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

FPDM 4

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

1.2: DESIGN TEAM MEMBERS

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GROUP P-TECH

Group Members :-

Mohd Azizul B. Mansur ( Group Leader )

Mohd Hafiz B. Zulkapli

Mohd Faisoul B. Hashim

Mohd Asri B. Mahmood

1.3: OVERALL OBJECTIVE FOR THE DESIGN

PROJECT

FPDM 8

To understand more about the design process

To fulfill customer requirements

To improve the design

To implement the design process

CHAPTER 2: UNDERSTANDING CUSTOMER

NEEDS

2.1: CUSTOMER REQUIREMENT

STATEMENT

PRESENTER :- MOHD AZIZUL B. MANSUR

FPDM 11

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

FPDM 13

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 3 1

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 9 1. Locking system [ ] [ ] [ ] 2. Easy bike loading 3. Fits all bike frame 4. Reachable height 5. Transport stability

FPDM 14

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 [ ] 70 30 0 Resist tension [ ] 55 40 5 Resist corrosion [ ] 45 45 10 Resist fatigue [ ] 55 40 5 Resist impact [ ] 30 65 5

2.2: HOUSE OF QUALITY

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CUSTOMER REQUIREMENTS

NO. Customer 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 Protect Bike 0 1 1 1 1 1                               5 22.7

2 No step ladder 1           0 1 0 1 1                     4 18.2

3 Easy bike loading   0         1         1 1 1 0             4 18.2

4 Durable     1         0       0       1 0 1       3 13.6

5 Clear rear door       0         1       0     0     1 1   3 13.6

6 Affordable         0         0       0     1   0   1 2 9.1

7 Do not rust           0         0       1     0   0 0 1 4.5

TOTAL 22 100

FPDM 17

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 Yield strength 0 1 1 1 1 1                               5 22.7

2 Resist bending 1           0 1 0 1 1                     4 18.2

3 Fit all bike frame   0         1         1 1 1 0             4 18.2

4 Cost     1         0       0       1 0 1       3 13.6

5 Material selection       0         1       0     0     1 1   3 13.6

6 Resist Impact         0         0       0     1   0   1 2 9.1

7 Aesthetics           0         0       1     0   0 0 1 4.5

TOTAL 22 100

FPDM 18

HOUSE OF QUALITY

2.5: PRODUCT DESIGN SPECIFICATION

FPDM 20

PRODUCT DESIGN SPECIFICATIONBicycle vehicle Roof Rack

aff ordable

safe

marketable

durable

functional

easy to use

cost less then RM 800

protect user

protect bike

not eastatics

stiff

long lasting

no sharp

electrically insulated

locking system

durable material

simple shape only

resist bending

resist impact

resist static load

resist bending

resist tension

lock and secure bike

lock f rame/ tyre with switch

reachable height

easy bike loading

steady transport

on the roof

clear rear door and hatch

max allowable weight height on rest

no step ladder

tension test

bending test

static load test

impact test

bending test

resist static load

<18.0Kn bending f orce

<270Kn of impact f orce

< 4.5 kN of tension f orce

< 240 kN of bending f orce

FPDM 21

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.

FPDM 22

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

FPDM 23

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

CHAPTER 3: CONCEPT GENERATION &

SELECTION

PRESENTER :- MOHD HAFIZ B. ZULKAPLI

3.1: FUNCTIONAL STRUCTURE

FPDM 26

USER

LOAD BIKE

SUPPORT BIKE

LOCK BIKE

NO STEP LADDER

LOCKING MECHANISM

CAR

PROTECT BIKE

FPDM 27

FUNCTIONAL SEQUENCE

Bicycle Vehicle Roof Rack

Assemble partsPut the assembled

Parts on the roofMount the roof rack

On the roof of vehicle

Rise up the bicycle to the roof rack

Handle with care

Slide the bicycle on toPosition & secure it with

locking mechanism

FPDM 28

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.

BRAINSTORMING

FPDM 30

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

FPDM 31

BICYCLE VEHICLE ROOF RACK

BICYCLE VEHICLE ROOF RACK

NO STEP LADDER

REACHABLE HEIGHT

DURABLE

LOCK AND SECURE BIKE

FPDM 32

BICYCLE LOCK

HANDLE

UPPER

FRAME

SHAFT

SEAT

WHEEL

FORK ARM

CRANK

LOWER FRAME

FPDM 33

MATERIAL FOR ROOF RACK

WOOD

ALLOY

STAINLESS STEEL

PLASTIC

COMPOSITE

FIBER

ALUMINIUM

PRODUCT DESIGN SPECIFICATIONS

FPDM 35

Bicycle vehicle Roof Rack

aff ordable

safe

marketable

durable

functional

easy to use

cost less then RM 800

protect user

protect bike

not eastatics

stiff

long lasting

no sharp

electrically insulated

locking system

durable material

simple shape only

resist bending

resist impact

resist static load

resist bending

resist tension

lock and secure bike

lock f rame/ tyre with switch

reachable height

easy bike loading

steady transport

on the roof

clear rear door and hatch

max allowable weight height on rest

no step ladder

tension test

bending test

static load test

impact test

bending test

resist static load

<18.0Kn bending f orce

<270Kn of impact f orce

< 4.5 kN of tension f orce

< 240 kN of bending f orce

3.2: CONCEPTS FOR PROJECTS

FPDM 37

CONCEPT GENERATION PROCESS

Clarify the Problem

Search Externally Search Internally

Explore systematically

Reflect on the Solutions and Process

STEP 1: CLARIFY THE PROBLEM

FPDM 39

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

FPDM 40

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

STEP 2: SEARCH EXTERNALLY

FPDM 42

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

FPDM 43

COMPETITORS 1

THULE SUPER G YAKIMA RAPTOR

FPDM 44

COMPETITORS 2

THULE YAKIMA-SIDEWINDER

STEP 3: SEARCH INTERNALLY

FPDM 46

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

STEP 3: EXPLORE SYSTEMATICALLY

FPDM 48

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)

3.3: MORPHOLOGICAL CHART

FPDM 50

BICYCLE VEHICLE ROOF RACK MORPH CHART1 2 3 4 5

Bicycle Lock Frame Wheel Arm Shaft Shaft

Material For Rack Plastic Composite Fiber Plastic Fiber

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

User Friendly Features Protect User Transport stability

Protect Roof

Easy To Use Lightweight

Locking Mechanism Switch ratcheting wheel strap

Rack Lever Clamp Integrated Cable Lock

FPDM 51

IMPLEMENTATIONBicycle 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

User Friendly Features Protect User ,Transport stability , Protect Roof, Easy To Use , Lightweight

Locking Mechanism Switch , ratcheting wheel strap, Rack Lever , Clamp , Integrated Cable Lock

3.4: PUGH CONCEPT EVALUATION MATRIX

FPDM 53

Evaluation MatrixConcept 1 Concept 2 Concept 3 Concept 4 Concept 5 Concept 6

Low cost

DATUM

+ - S + -

Easy to assemble + - S + -

Easy to operate + - S S S

Safety S S - S S

Light weight + - + + +

Attractive - - + - +

Multipurpose S + S S +

Long life S S S S S

Sum of + 4 1 2 3 3

Sum of - 1 5 1 1 2

Sum of ‘S’ 2 2 5 4 3

FPDM 54

Concept 1 Concept 2 Concept 3 Concept 4 Concept 5 Concept 6

Low cost S S -

DATUM

+ S

Easy to assemble - S - + -

Easy to operate - S - - S

Safety + + + + +

Light weight S S - + S

Attractive - S S + -

Multipurpose S S - S -

Long life S - + S S

Sum of + 1 1 2 5 1

Sum of - 3 1 5 1 3

Sum of ‘S’ 4 6 1 2 4

Evaluation MatrixEvaluation Matrix

FPDM 55

Concept 1 Concept 2 Concept 3 Concept 4 Concept 5 Concept 6

Low cost + + - + S

DATUM

Easy to assemble + + - + S

Easy to operate S + S + +

Safety S - S S S

Light weight - S - + -

Attractive S - + + +

Multipurpose S S - - S

Long life S S - - -

Sum of + 2 3 1 5 2

Sum of - 1 2 5 2 2

Sum of ‘S’ 5 3 2 1 4

Evaluation MatrixEvaluation Matrix

3.5: GROUP ANALYSIS OF RESULTS &

RECOMMENDATIONS

CHAPTER 4: FINAL DESIGN

PRESENTER :- MOHD ASRI B. MAHMOOD

4.1: DETAIL DESIGN

FPDM 59

ASSEMBLY MODEL

FPDM 60

EXPLODE VIEW

4.2: DFMA & SAFETY

FPDM 62

IMPORTANCE OF DFMA

REDUCE PART

REDUCE COMPONENT COST

REDUCE ASSEMBLY & MANUFACTURING COST

SIMPLIFY THE PRODUCT

EASY FOR USER TO USE THE PRODUCT

SAFETY

FPDM 64

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

FPDM 65

BRAINSTORMING- HAZARD

IDENTIFY ALL HAZARDS

FAILURES PROJECTILES

IMPROPER USE

FPDM 66

NO

DANGER FEATURE

AVOIDANCE PROTECTION

WARNINGFAIL-SAFE SAFE-LIFE CONTROL F.O.S PROTECT

SYSTEM

1. FRAME LOCK SLIDE ON TO THE RAIL

STOPER N/A MANUALLY CONTROL

CLAMP CAREFULLY

YES

2. SLIDING PART ARM LOCK CLOSE TOLERANCE

APPLY OIL FREGENTLY

MANUALLY CONTROL

N/A RAIL STOPPER

YES

3. BODY FRAME ABSORBER

BODY FRAMEADJUSTMENT

APPLY GREASE

MANUALLY 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 RACK

N/A MANUALLY OPERATED

N/A MANUAL HAND BOOK

YES

FAILURE MODE

FPDM 68

PART & FUNCTION

POTENTIAL FAILURE MODE

POTENTIAL EFFECT OF FAILURE

SEV

POTENTIAL CAUSE OF FAILURE

OCC

DETECTION METHOD & QUALITY CONTROL

DET

RPN

RECOMMENDED ACTIONS

• LOAD BICYCLE INTO RACK

•LOCK AND SECURE FRAME

•LOCK TYRES

•LOCK ARMS

•BICYCLE LOCKED AND SECURE

•STABILIZES BIKE

FRACTUTE FAILURE TO FUNCTION

8 • WEAR• FATIGUE•DEFORMATION•IMPROPER USE

6 •INCOMING PARTS INSPECTION•PRODUCT TESTING

5 240

•INITIATE RADIOGRAPHY TEST OF ALL ROOF RACK

JAMMED HAZARDOUS TO USER AND BIKE

8 •DIMENSION OUT OF SPECS•UNIT DAMAGED

5 •MEASURE & TEST PATTERN

3 120

•INTIATE PROGRAM TO MAINTAIN RACK DIMENSIONS

4.3: ERGONOMICS

FPDM 70

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

FPDM 71

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

FPDM 72

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

4.4: ADVANTAGE & DISADVANTAGES OF

FINAL DESIGN

FPDM 74

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

FPDM 75

DISADVANTAGES OF FINAL DESIGN

LOCK BICYCLE MANUALLY

NO AUTOMATIC FEATURE

ONLY ONE BICYCLE ROOF RACK CAN FIT TO THE ROOF

FPDM 76

CONCLUSION

Complete the design process

Applying the fundamentals of the design

Fulfill the customer need

Product is guaranteed successful in the market

THANK YOU