DES 3063 : PRODUCT DESIGN FUNDAMENTALS FINAL PRESENTATION

LECTURER : MR ROBERT LEE PRODUCT : BICYCLE VEHICLE ROOF RACK

CHAPTER 1: DESIGN PROBLEM & DESIGN TEAM

1.1: PROBLEMS DEFINITION & MISSION STATEMENT
PRESENTER :- MOHD FAISOUL B. HASHIM

Mission Statement : Bicycle Vehicle Roof Rack
 

Product Description – put bicycle on vehicle roof Key Business : 6 months development of beta prototype

Humanitarian Goals : 30% profit margin : initial 5 % market share : supplement to car accessories business Primary Market : Passenger vehicle users, focusing on bicycle users Secondary Market : bicycle user who like to travel Assumptions : durable, not too heavy, ecstatic Stakeholders : FPDM UniKL Avenues For Creative Design : Ergonomic shape, store capacity, strength , user friendly Scope Limitations : Materials, size , weight
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     

1.2: DESIGN TEAM MEMBERS

GROUP P-TECH
    

Group Members :Mohd Azizul B. Mansur ( Group Leader ) Mohd Hafiz B. Zulkapli Mohd Faisoul B. Hashim Mohd Asri B. Mahmood

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1.3: OVERALL OBJECTIVE FOR THE DESIGN PROJECT

 To

understand more about the design process fulfill customer requirements improve the design implement the design process

 To

 To

 To

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CHAPTER 2: UNDERSTANDING CUSTOMER NEEDS

2.1: CUSTOMER REQUIREMENT STATEMENT
PRESENTER :- MOHD AZIZUL B. MANSUR

QUESTIONAIRE
1. How would you best describe your familiarity with a product like that described above?
  

I was not aware of such a product Have investigated or researched such products Have purchased or regularly use a product like this

2. How often do you primarily use your bicycle vehicle roof rack?  Always  Seldom  Rarely 3. Who are basically relying on this kind of product?  Cyclist  Teenagers  Old person
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4. Is the appearance of the product is an important subject to you?  Yes, definitely  Somewhat important  Not very important 5. What color do you think is/are suitable for the roof rack?  Striking color (Yellow, Pink, Orange and etc)  Basic color (Yellow, Red, Blue, Black)  Dual color (E.g.. Black and White, Red and White, Black and Grey and etc) 6. What type of material should be the product made of?  Steel  Alloy  Composites 7. The product should be ……………  Bulky but light  Light and compact  Compact but heavy

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8. About what would you expect to pay for a new product like the one described?  Less than RM 250.00  RM 251.00 – RM 350.00  RM 351.00 – RM 450.00 9. What are the safety features that should be included (Answers should be based on priorities: 1 – Weak, 3 – Medium, 9 - Strong)
 

9
1.

3
] [ ]

1
[ ]

lock bike with support arm clamp

[

2. secure bike with steel trap

[

]

[

]

[

]

10. What are the other features that should be included in the product? (Answers should be based on priorities: 1 – Weak, 3 – Medium, 9 - Strong) 1 3  1. Locking system [ ] [ ]  2. Easy bike loading  3. Fits all bike frame  4. Reachable height  5. Transport stability

9 [ ]

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11. Special strength and resistance that you think are applicable to this product? (Answers should be based on priorities: 1 – Weak, 3 – Medium, 9 - Strong) 1 9 3 Resist bending Resist tension Resist corrosion Resist fatigue Resist impact [ [ [ [ [ ] ] ] ] ] 70 55 45 55 30 30 40 45 40 65 0 5 10 5 5

    

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2.2: HOUSE OF QUALITY

CUSTOMER REQUIREMENTS
NO. 1 2 3 4 5 6 7 Customer Req Protect Bike No step ladder Easy bike loading Durable Clear rear door Affordable Do not rust 1/2 0 1 0 1 0 0 0 1/3 1 1/4 1 1/5 1 1/6 1 1/7 1 0 1 0 1 0 0 1 0 1 1 1 0 0 0 1 1 1 0 1 0 1 0 0 1 1 0 0 1 1 0 2/3 2/4 2/5 2/6 2/7 3/4 3/5 3/6 3/7 4/5 4/6 4/7 5/6 5/7 6/7 SUM 5 4 4 3 3 2 1 22 %SUM 22.7 18.2 18.2 13.6 13.6 9.1 4.5 100

TOTAL

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TECHNICAL REQUIREMENTS
NO. Technical Req 1/2 1/3 1/4 1/5 1/6 1/7 2/3 2/4 2/5 2/6 2/7 3/4 3/5 3/6 3/7 4/5 4/6 4/7 5/6 5/7 6/7 SUM %SUM 1 2 3 4 5 6 7 Yield strength Resist bending Fit all bike frame Cost Material selection Resist Impact Aesthetics 0 1 0 1 0 0 0 1 1 1 1 1 0 1 0 1 0 0 1 0 1 1 1 0 0 0 1 1 1 0 1 0 1 0 0 1 1 0 0 1 1 0 5 4 4 3 3 2 1 22 22.7 18.2 18.2 13.6 13.6 9.1 4.5 100

TOTAL

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HOUSE OF QUALITY

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2.5: PRODUCT DESIGN SPECIFICATION

PRODUCT DESIGN SPECIFICATION
Bicycle vehicle Roof Rack affordable cost less then RM 800

safe

protect user

no sharp electrically insulated

protect bike

durable material locking system

marketable

not eastatics

simple shape only

durable

stiff long lasting

resist bending resist impact resist bending resist static load resist tension

<18.0Kn bending force <270Kn of impact force < 240 kN of bending force resist static load < 4.5 kN of tension force

bending test impact test bending test static load test tension test

functional easy to use

lock and secure bike

lock frame/ tyre with switch

reachable height

no step ladder

easy bike loading

steady transport

on the roof

clear rear door and hatch

max allowable weight height on rest

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PDS FOR BICYCLE VEHICLE ROOF RACK
Objectives are :- to design a bicycle roof rack for passenger vehicles - to design the system that allow a single person to load bikes on roof - to design the system that uses no step ladder Size : the system should be <1.5m long Cost : selling price < RM250.00 Quantity : Batches of 2000-5000 units for domestic market Materials: Lightweight composite materials-resist impact and bending.

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PDS FOR BICYCLE VEHICLE ROOF RACK

Marketable : not aesthetics – simple shape only Product life : 10-20 years Customers : Cyclist , outdoor enthusiastic Standards : to be checked Reliability : Maximum 2 % failure over life service Safety : no sharp edges, locking mechanism for frame , tire , folk of bike , clear door and hatch

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PDS FOR BICYCLE VEHICLE ROOF RACK

Ergonomics : must be user-friendly : easy to load and unload bike , one person able to load bike without using step ladder Competition : major car accessory companies Packing : standard car accessory for passenger vehicle :MPV, SUV, saloon cars Market :car accessory shops/dealers Patents : to be checked

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CHAPTER 3: CONCEPT GENERATION & SELECTION
PRESENTER :- MOHD HAFIZ B. ZULKAPLI

3.1: FUNCTIONAL STRUCTURE

USER

LOAD BIKE

NO STEP LADDER

SUPPORT BIKE

PROTECT BIKE
LOCKING MECHANISM

LOCK BIKE

CAR

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FUNCTIONAL SEQUENCE
Bicycle Vehicle Roof Rack

Assemble parts

Put the assembled Parts on the roof

Mount the roof rack On the roof of vehicle

Handle with care

Slide the bicycle on to Position & secure it with locking mechanism

Rise up the bicycle to the roof rack

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INTEGRAL OR MODULAR?

Easy to dismantled and assembled by the customers. Flexibility in use, where as it can be configured for different uses Easy to repair Easy to machine and produce Easy to upgrades where as the user needs evolve the product.

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BRAINSTORMING

BRAINSTORMING
 Group

brainstorming  Rules of brainstorming
    

Record all ideas generated Generate and discuss as many ideas as possible Think wild Generate ideas: no judgments Focus on one specific function

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BICYCLE VEHICLE ROOF RACK

NO STEP LADDER

DURABLE

BICYCLE VEHICLE ROOF RACK

REACHABLE HEIGHT
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LOCK AND SECURE BIKE

31

LOWER FRAME HANDLE

UPPER

FRAME

SHAFT SEAT
BICYCLE LOCK

CRANK WHEEL FORK
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ARM
32

WOOD

PLASTIC

ALLOY

MATERIAL FOR ROOF RACK

COMPOSITE

STAINLESS STEEL ALUMINIUM
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FIBER

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PRODUCT DESIGN SPECIFICATIONS

Bicycle vehicle Roof Rack

affordable

cost less then RM 800

safe

protect user

no sharp electrically insulated

protect bike

durable material locking system

marketable

not eastatics

simple shape only

durable

stiff long lasting

resist bending resist impact resist bending resist static load resist tension

<18.0Kn bending force <270Kn of impact force < 240 kN of bending force resist static load < 4.5 kN of tension force

bending test impact test bending test static load test tension test

functional easy to use

lock and secure bike

lock frame/ tyre with switch

reachable height

no step ladder

easy bike loading

steady transport

on the roof

clear rear door and hatch

max allowable weight height on rest

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3.2: CONCEPTS FOR PROJECTS

CONCEPT GENERATION PROCESS

Clarify the Problem

Search Externally

Search Internally

Explore systematically

Reflect on the Solutions and Process

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STEP 1: CLARIFY THE PROBLEM

CLARIFY THE PROBLEM
The challenge was to design a better bicycle rack.  The mission statement assumptions:     

The bicycle rack will be durable The bicycle rack will be affordable The bicycle rack will be safe The bicycle rack will allow a single person to load bike The bicycle rack will not use step ladder
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CUSTOMER NEEDS

Based on the assumptions , we had identified the customer needs of bicycle vehicle roof rack :The bicycle rack will be long-lasting The bicycle rack will be cost less than current rack The bicycle rack will protect user and bike The bicycle rack will allow a single person to load bike without using any step ladder

   

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STEP 2: SEARCH EXTERNALLY

SEARCH EXTERNALLY

Find existing solutions to overall problem and sub-problems

External Source : Interview Lead Users – Passenger vehicle users  Consult Experts - Car Accessories , bicycle user  Search Patents - Search available pattern  Search Published Literature – Research through published literature  Benchmark Related Product – Comparison with competitors
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COMPETITORS 1

THULE SUPER G

YAKIMA RAPTOR

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COMPETITORS 2

YAKIMA-SIDEWINDER

THULE

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STEP 3: SEARCH INTERNALLY

SEARCH INTERNALLY
     

Use personal knowledge to generate solution concepts Guidelines for useful improvement internal group search Suspended judgment Generate a lot of ideas – Brainstorming Process Except ideas that may seem infeasible Use graphical and physical media – Diagram, charts, pictures

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STEP 3: EXPLORE SYSTEMATICALLY

EXPLORE SYSYEMATICALLY

Collected concepts from internal and external search Organizing and synthesizing the solutions by:Functional Decomposition (Simplify Complicated System) Morphological Chart (Sub function versus Concept ) Inventive Principles (TRIZ)
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3.3: MORPHOLOGICAL CHART

BICYCLE VEHICLE ROOF RACK MORPH CHART
1 2 3 4 5

Bicycle Lock Material For Rack

Frame Plastic

Wheel Composite

Arm Fiber

Shaft Plastic

Shaft Fiber

Special Feature

Fit all bike frame

Fit wheel size from 24” to 29”

Compactable Designed to clear Bombproof with factory rear door and construction rack hatches

User Friendly Features Locking Mechanism

Protect User Switch

Transport stability Protect Roof Easy To Use ratcheting wheel Rack Lever strap
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Lightweight Integrated Cable Lock
50

Clamp

IMPLEMENTATION
Bicycle Lock Frame , Wheel , Arm , Shaft

Material For Rack

Plastic, Composite, Fiber , Plastic

Special Feature

Fit all bike frame, Fit wheel size from 24” to 29 , Compactable with factory rack, Designed to clear rear door and hatches , Bombproof construction Protect User , Transport stability , Protect Roof, Easy To Use , Lightweight

User Friendly Features

Locking Mechanism

Switch , ratcheting wheel strap, Rack Lever , Clamp , Integrated Cable Lock
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3.4: PUGH CONCEPT EVALUATION MATRIX

Evaluation Matrix
Concept 1 Concept 2 Concept 3 Concept 4 Concept 5 Concept 6
Low cost Easy to assemble

Easy to operate

D A T U M

+ +

-

S S

+ +

-

+

-

S

S

S

Safety Light weight

S +

S -

+

S +

S +

Attractive Multipurpose

S

+

+ S

S

+ +

Long life

S

S

S

S

S

Sum of + Sum of Sum of ‘S’

4 1 2

1
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3 1 4

3 2 3
53

5 2

Evaluation Matrix
Concept 1
Low cost Easy to assemble S -

Concept 2
S S

Concept 3
-

Concept 4 D A T U M

Concept 5
+ +

Concept 6
S -

Easy to operate

-

S

-

-

S

Safety Light weight Attractive Multipurpose Long life

+ S S S

+ S S S -

+ S +

+ + + S S

+ S S

Sum of + Sum of Sum of ‘S’

1 3 4

1 1 6

2 5
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1 3
54

1

4

Evaluation Matrix
Concept 1
Low cost Easy to assemble + +

Concept 2
+ +

Concept 3
-

Concept 4
+ +

Concept 5
S S

Concept 6 D A T U M

Easy to operate

S

+

S

+

+

Safety Light weight Attractive Multipurpose Long life

S S S S

S S S

S + -

S + + -

S + S -

Sum of + Sum of Sum of ‘S’

2 1 5

3 2 3

1 5
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2 2
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2

4

3.5: GROUP ANALYSIS OF RESULTS & RECOMMENDATIONS

CHAPTER 4: FINAL DESIGN
PRESENTER :- MOHD ASRI B. MAHMOOD

4.1: DETAIL DESIGN

ASSEMBLY MODEL

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EXPLODE VIEW

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4.2: DFMA & SAFETY

IMPORTANCE OF DFMA

REDUCE PART REDUCE COMPONENT COST REDUCE ASSEMBLY & MANUFACTURING COST SIMPLIFY THE PRODUCT EASY FOR USER TO USE THE PRODUCT
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SAFETY

IMPORTANCE OF SAFETY CONSIDERATION

AVOID ACCIDENCE ENSURE SAFETY OF USER AND PRODUCT ANALYZE THE HAZARD , RISK & POSSIBILITY OF FAILURE MINIMIZE THE RISK DESIGN SAFETY FEATURE FOR PRODUCT

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BRAINSTORMING- HAZARD
IMPROPER USE

IDENTIFY ALL HAZARDS

FAILURES

PROJECTILES

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NO

AVOIDANCE DANGER FEATURE
FAIL-SAFE SAFE-LIFE

PROTECTION WARNING CONTROL F.O.S PROTECT SYSTEM
YES

1.

FRAME LOCK

SLIDE ON TO THE RAIL

STOPER

N/A

MANUALLY CONTROL

CLAMP CAREFULLY

2.

SLIDING PART

ARM LOCK

CLOSE TOLERANCE

APPLY OIL FREGENTLY

MANUALLY CONTROL

N/A

RAIL STOPPER

YES

3.

BODY FRAME ABSORBER

BODY FRAME ADJUSTMENT

APPLY GREASEMANUALLY CONTROL

N/A

BEARING

NO

4.

TIRE CLAMP

CRUSH HAND

N/A

N/A

NO

5.

BICYCLE STABILITY

FALL OVER USER

BICYCLE THROUGHTLY LOCKED

N/A

MANUALLY OPERATED

N/A

SAFETY BAR

YES

6.

STORE BIKE

UNSTABLE

SLIDE THROUGH N/A RACK

MANUALLY OPERATED

N/A

MANUAL HAND BOOK

YES

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FAILURE MODE

PART & FUNCTION

POTENTIAL FAILURE MODE

POTENTIAL EFFECT OF FAILURE FAILURE TO FUNCTION

POTENTIAL SE CAUSE OF V FAILURE 8 • WEAR • FATIGUE •DEFORMATION •IMPROPER USE

OC DETECTION METHOD & DE RPN RECOMMENDED C QUALITY CONTROL T ACTIONS

• LOAD FRACTUTE BICYCLE INTO RACK

6

•INCOMING PARTS INSPECTION •PRODUCT TESTING

5

•LOCK AND SECURE FRAME

240 •INITIATE RADIOGRAPHY TEST OF ALL ROOF RACK

•LOCK TYRES

•LOCK ARMS

•BICYCLE LOCKED AND SECURE

JAMMED

•STABILIZES BIKE

HAZARDOUS TO 8 USER AND BIKE

•DIMENSION OUT 5 OF SPECS •UNIT DAMAGED

•MEASURE & TEST PATTERN

3

120 •INTIATE PROGRAM TO MAINTAIN RACK DIMENSIONS

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4.3: ERGONOMICS

IMPORTANCE OF ERGONOMICS

ENHANCE THE EFFECTIVENESS OF THE PRODUCT INCREASE THE CONVINIENCE OF PRODUCT REDUCE THE POSSIBILITY OF ERRORS HIGHER THE PRODUCTION INPUT INCREASE HIGH QUALITY WORK

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DESIGN PRINCIPLE
DESIGN FOR ADJUSTMENT

HEIGHT OF BIKE SIZE (DIAMETER OF TYRES) LENGTH OF SWING-ARM SIZE OF SWING-ARM DESIGN RANGE :- 5TH PERCENTILE FEMALE & 95TH PERCENTILE MALE
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ANTROPROMETRICS CALCULATIONS

FEMALE 5TH PERCENTILE :SHOULDER HEIGHT – KNUCKLE HEIGHT 132.3CM – 64.3 CM = 68.0 CM

 

MALE 95TH PERCENTILE:SHOULDER HEIGHT – KNUCKLE HEIGHT 152.4 CM – 80.4 CM = 72.0 CM

RANGE :- 68.0 CM – 72.0 CM

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4.4: ADVANTAGE & DISADVANTAGES OF FINAL DESIGN

ADVANTAGES OF FINAL DESIGN

EASY TO FIT FACTORY SPECS EASY TO LOAD & STORE BIKE FIRMLY PROTECTS & STABILIZES BIKE ON THE ROOF NO ELECTRICAL & ELECTRONIC COMPONENTS RACK CAN FIT ALMOST ALL BICYCLE FRAME

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DISADVANTAGES OF FINAL DESIGN

LOCK BICYCLE MANUALLY NO AUTOMATIC FEATURE ONLY ONE BICYCLE ROOF RACK CAN FIT TO THE ROOF

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CONCLUSION
 Complete

the design process

 Applying

the fundamentals of the design

 Fulfill

the customer need is guaranteed successful in the market
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 Product

THANK YOU

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