivered in same category usually.

    Utilizing those available distribution channels is the best economical option for cylindrical.

    Growth Estimation

    Initial few years are crucial newly established companies. Many companies go bankruptcy

    because of bad planning in their early lifetimes.

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    In order to be sure about success of our new business, we paid much attention to our first

    two years.

    We intend to make a reasonable growth for first two years that is to reach %30 of electrical

    toothbrush market of USA and Europe. Considering the confidence that our patent provides

    us, %30 is not much optimistic. Following figure shows our quarter based expectation forfirst two years.

    DISPOSING OR RECYCLING AT END OF PRODUCT LIFEThe rechargeable battery cannot be replaced, but it is easy to remove for recycling. Like any

    rechargeable battery, it contains substances that may pollute the environment if discarded

    with regular household waste. At the end of the toothbrushs life, always remove the

    battery before you discard the toothbrush, and recycle or dispose of the battery according

    to local waste management requirements. If you have any recycling questions, contact your

    local waste management office.

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    References-

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    8. http://www.spinbrush.com/Products_SpinBrushSwirl.html,

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