Revisi Final Report Fri-006 HKL

FINAL REPORT
PRODUCT DEVELOPMENT PRACTICUM
PRODUCTION SUPPORTING TOOL

“TANGALU”
Group :
FRI-006
Member :
Fadhilah (1201140343 /TI-38-01)
Shafira Tasyani Nasution (1201144223 /TI-38-01)
Wirandy Fajar Saputra (1201140359 /TI-38-01)
SCHOOL OF INDUSTRIAL AND SYSTEM ENGINEERING

TELKOM UNIVERSITY
BANDUNG
2017
PREFACE
Thank God we pray to the presence of God Almighty who has given grace and His gift to us so
we managed to finish this report.
This paper contains about the products we offer as a production tool and more specifically
products used to help the craftsmen shoes to minimize processing time and productivity.
Meanwhile this report describes the product development process of the product consists of
several phases based on labwork and ulrich product design and development as reference
therefore there are some changes done toward product.
This report is expected to provide benefits in the form of knowledge for the reader and in fact
can help direct the production of the craftsmen shoes. Writers realize that this paper is far from
perfect, therefore, criticism and suggestions from all parties which are constructive always we
expect for the perfection of this paper.
Finally, we extend our thanks to all those who have participated in the preparation of this paper
from start to finish. May the Almighty God continue to bless our efforts. Amen.
Bandung, 15/04/2017
FRI-38-006
i
TABLE OF CONTENTS
PREFACE.................................................................................................................................... i
TABLE OF CONTENTS ...........................................................................................................ii
CHAPTER I................................................................................................................................ 5
INTRODUCTION ...................................................................................................................... 5
I.1. PREFACE......................................................................................................................... 5
1.2. Problem Formulation ....................................................................................................... 5
1.3 Project Purpose ................................................................................................................. 5
1.4. Project Function ............................................................................................................... 5
1.5. Product Development Phases........................................................................................... 5
CHAPTER II .............................................................................................................................. 7
IDENTIFICATION OF PRODUCT DEVELOPMENT OPORTUNITIES, CONSUMER

NEEDS AND PRODUCT SPECIFICATIONS ......................................................................... 7
II.1. Mission Statement............................................................................................................... 7
II.2. Data Collection Methods and Customer Statement ........................................................... 7
II.2.1 Observation ................................................................................................................ 7
II.2.2 Interview .................................................................................................................... 8
II.3. Need Statement ................................................................................................................. 10
II.4. The Level of Importance and Satisfaction Questionnaires ............................................... 12
II.5. WAP Satisfaction and Importance Rate ........................................................................... 12
II.5.1 WAP Satisfaction Rate ................................................................................................ 13
II.5.2 WAP Importance Rate ................................................................................................ 14
II.6. Matriks Klein Grid ............................................................................................................ 14
II.7. Product Specification ........................................................................................................ 16
II.8. Planning Matrices ............................................................................................................... 1
II.9. HOQ Analysis ..................................................................................................................... 2
II.9.1 Table A (Customer Requirement) ................................................................................. 1
ii
II.9.2 Table B (Planning Matrix) ............................................................................................ 1
II.9.3 Table C (Technical Responses) ..................................................................................... 1
II.9.4 Table D (Inter-Relationships) ....................................................................................... 2
1.9.5 Table E (Technical Corelations) .................................................................................... 1
II.9.6 Table F (Target Matrix) ................................................................................................ 1
CHAPTER III ............................................................................................................................. 2
CONCEPT GENERATION & CONCEPT SELECTION ......................................................... 2
III.1. Concept Generation Analysis ............................................................................................ 2
III.1.1. Customer Needs Recap ............................................................................................... 2
III.1.2. Problem Clarification Analysis ................................................................................... 2
III.1.2.1. Interpetation Analysis of Customer Needs........................................................... 2
III.1.2.2. Black Box ............................................................................................................. 2
III.1.2.3. Decomposition ..................................................................................................... 3
III.1.3. Internal and External Searching Analysis ................................................................... 1
Table 36. Generate Ideas ........................................................................................................ 1
................................................................................................................................................ 1
III.1.4. Result of Internal and External Exploration Analysis ................................................ 1
III.1.4.1 Option Analysis of Each Function ........................................................................ 1
II.1.5 Analisis Systematic Exploration Analysis and Result .................................................. 5
II.1.5.1 Concept and Sketch Resulted ................................................................................. 5
II.2. Concept Selection Analysis ................................................................................................ 6
II.2.1. Determine Selection Criteria for Each Need Satetment ............................................... 6
II.2.2. Determine Weight of Each Selection Criteria .............................................................. 7
II.2.3 Concept selection .......................................................................................................... 7
II.2.4 Concept Scoring ............................................................................................................ 8
III.2.6 Selected 3D Design .................................................................................................... 10
CHAPTER IV ........................................................................................................................... 11
iii
PRODUCT ARCHITECTURE ................................................................................................ 11
IV.1. Description of Chosen Product........................................................................................ 11
IV.2 Product Scheme ................................................................................................................ 12
IV.3 Product Geometric Structure ............................................................................................ 13
IV.4 Identification of Fundamental and Insidental Interaction ................................................ 14
CHAPTER V ............................................................................................................................ 15
CONCURRENT ENGINEERING ........................................................................................... 15
V.1. Product Description .......................................................................................................... 15
V.2 C-Data Analysis ................................................................................................................. 15
IV.3 Design Decision Analysis ............................................................................................. 19
V.4 Refine Design Analysis ..................................................................................................... 25
V.5 Final Design ....................................................................................................................... 27
CHAPTER VI ........................................................................................................................... 28
VI.1 Product Part List/ Main Parts ........................................................................................... 28
VI.2 Product Spesification........................................................................................................ 29
VI.3 Translate Design Requirement of Part / Component........................................................ 29
VI.4 Material Screening & Ranking of Part / Component ....................................................... 30
VI.5 Seek Supporting Information of Part / Component .......................................................... 31
VI.6 Finite Element Analysis Test ............................................................................................. 1
VI.7 Chosen Material Analysis .................................................................................................. 1
CHAPTER VI ............................................................................................................................. 2
VII.1 Product Description .......................................................................................................... 2
VII.2 Design For Manufacturing and Assembly (part 1) ........................................................... 2
VII.2.1 Gambar part ................................................................................................................ 2
VII.2.2 Structure Assembly .................................................................................................... 3
VII.2.3 DFMA ........................................................................................................................ 3
VII.3 DFMA Suggestion (part 1) ............................................................................................... 4
iv
VII.3.1 Part Picture ................................................................................................................. 4
VII.3.2 Assembly Structure .................................................................................................... 4
VII.3.3 DFA Table of Measurement ....................................................................................... 5
VII.4 Design for Environment .................................................................................................... 5
VII.4.1 DFE Agenda ............................................................................................................... 5
VII.4.2 DFE Goals .................................................................................................................. 5
VII.4.3 Apply DFE Guidelines to Product ............................................................................. 6
VII.5 Part Deployment ............................................................................................................... 6
VII.5.1 Part Deployment ......................................................................................................... 6
VII.5.1.1 Metric and Value ................................................................................................ 6
VII.5.2 Part Deployment Result ............................................................................................. 8
VII.6 Failure Mode and Effec Analysis ..................................................................................... 8
CHAPTER VIII ........................................................................................................................ 10
CONCLUTION ........................................................................................................................ 10
VIII.1 Conclution .................................................................................................................. 10
VIII.2 Suggestion .................................................................................................................. 10
REFERENCE ........................................................................................................................... 11
v
LIST OF TABLES
Table 1. Mission Statement ..................................................................................................................... 7
Table 2. Observation Result .................................................................................................................... 8
Table 3. Interview 1 ................................................................................................................................ 8
Table 4. Interview 2 ................................................................................................................................ 9
Table 5. Interview 3 ................................................................................................................................ 9
Table 6. Interview 4 ................................................................................................................................ 9
Table 7. Need Statements ...................................................................................................................... 10
Table 8. Recap of Need Statements ...................................................................................................... 11
Table 9. Questionaire ............................................................................................................................ 12
Table 10. WAP Satisfaction Rate Measurement ................................................................................... 12
Table 11. WAP Continuation Measurement ......................................................................................... 12
Table 12. Perfomance Weighted ........................................................................................................... 13
Table 13. WAP Satisfaction Rate Measurement ................................................................................... 13
Table 14. WAP Continuation Measurement ......................................................................................... 13
Table 16. WAP Importance Rate .......................................................................................................... 14
Table 17. Continuation Measurement of WAP importance .................................................................. 14
Table 19. Satisfaction Value/Total Respondents .................................................................................. 14
Table 20. Resulted Mid Line (X) .......................................................................................................... 14
Table 21. Importance value/ Total respondents .................................................................................... 14
Table 22. Resulted Mid Line (Y) ......................................................................................................... 14
Table 23. Classification of customer need ............................................................................................ 15
Table 24. Product Specification ............................................................................................................ 16
Table 25. References ............................................................................................................................. 17
Table 26. Matrices Planning.................................................................................................................... 1
Table 27. Needs statement ...................................................................................................................... 1
Table 28. Planning Matrix....................................................................................................................... 1
Table 29. Technical responses ................................................................................................................ 1
Table 30. Inter-Relationships .................................................................................................................. 2
Table 31. Correlation Metric ................................................................................................................... 2
Table 32. Technical Corelations.............................................................................................................. 1
Table 33. Correlation between metric meaning ...................................................................................... 1
Table 34. Direction of Goodness............................................................................................................. 1
1
Table 35. Target Matrix .......................................................................................................................... 1
Table 36. Generate Ideas ........................................................................................................................ 1
Table 37. Combinating Table 1 ............................................................................................................... 2
Table 38. Combinating Table 2 ............................................................................................................... 1
Table 39. Table Combinating 3 ............................................................................................................... 2
Table 40. Table Combinating 4 ............................................................................................................... 3
Table 41 Combinating Table 5 ................................................................................................................ 4
Table 42. Recap of Combinating Table .................................................................................................. 5
Table 43 Weight of Each Selection Criteria. ........................................................................................... 7
Table 44. Selection Criteria Scoring Matrix ........................................................................................... 7
Table 45. Relative Score ......................................................................................................................... 8
Table 46. Concept Scoring ...................................................................................................................... 8
Table 47. Planning Matrices.................................................................................................................. 10
Table 48. Design Decision Right Handle .............................................................................................. 19
Table 49. Design Decision Handle Case ............................................................................................... 19
Table 50. Deisgn Decision Tool Case ................................................................................................... 20
Table 51. Design Decision Left Handle ................................................................................................ 20
Table 52. Design Decision Pivot Screw ................................................................................................ 21
Table 53. Design Decision Handle Case ............................................................................................... 21
Table 54. Design Decision Tool Case ................................................................................................... 22
Table 55. Design Decision Pivot Screw ................................................................................................ 22
Table 56. Design Decision Handle ........................................................................................................ 23
Table 57. Decision Decision Handle Case ............................................................................................ 23
Table 58. Design Decision Tool Case ................................................................................................... 24
Table 59. Design Decision Handle ........................................................................................................ 24
Table 60. Metric/Value/Unit ................................................................................................................. 29
Table 61. Left Handle Translate Design ............................................................................................... 29
Table 62. Right Handle Translate Design ............................................................................................. 30
Table 63. Seek Supporting Information Left Handle ............................................................................ 31
Table 64. Seek Supporting Infromation Right Handle .......................................................................... 32
Table 65. DFMA Measurement .............................................................................................................. 3
Table 66. DFMA Suggestion Measurement ............................................................................................ 5
Table 67. DFE Analysis .......................................................................................................................... 6
Table 68. Part Deployment Result .......................................................................................................... 8
Table 69. FMEA Analysis....................................................................................................................... 8
2
LIST OF FIGURES
Figure 1. Picture of Klein Grid Matrices .................................................................................. 15
Figure 2. Existing Hammer ...................................................................................................... 17
Figure 3. Existing plier ............................................................................................................. 17
Figure 4. House of Quality ......................................................................................................... 2
Figure 5. Black Box .................................................................................................................... 2
Figure 6. Decomposition ............................................................................................................ 3
Figure 7. Selection Criteria......................................................................................................... 6
FIgure 8. Selected 3D Design ................................................................................................... 10
Figure 9. Product Illustration .................................................................................................... 11
FIgure 10. Scheme Element Grouping ..................................................................................... 12
FIgure 11. Rough Geometric .................................................................................................... 13
FIgure 12. Interaction Identification ......................................................................................... 14
FIgure 13. Insidential Interaction Diagram .............................................................................. 14
FIgure 14. Manufacturing Aspect C Data Right Handle .......................................................... 15
FIgure 15. Manufacturing Aspect C Data Left Handle ........................................................... 15
FIgure 16. Manufacturing Aspect C Data Handle Case ........................................................... 16
FIgure 17. Manufacturing Aspect C Data Box Case ................................................................ 16
FIgure 18. Assembly Aspect Pivot Screw ................................................................................ 16
FIgure 19. Assembly Aspect Screw Pivot ................................................................................ 17
FIgure 20. Assembly Aspect Handle Case C Data ................................................................... 17
FIgure 21. Tool Case Assembly Aspect C Data ....................................................................... 17
FIgure 22. Environment Aspect Handle C Data ....................................................................... 17
FIgure 23. Environment Aspect Handle C data ........................................................................ 18
FIgure 24. Environment Aspeck Handle Case C Data ............................................................. 18
FIgure 25. Environment Aspect Tool Case C Data .................................................................. 18
Figure 26. Design Refinement Right Handle Analysis ........................................................... 25
Figure 27. Design Refinement Handle Case Analysis ............................................................. 25
Figure 28. Design Refinement Tool Case ................................................................................ 26
Figure 29. Design Refinement Left Handle.............................................................................. 26
Figure 30. FInal Design 3D ...................................................................................................... 27
Figure 31. Product Main Parts .................................................................................................. 28
Figure 32. Material Selection 1 ................................................................................................ 30
Figure 33. Material Selection 2. ............................................................................................... 31
3
Figure 34. Finite Element Analysis ............................................................................................ 1
Figure 35. Part Views ................................................................................................................. 2
Figure 36. Structure Assembly ................................................................................................... 3
Figure 37. Part Pictures .............................................................................................................. 4
Figure 38. Assembly Structure ................................................................................................... 4
Figure 39. DFA Agenda ............................................................................................................. 5
Figure 40. Metric and Value Part Deployment .......................................................................... 6
Figure 41 Part Deployment Part Specification ........................................................................... 6
Figure 42. Inter Correlation Part Deployment ............................................................................ 7
Figure 43. Target Matrix Part Deployment ................................................................................ 7
Figure 44. Final Model ............................................................................................................... 9
4
CHAPTER I
INTRODUCTION
I.1. PREFACE
Central Industry are centers of industry groups on a location / specific place which
consists of various similar business. One of the famous and oldest central industry in Bandung
is the central industry Cibaduyut. Various complementary businesses in Cibaduyut region is
very much, generally complementary businesses which dominate most are the workshop
production of shoes. Until the year 2011, there were approximately 844 business units that
consist of a workshop production of shoes or a sales outlet with workforce uptake
approximately arround 3590 labors.
The production of shoes is consist of 4 steps: make pattern, sewing, setting sole, and
finishing. In the process of the production there are a lot of tools used at the production process
of shoes, among others are wood shoe, hammer, plier, nail, knive, etc. Based on the observation,
the worker oftenly change their tool in the process of shoes production. As example the worker
is frequently change plier to hammer in production of shoes sole.
However the iteration of tool usage done in some production process cause an
unefficient work motion which ultimately can lead to decreased productivity. Therefore,
multifunction tool is needed for worker to work efficiently.
1.2. Problem Formulation

 How to design product appropriate as production process supporting tool
 How to develope products so that can be used especially for craftsmen needs
1.3 Project Purpose

 Discover shoe supporting production tool appropriate for the needs of craftsmen
 Develope the product in order to give better perfomance and minimized cost
1.4. Project Function

 Knowing the phase of product development
 Answer the needs of production’s suporting tool especially for shoe craftsmen
1.5. Product Development Phases

 Identification of product development oportunities, consumer needs and product
specifications
 Concept generation & concept selection
5
 Product architecture
 Concurrent engineering
 Material selection
 DFM, DFA, DFE, part deployment dan FMEA
6
CHAPTER II
IDENTIFICATION OF PRODUCT DEVELOPMENT OPORTUNITIES, CONSUMER

NEEDS AND PRODUCT SPECIFICATIONS
II.1. Mission Statement
Table 1. Mission Statement
Mission Statement
Tangalu is used to pull and push parts of shoes when it’s formed by using wooden shoe or used
Product Description to pull out nails after the finished formed shoes and push and paste certain parts or some
material being glued or used to hit another parts.
This is a versatile tool which combine plier, hammer, and supporting tool used to set shoes sole
Benefit Proposition
at once. Therefore the user can obtain up to 3 functions in only 1 simple tool.
Increasing the efficiency of sales for 20%
Lowering Production cost by 40% of selling price
Key Business Goal
Increasing the efficiency of manufacturing for 20%
Expanding into new locations
Primary Market Shoe maker
Secondary Market Craftsmen, Household
The tool is considered as unautomatic tool (operator needed)
Assumption and Constraint
There are no competitors (New product breakthrough)
User
Distributor
Production Division
Stakeholder
Marketing Division
Product Designer
Intellectual Property Rights
II.2. Data Collection Methods and Customer Statement

II.2.1 Observation
The most common method used for getting information about the various things around
us, is to observe those things and also the various processes related to those things.
Hence, it can be said that observation acts as a fundamental and the basic method of
getting information about anything. But it must be kept in mind that observation is not
just seeing things but it is carefully watching the things and trying to understand them
in depth, in order to get some information about them.
According to Oxford Concise Dictionary, observation means ‘accurate watching, noting

the phenomenon by which they occur in the nature with regard to the cause and effect
of mutual relations.’ In here observation is used to obtain both reliable and accurate
data, other than that this method is best for studying human behaviour. In this case we
analyze customer’s behaviour to know what they need most and probably the needs that
they don’t even realize.
7
The following are the result of observation done in Cibaduyut street, Bandung:
Table 2. Observation Result
No Kondisi Eksisting Penggunaan Produk Need Statement
1 Alat hanya memiliki satu fungsi Tangalu memiliki 3-5 alternatif fungsi
2 Tidak memiliki lengkungan sebagai pijakan jari pada handle Tangalu nyaman digunakan
3 Lambat laun produk akan mengalami korosi Tangalu memiliki resistensi terhadap karat
4 Produk memiliki bobot yang berat Tangalu ringan
5 Produk memiliki desain yang monoton Tangalu memiliki desain menarik
II.2.2 Interview
Interview is verbal questioning. In research, Lindzey Gardner has defined interview as “a
two-person conversation, initiated by the interviewer for the specific purpose of obtaining
research-relevant information and focused by him on the content specified by the research
objectives of description and explanation”. In here we use interview method to obtain
customer’s perception and their point of view toward the issues that we analyze on.
Therefore this research analyze both researcher and customer’s point of view to obtain
what customers need most.
The following are the result of interview done in Cibaduyut street, Bandung:
Table 3. Interview 1
Nama Pelanggan Doni Interviewer Wirandy
Alamat Jl. Raya Cibaduyut Tanggal 01/02/2017
Telepon -
Pertanyaan Customer Statement Need Statement

Produk berat sehingga membuat tangan
Kesulitan apa yang dirasakan pada produk ini? Tangalu ringan
mudah lelah
Perlukah pengembangan spesifikasi pada
Ya, semakin mengoptimalkan pekerjaan Tangalu memiliki 3-5 alternatif fungsi
produk ini?
Produk tidak hanya dapat kuat tapi
Fitur apa yang anda harapkan pada produk ini? mampu mengakodimir benda berukuran Tangalu dapat mencengkram benda kecil
mikro
Faktor apa yang menjadi pertimbangan utama

Jangka waktu penggunaan yang panjang Tangalu tahan lama
anda pada produk ini?
Ya, akan tetapi masih ada bagian tajam

Apakah menurut anda produk ini aman? Tangalu aman digunakan
pada sisi produk
Dapatkah produk ini memenuhi keinginan Tidak, karena produk tidak tahan terhadap
Tangalu memiliki resistensi terhadap karat
anda? korosi
8
Nama Pelanggan Ahmad Interviewer Wirandy
Telepon -

Kesulitan apa yang dirasakan pada produk Produk kurang nyaman digunakan terutama
Tangalu nyaman digunakan
ini? pada bagian pegangan
Ya, karena memudahkan pekerjaan Tangalu memiliki 3-5 alternatif fungsi
produk ini?
Fitur apa yang anda harapkan pada produk

Produk tahan banting Tangalu tahan terhadap benturan
ini?
Faktor apa yang menjadi pertimbangan

Kemudahan dalam pemakaian Tangalu mudah digunakan
utama anda pada produk ini?
Apakah menurut anda produk ini aman? Ya, asalakan sesuai dengan peruntukannya Tangalu aman digunakan
Komponen tangalu mudah dicari

Dapatkah produk ini memenuhi keinginan Tidak, karena komponen produk sulit dicari jika
anda? produk rusak
Tangalu mudah diperbaiki
Nama Pelanggan Fajar Interviewer Wirandy
Telepon -
Dimensi Tangalu sesuai kebutuhan

Produk besar dan berat sehingga
Kesulitan apa yang dirasakan pada produk ini?
membuat tangan mudah lelah
Tangalu ringan

Ya, semakin mengoptimalkan pekerjaan Tangalu memiliki 3-5 alternatif fungsi
produk ini?
Tangalu memiliki warna menarik
Produk memiliki nilai estetika/ eye
Fitur apa yang anda harapkan pada produk ini?
catching
Tangalu memilki desain menarik
Faktor apa yang menjadi pertimbangan utama

Produk memiliki harga yang murah Tangalu ekonomis
anda pada produk ini?
Tidak, karena produk terbuat dari bahan
Apakah menurut anda produk ini aman? Tangalu ramah lingkungan
yang tidak ramah lingkungan
Dapatkah produk ini memenuhi keinginan Ya, akan tetapi produk masih banyak
Tangalu mudah disimpan
anda? memakan tempat di toolbox
Nama Pelanggan Herman Interviewer Wirandy
Telepon -
Kesulitan apa yang dirasakan pada produk Dimensi produk menyulitkan untuk dibawa-
Tangalu mudah dibawa
ini? bawa

Ya, karena memudahkan pekerjaan Tangalu memiliki 3-5 alternatif fungsi
produk ini?
Fitur apa yang anda harapkan pada produk Produk tidak perlu dicuci/dibersihkan lagi
Tangalu memiliki resistensi terhadap noda
ini? setalah digunakan
Faktor apa yang menjadi pertimbangan

Adanya jaminan atas kualitas produk Tangalu bergaransi
utama anda pada produk ini?
Ya, akan tetapi lama-lama pegangan dapat
Apakah menurut anda produk ini aman? Tangalu memiliki material solid
menjadi rapuh
Dapatkah produk ini memenuhi keinginan Tidak, karena kerusakan pada part tang sulit
anda? diperbaiki
9
II.3. Need Statement
After the data resulted from observation and interview are obtained, then need statement
can be generated. The following are the recap of needs interpretation:
Table 7. Need Statements
Need Statement
Tangalu dapat menahan beban besar
Tangalu dapat mencengkram benda berukuran kecil
Tangalu memiliki 3-5 alternatif fungsi
Tangalu mudah digunakan
Tangalu ramah lingkungan
Tangalu aman digunakan
Tangalu mudah disimpan
Tangalu ringan
Dimensi tangalu sesuai kebutuhan
Tangalu bergaransi
Tangalu memiliki resitensi terhadap korosi
Tangalu tahan terhadap benturan
Tangalu memiliki material kokoh
Tangalu tahan terhadap noda
Tangalu memiliki desain menarik
Komponen tangalu mudah dicari
There are exactly 20 needs statement collected in the table above. After that we need to
recap the need statement toward quality product dimension and before generating the
questionnaire we need to simplify the need statements (analysis is explained below)
10
The following are the recap of need statement toward quality product dimension:
Table 8. Recap of Need Statements

No Product Quality Need Statement
1 Performance
2 Features Tangalu mudah digunakan
3 Conformance Tangalu ringan
4 Reliability Tangalu bergaransi
Durability Tangalu memiliki resitensi terhadap korosi
5
6 Aesthetics
7 Serviceability Tangalu mudah diperbaiki
In the table there are 15 needs statements remaining, it means there are 5 needs
statement eliminated. The analysis done by considering which needs statement have the
similarity. Such as: Tangalu serviceability easiness and its parts availability, Tangalu strength
also represents its solidity, Tangalu resistance toward corrosion represents its ability to resist
from stain, and the last is Tangalu which is easy to bring represents its easiness to be stored.
11
II.4. The Level of Importance and Satisfaction Questionnaires
The following is the questionnaire used:
Table 9. Questionaire
Tingkat
Variabel Kepentingan Kepuasan
1 2 3 4 1 2 3 4
A. Performance (Kualitas/Fungsi Utama Produk)
B. Features (Pelengkap Fungsi Utama/Dasar Produk)
Tangalu mudah digunakan
C. Conformance (Kemampuan Produk Mencapai Spesifikasi yang Ditawarkan)
Tangalu ringan
D. Reliability (Keandalan Produk/Kemungkinan Kecil Produk Untuk Tidak Berfungsi/Rusak)
Tangalu bergaransi
E. Durability (Ketahanan Produk/Kemampuan Produk Untuk Dapat Terus Berfungsi)
Tangalu memiliki resitensi terhadap korosi
F. Aesthetics (Tampilan Visual Produk)
G. Serviceability (Kemampuan Produk Untuk Diperbaiki)
II.5. WAP Satisfaction and Importance Rate

To conduct WAP measurement the recap of 14 attributes in spreaded questionnaire is
needed. There are 14 attributes which is symbolized by V, in WAP the data collection is
categorized by its value filled by consumer. WAP (Weight Average Perfomance) is used to
know the value/weight of importance and satisfaction toward consumer.
Table 10. WAP Satisfaction Rate Measurement
WAP SATISFACTION RATE MEASUREMENT
Value V1 V2 V3 V4 V5 V6 V7 V8 V9 V10 V11 V12 V13 V14
1 0 0 0 1 0 0 0 2 1 1 0 3 5 1
Total Respondent
2 1 3 1 2 2 2 4 7 4 6 6 9 11 8
Answered
3 18 18 16 13 9 14 16 11 16 16 16 12 11 7
4 11 9 13 14 19 14 10 10 9 7 8 6 3 14
TOTAL 30 30 30 30 30 30 30 30 30 30 30 30 30 30
Table 11. WAP Continuation Measurement

12
1 0 0 0 1 0 0 0 2 1 1 0 3 5 1
Performance Weighted 2 2 6 2 4 4 4 8 14 8 12 12 18 22 16
3 54 54 48 39 27 42 48 33 48 48 48 36 33 21
4 44 36 52 56 76 56 40 40 36 28 32 24 12 56
TOTAL 100 96 102 100 107 102 96 89 93 89 92 81 72 94
Table 12. Perfomance Weighted

Performance Weighted / Toal of respondent
V1 V2 V3 V4 V5 V6 V7 V8 V9 V10 V11 V12 V13 V14
3,33 3,20 3,40 3,33 3,57 3,40 3,20 2,97 3,10 2,97 3,07 2,70 2,40 3,13
After the measurement the satisfaction generated from each attribute can be seen, as
shown below the highest satisfaction is produced by V5 and the lowest satisfaction is
produced by V13.
By multiplying the value given by respondent with total value for each need statement.
Then WAP is done by dividing the perfomance weighted value to total respondents.
II.5.1 WAP Satisfaction Rate

Table 13. WAP Satisfaction Rate Measurement
WAP SATISFACTION RATE MEASUREMENT
1 0 0 0 1 0 0 0 2 1 1 0 3 5 1
Total Respondent
2 1 3 1 2 2 2 4 7 4 6 6 9 11 8
Answered
3 18 18 16 13 9 14 16 11 16 16 16 12 11 7
4 11 9 13 14 19 14 10 10 9 7 8 6 3 14
TOTAL 30 30 30 30 30 30 30 30 30 30 30 30 30 30
Table 14. WAP Continuation Measurement

1 0 0 0 1 0 0 0 2 1 1 0 3 5 1
3 54 54 48 39 27 42 48 33 48 48 48 36 33 21
4 44 36 52 56 76 56 40 40 36 28 32 24 12 56
TOTAL 100 96 102 100 107 102 96 89 93 89 92 81 72 94

Performance Weighted / Toal of respondent
V1 V2 V3 V4 V5 V6 V7 V8 V9 V10 V11 V12 V13 V14
3,33 3,20 3,40 3,33 3,57 3,40 3,20 2,97 3,10 2,97 3,07 2,70 2,40 3,13
After the measurement the satisfaction generated from each attribute can be seen, as
shown below the highest satisfaction is produced by V5 and the lowest satisfaction is
produced by V13.
13
II.5.2 WAP Importance Rate
Table 16. WAP Importance Rate
WAP IMPORTANCE RATE MEASUREMENT
1 0 2 0 0 0 1 0 3 4 1 0 5 10 0
Total Respondent
2 1 3 3 4 2 6 6 6 8 5 3 9 7 5
Answered
3 19 15 8 10 9 11 16 13 9 14 17 12 11 13
4 10 10 19 16 19 12 8 8 8 10 10 4 2 12
TOTAL 30 30 30 30 30 30 30 30 29 30 30 30 30 30
Table 17. Continuation Measurement of WAP importance

1 0 2 0 0 0 1 0 3 4 1 0 5 10 0
3 57 45 24 30 27 33 48 39 27 42 51 36 33 39
4 40 40 76 64 76 48 32 32 32 40 40 16 8 48
TOTAL 99 93 106 102 107 94 92 86 79 93 97 75 65 97

Performance Weighted / Total of respondent
V1 V2 V3 V4 V5 V6 V7 V8 V9 V10 V11 V12 V13 V14
3,30 3,10 3,53 3,40 3,57 3,13 3,07 2,87 2,72 3,10 3,23 2,50 2,17 3,23
After the measurement the importance generated from each attribute can be seen, as
shown below the highest importance is produced by V3 and the lowest satisfaction is
produced by V13.
SATISFACTION PERFOMANCE VALUE / TOTAL OF RESPONDENTS
V1 V2 V3 V4 V5 V6 V7 V8 V9 V10 V11 V12 V13 V14
3,33 3,20 3,40 3,33 3,57 3,40 3,20 2,97 3,10 2,97 3,07 2,70 2,40 3,13
II.6. Matriks Klein Grid

Table 19. Satisfaction Value/Total Respondents
SATISFACTION PERFOMANCE VALUE / TOTAL OF RESPONDENTS
V1 V2 V3 V4 V5 V6 V7 V8 V9 V10 V11 V12 V13 V14
3,33 3,20 3,40 3,33 3,57 3,40 3,20 2,97 3,10 2,97 3,07 2,70 2,40 3,13
This table is used to determine the resulted mid line (x) in matrix klein grid which later
divides each variable into 4 differents category. The calculation is done by dividing
satisfaction value over total respondents.
Table 20. Resulted Mid Line (X)
Mid Line (X) : 3,13
Table 21. Importance value/ Total respondents
PERFOMANCE IMPORTANCE VALUE / TOTAL OF RESPONDENTS
V1 V2 V3 V4 V5 V6 V7 V8 V9 V10 V11 V12 V13 V14
3,30 3,10 3,53 3,40 3,57 3,13 3,07 2,87 2,72 3,10 3,23 2,50 2,17 3,23
Table 22. Resulted Mid Line (Y)
14
Just like the previous table, this table is used to determine the resulted mid line (y) in matrix
klein grid which later divides each variable into 4 differents category. The calculation is done
by dividing importance value over total respondents.
Mid Line (Y) : 3,07
Matriks Klein Grid High Impact

Expected
KEPENTINGAN
4,00
3,50 v3 v5
v4
v1
v11
V14
v10 v2 v6
3,00 v7 KEPUASAN
0,00 0,50 1,00 1,50 2,00 2,50 3,00v8 3,50 4,00
v9
2,50
v12
V13
2,00
1,50
1,00
0,50
0,00
Low Impact Hidden
Figure 1. Picture of Klein Grid Matrices
Table 23. Classification of customer need
Expected High Impact Low Impact Hidden
V10 V1 V8 V7
V11 V2 V9
V3 V12
Variabel
V4 V13
V5
V6
V14
15
As shown below, based on the result it can be concluded that in this Klein Grid Matrices
the attributes is categorized into 4 class:
 Expected, in this class there are 2 attributes where V10 (Corossive Resistance) and V11
(Bumps withstands abbility) are the thing which is expected from the product. Where
the lack of this need fulfillment can lead to dissatisfaction.
 High Impact, in this class there are 7 attributes where V1 (Load withstand abbility), V2
(Detailed Grip), V3 (Many alternative functions), V4 (Easiness to use), V5 (Safe to
use), V6 (Comfortable), V14 (Easy to fix) give great impact toward customer. The
customer is really consider these attributes important and give them great satisfaction.
 Low Impact, in this class there are 4 attributes where V8 (Easiness to bring), V9
(Guarantee), V12 (Interesting design), V13 (Interesting color) give less impact toward
customer which mean this attributes are not really important according to customer’s
opinion.
 Hidden, in this class there’s only 1 attributes where this attributes V7 (Light weight) can
give a relative impact depend on product’s context.
II.7. Product Specification

Specifications consist of metrics and values (table needs, metrics, value, unit) and here are
some specifications stated, these specifications are resulted from identification of need
statements of customer. The following is the recap of product specifications:
Table 24. Product Specification

No Metric Value Unit
1 Maximum load capacity 100-50 Kg
2 Total components <5 Binary
Brinell Hardness Number
3 Material hardness >150
(BHN)
4 Product length 16-19 cm
5 Product width 7-9 cm
6 Product 's level of accuracy <1 cm
7 Range of alternative functions 3-5 Binary
8 Product volume 3000-3500 cm3
9 Product mass 0,5-1 kg
10 Maximum angle product dimension >25 degree
11 Attenuation from vibration <10 Hz
12 Product lifetime >2 year
13 Corrosion rate <0,6 mm/y
14 Tangalu has interesting color subjective subjective
15 Total interaction between consumer and product <5 Phase
16
Table 25. References
REFERENCE
http://eprints.uny.ac.id/12244/1/39_Fis_Munasir_Yulie2.pdf
https://www.pivotpins.com/pdf/mechanical_properties_of_steel.pdf
https://www.flipkart.com/stanley-70-482-lineman-
plier/p/itmdtwzdgsuqfdwb?pid=PLIDTWZDGSUQFDWB&srno=b_1_3&o
tracker=browse&lid=LSTPLIDTWZDGSUQFDWBI7T7AU
https://www.amazon.com/Stanley-84-102-8-Inch-Long-
Plier/dp/B0001IW518
http://www.sonneville.com/fileadmin/media/sonneville/downloads/
LVT_Vibration_attenuation_report_English_August_2011.pdf
Figure 3. Existing plier Figure 2. Existing Hammer
17
II.8. Planning Matrices
Table 26. Matrices Planning
Normalized raw weight

Customer Satisfaction
Improvement ratio
Matriks Klein Grid
Importance to
Performance
Raw weight
Sales point
Customer
Goal
NO Needs Statement
1 Tangalu can withstand a large load HIM 3,33 3,30 3,32 1,00 1,5 4,93 0,09
2 Tangalu can grip detailed part HIM 3,20 3,10 3,15 0,98 1,5 4,58 0,08
3 Tangalu has some alternative functions HIM 3,40 3,53 3,47 1,02 1,5 5,40 0,09
4 Tangalu is easy to use HIM 3,33 3,40 3,37 1,01 1,5 5,15 0,09
5 Tangalu is safe to use HIM 3,57 3,57 3,57 1,00 1,5 5,35 0,09
6 Tangalu is comfortable to use HIM 3,40 3,13 3,27 0,96 1,5 4,52 0,08
7 Tangalu is light HID 3,20 3,07 3,13 0,98 1,5 4,50 0,08
8 Tangalu is easy to bring LIM 2,97 2,87 2,92 0,98 1 2,82 0,05
9 Tangalu has guarantee LIM 3,10 2,72 2,91 0,94 1 2,56 0,04
10 Tangalu is corrosive resistant EXP 2,97 3,10 3,03 1,02 1,2 3,80 0,07
11 Tangalu can withstand any bump EXP 3,07 3,23 3,15 1,03 1,2 3,99 0,07
12 Tangalu has interesting design LIM 2,70 2,50 2,60 0,96 1 2,41 0,04
13 Tangalu has interesting color LIM 2,40 2,17 2,28 0,95 1 2,06 0,04
14 Tangalu is easy to fix HIM 3,13 3,23 3,18 1,02 1,5 4,93 0,09
TOTAL 56,99 1,00
There are some considerations in matrices planning:

 Matrices of Klein Grid, in this column is the recap of classification of attributes which
already classed into 4 class. High Impact, Expected, Hidden, and Low Impact.
 Customer Satisfaction Perfomance, this column is about the recap of WPA of
satisfaction.
 Importance to Customer, this column contains of the result of WPA importance
measurement.
 Goal, this column is consist of the average of importance level and customer satsfaction.
 Improvement Ratio, this ratio can be achieved by dividing goal toward satisfaction rate.
 Sales point, there are some consideration used to determine sales point:
o If from klein grid matrices the attribute is classified as low impact, the value is
1. It means metric is met, but there is no value added for product sales.
o If from klein grid matrices the attribute is classified as expected, the value is 1,2.
It means metric is met, but value added product sales are not significant.
o If from klein grid matrices the attribute is classified as high impact, the value is
1,5. It means metrics is met, and value added of product sales is significantly
changes.
1
o Raw weight, in order to obtain the value of raw weight, the importance should
be multiplied by improvement ration and sales point.
o Normalized raw weight, the value is raw weight divided by the sum of total raw
weight. The total of normalized raw weight should be 1.
II.9. HOQ Analysis
House quality or commonly called the House of Quality (HOQ) is a stage or the first
iteration of the application of the methodology Quality Function Deployment (QFD). The
following is the framework of HOQ.
Figure 4. House of Quality
2
II.9.1 Table A (Customer Requirement)
The following is the 14 needs statement:
Table 27. Needs statement
Metric
Needs Statement
Tangalu can withstand a large load

1
Tangalu can grip detailed part
2
Tangalu has some alternative functions
3
Tangalu is easy to use
4
Tangalu is safe to use
5
Tangalu is comfortable to use
6
Tangalu is light
7
Tangalu is easy to bring
8
Tangalu has guarantee
9
Tangalu is corrosive resistant

10
Tangalu can withstand any bumps

11
Tangalu has interesting design

12
Tangalu has interesting color

13
Tangalu is easy to fix

14
1
II.9.2 Table B (Planning Matrix)
The following is the planning matrix that is previously resulted:
Table 28. Planning Matrix
Importance to customers
Normalized raw weight

Customer satisfaction
Improvement ratio
perfomance
Raw weight
Sales point
Goal
3,33 3,30 0,995 1,5 4,92525 4,92525 0,086423
3,20 3,10 0,984375 1,5 4,577344 4,577344 0,080319
3,40 3,53 1,019608 1,5 5,403922 5,403922 0,094822
3,33 3,40 1,01 1,5 5,151 5,151 0,090384
3,57 3,57 1 1,5 5,35 5,35 0,093876
3,40 3,13 0,960784 1,5 4,515686 4,515686 0,079237
3,20 3,07 0,979167 1,5 4,504167 4,504167 0,079034
2,97 2,87 0,983146 1 2,818352 2,818352 0,049454
3,10 2,72 0,939377 1 2,558993 2,558993 0,044903
2,97 3,10 1,022472 1,2 3,803596 3,803596 0,066742
3,07 3,23 1,027174 1,2 3,985435 3,985435 0,069932

0,214459 0,226114
2,70 2,50 0,962963 1 2,407407 2,407407 0,042243
2,40 2,17 0,951389 1 2,061343 2,061343 0,03617
3,13 3,23 1,015957 1,5 4,927394 4,927394 0,086461

0,270911 0,279557
II.9.3 Table C (Technical Responses)

The following is the metric of Tangalu:
Table 29. Technical responses
Attenuation from vibration
Metric
Product 's level of accuracy
Total interaction between
maximum angle product

Maximum load capacity
consumer and product
product component
Range of alternative
Material hardness
Product volume
Product lifetime
Product length
Product width
Corrosion rate
Product mass
Subjective
dimension
functions
Needs Statement
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
1
II.9.4 Table D (Inter-Relationships)
Table 30. Inter-Relationships

Metric


product component
Material hardness
Product volume
Product lifetime
Product length
Product width
Corrosion rate
Product mass
Subjective
dimension
functions
Needs Statement
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Tangalu can withstand a large load 9 0 9 1 1 0 0 1 3 0 0 3 3 0 0
0,777809 0 0,777809 0,086423 0,086423 0 0 0,086423 0,25927 0 0 0,25927 0,25927 0 0
Tangalu can grip detailed part 0 0 0 9 9 9 0 1 1 1 0 0 0 0 0
0 0 0 0,722867 0,722867 0,722867 0 0,080319 0,080319 0,080319 0 0 0 0 0
Tangalu has some alternative functions 0 0 1 1 1 1 9 0 0 0 0 1 1 0 0
0 0 0,094822 0,094822 0,094822 0,094822 0,853402 0 0 0 0 0,094822 0,094822 0 0
Tangalu is easy to use 0 9 0 3 3 0 0 9 3 1 1 0 0 0 0
0 0,81346 0 0,271153 0,271153 0 0 0,81346 0,271153 0,090384 0,090384 0 0 0 0
Tangalu is safe to use 0 0 0 3 3 0 0 9 3 1 1 0 0 0 0
0 0 0 0,281629 0,281629 0 0 0,844887 0,281629 0,093876 0,093876 0 0 0 0
Tangalu is comfortable to use 0 0 0 3 3 0 0 3 3 1 9 0 0 0 0
0 0 0 0,23771 0,23771 0 0 0,23771 0,23771 0,079237 0,71313 0 0 0 0
Tangalu is light 1 1 1 3 3 0 0 0 9 0 3 0 0 0 0
0,079034 0,079034 0,079034 0,237103 0,237103 0 0 0 0,71131 0 0,237103 0 0 0 0
Tangalu is easy to bring 0 3 0 3 3 0 0 9 9 1 0 0 0 0 0
0 0,148361 0 0,148361 0,148361 0 0 0,445082 0,445082 0,049454 0 0 0 0 0
Tangalu has guarantee 1 1 1 1 1 1 1 1 1 1 1 1 1 0 1
0,044903 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Tangalu is corrosive resistant 0 0 0 1 1 0 0 1 0 0 0 9 9 0 0
0 0 0 0,066742 0,066742 0 0 0,066742 0 0 0 0,600674 0,600674 0 0
Tangalu can withstand any bumps 3 0 3 1 1 0 0 1 3 0 0 3 0 0 0
0,209797 0 0,209797 0,069932 0,069932 0 0 0,069932 0,209797 0 0 0,209797 0 0 0
Tangalu has interesting design 0 0 0 0 0 0 0 0 0 3 0 0 0 9 1
0 0 0 0 0 0 0 0 0 0,126728 0 0 0 0,380184412 0,042243
Tangalu has interesting color 0 0 0 0 0 0 0 0 0 0 0 0 0 9 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0,325532903 0
Tangalu is easy to fix 0 0 0 0 0 0 0 0 0 0 0 9 1 0 9
0 0 0 0 0 0 0 0 0 0 0 0,778148 0,086461 0 0,778148
Table 31. Correlation Metric

Korelasi VoC dengan Metrik
Simbol Arti Nilai
Not Linked (tidak berhubungan sama sekali) 0
Possibly Linked (berhubungan tapi sangat sedikit sekali) 1
Blank
Moderately Linked (cukup berhubungan) 3
Strongly Linked (sangat berhubungan) 9
2
1.9.5 Table E (Technical Corelations)
Table 32. Technical Corelations
v v
v vv v v v
v v x xx v
v x
v v x
v v v x
vv v
v v v v vv
MTB MTB MTB TB TB MTB MTB TB LTB MTB LTB MTB LTB TB LTB


product component
Material hardness
Product volume
Product lifetime
Product length
Product width
Corrosion rate
Product mass
Subjective
dimension
functions
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Table 33. Correlation between metric meaning

Korelasi Antar Metrik
Simbol Arti
√√ Strong Positive Impact
√ Moderate Positive Impact
blank No Impact
Moderate Negative Impact
Strong Negative Impact
Table 34. Direction of Goodness
Direction of Goodness
Singkatan Arti
MTB The More The Better (semakin tinggi atau banyak semakin bagus)
LTB The Less The Better (semakin kecil atau sedikit semakin bagus)
TB Target is Best (untuk ukuran tertentu sudah bagus)
In this section which is about technical corelations, it shows about the corelation between
metrics. Which is symbolized by some symbol (shown in table.33), each symbol has one
meaning and each corelation also has direction of goodness (shown in table.34)
1
II.9.6 Table F (Target Matrix)
Table 35. Target Matrix
Satuan Kg Binary N (kgf) cm cm cm Binary cm3 kg degree Hz year mm/y subjective Phase
3000-
Target / Value 100-50 <5 100-150 16-19 7-9 <1 3-5 0,5-1 >25 <10 >2 <1 subjective <5
3500
Kontribusi 1,111543 1,040855 1,161463 2,216743 2,216743 0,817689 0,853402 2,644554 2,49627 0,519998 1,134494 1,942711 1,041227 0,705717315 0,82039
Normalisasi Kontribusi 0,053636 0,050225 0,056045 0,106966 0,106966 0,039457 0,04118 0,12761 0,120454 0,025092 0,054744 0,093743 0,050243 0,034053472 0,039587
Ranking 8 10 6 3 3 13 11 1 2 15 7 5 9 14 12
From this table the reseacrher can conclude what metric has the priority to be looked at,
because in practice to have more specifications on product means more cost. Therefore, it’s
important to know the rangking of metrics generated.
From the measurement we know that Product volume and mass are top 2 metrics,
because this metric has much correlation to customer needs while product aesthetics and its
dimension angle has not significant toward customer needs.
1
CHAPTER III
CONCEPT GENERATION & CONCEPT SELECTION
III.1. Concept Generation Analysis

III.1.1. Customer Needs Recap
III.1.2. Problem Clarification Analysis

III.1.2.1. Interpetation Analysis of Customer Needs
The customer needs used before is evaluated based on the functions that is
needed to be applied. Based on the case there several customer needs that is cut from
the list of customer needs
III.1.2.2. Black Box
User can use
User can save Tangalu Product is used
User can
maintain
Figure 5. Black Box
2
III.1.2.3. Decomposition
Withstand a large load
Grip detailed part
Has some alternative functions
Easy to use Product is used
Safe to use
Users use product
Comfortable to use
Corrosive resistant
Has interesting design
Has interesting color
Users save
product
Easy to bring
Total interaction between consumer and
Users maintain
product
Easy to fix
Figure 6. Decomposition
The problem’s distribution classified based on its usage, product saving
mechanism and its maintainability.
3
III.1.3. Internal and External Searching Analysis
Table 36. Generate Ideas
Ide
Option 1 Option 2 Option 3 Optian 4
Function
Tangalu can withstand a

large load
Application of mechanical Application of prop system

lever on the tool on tool's work area
Tangalu can grip detailed

part
Designed to ease gripping Designed to ease gripping
square and hexagonal cable components with
Grip cylindrical object components locking system
Tangalu has some

alternative functions
Applied penknife as cutting

As hammer tool As crowbar Hole making mechanism
Completed with usage

Plier standard dimension Anti slip handle guideline
Safety lock to keep

There are no sharp edges children from using Anti slip handle
Tangalu is comfortable to
use
Handle design is
Hand grip curve handle ergonomic Lock system
Tangalu is light
Product is mini shaped

Product is thin shaped version
Product is completed
Tangalu can be folded Product is thin shaped with case
Tangalu is corrosive
resistant
The tool is plated The tool is water resistant
Tangalu has interesting

design
Handle design is curved Helix hand grip design Adjustable handle size

color
Using colorful pattern Using dark pattern Wood pattern Monochrome pattern
Sparepart is available in
product easy to be overhauled market
III.1.4. Result of Internal and External Exploration Analysis

III.1.4.1 Option Analysis of Each Function
Make a systematic exploration using the concept of a combination of tables. The
results of systematic exploration resulted in some product concept will be further
developed.
These are the results of each combinating table:
1
Table 37. Combinating Table 1
Option 1
Option 1 Option 2
Concept Option 3 Optian 4 Option 5

large load
Application of mechanical lever on Application of prop system on tool's

the tool work area

part
Designed to ease gripping square and Designed to ease gripping cable

Grip cylindrical object hexagonal components components with locking system
Tangalu has some

As hammer Applied penknife as cutting tool As crowbar Hole making mechanism
Plier standard dimension Anti slip handle Completed with usage guideline
There are no sharp edges Safety lock to keep children from using Anti slip handle
use
Hand grip curve handle Handle design is ergonomic Lock system
Tangalu is light
Product is thin shaped Product is mini shaped version
Tangalu can be folded Product is thin shaped Product is completed with case
resistant

design

color
product easy to be overhauled Sparepart is available in market
2
Table 38. Combinating Table 2
Option 2
Option 1 Option 2 Option 3 Optian 4 Option 5
Concept
Tangalu can
withstand a large
load
Application of mechanical Application of prop system on

lever on the tool tool's work area
Tangalu can grip

detailed part
Designed to ease gripping Designed to ease gripping cable
square and hexagonal components with locking
Grip cylindrical object components system
Tangalu has some

alternative
functions
Tangalu is easy to
use

Tangalu is safe to
use
Safety lock to keep children

There are no sharp edges from using Anti slip handle
Tangalu is
comfortable to use
Tangalu is light
Tangalu is easy to
bring
Tangalu is
corrosive resistant
Tangalu has
interesting design
Tangalu has
interesting color
Tangalu is easy to
fix
product easy to be
overhauled Sparepart is available in market
1
Table 39. Table Combinating 3
Option 3
Option 1 Option 2
Concept Option 3 Optian 4 Option 5

large load


part
Designed to ease gripping
Designed to ease gripping square cable components with
Grip cylindrical object and hexagonal components locking system
Tangalu has some alternative

functions

Safety lock to keep children from

There are no sharp edges using Anti slip handle
Tangalu is comfortable to use
Tangalu is light
Product is completed with

Tangalu can be folded Product is thin shaped case
Tangalu is corrosive resistant

design
Tangalu has interesting color
2
Table 40. Table Combinating 4
Option 3
Concept

large load
Application of mechanical lever on Application of prop system on tool's

the tool work area

part
Designed to ease gripping square and Designed to ease gripping cable

Grip cylindrical object hexagonal components components with locking system
Tangalu has some

Plier standard dimension Anti slip handle Completed with usage guideline
There are no sharp edges Safety lock to keep children from using Anti slip handle
use
Tangalu is light
resistant

design

color
3
Table 41 Combinating Table 5
Option 4
Concept
Tangalu can
withstand a large
load
Tangalu can grip

detailed part
Designed to ease gripping Designed to ease gripping cable
square and hexagonal components with locking
Grip cylindrical object components system
Tangalu has some

alternative
functions
Tangalu is easy to
use
Tangalu is safe to
use
Safety lock to keep children

There are no sharp edges from using Anti slip handle
Tangalu is
comfortable to use
Tangalu is light
Tangalu is easy to
bring
Tangalu is
corrosive resistant
Tangalu has
interesting design
Tangalu has
interesting color
Tangalu is easy to
fix
product easy to be
overhauled Sparepart is available in market
4
II.1.5 Analisis Systematic Exploration Analysis and Result
II.1.5.1 Concept and Sketch Resulted
After conduct the combinating table, here is the recap of the seleced
ideas from each option:
Table 42. Recap of Combinating Table
Ide
Konsep 1 Konsep 2 Konsep 3 Konsep 4 Konsep 5
Function

large load
Application of mechanical lever Application of mechanical lever Application of prop system on Application of prop system on Application of prop system on
on the tool on the tool tool's work area tool's work area tool's work area

part Designed to ease gripping Designed to ease gripping Designed to ease gripping Designed to ease gripping
square and hexagonal square and hexagonal square and hexagonal square and hexagonal
components Grip cylindrical object components components components
Tangalu has some

As hammer Hole making mechanism Applied penknife as cutting tool As crowbar As crowbar

Anti slip handle Completed with usage guideline Completed with usage guideline Plier standard dimension guideline
Safety lock to keep children Safety lock to keep children

There are no sharp edges from using Anti slip handle Anti slip handle from using
use
Hand grip curve handle Hand grip curve handle Lock system Handle design is ergonomic Hand grip curve handle
Tangalu is light
Product is thin shaped Product is thin shaped Product is thin shaped Product is thin shaped
Product is completed with

Tangalu can be folded Product is completed with case Product is completed with case Product is completed with case case
resistant
The tool is water resistant The tool is plated The tool is plated The tool is plated The tool is water resistant

design
Helix hand grip design Adjustable handle size Adjustable handle size Helix hand grip design Helix hand grip design

color
Using colorful pattern Wood pattern Using dark pattern Wood pattern Wood pattern
Sparepart is available in
Sparepart is available in market product easy to be overhauled product easy to be overhauled Sparepart is available in market market
5
II.2. Concept Selection Analysis
II.2.1. Determine Selection Criteria for Each Need Satetment
For determining the selection criteria, customer needs and stakeholder

needs should be analyzed and classified each customer needs based on its
similarities.
Figure 7. Selection Criteria

• Easiness to use, there are some customer needs categorized in this criteria such
as tangalu’s usage easiness, tangalu’s safe usage, and its comfortable usage.
• Product perfomance, this criteria is all about product’s perfomance when used
by the user. There are some need statements classified in this criteria such as
withstand large load, grip detailed part and its alternative functions.
• Aesthetics, such as tangalu’s design and color
• Product Durbaility, customer needs included is its resistance from corrosive
• Mobility, this criteria is about product’s mobility when its moved to another
place. The only need statement included is tangalu bringing easiness.
• Serviceability, this is about product’s speciality to be repaired.
• Production cost and safety are stakeholder needs which is out of control from
designer team.
6
II.2.2. Determine Weight of Each Selection Criteria
Table 43 Weight of Each Selection Criteria.
The weight of selection criteria is determined by the level importance to

customer of each need statements. Then each level importance of each need
statements is totaled based on their selection criteria and the total is the weight of
each selection criteria.
II.2.3 Concept selection

Table 44. Selection Criteria Scoring Matrix
7
Table 45. Relative Score
Relative Score Sign
Better than
reference +
Same as reference 0
Worse than
reference -
II.2.4 Concept Scoring
Table 46. Concept Scoring
After doing concept scoring for every concepts idea based on selection criteria,
using weighted score rating, in total we obtained that the highest total score is concept
E. Thus, we decide to develop the concept E with total score of 3.4868.
Then, we are processing our previous need statement again. This will give the
percentage of need statement priority that will be our focused for developing the
product.
8
9
Table 47. Planning Matrices
Improvement ratio
Matriks Klein Grid
Normalized raw
Importance to
Performance
Raw weight
Satisfaction
Sales point
Percentage
Customer
Customer
weight
Goal
NO Needs Statement
1 Tangalu can withstand a large load HIM 3,33 3,30 3,32 1,00 1,5 4,93 0,11
8%
2 Tangalu can grip detailed part HIM 3,20 3,10 3,15 0,98 1,5 4,58 0,11 7%
3 Tangalu has some alternative functions HIM 3,40 3,53 3,47 1,02 1,5 5,40 0,15 8%
4 Tangalu is easy to use HIM 3,33 3,40 3,37 1,01 1,5 5,15 0,07 8%
5 Tangalu is safe to use HIM 3,57 3,57 3,57 1,00 1,5 5,35 0,07 8%
6 Tangalu is comfortable to use HIM 3,40 3,13 3,27 0,96 1,5 4,52 0,07 7%
7 Tangalu is corrosive resistant EXP 2,97 3,10 3,04 1,02 1,2 3,80 0,06 7%
8 Tangalu is easy to bring LIM 2,97 2,87 2,92 0,98 1 2,82 0,05 7%
9 Tangalu is easy to fix HIM 3,13 3,23 3,18 1,02 1,5 4,93 0,09 8%
10 Tangalu has interesting design LIM 2,70 2,50 2,60 0,96 1 2,41 0,05 6%
11 Tangalu has interesting color LIM 2,40 2,17 2,28 0,95 1 2,06 0,04 5%
12 Production Cost 15%
13 Safety 5%
TOTAL 34,40 33,90 34,15 10,91 14,70 45,94 0,87 0,80
III.2.6 Selected 3D Design
FIgure 8. Selected 3D Design
10
CHAPTER IV
PRODUCT ARCHITECTURE
IV.1. Description of Chosen Product
Product Description
Name: Tangalu
Basically this tool is used to pull and push parts of shoes when it’s formed by using
wooden shoe or used to pull out nails after the finished formed shoes and push and paste
certain parts or some material being glued or used to hit another parts. This tool works
supported by pivot screw which control the rotation movement of handle.
This product is the combination of hammer and plier which is structured to be a
multifunction tool to increase work efficiency. This tool is also completed with magnetic lock
to increase the usage safety
Figure 9. Product Illustration
11
IV.2 Product Scheme
SCHEME ELEMENT GROUPING
Handle Fixed Jaw

Receiving
Energy
Controling
Transfering
Tangalu's
Force
stranglehold
Locking
Locking system
handle
Pivot- Tool Case

Gripping Levering
Screw
Stuff stuff
Holding
loads Sealing rotary Easing to
movement bring the
Adjustable
Jaw
Transporting
stuff
Pin Tool Case
FIgure 10. Scheme Element Grouping
Factor Determination Analysis:

1 Handle  Geometric Integration and Precision because the handle is
used to control the grip and at the same time can be the
clench to transfer force (hammering and levering)
 Accommodating Variety because the handle design can
vary to many types or form based on customer needs or
trend.
2 Locking System  Similarity of Design because the process of making the

jaw is the same by using milling machine. Therefore the
production becomes more economics
 Geometric Integration and Precision because the handle is
used to grip and hammer
12
3 Fixed Jaw  Similarity of Design because the process of making the
used to grip and hammer
4 Adjustable Jaw  Similarity of Design because the process of making the

used to grip and lever
5 Pin  Capabilities of Vendors because the product is come from

supplier
6 Tool Case  Capabilities of Vendors because the product is come from
supplier
Table 3.1. Factor Determination Analysis
IV.3 Product Geometric Structure
FIgure 11. Rough Geometric
13
IV.4 Identification of Fundamental and Insidental Interaction
INTERACTION IDENTIFICATION
NO FUNDAMENTAL NO INSIDENTAL
The gripper is designed to grip The gripper can be worn out

1 1
hexagonal after long term usage
Locking system used magnet

2 Locking system designed to mechanism and after
increase both easiness and longterm can lose its
safety of usage 2 magnecity characteristic
The handle cant resist from
3 Handle can be resist from stain which make the handle
corrosive 3 is slippery to hold
FIgure 12. Interaction Identification

INSIDENTIAL INTERACTION DIAGRAM
Tangalu User Adjustable Jaw

Worn-out
Slippery
Fixed Jaw
Handle
Broken
Worn-out
Key Lock Pin
FIgure 13. Insidential Interaction Diagram

This insidental interaction diagram shows that there are several risks that can be done during
the usage of the product. The first one is the user which can experience slippery when hold the
handle or probably the jaw is already worn out during the usage. Basically each part shown in
the picture has causalities therefore every change done in every part can affect the whole parts.
The second one is the keylock can be worn out after long time usage so that can’t be used to
lock the jaw.
14
CHAPTER V
CONCURRENT ENGINEERING
V.1. Product Description

Tangalu is used to pull and push parts of shoes when it’s formed by using wooden shoe or
used to pull out nails after the finished formed shoes and push and paste certain parts or some
From the existing condition there are some problem that can be seen in several aspect, such
as: manufacturing, assembly, environment, dll. In this case the manufacturing feels much
unefficient process of the production that lead to lack of productivity, while environment
department feels much waste and polution is caused from the unefficient process done in the
manufacturing.
There are also some problem in the current condition on assembly workstation such as the
unefficient method to assembly the product due to the defective product after months of usage.
V.2 C-Data Analysis
Manufacturing Aspect:
C Data Value Chunk

ID PLIER101
Elements Right Handle
Conditions Handle is made through machining process
Descriptor Fair 0.3
Reason Long production time and produce much waste
Suggestion Use Casting process to produce part
Nilai Total 0.3
FIgure 14. Manufacturing Aspect C Data Right Handle

Based on the existing condition of the chunk, it’s known that the made of the product is
done through machining process. Therefore for suggestion it’s better to make product through
casting process because there will no excess waste material in the making of the product.
C Data Value Chunk

ID PLIER104
Elements Left Handle
Conditions Handle is made through machining process
Descriptor Fair 0.3
Reason Time consuming and result much waste
Suggestion Use casting method to produce part
Nilai Total 0.3
FIgure 15. Manufacturing Aspect C Data Left Handle
15
Based on the existing condition of the product, known that the made of the product is done
through machining process. Therefore for suggestion it’s better to make product through casting
process because there will no excess waste material in the making of the product.
Chunk
C Data Value
ID PLIER102
Elements Handle Case
Conditions Handle Case has helix pattern
Descriptor Fair 0.5
Reason Helix patern in the handle case complicate its production process
Suggestion Eliminate helix pattern
Nilai Total 0.5
FIgure 16. Manufacturing Aspect C Data Handle Case

Based on the existing condition of the product, known that the design of handle case is
helical and increase the grip accuracy to user but it’s vulnerable and hard to make therefore its
best to eliminate the helical pattern and redesign it based on finger grip.
Chunk
C Data Value
ID PLIER103
Elements Tool Case
Conditions The thickness of tool case is > 1 cm
Descriptor Fair 0.3
Reason More material is used so that prolong its production
Suggestion Thin the thickness of the case
Nilai Total 0.3
FIgure 17. Manufacturing Aspect C Data Box Case

From the observation its known that the tool case is pretty thick ( > 1 cm) and
manufacturer feels that its way to thick and can be thinned a couple mm to save cost of
material.
Assembly Aspect:
ID PLIER201
C Data Value Chunk
Elements Pivot Screw
Conditions Pivot screw diameter mostly equal to Handle hole diameter
Descriptor Good 0.5
Reason The pivot screw can be assemble well
Suggestion Pivot screw has more precise diameter and given tolerance so that can be fit
Nilai Total 0.5
FIgure 18. Assembly Aspect Pivot Screw

Based on the existing condition of the product, known that pivot screw is used for
assembling left and right handle therefore it needs very high accuracy in its production due to
the risk of pivot screw diameter larger/smaller to handle’s hole and cant be assembled. The
suggestion is to increase the accuracy and the quality of production and give minimum
acceptable tolerance.
16
C Data Value Chunk
ID PLIER204
Elements Pivot Screw
Conditions Pivot screw diameter mostly equal to Handle hole diameter
Descriptor Good 0.5
Reason The pivot screw can be assemble well
Suggestion Pivot screw has more precise diameter and given tolerance so that can be fit
Nilai Total 0.5
FIgure 19. Assembly Aspect Screw Pivot

Based on the existing condition of the product, known that pivot screw is used for
assembling left and right handle therefore it needs very high accuracy in its production due to
the risk of pivot screw diameter larger/smaller to handle’s hole and cant be assembled. The
suggestion is to increase the accuracy and the quality of production and give minimum
acceptable tolerance.
Chunk
C Data Value
ID PLIER202
Conditions The handle case assembled using glue
Descriptor Poor 0.2
Reason Handle case can be loose easily
Suggestion Using heat treatment to make the handle case attached permanently
Nilai Total 0.3
FIgure 20. Assembly Aspect Handle Case C Data

The existing condition of handle case is that its assembled by using glue and from most
case glue is not strong enough to hold the force and makes it easily loose. The suggestion its
best to use heat treatment. It means that he handle case material is heated to the handle so that
its permanently join the handle and makes stronger bonding which ultimately makes it not loose
anymore.
Chunk
C Data Value
ID PLIER203
Elements Tool Case
Conditions Tool Case used hinge for its open close mechanism
Descriptor Fair 0.4
Reason Assembly time needed is much consuming
Suggestion Using slider as open and close mechanism
Nilai Total 0.4
FIgure 21. Tool Case Assembly Aspect C Data

Based on the existing condition of the product can be seen that the mechanism of the tool
case is using hinge, but because it needs more component and longer production time its
suggested to change the mechanism by using slider.
Environment Aspect:
C Data Value Chunk

ID PLIER301
Elements Handle
Conditions Using CNC Machine
Descriptor Fair 0.4
Reason To reduce excess material waste from production process
Suggestion Casting process
Nilai Total 0.4
FIgure 22. Environment Aspect Handle C Data

17
C Data Value Chunk

ID PLIER304
Elements Left Handle
Conditions Using CNC Machine
Descriptor Fair 0.4
Reason To reduce excess material waste from production process
Suggestion Casting process
Nilai Total 0.4
FIgure 23. Environment Aspect Handle C data

C Data Value Chunk

ID PLIER302
Conditions The thickness of handle case > 5 mm
Descriptor Fair 0.4
Reason The more plastic material used for making handle case can result more waste which is harmful for environment
Suggestion Minimization of plastic used or thin the handle case to reduce waste
Nilai Total 0.4
FIgure 24. Environment Aspeck Handle Case C Data

From the observation can be seen that the amount material should be in the exact amount
so that no waste is resulted.
Chunk
C Data Value
ID PLIER303
Elements Tool Case
Conditions The thickness of tool case is > 1 cm
Descriptor Fair 0.4
Reason The more wood used hence the more waste resulted
Suggestion Minimization of tool case thick hence waste can be reduced
Nilai Total 0.4
FIgure 25. Environment Aspect Tool Case C Data

From the observation can be seen that the amount material should be in the exact amount
so that no waste is resulted.
18
IV.3 Design Decision Analysis
Table 48. Design Decision Right Handle
Design Decision
C Data ID PLIER101
To : Right handle made through
Design Decision casting instead of machining
process
Consequences
Production Quicker production process
Environment Less waste is resulted
From the deisgn decision about right handle known that production and environment
are the aspects impacted by the change. Which positively give better perfomance in production
process and the reduced waste.
Table 49. Design Decision Handle Case
Design Decision
C Data ID PLIER102
Design Decision To : Eliminate helix pattern
Consequences
Easiness in manufacturing the

Production
part
The usage will be more

Usage
comfortable
This design decision is about elimination of helical pattern and cause some impacts
toward production and usage aspect. In production it gives easiness and comfortable for usage
aspect.
19
Table 50. Deisgn Decision Tool Case
Design Decision
C Data ID PLIER103
To : Thin the thickness of the

Design Decision
case
Consequences
No effect, the change doesn't

Distribution
affect distribution factor
Easier to bring since the weight

Usage
becomes lighter
Easier to recycle since the

Disposal/ Recycling amount of material needed to
make the tool case is much lesser
Design decision is to thin the thickness of the case and the decision has caused some
impacs especially toward usage, production, and disposal aspects. The impacts are overall good
on the betterment of the product such as : quicker production, easiness of usage, easiness to
recycle, etc.
Table 51. Design Decision Left Handle
Design Decision
C Data ID PLIER104
Left handle is made through
Design Decision casting instead of machining
process
Consequences
From the deisgn decision about right handle known that production and environment
are the aspects impacted by the change. Which positively give better perfomance in production
process and the reduced waste.
20
Table 52. Design Decision Pivot Screw
Design Decision
C Data ID PLIER201
To : Pivot screw given more
Design Decision precise diameter and given
tolerance so that can be fit
Consequences
The production becomes harder

Production
because more precise needed
The parts are more likely to
be easily to be assembled
Assembly because the tolerance
guarantee its assembly
easiness
Pivot screw tolerance is the design decision which cause production becomes harder
since precise is needed and in assembly aspect it cause the reliable result because the tolerance
gives the assembly easiness
Table 53. Design Decision Handle Case
Design Decision
C Data ID PLIER202
To :Use heat treatment to

Design Decision attach the handle case
permanently to handle
Consequences
Harder assembly process

Assembly because heat treatment itself
need machine and operator
The usage becomes much comfy
Usage because the handle case can't
loose easily anymore
For handle case the design decision is to use heat tretmet instead of glue, this decision
has caused some impacts toward several aspect, such as: assembly and usage aspects. In
assembly aspect this implementation needs machine and more operator therefore its more
troublesome despite the fact that the usage becomes more reliable for user.
21
Table 54. Design Decision Tool Case
Design Decision
C Data ID PLIER203
To : Use slider as open and

Design Decision
close mechanism
Consequences
Easier production and less
Production
overhead cost production
Distribution No effect
The usage becomes more

efficient since the total
Usage
interaction needed to use is
minimized
Easier to be recycled since
the tool case is mostly
Disposal/ Recycling
consist only by wood (not
much extra item involved)
The design decision for tool case is to use slider mechanism instead of hinge, however
this change make usage, production, and disposal aspects affected. These impacts such as:
easiness on production and usage make much improvement toward tool case and the product
itself.
Table 55. Design Decision Pivot Screw
Design Decision
C Data ID PLIER204
To : Pivot screw given more
Design Decision precise diameter and given
tolerance so that can be fit
Consequences
The production becomes harder

Design Decision
because more precise needed
The parts are more likely to

be easily to be assembled
Assembly because the tolerance
guarantee its assembly
easiness
The design decision on left handle chunk is about tolerance of the pivot screw. This
decision has cause some consequences especially for production process which becomes harder
because its precise and in assembly aspect which guarantee the precise level of the assembly.
22
Table 56. Design Decision Handle
Design Decision
C Data ID PLIER301
To : Use Casting method
Design Decision instead of CNC machining
process
Consequences
Less time needed and no waste
Production
is resulted
Less waste is resulted which

Environment
is better for environment
Better recycling because its

Disposal/ Recycling material is eco friendly hence
result no harm for environment
Design decision of this ID is about the process of the made of product which cause some
consequence. Such as in production gives less time and in environment aspect makes the waste
reduced.
Table 57. Decision Decision Handle Case
Design Decision
C Data ID PLIER302
To : Minimize plastic
Design Decision material used or thin the
handle case
Consequences
Easiness in manufacturing the

Production
part
The thinner the product is the

Distribution easier the product to be
packaged and distributed
The thinner the product means

Disposal/ Recycling the less material used so that
its much easier to be recycled
The minimization of material used which cause some consequence in this case the
material used is plastic. The decision is to thin the case or minimize the usage of the material.
So that in production gives less time and in environment aspect makes the waste reduced.
23
Table 58. Design Decision Tool Case
Design Decision
C Data ID PLIER303
To :Minimize tool case thick

Design Decision
hence waste can be reduced
Consequences
The thinner the product is the

Distribution easier the product to be
packaged and distributed
Easier to bring since the

Usage
weight becomes lighter
Easier to recycle since the

amount of material needed to
Disposal/ Recycling
make the tool case is much
lesser
Design decision of this ID is about the process of the made of product which cause some
consequence. Such as in production gives less time and in environment aspect makes the waste
reduced.
Table 59. Design Decision Handle
Design Decision
C Data ID PLIER301
To : Use Casting method
Design Decision instead of CNC machining
process
Consequences
Less time needed and no waste

Production
is resulted
Less waste is resulted which

Environment
is better for environment
Better recycling because its

Disposal/ Recycling material is eco friendly hence
result no harm for environment
Basically is almost the same with the previous one, design decision of this ID is about
the process of the made of product which cause some consequence. Such as in production gives
less time and in environment aspect makes the waste reduced.
24
V.4 Refine Design Analysis
Refine the Design Right handle chunk
Analisis
From design decision stated that for Right handle, the change which is applicated is to replace
machining process by casting process. There are some analysis from several point of view below
Production Faster production process
Assembly -
Usage -
Environment No waste is resulted
Figure 26. Design Refinement Right Handle Analysis

Refine the Design Handle case chunk
Analisis
From design decision stated that for handle case, the change which is applicated is to replace the shape of the
handle case based on finger grip. There are some analysis from several point of view below
Production Easier production process
Assembly -
Usage More comfy usage for the user
Environment -
Figure 27. Design Refinement Handle Case Analysis
25
Refine the Design Tool Case chunk
Analisis
From design decision stated that for handle case, the change which is applicated is to replace the mechanism and shape of
tool case by using slider. There are some analysis from several point of view below
Easier production process and

Production less component needed
Assembly faster assembly process
Usage -
Figure 28. Design Refinement Tool Case

Refine the Design Left Handle chunk
Analisis
From design decision stated that for left handle, the change which is applicated is to
replace machining process by casting process. There are some analysis from several
point of view below
Production Faster production process
Assembly -
Usage -
Environment No waste is resulted
Figure 29. Design Refinement Left Handle
26
V.5 Final Design
Figure 30. FInal Design 3D
Analysis:
The physical design is barely same with the previous one but the changes made to better
the product are: Left handle and pivot screw is made at once hence minimize both time
production and assembly time. The second change is to apply further production planning to
make the production is friendly to environment and make less defect product. The last one is to
make user guidance of usage to make the user know the capabillity of the product so that user
wont force the product to do some heavy work, in orther to long last the lifetime of product.
27
CHAPTER VI
MATERIAL SELECTION
VI.1 Product Part List/ Main Parts
The product part list/ main parts is shown below:
Description:
(1) Left Handle: Used to wring component/object simulteneously

with right handle and transfer force to object.
(2) Right Handle : Used to wring component together with left

handle and can be used as lever for doing some shoe works
Figure 31. Product Main Parts

Basically the product (Tangalu) Consist of several parts, such as: Handle, Case, Pivot
screw, dll. The main parts of this product just consist of two parts: Left and Right handle where
the main function runs.
28
VI.2 Product Spesification
This is the specification of product which is obtained in previous module:
Table 60. Metric/Value/Unit
No Metric Value Unit
1 100-50 Kg
2 Total components
<5 Binary
Brinell Hardness Number

3 Material hardness >150
(BHN)
4 Product length 16-19 cm
5 Product width 7-9 cm
6 Product 's level of accuracy <1 cm
7 Range of alternative functions 3-5 Binary
8 Product volume 3000-3500 cm3
9 Product mass 0,5-1 kg
10 Maximum angle product dimension >25 degree
11 Attenuation from vibration <10 Hz
12 Product lifetime >2 year
13 Corrosion rate <0,6 mm/y
14 Tangalu has interesting color subjective subjective
15 Total interaction between consumer and product <5 Phase
VI.3 Translate Design Requirement of Part / Component

Part : Left Handle
Part : Material changes (perubahan material)
The part shown below is LeftHandle which is used for transfering force or act as
A. FUNCTION : Transfer force to object and wring object
hammer and squeeze the work object together with right handle. In order to
B. CONSTRAINT : Fracture Toughness > 10 Mpa.m.1/2
withstand an enermous number of force the material used should be tough The part shown below is Right Ha
enough to withstand the external force given to the tool. C. OBJECTIVES : Maximum Strength Lever and squeeze the work object
desired for this main part should b
D. FREE VARIABLES : Choose the materials which is also act as hammer, this p
Keterangan:
1. Function : Withstand and transfer force to work object.
2. Constraint : - Fracture Toughness > 10 Mpa.m.1/2
3. Objective : Maximum Strength
4. Free Variables : Choose the materials
Table 61. Left Handle Translate Design

Part: Right Hanlde
29
Part : Material changes (perubahan material)
A. FUNCTION : Transfer force to object and wring object

B. CONSTRAINT : Fracture Toughness > 10 Mpa.m.1/2
The part shown below is Right Handle which is used for transfering force or act as
Lever and squeeze the work object together with left handle. Material which is C. OBJECTIVES : Maximum Strength
desired for this main part should be good and strength but different with left handle
which is also act as hammer, this part doesnt have to be tough enough. D. FREE VARIABLES : Choose the materials
Keterangan:
1. Function : Withstand and transfer force to work object.
2. Constraint : - Fracture Toughness > 10 Mpa.m.1/2
3. Objective : Maximum Strength
4. Free Variables : Choose the materials
Table 62. Right Handle Translate Design

VI.4 Material Screening & Ranking of Part / Component
These are the material screening and rangking conducted in each part :
Part : Left Handle
SCREENING : Fracture Toughness > 10 Mpa.m.1/2
RANK :
-Maximum toughness
-Fracture Toughness > 10 Mpa.m.1/2
RESULT :
-Ti Alloys
-Carbon steels
-Steel Alloys
Figure 32. Material Selection 1

Left handle is used to transfer force (Hammering) and wrip work object (pliering)
therefore this part need toughness and low risk of fracture as well. In order to minimize the risk
the material used should be strong enough to cover the external force, hence alloys steel and
cast iron can be alternative to obtain the best possibility.
30
Part : RightHandle
SCREENING : Strength > 500 MPa
RANK :
-Minimum Cost
-Strength > 500 MPa
RESULT :
-Cast Irons
-Carbon Steels
-Stainless Steels
Figure 33. Material Selection 2.

Different with left handle, right handle has an alternative function as lever to help shoe
maker and in this activity the external force applied to part is actually small therefore its best to
find the strongest material with the minimum cost, hence the cost of production can be
optimized.
VI.5 Seek Supporting Information of Part / Component

Table 63. Seek Supporting Information Left Handle
PART : Left Handle
Material 1 Material 2 Material 3
Kategori
Ti Alloys Carbon Steels Steel Alloys
Yield Strength 3,70E+11 2,21E+11 6,20E+11
Titanium alloys are metals that contain a mixture of The term "carbon steel" may also be used in
Steel alloys, like stainless steel, have become
titanium and other chemical elements. Such alloys reference to steel which is not stainless steel; in
ubiquitous materials for constructing everything
have very high tensile strength and toughness (even at this use carbon steel may include alloy steels.
from household cookware to buildings to modern
extreme temperatures). They are light in weight, have
art. The alloy has many attributes that make it
extraordinary corrosion resistance and the ability to As the carbon percentage content rises, steel has
useful, such as an excellent shine, a surface that
Sifat Material withstand extreme temperatures. However, the high the ability to become harder and stronger
resists corrosion and rust and that is durable under
cost of both raw materials and processing limit their through heat treating; however, it becomes less
harsh weather conditions. - High fatigue resistance
use to military applications, aircraft, spacecraft, ductile. Regardless of the heat treatment, a
- Good plasticity in cold condition
medical devices, highly stressed components such as higher carbon content reduces weldability. In
- High quality with competitive price
connecting rods on expensive sports cars and some carbon steels, the higher carbon content lowers
- Good combination property
premium sports equipment and consumer electronics the melting point
Harga 7,835 USD/kg 0,436 USD/kg 3 USD/kg
This material is currently much used in industry This material is currently much used in industry This material is currently much used in industry
Ketersedian Di Pasar
therefore its availability is good therefore its availability is good therefore its availability is good
Pegaruh Terhadap Alam Mostly metal compound is easy to recycle Mostly metal compound is easy to recycle Mostly metal compound is easy to recycle
Sumber (Harga) Solidworks Solidworks Alibaba.com
Supporting information used here is meant to give more consideration to chose the best
material for the part. In this case its best to consider the strength of the material, its characteristic
31
whether its appropriate or not and its price. As we can see in the table above steel alloy has the
biggest strength and carbon steel has the lowest price although carbon steel doesnt have good
strength. The reference we use to obtain the information is wikipedia.com and solidworks to
obtain the price/kg.
Table 64. Seek Supporting Infromation Right Handle
PART : Right Handle
Material 1 Material 2 Material 3
Kategori
Cast Irons Carbon Steels Stainless Steel
Yield Strength 2,76E+11 2,83E+11 1,72E+11

Stainless steel is notable for its corrosion resistance, and it is
Cast iron is a group of iron-carbon alloys with a carbon
widely used for food handling and cutlery among many other
content greater than 2%.[1] Its usefulness derives from its The term "carbon steel" may also be used in
applications.
relatively low melting temperature. Cast iron tends to be reference to steel which is not stainless steel; in this
brittle, except for malleable cast irons. With its relatively use carbon steel may include alloy steels.
Stainless steel is used for corrosion-resistant tools such as this
low melting point, good fluidity, castability, excellent
nutcracker
machinability, resistance to deformation and wear As the carbon percentage content rises, steel has the
Sifat Material Stainless steel does not readily corrode, rust or stain with water
resistance, cast irons have become an engineering ability to become harder and stronger through heat
as ordinary steel does. However, it is not fully stain-proof in
material with a wide range of applications and are used in treating; however, it becomes less ductile.
low-oxygen, high-salinity, or poor air-circulation
pipes, machines and automotive industry parts, such as Regardless of the heat treatment, a higher carbon
environments.[2] There are various grades and surface finishes
cylinder heads (declining usage), cylinder blocks and content reduces weldability. In carbon steels, the
of stainless steel to suit the environment the alloy must endure.
gearbox cases (declining usage). It is resistant to higher carbon content lowers the melting point
Stainless steel is used where both the properties of steel and
destruction and weakening by oxidation
corrosion resistance are required.
Harga 0,7 USD/kg 0,436 USD/kg 3,626 USD/kg
This material is currently much used in industry therefore This material is currently much used in industry This material is currently much used in industry therefore its
Ketersedian Di Pasar
its availability is good therefore its availability is good availability is good
Pegaruh Terhadap Alam Mostly metal compound is easy to recycle Mostly metal compound is easy to recycle Mostly metal compound is easy to recycle
Sumber (Harga) Solidworks Solidworks Solidworks
Supporting information used here is meant to give more consideration to chose the best
material for the part. In this case its best to consider the strength of the material, its characteristic
whether its appropriate or not and its price. As we can see in the table above Carbon steel has
the biggest strength and stainless steel has the lowest price. In this comparison we can see that
carbon steel has the biggest strength with the most minimum price. The reference used here to
obtain the onformation is wikipedia.com and soldiworks.
32
VI.6 Finite Element Analysis Test
Solidworks Simulation Test (Static)
Part : Left Handle
Titanium alloys Carbon alloys Steel alloys
Part : Right Handle

Cast irons Carbon steels Stainless steel
Figure 34. Finite Element Analysis
In this simulation test, the test which is conducted is statis test to identify the strength
of each material toward the external loads. The simulation is done toward two different part and
each is simulated in 3 different materials.
 First part is Left handle, the best material to use is steel alloy with yield strength =
620400000000 MPa.
 The second part is Right handle, the best material to use is carbon steel with yield
strength = 282700000000 MPa.
1
VI.7 Chosen Material Analysis
Summary
Material Properties : : like stainless steel, have become ubiquitous materials for constructing
Steel alloys,
everything from household cookware to buildings to modern art. The alloy has many
attributes that make it useful, such as an excellent shine, a surface that resists
corrosion and rust and that is durable under harsh weather conditions. - High fatigue
resistance
- Good plasticity in cold condition
- High quality with competitive price
- Good combination property
Price : 7,835 USD/kg
Market Availability :
This material is currently much used in industry therefore its availability is good
Environment Effect : Mostly metal compound is easy to recycle
Summary
The term "carbon steel" may also be used in reference to steel which is not
Material Properties : stainless steel; in this use carbon steel may include alloy steels.
As the carbon percentage content rises, steel has the ability to become harder and
stronger through heat treating; however, it becomes less ductile. Regardless of the
heat treatment, a higher carbon content reduces weldability. In carbon steels, the
higher carbon content lowers the melting point
Price USD 1000/ton

Market Availability : This material is currently much used in industry therefore its availability is good
Environment Effect : made of rubber therefore basically these materials can cause polution toward
environemnt
1
CHAPTER VI
DFM, DFA, DFE, Part Deployment dan FMEA
VII.1 Product Description
Tangalu is used to pull and push parts of shoes when it’s

formed by using wooden shoe or used to pull out nails after the
finished formed shoes and push and paste certain parts or some
VII.2 Design For Manufacturing and Assembly (part 1)
VII.2.1 Gambar part
Completed
Part View Exploded View
Figure 35. Part Views
2
VII.2.2 Structure Assembly
Right Handle Case
1 PCS
Left Handle Right Handle

Left Handle Case
1 PCS 1 PCS
1 PCS
Figure 36. Structure Assembly

VII.2.3 DFMA
Table 65. DFMA Measurement
Design for Manufacture and Assembly
Roda Trolley
Handling Code
Insertion Code
Handling Insertion Unit Supporting Extended

Item Name: Part Sub or PCB Unit Operation Unit Material Unit Part Cost Extended
QTY
Time per Time per Operation Material Cost Operation

Assembly or Operation Cost (Rp) Cost (Rp) (Rp) Part (cost)
Item (sec) Item (sec) Time (Rp) Time (min)
Left Handle Case 1 8.8 6,35 3.1 5 11,35 Rp 1,52 Rp 1.000 Rp 500 Rp 1.502 Rp 1.502 11,35
Left Handle 1 8.8 6,35 3.1 5 11,35 Rp 1,52 Rp 8.000 Rp 500 Rp 8.502 Rp 8.502 11,35
Right Handle Case 1 8.8 6,35 3.1 5 11,35 Rp 1,52 Rp 1.000 Rp 500 Rp 1.502 Rp 1.502 11,35
Right Handle 1 8.8 6,35 3.1 5 11,35 Rp 1,52 Rp 8.000 Rp 500 Rp 8.502 Rp 8.502 11,35
Pivot Screw 1 8.9 7 3.5 7 14 Rp 1,87 Rp 500 Rp 500 Rp 1.002 Rp 1.002 14,00
Pin Locker 2 0.2 1,88 0.0 1.5 3,850278 Rp 0,51 Rp 1.000 Rp 500 Rp 1.501 Rp 3.001 7,70
TOTAL Rp 24.009 67,10
3
VII.3 DFMA Suggestion (part 1)
VII.3.1 Part Picture
Keterangan Gambar
Left Handle Case
Right Handle Case
Left Handle
Right Handle
Pin Locker
Figure 37. Part Pictures

VII.3.2 Assembly Structure
Right Handle Case
1 PCS
Left Handle Right Handle

Left Handle Case
1 PCS 1 PCS
1 PCS
Figure 38. Assembly Structure
4
VII.3.3 DFA Table of Measurement
Table 66. DFMA Suggestion Measurement
Design for Manufacture and Assembly
Roda Trolley
Handling Code
Insertion Code
Handling Insertion Unit Supporting Extended
Item Name: Part Sub or PCB Unit Operation Unit Material Unit Part Cost Extended Part
QTY
Time per Time per Operation Material Cost Operation
Assembly or Operation Cost (Rp) Cost (Rp) (Rp) (cost)
Item (sec) Item (sec) Time (Rp) Time (min)
Left Handle Case 1 8.8 6,35 3.1 5 11,35 Rp 0,63 Rp 1.000 Rp 500 Rp 1.501 Rp 1.501 11,35
Left Handle 1 8.8 6,35 3.1 5 11,35 Rp 0,63 Rp 8.000 Rp 500 Rp 8.001 Rp 8.001 11,35
Right Handle Case 1 8.8 6,35 3.1 5 11,35 Rp 0,63 Rp 1.000 Rp 500 Rp 1.001 Rp 1.001 11,35
Right Handle Pivoted 1 8.8 6,35 3.1 5 11,35 Rp 0,63 Rp 8.500 Rp 500 Rp 8.001 Rp 8.001 11,35
Pin Locker 2 0.2 1,88 0.0 1.5 3,850278 Rp 0,21 Rp 1.000 Rp 500 Rp 2.000 Rp 4.001 7,70
TOTAL Rp 22.503 53,10
Based on the measurement of DFMA with the pivot screw is joint together to right handle makes
cost of production is cheaper than before. This is because the extended part(cost) is Rp. 22503
or moreless Rp. 2000 cheaper than existing condition.
VII.4 Design for Environment

VII.4.1 DFE Agenda
DFE AGENDA
DFE Team
Wirandy Fajar Saputra
Fadhilah
Shafira Tasyani Nasution
DFE Goals
Creating a product from an environmentally friendly material
Environmentally friendly manufacturing process
Figure 39. DFA Agenda

VII.4.2 DFE Goals
 Eco friendly product
 Eco friendly manufacturing
 Create longlasting Product
 Ease to recycle
5
VII.4.3 Apply DFE Guidelines to Product
Table 67. DFE Analysis
No. Design for Environment Element Reason Action Environmental Impact
In order to eliminate excess waste in the

Apply the cleaner production processes Make visual Design to support
1 production process and also increase the Cleaner workstation less polution
for products and components production process cleaner
better product quality
Re-arrange the production

Reduce the amount of material More excess material results more waste and
2 planning in order to know what Minimized waste
excessive use of raw materials that's not safe for environment
part that can be optimized
Set the product so as to avoid rejects Make SOP for production

Rejected product will not be used or sold Efficieny of production which leads
3 and reduce waste in the production process to minimize any rejects
therefore the product will just be a waste to minimized waste
process in production process
Cleaner production process makes more the
Apply 5S in the workstation and
Apply the cleaner production processes health quality in workstation increased and
4 the culture of clean production Cleaner workstation less polution
and efficient. efficiency in process makes less waste
in worksatation
toward environment
Part Spesifikasi
VII.5 Part Deployment
VII.5.1 Part Deployment
Metrik
VII.5.1.1 Metric and Value
3000-3500
Metrik Value Product volume
100-50 0,5-1
Maximum load capacity Product mass
<5 maximum angle product >25

Total interaction between consumer
and product dimension
Material hardness >150 Attenuation from vibration

<10
16-19 >2
Product length Product lifetime
7-9 <0,6
Product width Corrosion rate
<1 subjective
Product 's level of accuracy Subjective
3-5 3
Range of alternative functions Product Component
Figure 40. Metric and Value Part Deployment
VII.5.1.2 Part Specification

Vibration attrenuation rate
Product's level of accuracy
Alternative Functions
Degree of dimension
Number of Part
Product Length
Product Height
Corrosion Rate
Product Width
Subjective
Density
Total interaction
PL PW PH NP MH PLA AF DD VAR CR SB TI
Figure 41 Part Deployment Part Specification

6
VII.5.1.2 Inter Correlation Metric and Part Specification
Vibration attrenuation rate

Product's level of accuracy
Part Spesifikasi
Alternative Functions
Degree of dimension
Normalisasi Kontribusi
Number of Part
Product Length
Product Height
Corrosion Rate
Product Width
Subjective
Density
Total interaction
Metrik
Metrik Value PL PW PH NP MH PLA AF DD VAR CR SB TI
100-50 9 9 9 1 1 0 0 0 0 0 0 0 0,054
0,48 0,48 0,48 0,05 0,05 - - - - - - - 1,56
<5 0 0 0 3 1 1 1 0 0 0 0 0 0,050
Total interaction between consumer
and product - - - 0,17 0,06 0,06 0,06 - - - - - 0,33626931
0 0 0 0 0 0 3 0 3 3 0 0 0,056
Material hardness >150
- - - - - - 0,32 - 0,32 0,32 - - 0,96269431
16-19 0 0 0 0 0 3 3 1 1 1 0 1 0,107
Product length
- - - - - 0,12 0,12 0,04 0,04 0,04 - 0,04 0,41179814
7-9 0 0 0 0 0 3 3 1 1 1 0 1 0,107
Product width
- - - - - 0,36 0,36 0,12 0,12 0,12 - 0,12 1,20454249
<1 3 3 3 3 0 0 3 1 1 1 0 0 0,039
0,16 0,16 0,16 0,16 - - 0,16 0,05 0,05 0,05 - - 0,98538348
3-5 3 3 3 3 3 3 0 0 0 0 0 0 0,041
Range of alternative functions
0,12 0,12 0,12 0,12 0,12 0,12 - - - - - - 0,74123665
3000-3500 9 9 9 3 0 1 0 1 0 0 3 0 0,128
Product volume 1,15 1,15 1,15 0,38 - 0,13 - 0,13 - - 0,38 - 4,466
0,5-1 0 0 0 1 9 3 1 1 1 3 1 0 0,120
Product mass
- - - 0,12 1,08 0,36 0,12 0,12 0,12 0,36 0,12 - 2,409
maximum angle product >25 1 1 1 0 1 0 0 0 1 0 0 0 0,025
dimension 0,03 0,03 0,03 - 0,03 - - - 0,03 - - - 0,125
3 3 3 0 3 0 0 0 0 0 0 1 0,055
<10 0,16 0,16 0,16 - 0,16 - - - - - - 0,05 0,712
>2 1 1 1 0 9 0 0 0 3 0 1 0 0,094
Product lifetime
0,09 0,09 0,09 - 0,84 - - - 0,28 - 0,09 - 1,500
<0,6 1 1 1 0 3 0 1 0 0 0 1 0 0,050
Corrosion rate
0,05 0,05 0,05 - 0,15 - 0,05 - - - 0,05 - 0,402
subjective 1 1 1 0 1 0 0 0 0 0 0 3 0,034
Subjective
0,03 0,03 0,03 - 0,03 - - - - - - 0,10 0,238
3 0 0 0 9 0 0 9 0 0 0 0 3 0,040
Product Component
- - - 0,36 - - 0,36 - - - - 0,12 0,831
Figure 42. Inter Correlation Part Deployment
VII.5.1.2 Part Deployment Target Matrics

Tingkat Kesulitan 3 3 3 4 2 2 2 2 2 2 2 2
Target 18 cm 8 cm 3 cm 6 parts 500 MPA 0,95 3 functions 20 degree 95% rate 0,5 mm/ year - 2 interactions
Kontribusi 2,29 2,29 2,29 1,37 2,54 1,15 1,55 0,46 0,96 0,90 0,65 0,44
Normalisasi Kontribusi 0,135 0,135 0,135 0,081 0,150 0,068 0,092 0,028 0,057 0,053 0,038 0,026
Rank 2 2 2 6 1 7 5 11 8 9 10 12
Figure 43. Target Matrix Part Deployment
7
VII.5.2 Part Deployment Result
Table 68. Part Deployment Result

Normalisasi
Rank Kode Part Specification
Kontribusi
1 MH 0,150 Material hardness
2 PL 0,135 Product Length
2 PW 0,135 Product Width
2 PH 0,135 Product Height
5 AF 0,092 Alternative Functions
6 NP 0,081 Number of Part
7 PLA 0,068 Product's level of accuracy
8 VAR 0,057 Vibration attrenuation rate
9 CR 0,053 Corrosion Rate
10 SB 0,038 Subjective
11 DD 0,028 Degree of dimension
12 TI 0,026 Total interaction
Analysis:
From the part deployment is known that the priority of part specification is:
Material hardness at the first place and Product length, height, and width at
the second place to be prioritized. The rank is got based on normalization of
contribution done is part deployment.
VII.6 Failure Mode and Effec Analysis

Table 69. FMEA Analysis
Failure Mode and Effect Analysis Worksheet
Process or Product : Tangalu FMEA Number :1
FMEA Team FRI-006 FMEA Date (Original) :
Team Leader RND (Revised) :
FMEA Design Action Results
Occurences
Occurences
Detection
Detection
Severity
Severity
Current Responsibility and
Line
RPN
RPN
Potential Failure Potential Effect(s) of Potential Cause(s) of Current Controls, Recommended
Component and Function Controls, Target Completion Action Taken
Mode Failure Failure Detection Action
Prevention Date
Give note contains of

information about
Make product
The handle can not be it will occur if the handle product strength
Handle Cracked 6 5 - - 5 150 Mr. RND, 12/04/2017 information printed in 4 3 3 36
used to grip object falls from height capaibility when given
the box case
1 Left Handle any kind of external
force in the box case
Can be used to lever Give instruction of

It will occur in long term Make tutorial guide of
Lever dulled shoe in production 6 6 - - 5 180 usage or user guide Mr. RND, 12/04/2018 6 5 5 150
period after much usage usage for every tangalu
process note
It will be happened if the Choose more suitable

The platform cant be Doing further planing
Ripped Case 5 handle case is given 5 - - 4 100 material for durable Mr. RND, 12/04/2017 4 4 3 48
gripped properly for material selection
enermous force handle case
2 Right Handle
It will happen if used to Give instruction of
The hammer's surface Make tutorial guide of
Hammer tip cracked 6 hammer a very hard 5 - - 5 150 usage or user guide Mr. RND, 12/04/2018 5 5 5 125
is not flat anymore usage for every tangalu
object note
Based on the analysis, we know that there are several potential failures that can be
happened, such as: handle cracked, and dull lever for left handle and ripped case and cracked
hammer tip on right handle. From those potential failure the value of RPN is 150, 180, 100,
150.
As suggestion there are several improvement done toward product such as: better the
production planning so that the prduct is accurately made and minimized the risk of defect
8
product, the second one is to make guidance of usage to user so that user know the capabillity
of the product and make the product lifetime long lasting. The RPN after improvement is
36,150,48,125. SInce the value of RPN is getting smaller hence the improvement is affecting
the product well.
Figure 44. Final Model
The physical design is barely same with the previous one but the changes made to better
the product are: Left handle and pivot screw is made at once hence minimize both time
production and assembly time.
The second change is to apply further production planning to make the production is
friendly to environment and make less defect product. The last one is to make user guidance of
usage to make the user know the capabillity of the product so that user wont force the product
to do some heavy work, in orther to long last the lifetime of product.
9
CHAPTER VIII
CONCLUTION
VIII.1 Conclution
Based on phases done in order to get the best product with the minimized cost, the product has
changed many times. Customer, manufacturer and stakeholder are mutually communicate to
obtain the neutral point so that the product can be made well. After all, this product can fulfill
the needs of craftsmen and can absolutely increase the rae of productivity.
VIII.2 Suggestion
There are some suggestion that is offered by the writers for beter product development. In
which for the next product development is better to have more suggested design and more
analysis so that the best of the best product can be obtained. Using a true professional or an
expert to guide the researcher to obtain the beter product.
10
REFERENCE
(t.thn.). Diambil kembali dari Material Prices: www.alibaba.com

(2017). Diambil kembali dari Product Material Information: www.Indotrading.com
Product Design and Development. (2017).
product development (new product development, or NPD). (2012). Diambil kembali dari
Tech Target: http://searchcio.techtarget.com/definition/product-development-or-new-
product-development-NPD
University, P. D. (2017). Product Development Module . Dalam Product Development (hal.
1-65). Bandung: Product Development Laboratory Telkom University.
11

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FINAL REPORT

PRODUCT DEVELOPMENT PRACTICUM

PRODUCTION SUPPORTING TOOL

SCHOOL OF INDUSTRIAL AND SYSTEM ENGINEERING

TABLE OF CONTENTS ...........................................................................................................ii

1.2. Problem Formulation ....................................................................................................... 5

1.3 Project Purpose ................................................................................................................. 5

1.4. Project Function ............................................................................................................... 5

1.5. Product Development Phases........................................................................................... 5

IDENTIFICATION OF PRODUCT DEVELOPMENT OPORTUNITIES, CONSUMER

II.1. Mission Statement............................................................................................................... 7

II.2. Data Collection Methods and Customer Statement ........................................................... 7

II.2.1 Observation ................................................................................................................ 7

II.2.2 Interview .................................................................................................................... 8

II.3. Need Statement ................................................................................................................. 10

II.4. The Level of Importance and Satisfaction Questionnaires ............................................... 12

II.5. WAP Satisfaction and Importance Rate ........................................................................... 12

II.5.1 WAP Satisfaction Rate ................................................................................................ 13

II.5.2 WAP Importance Rate ................................................................................................ 14

II.6. Matriks Klein Grid ............................................................................................................ 14

II.7. Product Specification ........................................................................................................ 16

II.8. Planning Matrices ............................................................................................................... 1

II.9. HOQ Analysis ..................................................................................................................... 2

II.9.1 Table A (Customer Requirement) ................................................................................. 1

II.9.3 Table C (Technical Responses) ..................................................................................... 1

II.9.4 Table D (Inter-Relationships) ....................................................................................... 2

1.9.5 Table E (Technical Corelations) .................................................................................... 1

II.9.6 Table F (Target Matrix) ................................................................................................ 1

CHAPTER III ............................................................................................................................. 2

CONCEPT GENERATION & CONCEPT SELECTION ......................................................... 2

III.1. Concept Generation Analysis ............................................................................................ 2

III.1.1. Customer Needs Recap ............................................................................................... 2

III.1.2. Problem Clarification Analysis ................................................................................... 2

III.1.2.1. Interpetation Analysis of Customer Needs........................................................... 2

III.1.2.2. Black Box ............................................................................................................. 2

III.1.2.3. Decomposition ..................................................................................................... 3

III.1.3. Internal and External Searching Analysis ................................................................... 1

Table 36. Generate Ideas ........................................................................................................ 1

III.1.4. Result of Internal and External Exploration Analysis ................................................ 1

III.1.4.1 Option Analysis of Each Function ........................................................................ 1

II.1.5 Analisis Systematic Exploration Analysis and Result .................................................. 5

II.1.5.1 Concept and Sketch Resulted ................................................................................. 5

II.2. Concept Selection Analysis ................................................................................................ 6

II.2.1. Determine Selection Criteria for Each Need Satetment ............................................... 6

II.2.2. Determine Weight of Each Selection Criteria .............................................................. 7

II.2.3 Concept selection .......................................................................................................... 7

II.2.4 Concept Scoring ............................................................................................................ 8

III.2.6 Selected 3D Design .................................................................................................... 10

IV.1. Description of Chosen Product........................................................................................ 11

IV.2 Product Scheme ................................................................................................................ 12

IV.3 Product Geometric Structure ............................................................................................ 13

IV.4 Identification of Fundamental and Insidental Interaction ................................................ 14

CONCURRENT ENGINEERING ........................................................................................... 15

V.1. Product Description .......................................................................................................... 15

V.2 C-Data Analysis ................................................................................................................. 15

IV.3 Design Decision Analysis ............................................................................................. 19

V.4 Refine Design Analysis ..................................................................................................... 25

V.5 Final Design ....................................................................................................................... 27

VI.1 Product Part List/ Main Parts ........................................................................................... 28

VI.2 Product Spesification........................................................................................................ 29

VI.3 Translate Design Requirement of Part / Component........................................................ 29

VI.4 Material Screening & Ranking of Part / Component ....................................................... 30