Product Design Team6

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FACULTY OF ENGINEERING AND BUILD ENVIRONMENT

DEPARTMENT OF MECHANICAL AND MATERIAL ENGINEERING

KKKP 4274 Product Design

4th Year Semester I 2011/2012

Product Design Project Final Report :

Arthritis Hand-Aids

Design Team 6

1. CHAN KIEN HO ( A125070 )

2. HOW YONG CHIAN ( A123700 )

3. MOHAMAD MUSTAKIEM BIN MOHD ZAKI ( A123754 )

4. MUHAMMAD IDHAM BIN SABTU ( A124520 )

5. NURUL NUUR ASHIEKEEN BINTI ZULKIFLEE ( A126457 )

Lecturer : PROF. MADYA DR. DZURAIDAH ABD. WAHAB

Supervisor : DR. RIZAUDDIN RAMLI

Due Date : 23 December 2011

i

Contents

CHAPTERS PAGES

I. Contents i II. Acknowledgement ii III. Executive Summary iii 1.0 Gantt Chart 1 2.0 Brainstorming 1 3.0 Problem Statement 2 4.0 Design Objectives 2 5.0 Analysis Of Survey Results 3 6.0 Quality Function Deployment (QFD) 4

6.1 House Of Quality 7 7.0 Product Design Specification (PDS) 8 8.0 Functional Decomposition 10 9.0 Concept Generation 11

9.1 Morphological Chart 12 9.2 Concept Combination 14

10.0 Concept Evaluation 15 10.1 Pugh’s Concept Selection 16 10.2 Concept Comparison 17

11.0 Concept Selection 18 11.1 Weighted Decision Matrix 19 11.2 Final Concept 19

12.0 Embodiment Design 20 12.1 Product Architecture 21 12.2 Failure Mode & Effect Analysis (FMEA) 22 12.3 Design For X (DfX) 23

13.0 Detailed Design 31 13.1 Exploded View And Bill Of Material (BOM) 32 13.2 Engineering Analysis 33

14.0 Material And Costing 37 14.1 Material Selection 37 14.2 Cost Estimation 39

15.0 Conclusion 40 16.0 References 42 17.0 Appendix 43

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ACKNOWLEDGEMENT

First and foremost, it is grateful to have team members who are committed and devote a

lot of efforts to finish the project within the time given. Next, a special gratitude to our

lecturer, Prof. Madya Dr. Dzuraidah Abd. Wahab who is dedicated in teaching the

course KKKP4274 Product Design, willing to guide and help us to complete the project.

Besides, we would also like to thank to our supervisor, Dr. Rizauddin Ramli who has

spent his time to do meeting with us, providing us the valuable opinions and suggestions

to improve our project.

We feel very fortunate to be given this opportunity to conduct this task because

along doing this project, a lot of information and knowledge can be gains and very clear

visualize of theory that we learns in class that will apply at real industries. The

knowledge and experience are benefits to us when we entered the real works in future as

an engineer. This project we not considered as burden but it is learning process that

teaches us how to apply the knowledge, skills, interaction and communication to others

and a lot more.

Last but not least, thanks to friends and others that involved in this project for

giving their supports, helps and brainstorm to solve the problem we faced. All this co-

operation is greatly appreciated for completing this product design project.

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EXECUTIVE SUMMARY

In this project, we were re-designing the current arthritis tool in market so that the

product can be more reliable, high impact resistance, parts inter-changeability and

comfortable to use. 30 survey forms were distributed to the public who are facing the

arthritis problem. The survey was emphasized on difficulty level of daily activities and

the comments & suggestion for the new product. After analyze the survey result, we

determined the engineering characteristic rank order according to the customer’s

requirements in House of Quality. Higher activity diagram is the general information

about the functions that will performed by the product and functional modeling described

the detail function process. For concept generation, few alternatives for each part of

product were presented in graphical method and 15 concepts were chosen based on the

alternatives. 6 concepts left after concept evaluation by using Pugh’s method. The

advantages and disadvantages of each concept were listed and best concept was generated

through weighted decision matrix. The 4 general steps to construct the product

architecture are combined the functional diagram, modular chunks, relationship on

hierarchy components structure and incidental interaction. The parametric designs

include Failure Mode Effect Analysis for part function, detail drawing, dimension &

tolerance, assembly & exploded view and stress analysis in critical parts. Design for X

also has been included inside the report. The material selection by using CES 2005 and

cost estimated for product were the last section in project.

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1.0 GANTT CHART

Once the team member has been decided, we have planned and executed the activities

and tasks according to the gantt chart below.

2.0 BRAINSTORMING

In order to start the project of product design, all the team member shall sit together and

start brainstorming. Brainstorming is a group creativity technique to generate ideas where

all the member will give suggestions on what product shall be developed. Eventually, we

have decided to focus on Arthritis Multifunctional Tools where we name it as “Arthritis

Hand Aids”. There are several ideas being discussed as listed below and shown in

appendix A1 and A2.

i. Gym Equipment for Handicap

ii. GPS Holder at Motorbike

iii. Portable and Adjustable Chair

iv. Emergency Car Key Chian

v. Arthritis Multifunctional Tools

vi. Adjustable Allen Key

vii. Automatic Lamp

viii. Multifunctional Torch Light

Gantt ChartWeek 11/9 18/9 25/9 2/10 9/10 16/10 23/10 30/10 6/11 13/11 20/11 27/11 4/12 11/12 18/12

Task w1 w2 w3 w4 w5 w6 w7 w8 break w9 w10 w11 w12 w13 w14

Brainstorming ( Ideas to develop new product)

Proposal Report 1 (problems, survey results, PDS, QFD)

Proposal report 2 (conceptual design , functions )

Embodiment design ( detail drawing, analysis, )

1 .

2 .

3 . Presentation ‐ brainstorming results

No.

Design Team Formation

4 . Conduct surveys

5 .

7 .

6 . Presentation ‐ proposal report 1

8 Presentation ‐ proposal report 2

9 .

10 . Compile Final Report

11 . Presentation ‐ final report

12 . Team meeting

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3.0 PROBLEM STATEMENT

Arthritis is a disease that causes pain and loss of movement of the joints. Arthritis

literally means inflammation of one or more joints. However, we would like to focus on

people with hand arthritis who having difficulties using their hands to perform daily

activities. Hand arthritis is specifically very painful and debilitating due to the fact that

hands have nineteen long bones and eight small bones that has several small joints in

between.

People with hand arthritis often find that pain, stiffness and fatigue cause

problems when performing simple task such as opening a door knob and a softdrink can,

using a screwdriver, carrying plastic bags with load during shopping. Therefore, we

would like to design a hand aids tool meanwhile integrate as many function as possible.

The hand aids tool is portable, light weight, easy to use and store. The product

will be given focus on the stress-strain analysis, to ensure it will not undergo deformation

and failure when certain amount of force being applied. The cost of product shall within

the range of RM30-RM50.

4.0 DESIGN OBJECTIVES

4.1 The objectives of designed product is stated as below:

i. To aids the people with hand arthritis to do a range of daily task, solving the

problem of using hand to grip, hold and apply force on something

ii. To develop a hand aids tool which is multifunctional and reliable

iii. To improve the current existing design based on the requirement of customers

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4.2 The objectives is clarified through the objective tree as below:

Figure 4.1 Objectives Tree

5.0 ANALYSIS OF SURVEY RESULTS

In order to identify the needs of customers, information is being gathered through

customer surveys. A total number of 30 questionnaire is distributed to people who are

suffering from hand pain or arthritis. Part of the survey is being conducted at Hospital

Serdang to obtain a better and accurate information. The questionnaire is shown in

appendix B1 to B4 Basically the questionnaire is divided into 4 sections where part 1 and

part 2 is to investigate the level of difficulty for the response to perform the listed

activities, then focus is given on these elements as to fulfill the customer needs. Whereas

part 3 is to collect the opinion of customer to determine the product features they desired.

Part 4 is to indicate the willingness of customer to purchase product. All the raw data is

summarized into a bar chart as shown in appendix B5 to B7. A mind mapping of survey

question also shown in appendix B8.

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6.0 QUALITY FUNCTION DEPLOYMENT (QFD)

Quality Function Deployment (QFD) is also known as House of Quality where the main

function we build this diagram in this product design to determine prioritize customer

demands and customer needs, spoken and unspoken, translating these needs into actions

and designs such as technical characteristics and specifications, and to build and deliver a

quality product or service, by focusing various functions toward achieving a common

goal of customer satisfaction for this arthritis tool.

Below are the steps to construct an efficient and accurate QFD. There are 11 steps

involved.

i. The Customer Requirement (Demanded Quality).

We need to identify who is our product’s customer and try to gather the information

from the particular group of people what is the requirement on the new designed

product. From the survey analysis, we only interpreted the result of survey’s

statements that get high customer’s vote to few important functions such as light

weight, clamp and clip tightly, adjustable for different size and task, easy to carry,

easy to put on, multiply the force efficiently and aesthetic.

ii. Regulatory Requirement.

Beside that the requirement that customer requested. We also document requirements

that are dictated by management or regulatory standards that the product must adhere

to. For example, Safety, comfortable used, anti corrosion and robust.

iii. Customer Weight/Important.

On a scale from 1 - 5, customers then rate the importance of each requirement. This

number will be used later in the relationship matrix. But on our QFD construction,

we try to analysis the scale based on the number of customer’s vote.

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iv. Competitive Analysis.

In this section, we also need the customers to judge or give the comments about our

new designed product with compare to the other competitors.

v. Quality Characteristic.

This can be called as “Voice of Engineer”. Few characteristics that we suggested in

order to improve the product quality and meet the customer needs. The

characteristics are No. of color, size, fatigue, toughness, hardness, environment effect,

physical appearance, cost and type of materials.

vi. Direction of Improvement.

Based on our logical thinking and decision, the movement of the each Quality

Characteristic was determined. For example, Size and Cost or the product must be

reduced and Fatigue and Toughness should be increased.

vii. Relationship Matrix.

The relationship matrix is where determines the relationship between Quality

Characteristic and Demanded Quality. Relationships can either be weak, moderate,

or strong. For example, The Weight has the moderate relationship with Size because

Type of Material has a great contribution into the product Weight. But, Size has a

strong relationship with Multiply the Force Efficiently because apply the same force

at different length will get the different torque.

viii. Organization Difficulty.

Rate the design attributes in terms of organizational difficulty. It is very possible that

some attributes are in direct conflict. In our decision, 0 represent easy to accomplish

and 10 represent extremely hard to implement. One of the targets that hard to achieve

or implement among the Quality Characteristic is Fatigue because it requires

expensive software like Autodesk Inventor for stress-strain analysis. Another than

that, plenty time also needed for the design engineer to get the optimum design.

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ix. Target Value for Quality Characteristic.

The target of the product for each descriptor is still in un-certainty because the

improvement for the features still needed and the mechanism for the adjustable

clamping function is still in un-known state. The target value will be determined

once the final design is coming out.

x. Correlation Matrix.

In this section, we examined how each of the Quality Characteristic impact to each

other. After that, we document strong negative relationships between technical

descriptors and work to eliminate physical contradictions. The number of color in the

product has no relationship with the environment effect. But they type of material

used will has strong effect to the manufacturing cost and conflict will occur between

this two characteristics. Then we need to observe the Rank Order to determine which

Characteristic is the most important among them.

xi. Absolute Importance and Rank Order.

The absolute important for each Quality Characteristic is the product between

Customer Important value and cell value in the Relationship Matrix. After that, we

determined the rank Order according Absolute Important. The higher Absolute

Important will get the priority compare to lower value.

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6.1 House of Quality

From the figure above, we can conclude that the priority of improvement should

be first given to size , second is fatigue, third is hardness and follow by toughness, type of

material, physical appearance, colours and hardness

Column 1 2 3 4 5 6 7 8 9

Direction of Improvement▼ ▼ ▲ ▲ ▲ ▲ ▲ ▼ ▲

1 9 7.0 3.0 Light Weight Ο Ο Θ 4 2

2 2.3 1.0 Safety 2 3

3 9 7.0 3.0 Clamp and clip tightly Θ 4 2

4 9 11.6 5.0 Multiply the force efficiently Θ Ο Θ 3 2

5 9 7.0 3.0 Adjust for different size Θ Θ 4 1

6 9 11.6 5.0 Adjust for different task Ο Θ 4 1

7 9 11.6 5.0 Easy to carry Θ ▲ 2 4

8 9 7.0 3.0 Easy to put on Ο 2 3

9 9 2.3 1.0 Confortable used Θ Ο Ο 3 2

10 1 7.0 3.0 Easy to operate ▲ 2 4

11 9 7.0 3.0 Robust Θ Θ Θ Ο Θ Θ 2 3

12 9 11.6 5.0 Anti‐corrosion Θ Ο Ο 4 2

13 9 7.0 3.0 Aesthetic Θ Θ Ο ▲ ▲ 2 3

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Target or Limit ValueDifficulty

( 0=Easy to Accomplish, 10=Extremely Difficult )

Max Relationship Value in Column 9 9 9 9 9 9 3 9 9

Weight / Importance 62.8 279 258.1 167.4 62.8 195.3 74.4 258 167.4

Relative Weight % 4.2 18.6 17.2 11.1 4.2 13 4.9 17.2 11.1

Rank order 6 1 2 4 6 3 5 2 4

Type of material

Our Company

Competitive Analysis

(0=worst, 5=best)

Row #

Max. R

elationship Value In Row

Relative Weight

Weigh

t / Im

portan

ce

No. of colour

size

Fatigue

Toughness

Competitor 1

3 5 7 3 3 6 2 9

Hardness

Environment effect

Physical appearance

Cost

Quality

Characteristic

Demanded

Quality

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7.0 PRODUCT DESIGN SPECIFICATION (PDS)

i. Product Title

Arthritis Hand-Aids

ii. Purpose

To provide the hand arthritis people a convenient way to grip, hold and apply force

on something.

iii. New and Special Features

‐ Combination of various function in one tool

‐ Ergonomic handle for better gripping

‐ Adjustable size of gripper to grip objects with different diameter

iv. Competition

Compete against other single function arthritis tool

v. Intended Market

‐ Sell to people who have hand arthritis.

‐ Product will be promoted through medical centre

vi. Need for product

‐ User survey has shown 85% of respondent will to pay more for an aid equipment.

‐ Most of them having difficulty in dressing and grooming, eating.

‐ Activities such as hold and grip are highly ranked as hard to be performed, which

means they demand a tool that helps them to overcome these difficulties.

‐ The designed product should be portable, weight and size are to be concerned.

vii. Relationship to existing products line

This is a start-up venture. No other products currently exist.

viii. Price

We anticipate selling a hand-aids tool for around RM30-50

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ix. Functional Performance

‐ Allow to hock clothes

‐ Allow to open soft drink cans

‐ Allow to grip on round objects such as door knob, bottle cap

‐ Able to be applied force 100N without failure

x. Physical Requirements

‐ Length 30cm

‐ Light Weight 500g

‐ Cylinder shape with sphere head and round edges

‐ Smooth but not slippery surface

xi. Service Environment

Product Material should be stable from 0°C to 100°C

xii. Life-cycle issues

Gripping mechanism should not fail for 5000 cycles.

xiii. Human Factors

‐ No sharp edges or corners to cause cuts or snag clothing

‐ Handle must be ergonomic shape for comfortable purpose

‐ User friendly, simple to operate the function

xiv. Corporate Constraints

‐ Must be marketed within 1 year

‐ Must confirm to corporate code of ethics

xv. Legal requirements

No toxic materials to be associated with material

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8.0 FUNCTIONAL DECOMPOSITION

In solving any complex problem, a common tactic is to decompose the problem into

smaller parts that are easier to manage. When customer’s need is captured, a model of

showing how the product should function is required to clarify and design the product

architecture. Product architecture is the arrangement for the physical elements of a

product to carry out its required functions.

In this report, we will develop process description using an Activity Diagram. A

high level user activities are networked to show the full cycle of a product. Next, by using

the Activity Diagram, a function structure for the product is formulated. Function

structure is defined as an input-output model that maps energy, material and signal flows

to a transformed and desired state. A higher activity diagram is shown in appendix C1

and the functional modeling is shown in appendix C2 to C5.

The method to perform functional decomposition are:

i. State the overall function that needs to be accomplished

Develop a “black box” model of the product to shows the flow in and flows out

need to be identified.

ii. Create descriptions of sub-functions

Decomposing the overall function in “black box” into sub-functions. Each sub-

function represents a change or transformation in the flow of energy, material or

information.

iii. Arrange the sub-functions in logical order

For our problem this is a trivial step, but for other design problems it can be major

to follow the sequence of sub-functions

iv. Refine the sub-functions

Refinement stops when a sub-function can be fulfilled by a single solution that is an

object or action, and the level of detail is sufficient to address the customer needs.

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9.0 CONCEPT GENERATION

The techniques of concept generation including Trigger words, Checklist, Analogy,

Morphological Analysis, and Brainstorming. In this report, we are using Morphological

Analysis where a Morphological Chart is developed to generate 15 concepts. The concept

combination is shown in appendix D1 to D3

A morphological chart is a visual way to capture the necessary product functionality

and explore alternative means and combinations of achieving that functionality. For each

element of product function, there may be a number of possible solutions. The chart enables

these solutions to be expressed and provides a structure for considering alternative

combinations. The method to construct a Morphological Chart are:

i. List the product functions

List functions according to a predetermined order - most important, position in

structure, energy flow, information flow. Care should be taken to list functions and

not components - e.g. 'warning indicator' rather than 'bell'. Always ask 'what function

is this component fulfilling?' Each function should be mutually exclusive.

ii. List the possible 'means' for each function

Think about new ideas, as well as known solutions or components and where possible

ideas should be expressed visually as well as in words. Any important characteristics

of the solutions should be recorded. Try to maintain the same level of generality for

each possible solution.

iii. Chart functions and means and explore combinations

Draw up a chart containing all possible sub-solutions. This is the 'morphological chart'

which should represent the total 'solution space' for the product. Try wherever

possible to express all options visually as to identify feasible combinations of sub-

solutions. The total number of combinations may be very large, so they may need to

be limited to the most feasible or attractive options. Name each viable combination as

a potential solution for further evaluation later.

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9.1 Morphological Chart

Sub functions Concepts

A B C D E

1.0 Hold the handle of tools

1.1 Grip tool Flat Rectangular

Centre Hollow

Dent/Groove

Curved

Cylinder

1.2 Grasp to use tool

Rough & Grain Surface

Smooth & Shiny Surface

Rubber Layer Surface

2.0 To Clip Object

2.1 Positioning the Clipper

Fixed

Extend & Retract

Flipped

2.2 Picking up objects

Pliers Style

Double Fork Style

Clamping Style

2.3 Using the clipping Mechanism

Push button

Slide button

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3.0 To grip object

3.1 Fitting object into gripper

Round Head

Square Head

Pentagon Head

Hexagon Head

3.2 Positioning the gripper

Fixed

XY plane 180° Adjustable

XZ plane 180° Adjustable

XY & XZ plane 180° Adjustable

3.3 Holding object in gripper

Flat Teeth

Rough Teeth Full & Flat Full & Rough

3.4 Opening or turning an object

Hand Rotate Automatic Rotate

3.5 Using the gripper mechanism

Push Button

Slide Button

4.0 To hook object

4.1 Picking up object

Sharp Head Hook

Flat Head Hook

Round Head Hook

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9.2 Concept Combination

Subfunctions Concepts

A B C D E

1.1

Grip tool

Flat

Rectangular

Centre Hollow

Dent/Groove

Curved

Round Cylinder

1.2

Grasp to use tool

Rough & Grain Surface

Smooth &

Shiny Surface

Rubber Layer

Surface

2.1

Positioning the Clipper

Fixed

Extend & Retract

Flipped

2.2

Picking up objects

Plyer Style

Double Fork

Style

Clamping Style

2.3

Using the clipping Mechanism

Push button

Slide button

3.1

Fitting object into gripper

Round Head

Square Head

Pentagon Head

Hexagon Head

3.2

Positioning the gripper

Fixed



XY & XZ plane

180° Adjustable


Flat Teeth

Rough Teeth

Full & Flat

Full & Rough


Hand

Automatic


Push Button

Slide Button


Sharp Head Hock

Flat HeadHock

Round Head Hock

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10.0 CONCEPT EVALUATION

Evaluation involves comparison, followed by decision making. To make a valid

comparison the concepts must exist at the same level of abstraction. There are many

techniques for concept evaluation such as Comparison based on absolute criteria, Pugh’s

concept selection method, Measurement scales, Weighted Decision Matrix, Analytical

Hierarchy Process (AHP), and Methods of Decision Analysis.

In this report, we are using Pugh’s concept selection method since it is a

particularly good method for deciding on the most promising design concept at the concept

stage. This method compares each concept relative to a reference or datum concept and for

each criterion determines whether the concept in question is better than, worse than, or

about similar to the reference concept.

This matrix-based approach was proposed by Pugh (1991), which is also known as

Concept Screening. The steps being taken to a construct Pugh’s concept selection table are:

Step 1: Generate an assortment of ideas or concepts

Step 2: Prepare a criteria list

Step 3: Pick a datum

Step 4: Evaluate each alternative by rating them with “+”, “-” and “0”

Step 5 Rank the concept by referring the sums up scores

Step 6 Choose 6 best optimised hybrid concept

Step 7 Seek opportunities for improvement

Step 8: Apply more rigorous engineering disciplines to hybrid design

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10.1 Pugh’s Concept Selection

( 1 ) ( 2 ) ( 3 ) ( 4 ) ( 5 ) ( 6 ) ( 7 ) ( 8 ) ( 9 ) ( 10 ) ( 11 ) ( 12 ) ( 13 ) ( 14 ) ( 15 )

1 . Manufacturing cost ‐ ‐ 0 0 ‐ 0 ‐ ‐ 0 0 0 ‐ 0 0 0

2 . Material 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

3 . Weight ‐ ‐ ‐ 0 ‐ 0 ‐ 0 ‐ 0 ‐ ‐ 0 ‐ ‐

4 . Aesthetic + + + + + + + + + + + + + + +

5 . Durability + + + + + + + + + + + + + + +

6 . Portability 0 + + 0 + + + + 0 0 + + + + +

7 . Comfortable to hold and use

Grip the tools + ‐ 0 + + ‐ + + ‐ 0 ‐ + ‐ 0 ‐

Grasp to use + 0 ‐ 0 0 0 ‐ ‐ + 0 + 0 ‐ + ‐

8 . Ease of clipping objects

Positioning the clipper + + + + + + + + + + + + + + +

Picking up objects + + + + + + + + + + + + + + +

Using the clipping mechanism + + + + + + + + + + + + + + +

9 . Ease of gripping objects

Fitting object into gripper ‐ 0 0 0 0 ‐ 0 ‐ ‐ ‐ ‐ 0 ‐ ‐ ‐

Positioning the gripper 0 ‐ ‐ 0 ‐ ‐ ‐ ‐ 0 0 ‐ 0 ‐ ‐ ‐

Holding object in gripper + 0 0 + 0 + 0 + 0 0 0 0 + + 0

Opening or turining an object ‐ ‐ ‐ 0 ‐ 0 ‐ 0 ‐ 0 ‐ ‐ 0 ‐ ‐

Using the gripper mechanism + + + + + + + + + + + + + + +

10 . Ease of hooking objects

Picking up objects ‐ 0 0 + + 0 + 0 ‐ ‐ + + 0 0 ‐

Sum of " + " ( better than ) 9 7 7 9 9 8 9 9 7 6 9 9 8 9 7

Sum of " ‐ " ( worse than ) 5 5 4 0 4 3 5 4 5 2 5 3 4 4 7

Sum of " 0 " ( similar as ) 3 5 6 8 4 6 3 4 5 9 3 5 5 4 3

Net Score 4 2 3 9 5 5 4 5 2 4 4 6 4 5 0

Rank 7 13 12 1 3 3 7 3 13 7 7 2 7 3 15

Continue ? ( Yes = Y, No = N) N N N Y Y Y N Y N N N Y N Y N

Selection CriteriaConcepts

DATUM

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10.2 Concept Comparison

From the Pugh’s concept selection method, the six concepts with highest rank are selected

for further evaluation. The six chosen concepts are concept(4), (5), (6), (8), (12) and (14).

They are to be compared in terms of advantages and disadvantages, where the comparison

of concept (4) is shown as below and remaining is in appendix E1 to E5. The visual view

of six concepts is also shown through hand sketches for better understanding.

I) Concept (4)

Advantages Disadvantages

a) More application and task can be

performing.

b) Very ergonomic such as comfortable to

hold and use.

c) The gripper and clipper can be adjust for

desired size and high accuracy to lock it

properly with the helps of slide button and

other mechanism.

d) Special features such as the clipper can in

and out from the holder.

a) Increase the manufacturing process,

cost and design.

b) Will lower the durability and life

cycles of product due to adding more

function.

c) Do not have high degree of freedom to

move the head part due to fixed.

d) More different material has to use and

must follow standard quality for

medical product.

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11.0 CONCEPT SELECTTION

Concept selection is the process of narrowing the set of concept alternatives under

consideration. In this report, we are using the Weighted Decision Matrix method which

also known as Concept scoring because it is easy to understand and apply. Concept scoring

is used when increased resolution will better differentiate among competing concepts. In

this stage, we weighs the relative importance of the selection criteria and focuses on more

refined comparisons with respect to each criterion. The concept scores are determined by

weighted sum of ratings.

This approach can be good at indicating the front runners, but numerical methods

like this can be dangerous, as they tend to imply only one 'right' answer. It should always

be remembered that both the weightings and the ratings are subjective and arbitrary, and

thus although a quantitative answer is gained, it too is subjective. This approach is also

extremely sensitive to small changes and it can be easy to 'cook the books', so it needs to

be used with caution. The method to construct a Weighted Decision Matrix table are:

i. List the most important features

These should have been determined during the product definition phase and form

the criteria against which rival solutions will be judged.

ii. Determine weightings

Some features will be more critical than others. Assign weightings to each, so that

their relative merits are accounted for. Ideally, the weightings should be

determined in partnership with the target customers.

iii. Rating each option

Suppose the rating should be led by customers to remove personal bias from

amongst the design team.

iv. Calculate the weighted totals

Multiply the score by the weighting for each feature and sum the totals.

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11.1 Weighted Decision Matrix

1 . Manufacturing cost 25% 3 0.75 3 0.75 5 1.25 3 0.75 2 0.50 3 0.75

2 . Material 5% 4 0.20 4 0.20 4 0.20 4 0.20 4 0.20 4 0.20

3 . Weight 3% 4 0.12 2 0.06 4 0.12 2 0.06 2 0.06 2 0.06

4 . Aesthetic 2% 5 0.10 4 0.08 1 0.02 5 0.10 3 0.06 3 0.06

5 . Durability 5% 3 0.15 2 0.10 2 0.10 3 0.15 2 0.10 2 0.10

6 . Portability 10% 2 0.20 3 0.30 3 0.30 4 0.40 2 0.20 3 0.30

7 . Comfortable To Hold and Use 20% 5 1.00 4 0.80 3 0.60 4 0.80 3 0.60 3 0.60

8 . Ease of clipping objects 10% 4 0.40 2 0.20 4 0.40 4 0.40 4 0.40 4 0.40

9 . Ease of gripping objects 10% 4 0.40 2 0.20 3 0.30 3 0.30 3 0.30 2 0.20

10 . Ease of hocking objects 10% 5 0.50 5 0.50 3 0.30 3 0.30 5 0.50 3 0.30

Total Score

Rank

Continue ?

R= Rating ( 1 = Inadequate, 2 = Weak, 3 = Satisfactory, 4 = Good , 5 = Excellent )

S = Weighted Score

R

( 6 )

R S

( 8 )

R S

( 12 )

R S

( 14 )

R S

2.92

6

No

2.97

5

No

3.59

2

No

3.46

3

No

3.82

1

Yes

3.19

4

No

SSelection Criteria

Concepts

Weight

( %)

( 4 )

R S

( 5 )

11.2 Final Concept

From the weighted decision matrix table, we have determined concept(4) as the most

preferable concept since it has the highest score among the other concepts. The remaining

concepts will be revised and keep as reference.

In conclusion, our final concept is concept (4) which will be proceeded to

embodiment design and various analysis.

20

12.0 EMBODIMENT DESIGN

The definition of embodiment design according to Pahl and Beitz (2007) runs as follow:

“Embodiment Design is the part of the design process starting from the principle solution

or concept of a consumer product. The design should be developed in accordance with

engineering and economical criteria”. This is a pure technical and economical

consideration of Embodiment Design but a product has more aspects than only the

technical and economical ones. A product can also bring aspects about emotion, beauty,

appeal and happiness the other values in live. People like to pay for these values if the

earnings are higher than the cost of the basic needs.

The embodiment design refines the abstract concepts to blueprints. A blueprint

denotes a model of the institutional rules that is more concrete than in the concept but still

independent of implementation details. In other words, the concept comprises at most a

verbal description of the institutional rules or algorithms. As such, many different

blueprints can be found that realize the same concept. During the embodiment design this

verbal descriptions are transformed into a model with sufficiently low level of abstraction

that traditional design techniques may be applied in order to implement it: the concept

becomes form (Pahl & Beitz 2007).

The Embodiment Design phase is the part of the design process which is concerned

about the production of the product concept, the engineering and the economical feasibility.

The production contains the parts making and the product assembling.

In brief, the embodiment process is the bridge between the conceptual stage of the

design process and the detail design stage. A more detailed analysis of the selected

concepts is undertaken in the embodiment stage of the design process. In this report, our

embodiment design consist of Product Architecture, Failure Mode and Effects Analysis

(FMEA), and Design For X.

21

12.1 Product Architecture

There are 4 basic steps that need to be constructed in order to generate the product

architecture. First, list out the functional structure of the product and arrange in proper

location that close to each other (Appendix F1). Second, categorize and combine the

structures/elements into few building blocks according to their function properties

(Appendix F2). Third, generate the components hierarchy structure and simple geometric

view of product (Appendix F3). Finally, determine the incidental interactions between the

building blocks during operation (Appendix F4).

For the functional structure of the product, the black boxes functional structures

that generated at previous part were simplified and combined together. The inputs of the

model are hand, energy operating situation and after used condition. After using, the

outputs of the model include sound, object and energy released. The energy transit line

for each function will be represented by different colors. For example, the energy transit

line for gripping is in red color.

The modular chunks will be established with combine all the related functional

structures into a block. The major functions of the product include gripping, clipping,

rotate for objects opening and hanging. The main function of handle is to magnify the

applied energy into larger torque. At the rough geometric part section, list out all the

product’s components except the standard parts like screws and nuts. Arrange the

components into hierarchy structure and determine the interaction of the components

between and within chunks. The geometric layout of product is shown in front, back and

also side view.

In the incidental interaction part, the interaction elements include vibration,

bending, stress concentration, unbalance force and environment effect. When hanging the

object by hook, the stress concentration and vibration occur near to the cross head part

due to the screw location. At rotating the adjustable and cross heads, force that applied to

generate torque will bend the handle. Normally, the cross head will be used at kitchen or

bathroom so the environment conditions such as acidity of detergent, water temperature

will give the effect to the product surface. The unbalance force exist because the total

weight of the cross head and adjustable head at the top is not exact same with the weight

of clipper system at the bottom.

22

12.2 Failure Mode & Effect Analysis (FMEA)

Failure Mode and Effects Analysis (FMEA) is a method to identify potential failure

modes for our Arthritis tool product, to assess the risk associated with those failure modes,

to rank the issues in terms of importance and to identify and carry out corrective actions

to address the most serious concerns. To assess the risk associated with the issues

identified during the analysis and to prioritize corrective actions, Risk Priority Numbers

(RPNs) method is used. RPN evaluated by this formulation RPN = Severity (S) x

Occurrence (O) x Detection (D).

For this method, our team was decided to choose picking object, clipping object,

gripping object and opening water tab as a part function. This part function based on the

overall functions and functional modeling for product that being developed. It is

importance to rating the severity, occurrence and detection by refer the guidelines from

books and notes. The purpose by referring the guidelines to give better explanation on

how to numbering and rating the factors mention properly and not by suggestion.

By applied FMEA, It can contribute to improved designs for products and

processes, resulting in higher reliability, better quality, increased safety, enhanced

customer satisfaction and reduced costs. The tool can also be used to establish and

optimize maintenance plans for repairable systems or contribute to control plans and

other quality assurance procedures. It provides a knowledge base of failure mode and

corrective action information that can be used as a resource in future troubleshooting.

Appendix G1 shows the Failure Mode and Effect Analysis (FMEA) for picking

and clipping Arthritis tool product. Meanwhile, Appendix G2 shows the Failure Mode

and Effect Analysis (FMEA) for gripping and opening water tab for Arthritis tool product.

23

12.3 Design For X (DFX)

X in DfX stands for manufacturability, inspectability, recyclability and others. These

words are made up of two parts: life cycle business process (x) and performance measures

(bility), that is X=x+bility. If a DfX tool focuses on one life cycle process and uses more

than one performance metrics, it is referred to as tool of the “Design for the Life Cycle”

type. On the other hand, if a DfX tool focus on one performance metric but covers a range

of life cycle processes, it is then referred to as a tool of the “Design for the

Competitiveness” type.

Most Popular DfX Tools:

Design for Assembly/ Disassembly/ Maintabability (DfA)

Design for Cost (DfC)

Design for EMC (DfE)

Design for Installation (DfI)

Design for Quality (DfQ)

Design for Recycling (DfR)

Design for Reuse (DfR)

Design for Serviceability (DfS)

Design for Speed (DfS)

Design for Six Sigma (DfSS)

Design for Testability (DfT)

Design for Warranty (DfW)

Design for Usability (DfU)

Design for Validation (DfV)

A generic DfX model can provide a platform for integrating a DfX tool with other

decision support systems used in product development such as CAD/CAM (computer

Aided Design and Manufacture), CAPP (Computer Aided Production management), to

facilitate the flow of data and decision between them. Successful DfX tools define clearly

24

their specific areas of concern and thus provide the essential focus for the project team to

make the best use of resources available to them. Below stated the function of a DfX tool:

1) Gather and present facts about products and processes

2) Clarify and analyze relationship between products and processes

3) Measure performance

4) Highlight strengths and weaknesses and compare alternatives

5) Diagnose why an area is strong or weak

6) Provide redesign advice on how a redesign can be improves

7) Predict what-if effects

8) Carry out improvements

9) Allow iteration to take place

As it was too many of DfX tools, it have become difficult to choose a DfX which is

most appropriate for the problem at hand. There is a few general guidelines regarding

when and where to apply what DfX, firs, for tool of Design for Assembly, it should be

used to rationalize products assortments and structures before other types of DfX tools.

Second, the number of factors such as availability, applicability, vendor experience and

others affected which DfX tool should be used. The last but not least, DfX should be used

as early as feasible and the problem is and where it lies determine what DfX to use.

Furthermore, for the design of product arthritis hand tool, there are few of tools have

been selected and focused for the design analysis, as stated below:

Design for Assembly

Design for Manufacturing

Design for Reliability

Design for Human Factors

Design for Environment

25

12.3.1 Design For Assembly (DfA)

DfA were introduced in 1970s, one of the earliest works, Hitachi Assemblability

Evaluation Method (Hitachi AEM). DfA once pushed by automation technology but now

more in manual assembly. DfA meaning as the design of the product for the ease of

assembly. Furthermore, it is defined as making decision in product development related

to products, and process and plants. The aim is to simplify the product so that the cost of

assembly is reduced. Research found that DfA can be the key to high productivity in

manufacturing. The Boothroyd-Dewhurst method for DfA process follow these steps:

i. Select an assembly method for each part

ii. Analyses the parts for the given assembly methods

iii. Refine the design in response to shortcomings identified by the analysis

iv. Loop to step 2 until the analysis yields a sufficient design

Figure 11.3(a): Arthritis Hand Aids product.

C1

C2

B

A C

A1

A2

26

As for part A, the handle, it is actually made of two semi-cylindrical shape, we

mark it as A 1 and A 2. Both parts been engage by two snap-fit joints, located at upper

and lower section A. We have decided to choose type annular snap-fit joints because we

can designed the joint to be either detachable, difficult to disassemble or inseparable,

depending on the dimension of the insert and the return angle. We have decided to make

our product with high maintainability, so the annular snap-fit must be a detachable one.

We have mark the inserts located at A 1 with diameter of 3 mm and the hub located at A

2 with diameter of 5 mm.

Figure 11.3(b): Typical annular snap-fit joint.

For part B, the clipper section, it include bottom and upper clipper. Both was

engage together by fastener. Later, to fit the combine clipper (metal) with the plastic part,

still using fastener. To make sure that the joint between the plastic and metal allows the

plastic part to expand without regard to the expansion of the metal part, we are adding a

shoulder fasteners. When the clipper part itself was assemble, it was engage to the

handler also by a fastener. For part C, the head section which include tab opener and door

opener, both located on opposite side, we mark tab opener as C 1 and door opener as C 2.

To engage C 1 and C 1 use fastener located at the back of each part then when both was

assemble, to fit it into the handler, also using a fastener. For hook attached at Part C, it

was engage to the head by screw fastener.

A 2 A 1

Insert Hub

27

Figure 11.3(c) : Use of shoulder fasteners between the fastener and the plastic.

The Therbligs motions required for operator during assembly process are grasp,

position, hold and lastly assemble, applied for all part A, B and C. There are some basic

guidelines for DfA that our group design try to apply to product arthritis hand tool:

Guidelines Application to product

Minimize part count by incorporating multiple functions into single parts

Part C, there were two different function, assemble into single parts.

Modularize multiple parts into single subassemblies

Part B was attached directly to the handler subassemblies.

Assemble in open space, not in confined spaces; never bury important components

However, Part C was designed to be buried under handler, as for aesthetic and ergonomic decision.

Make parts such that it is easy to identify how they should be oriented for insertion

The upper and lower of handler differentiate by the button channel shape, operator can easily identified it.

Prefer self-locating parts Part A was insert by snap-fit joints.

Eliminate tangly parts Part B was retract back after use to avoid be tangled outside product.

Color code parts that are different but shaped similarly

We may color code at tab and door opener head for this purpose.

Design the mating features for easy insertion Part C apply this in order to insert it to the handler.

Eliminate fasteners We cannot avoid this as all part was best fit by fastener to make sure of its engagement.

Place fasteners away from obstructions; design in fastener access

All fasteners on the product has its own access.

Deep channels should be sufficiently wide to provide access to fastening tools; eliminate channels if possible

Fastener was attached before the Part A was snap-fit together, so fastening tool easily reach to fasteners.

Ensure sufficient space between fasteners and other features for a fastening tool

No fasteners was designed close to each other on the product.

28

12.3.2 Design For Manufacturing (DfM)

DfM is the process of proactively designing products to optimize all the manufacturing

functions such as fabrication, assembly, test, procurement, shipping, delivery, service and

repair. Furthermore DfM is to assure the product has the best cost, quality, reliability,

regulatory compliance, safety, time-to-market, and customer satisfaction.

Besides that, it is important to use specific design guidelines for part to be

produced by specific processes. Part A and C was completely produced by plastic

injection molding process. Besides that, polypropylene plastic is well known for molding

process. Part B, the clipper also was made by same material where it is made in

house. Same as with fastener, we are using the standard size and shape. The product also

was design avoiding mirror image parts, it can be use both right or left hand modes.

Although the product not design symmetrical, worker or robot could still easily install the

part either upward or backward. It means that product can be installed starting first by

Part C or Part B. Any other way, but it must the assemble of Part A become the last

process.

12.3.3 Design For Reliability (DfR)

Reliability is the ability of an assert to survive a specific period of time without failure.

At present there are three main approaches to ensuring that a design will be reliable:

reliability prediction, design techniques and development or pre-production reliability

testing. From these, designers can model their designs quickly and simply to identify

areas which are most likely to cause reliability problems. In this report, has been included

design technique using Failure Mode and Effects Analysis (FMEA) as to determine the

product reliability.

29

12.3.4 Design For Human Factors (DfHF)

Human factors discover and applies information about human behavior, abilities,

limitations, and other characteristics to the design of product and environments for

productive, safe, comfortable, and effective human use. As the product focused for

people with arthritis disease condition, they have certain capabilities and limitations, and

the product must be designed with an understanding of the patients component subsystem

requirements. Besides that, our group design have been referring to The Material

Information Society for Medical Material to make sure that material been decided is safe

for use of arthritis patients. The material been used is polypropylene plastic. We also

have referring to NIOSH’s guide for hand tools. From that, we have try to follow few

guidelines with our product design, stated as follow:

Guidelines Application to product

Handle diameter is 1 ¼ inches to 2 inches

(31.75 mm to 50.8 mm)

The product has handle with diameter of

40mm.

For double-handled pinching, gripping, or

cutting tools, applied spring-loaded to

return the handles to the open position

The product clipper was attached with

spring-loaded in between.

For task requiring high force, tool’s handle

length must longer than widest part of

hand, between 4 inches to 6 inches ( 101.6

mm to 152.4 mm)

When consumer using either the clipper

part or opener part, their hand was in

between handler, length about 100 mm.

Table 11.3(a) : NIOSH’s guide for hand tools

30

12.3.5 Design For Environment (DfE)

The goal of DfE is to enable design teams to create eco-efficient and eco-effective

products while adhering to their cost, quality and schedule constraint. There at least two

types of guidelines, prescriptive and suggestive guidelines. Prescriptive is about what

designers should or should not do, also known as design rules. On the other hand,

suggestive is guidelines represent accumulated knowledge but not strict rules. Here are

steps to designing innovative products with minimal environmental impact:

1) Map the product lifecycle

2) Identify the main environmental impacts

3) Select relevant DfE strategies

4) Generate design concepts

Next, DfE guidelines was then are divided into four principles strategies, design for

dematerialization, design for detoxification, design for revalorization and design for

capital protection and renewal. Our group design decided to focus more on design for

revalorization which is seeks to recover, recycle or reuse the residual materials and

energy that are generated at each stage of product life cycle, thus eliminating waste and

reducing virgin resource requirement. This later was discuss more during topic of Product

Recovery, Reuse and Recycle.

31

13.0 DETAILED DESIGN

In the engineering drawing of the Arthritis Hand Aids product, we have split it into 3

main section namely Head, Handle and Clipper. The Head section consists of sub-part

such as Adjustable Head, Tap head , Belt , Teeth, Screws and Hook. Whereas, the Handle

section consists of Top Handle, Bottom Handle, Top Button For Clipper, Bottom Button For

Teeth, Top Button For Teeth and Screws. Finally, the Clipper section consists of Upper Clipper,

Bottom Clipper, Pin, Spring and Screw. In this report, the parts such as screws, spring and

pin are not included in drawing because they are standard parts. By Using Solid Work

2010 software, the product is being sketched in 3D view as shown figure 12.0(a) and

figure12.0(b). The detail drawing of each sub-parts is also shown in this report in

appendix F1 to F5.

Figure 12.0(a) Arthristis Hand Aids (tap head 3D view)

Figure 12.0(b) Arthristis Hand Aids (adjustable head 3D view)

32

13.1 Exploded View And Bill Of Material (BOM)

33

13.2 Engineering Analysis

Engineering analysis is performed for two critical part which are handle and tap head.

The material Polyamides (PA) type 6 is selected for stress and displacement analysis

because it is the most-used engineering materials, with excellent impact strength,

moldability and paintability, fair heat resistance, and good wear and friction

characteristics. The analysis is shown as below:

13.2.1 Handle

I) Stress Analysis For Handle ( Force Applied =100N )

Figure 12.3(a) Von Mises Stress Analysis For Handle

34

II) Displacement Analysis For Handle ( Force Applied =100N )

Figure 12.3(b) Displacement Analysis For Handle

III) Summary of Handle Analysis Results

35

13.2.2 Tap Head

I) Stress Analysis For Tap Head ( Force Applied = 100N )

Figure 12.3(c) Von Mises Stress Analysis For Tap Head

II) Displacement Analysis For Tap Head ( Force Applied = 100N )

36

Figure 12.3(d) Displacement Analysis For Tap Head

III) Summary of Handle Analysis Results

From the analysis done on the two components using Software Solid Word 2010,

the result differentiates based on the shade of colours. Blue area means that area is of a

lower stress and lower displacement, high stress and displacement the red is of the

opposite condition. Both components show that they can withstand the force being

applied without failure. Analysis for Mass properties for overall design is shown in

appendix H, the total mass of product is 320g and the volume is 28.60m3.

37

14.0 MATERIAL AND COSTING

14.1 Material Selection

By using Cambridge Engineering Selector (CES) 2005, we have set a few stage to filter

according to the desired range of material properties.

Stage 1

For Stage 1, material which are having young modulus, 0.1GPa and fracture toughness

0.1MPa /m2 is taking into consideration. This is to ensure our product can withstand

certain amount of force without failure.

Figure 14.1(a) Material Selection-Stage 1 using CES

38

Stage 2

For stage 2, material which has good durability against wear and fresh water is taken into

consideration. The product should have good resistivity to water because it is used to

open water tap in bathroom or a washing sink. The product should also not easy to tear

and wear so that it will have a longer life cycle.

Figure 14.1(b) Material Selection-Stage 2 using CES

Stage 3

Finally, the stage 3 is a limit stage where we limit the material to polymers, price of

material below RM15/ kg and a maximum density 1200 kg/m3 This will help in narrow

down the choices and we can compare the properties of remaining material easily.

Figure 14.1(c) Material Selection-Stage 3 using CES

39

14.2 Cost Estimation

In order to fabricate a Arthritis Hand Aids, there are 9 manufactured parts and another 9

purchased parts need to be assembled to become the final product. We have chosen

Polyamides (PA), as the material to fabricate our product since it has average material

cost, high durability against water and wear. The details of PA is shown in appendix I.

i. Manufactured Parts ( Total Manufacturing Cost =RM20 )

Part No.

Description Material volume (m3)

Density (kg/m3)

Mass (kg)

(RM) cost/ kg

Qty Cost (RM)

001 Adjustable head PA 3.0E-04 1130 3.4E-01 14.5 1 4.92

002 Belt PA 7.5E-06 1130 8.5E-03 14.5 1 0.12

003 Bottom clipper PA 6.0E-06 1130 6.8E-03 14.5 1 0.10

004 Bottom handle PA 8.0E-05 1130 9.0E-02 14.5 1 1.31

005 Hook PA 6.0E-06 1130 6.8E-03 14.5 1 0.10

006 Tap head PA 3.0E-04 1130 3.4E-01 14.5 1 4.92

007 Teeth PA 8.0E-06 1130 9.0E-03 14.5 4 0.52

008 Top handle PA 8.0E-05 1130 9.0E-02 14.5 1 1.31

009 Upper clipper PA 6.0E-06 1130 6.8E-03 14.5 1 0.10

Total Material Cost 13.39

ii. Purchased Parts

Item No.

Description Material (RM) Cost/Qty

Qty. Cost (RM)

1 Pin Cast iron 0.40 1 0.40

2 Spring Cast iron 0.80 1 0.80

3 Screw for clipper Cast iron 0.10 1 0.10

4 Screw for teeth Cast iron 0.10 4 0.40

5 Top button for clipper Polyamides (PA) 0.50 1 0.50

6 Bottom button for teeth Polyamides (PA) 0.50 1 0.50

7 Screw for button up Cast iron 0.10 1 0.10

8 Top button for teeth Polyamides (PA) 0.50 1 0.50

9 Screw fot head and handle Cast iron 0.10 4 0.40

Total Purchasing Cost 3.70

Overall Cost = Manufacturing Cost + Material cost + Purchasing Cost

= RM 20 + RM 13.39 +RM 3.70

= RM 37.09 /product#

40

15.0 CONCLUSION

We have started this product design project by forming group, listing out all the task to be

done using a Gantt Chart. Eight ideas has been generated during the brainstorming

session, where decision is made by everyone to proceed our project with a product

namely "Arthritis Hand Aids".

We have identified the problems and define three main objectives of designed

product to be achieved at the end of project. The designed product shall comprise the

good elements such as features, performance and convenience. A survey is conducted

where 30 questionnaires is distributed to gathered information and needs of customers.

The surveys shows that most of respondent are having difficulties in performing daily

task such as open a door knob, open water tap, picking up clothes and other activities.

The collected information enables us to proceed with Quality Function

Deployment(QFD), where a House of Quality is developed to show the priority of

improvement should be given to size of product and mechanical properties such as

fatigue and hardness.

Next, we have developed an activity diagram and functional modeling which

comprises the 4 main activities namely Gripping, Opening, Picking and Clipping. After

which, we proceed to the concept generation by using a Morphological to obtain 15

different combination of sub-function concepts. We have evaluated the 15 concepts using

Pugh’s Concept Selection then reduced to 6 concepts. The remaining 6 concepts are

being further compared through Weighted Decision Matrix, eventually the concept(4) is

chosen as the final concept.

In this report, our embodiment design consist of Product Architecture, Failure

Mode and Effects Analysis (FMEA), and Design For X. For the detail design, we have

split the product into 3 main section namely Head, Handle and Clipper. CAD drawing of

each parts is skectched, follow by an Exploded View and Bill Of Material (BOM) which

shows that product consist of 18 parts.

41

The engineering analysis shows that the handle part can withstand 100N force and

the tap head can withstand 50N force. Polyamides (PA) is selected to fabricate some parts

our product whereas other standard parts is purchased. The overall cost for our product is

RM37.09 which satisfy the statement in PDS.

In brief, our objectives in this project is achieved because we have developed a

tool to assist the hand arthritis people to perform certain daily task. The tool is

multifunction and better than current existing design since we the have the adjustable

gripper head which allow to grip different diameter objects, as well as the extendable and

retractable clipper which is convenient to use and store.

42

16.0 REFERENCES

Dieter, G.E. 2000. Engineering Design: A Materials and Processing Approach (3rd

Edition), New York: McGraw Hill Inc.

Moultrie, J. 2011. Morphological Charts.

http://www.ifm.eng.cam.ac.uk/dmg/tools/concept/morph.html

Otto, K.N. and Wood, K.L. 2000. Product Design: Techniques in Reverse Engineering

and New Product Development, Prentice Hall.

Pahl, G. and Beitz, W. 2007. Engineering Design - A systematic Approach (2nd Edition),

London: Springer-Verlag.

Quality-One International, Inc. 1995-2001. QFD (Quality Function Deployment).

http://www.quality-one.com/services/qfd.php

ReliaSoft Corporation, 2004. Basic Concepts of FMEA and FMECA.

http://www.weibull.com/hotwire/issue46/relbasics46.htm.

Sullivan, L.P., 1986. Quality Function Deployment. Quality Progress, pg 39-50.

Ulrich, K.T. & Eppinger, S.D. 2007. Product Design and Development (4th edition),

McGraw-Hill.

Ullman, D.G. 2003. The Mechanical Design Process (3rd Edition), New York: McGraw-

Hill Inc.

David, M.A. 2011. Design For Manufacturability.

http://www.design4manufacturability.com/DFM_article.htm

43

Appendix A1

i. Gym Equipment For Handicap

Handicaps often cannot use standard workout

equipment, so they need alternatives.

The designed equipment is comfortable and allows

those with physical handicaps to get the exercise that

they need to be healthy

ii. GPS Holder At Motorbike

Motorbikers having difficulty in using GPS while they

are travelling, they need something to hold the GPS.

The designed holder shall easy to install and release

on the vehicle, provide extra safety for the GPS

devices

iii. Foldable And Adjustable Chair

The common chairs are with fixed height and

consume space to store it.

The designed chair shall not too heavy, bulky, or

complicated, meanwhile it should be portable and

stackable, provide suitable height for adult or children.

iv. Emergency Car Key Chain

The designed car key chain is useful during

emergency such as during an accident, being trapped

in car. It comprises a safety blade seat belt cutter,

steel point auto glass breaker, battery powered LED

light and sonic alarm sound

44

Appendix A2

v. Arthritis Multifunctional Tools

A multifunctional tools that helps the arthritis patients

to grip object is designed since some daily performed

action might cause pains on their joints.

Example of functions: bottle opener, key turner, door

knob opener, tap turner etc

vi. Adjustable Allen Key

A common allen key set consists of different head

sizes allen key.

The newly designed adjustable allen key is to

integrated all head sizes into a single component.

vii. Automatic Lamp

The ordinary lamp post in a park or garden can be

improved to be self-supply electricity by adding a

solar panel.

It recharged by sunlight and automatic turning on at

dusk with a built-in light sensor.

viii. Multifunctional Torch Light

A torch light is very useful during jungle tracking or

during black out at night

A multifunctional torch light is to be designed for long

period outdoor activities purpose, has a solar panel to

recharge itself and also charge other electronic items

such as handphone, and as a defense tool

45

Appendix B1

46

Appendix B2

47

Appendix B3

48

Appendix B4

49

Appendix B5 Questionnaire Part I

Part I - Question

I-A1 : Dress yourself with shoelaces and buttons

I-A2 : Shampoo your hair

I-A3 : Brushing teeth using toothbrush

I-B1 : Stand up from straight chair

I-B2 : Get in and out from bed

I-B3 : Get in and out from car

I-C1 : Lift a full glass to your mouth

I-C2 : Using fork and spoon / chopsticks

I-C3 : Using hand to hold and lift food to your mouth

I-D1 : Walk on flat ground

I-D2 : Walk on uneven ground

I-D3 : Climbing up and down of stairs

Question No I-A1 I-A2 I-A3 I-B1 I-B2 I-B3 I-C1 I-C2 I-C3 I-D1 I-D2 I-D3

Total Count of

(3) And (4) 25 14 21 18 16 15 19 23 17 9 14 17

Relative Frequency 83.3 46.7 70.0 60.0 53.3 50.0 63.3 76.7 56.7 30.0 46.7 56.7

Table 4.1 Total Count Of (4) And (5) And Relative Frequency For Questions In Part I

Figure 5.1 Pareto Diagram - Frequency Of Responses Against Question Number

83.376.7

70.063.3 60.0 56.7 56.7 53.3 50.0 46.7 46.7

30.0

0.0

20.0

40.0

60.0

80.0

100.0

Relative

Frequency ( % )

Question No.

Pareto Plot of Responses ‐Part I

50

Appendix B6

Questionnaire Part II

Part II - Question

II-A1 : Wash and dry your body

II-A2 : Get on and off the toilet

II-B1 : Reach something from above your head

II-B2 : Bend down to pick up something

II-C1 : Open door knob

II-C2 : Open water tab

II-C3 : Open jars lid

II-C4 : Open car doors

II-C5 : Pulling a shirt

II-C6 : Pull a plug

II-C7 : Pull a key from a door knob

II-D1 : Writing using pen

II-D2 : Taking a pan from kitchen

II-E1 : Driving a car

II-E2 : Run errands/ shopping

II-E3 : Do chores (vacuuming, laundry, gardening)

II-E4 : Swimming

Table 5.2 Total Count Of (4) And (5) And Relative Frequency For Questions In Part II


Question No II-A1 II-A2 II-B1 II-B2 II-C1 II-C2 II-C3 II-C4 II-C5 II-C6 II-C7 II-D1 II-D2 II-E1 II-E2 II-E3 II-E4

Total Count of (4) and (5)

13 13 25 22 24 23 25 22 16 22 23 22 23 20 16 25 27

Relative Frequency

43.3 46.4 83.3 75.9 80.0 76.7 86.2 73.3 53.3 73.3 76.7 73.3 79.3 69.0 53.3 83.3 90.0

90.0 86.2 83.3 83.3 80.0 79.3 76.7 76.7 75.9 73.3 73.3 73.3 69.0

53.3 53.346.4 43.3

0.0

20.0

40.0

60.0

80.0

100.0

Relative Frequency (%)

Question No.

Pareto Plot of Response ‐Part II

51

Appendix B7

Questionnaire Part III

Part III - Question

A : The weight of product B(i) : Appearance- Shape B(ii) : Appearance- Color C : Size of the product D : Alarm siren for emergency used E : Product material F : Easy to carry along at any time

Question No A B(i) B(ii) C D E F

Total Count Of (4) And (5) 26 11 6 23 13 19 22

Relative Frequency 86.7 36.7 20.0 76.7 43.3 65.5 73.3

Table 5.3 Total Count Of (4) And (5) And Relative Frequency For Questions In Part III


Questionnaire Part IV

86.776.7 73.3

65.5

43.3 36.720.0

0.0

20.0

40.0

60.0

80.0

100.0

A C F E D B(i) B(ii)Relative

Frequen

cy

Question No.

Pareto Plot of Response ‐Part III

52

Appendix B8 Mind Mapping of Survey

53

Appendix C1

Higher Activity Diagram

Purchase

Transport Un-pack Store

Operating Condition

Gripping Opening Picking Clipping

Move gripper head to object

Adjust to fit

Apply force to rotate

Pull out

Store

Attach cross head to tab

Press to fit the head with tab


Pull out

Find out the hang point

Attach hock to hang point

Pick up tool and object

Release object

Clipper open

Positioning

Release force to clip

Apply force to release object

Pick up tool and object

Adjust to loss

NO

NO

54

Appendix C2

I) Picking Object (hook)

Find the hang point on the

object

Reach tool near to

the object

Attach hook to the

hang point

Pick up the object

upwards

Locating the object

to desired place

Release object from the hook

Object

Hand force

Situation Object location

Hand force

Holding force

Hanging location

Sound

Not good

Good

Pull force

Force

Object , Hand

55

Appendix C3

II) Clipping Object

Larger force

Force

Object

Stop motion

Clip object

Move to clip object

Guide to clipping

object

Convert to larger force

Apply hand

force

Reach

clipper near to the object

Hand force

Situation

Low clip ability

Clipper near to object

Hand

Kinetic energy Force High force

Motion

Release motion

Release Force

Perfect clipped object

Kinetic energy in object, sound

56

Appendix C4

III) Gripping Object

Object & hand

Force

Release tool

Object opened

Stop motion

Force

Apply larger force to rotate

Sound


Adjust the mechanism to

fix

Fix or loss

Holding force Hand force

Situation

Apply force to attach the head

to object

Hand & Object

Force

Release motion

Force

Large force

57

Appendix C5

IV) Opening Water Tap

Holding force Hand force

Situation

Press and fit

Object & hand

Apply force to rotate Water tap shape

Sound, Large Force

Convert to large force

Force

Guide to rotate

Large force

Anticlockwise motion

Low

High

Stop motion

After used

Apply opposite rotating force

Water flow condition

Convert to large force

Large force

Guide to rotate Stop motion Water stop

Move and attach to water tap

Force Release Kinetic force

Hand

58

Appendix D1


(1) (2) (3) (4) (5)

1.1 Grip tool

Dent/Groove

Round Cylinder

Curved

Dent/Groove

Dent / Groove


Rough & Grain

Surface

Rubber Layer

Surface

Smooth &

Shiny Surface

Rubber Layer

Surface

Rubber Layer

Surface


Fixed

Extend & Retract

Extend & Retract

Extend & Retract

Flipped


Clamping Style

Clamping Style

Double Fork

Style

Pliers Style

Double Fork

Style


Push button

Push button

Slide button

Slide button

Push button


Hexagon Head

Round Head

Round Head

Round Head

Round Head


Fixed

XY & XZ plane

180° Adjustable

XY & XZ plane

180° Adjustable

Fixed



Rough Teeth

Full & Rough

Full & Flat

Rough Teeth

Full & Flat


Automatic

Automatic

Automatic

Hand

Automatic


Push Button

Push Button

Slide Button

Slide Button

Push Button


Sharp Head Hock

Flat Head Hock Flat Head Hock

Round Head Hock

Round Head Hock

59

Appendix D2


(6) (7) (8) (9) (10)

1.1 Grip tool

Flat

Rectangular

Centre Hollow

Dent/Groove

Round Cylinder

Curved


Rubber Layer

Surface

Smooth &

Shiny Surface

Smooth &

Shiny Surface

Rough & Grain

Surface

Rubber Layer

Surface


Flipped

Extend & Retract

Extend & Retract

Flipped

Fixed


Pliers Style

Double Fork

Style

Pliers Style

Double Fork

Style

Pliers Style


Slide button

Push button

Slide button

Slide button

Push button


Square Head

Round Head

Pentagon Head

Square Head

Square Head




XY & XZ plane

180° Adjustable

Fixed

Fixed


Rough Teeth

Full & Flat

Flat Teeth

Full & Flat

Full & Rough


Hand

Automatic

Hand

Automatic

Hand


Slide Button

Push Button

Slide Button

Slide Button

Push Button


Flat Head Hock

Round Head Hock

Flat Head Hock

Sharp Head Hock

Sharp Head Hock

60

Appendix D3


(11) (12) (13) (14) (15)

1.1 Grip tool Flat

Rectangular

Centre Hollow

Round Cylinder

Curved

Flat

Rectangular


Rough & Grain

Surface

Rubber Layer

Surface

Smooth &

Shiny Surface

Rough & Grain

Surface

Smooth &

Shiny Surface


Fixed

Flipped

Fixed

Flipped

Extend & Retract


Double Fork

Style

Clamping Style

Pliers Style

Clamping Style

Clamping Style


Push button

Slide button

Push button

Slide button

Slide button


Pentagon Head

Round Head

Pentagon Head

Pentagon Head

Hexagon Head



Fixed



XY & XZ plane

180° Adjustable


Full & Flat

Full & Flat

Flat Teeth

Rough Teeth

Full & Rough


Automatic

Automatic

Hand

Automatic

Automatic


Push Button

Push Button

Slide Button

Push Button

Push Button


Round Head Hock

Round Head Hock

Flat Head Hock

Flat Head Hock

Sharp Head Hock

61

Appendix E1

II) Concept (5)



performing.


hold and use.

c) The gripper and clipper can be adjust for

desired size and high accuracy to lock it

properly with helps of slide button.

d) Very flexible to flip or move for

comfortable used by customer to perform

certain task.

e) Less power to gripping and turning since

it helps with automatic system.


cost and design.

b) Will lower the durability and life cycles

of product due to adding more function.

c) High tendency especially the part that

can be rotate or flip to fracture.

d) Increase the weight of the product

since additional power source such as

Battery cell is added.

62

Appendix E2

III) Concept (6)



performing.

b) Certain part in the product such as gripper

or holder and fitting shape is easy to

make.

c) The gripper and clipper can be adjusted

for desired size.

d) Very flexible to flip or move comfortably

to perform certain task.


cost and design such as we have to

remove the sharp edges.

b) Not very ergonomic especially at the

tool holder since it is flat and the fitting

shape is not very convenience to fit

other shapes.

c) Will lower the durability and life

cycles of product due to adding more

function.

d) High tendency to fracture

especially the part that can be rotate or

flip.

63

Appendix E3

IV) Concept (8)



performing.

b) Very ergonomic such as

comfortable to hold and use.


for desired size.

d) Reduce type material of material since the

overall part not using rubber material.

e) Special features such as the clipper can in

and out from the holder.


cost and design such as we have to

remove the sharp edges.

b) It may be slippery to hold since no

rubber layer, not suitable to used when

the hand is wet.

c) Will lower the durability and life cycles

of product due to adding more function.

d) High tendency to fracture especially the

part that can be rotate or flip.

64

Appendix E4

V) Concept (12)



performing.

b) Comfortable to hold and use.


for desired size.

d) Unique and comfortable holder



a) Increase the manufacturing process, cost

and design.

b) Will lower the durability and life cycles of

product due to adding more function.

c) Do not have high degree of freedom to

move the head part due to fixed.

d) More different material has to use and

must follow standard quality for medical

product.

e) Increase the weight of the product since

additional power source such as Battery

cell is added.

65

Appendix E5

V) Concept (14)



performing.


hold and use.

c) The grip, grasp and clipping object can be

adjusted for desired size.

d) Unique and very comfortable holder

where the rough and grain surface reduce

the slippery.



a) Increase the manufacturing process, cost

and design.

b) Will lower the durability and life cycles of

product due to adding more function.

c) Increase the weight of the product since

additional power source such as Battery

cell is added

d) The overall shape do not convenience and

not portable.

66

Appendix F1

I) Functional Structure of product

Press to fit

Adjust to fix with object

Reach to the object

Lock to the location

Hold the body tightly

Rotate Reverse

rotation

Reverse mechanism

Hock

Lift

Release object

Pull out clipper from body Release to clamp Un-clamp

Retract

Pull out directly

Pull out directly

Hand

Force

Situations

Reach to the object

Apply force to open clipper

After used

Sound, energy

Object

Sound, energy

67

Appendix F2

II) Cluster the Elements into Module Chunks

Press to fit

Adjust to fix with object

Reach to the object

Lock to the location

Hold the body tightly

Rotate Reverse

rotation

Reverse mechanism

Hock

Lift

Release object

Pull out clipper from body Release to clamp Un-clamp

Retract

Pull out directly

Pull out directly

Hand

Force

Cross head

Adjustable head

Handle

Hook

Sound, energy

Object

Sound energy Reach to the

object

Apply force to open clipper

Gripper

Situations

68

Appendix F3

III) Rough Geometric Layout

(1) Components hierarchy

Arthritis tool

Handle

Adjustable head

Cross head

Clipper Hook

Upper

Lower Gripping tooth

Belt

Rubber

Rubber

Button

Rubber

Upper h lf

Lower

Button

Pin

Spring

Interaction between chunks

Interaction within chunks

69

Appendix F3

(2) Geometric Layout

Handle

Cross head

Rubber

Adjustable head ButtonsClipper

Front view

Front view

Side view

Gripping tooth

70

Appendix F4

IV) Incidental Interactions

Environment

Handle

Clipper

Hook Cross head

Adjustable head

Bending, Environment

Vibration

Environment

Stress concentration

Unbalance force

71

Appendix G1

Part function

Mode of failure

Cause of failure

Effects of failure

(S)

(O)

(D)

Risk of Priority (RPN)

Detection method

Correction action

New (S)

New (O)

New (D)

New (RPN)

Picking object

-Hook does not attach to object and not fitted. -The hook is slagging. -Unable to hang object.

-Improper thickness at the tip of hook. -Heavy load. -Length of curve at hook is short.

-Unable to picking object. -Fracture or failure of hook. -The object easy to slip.

6

4

5

5

4

4

7

6

9

210

96

180

-Difficulty in attach object to the hook. -The shape of hook slightly deformed. -Inspection at the hook

-Use better material that not effected by large force apply. -Use high robust material. -Improve the design

3

2

4

4

2

3

7

6

9

84

24

108

Clipping object

-The end of clipper unable to open and close. -The clipper stuck. - Hard to clip the object.

-Malfunction Of spring at the clipper. - Failure of push button mechanism. - Worn out of clipper teeth and alignment.

-Unable to clip the object. -The clipper unable in and out. -Improper to clipping object.

5

6

3

3

8

2

7

6

5

105

288

30

-Inspection and remove the clipper from gripper. -The clipper does not function. -Difficulty to clipping.

-Replace with standard new clipper. -Find the source of failure and try to adjust if possible. -Replace with new clipper.

4

5

3

2

5

1

7

6

5

56

150

15

72

Appendix G2

Part function

Mode of failure

Cause of failure

Effects of failure

(S)

(O)

(D)

Risk of Priority (RPN)

Detection method

Correction action

New (S)

New (O)

New (D)

New (RPN)

Gripping Object

-Gripper does not attach smoothly. -Unable to retract and expand. -Unable grip for object that slippery and tight.

- Teeth broken or worn out. - Failure of push button and the mechanism. -Unsuitable force and torque applied

-Object does not grip safely. -Unable to adjust with different size. -Fracture or broken and damage the object

6

6

7

5 7 6

6 4 8

180

168

336

-Inspection to the gripper. -No changes When press. -Difficulty to rotate and pull.

-Replace the renewable teeth. -Use better material for the mechanism. -Apply the sufficient and try to minimize force and torque initially.

5 5

5

5

6

4

6

4

8

150

120

160

Opening Water

Tab

-Unable to open the water tab that too tight -Unable to attach or fitted object smoothly

-Unsuitable force and torque applied. -Unsuitable press applied.

-Fracture or broken. - Object does not open safely.

5

6

6 4

8 5

240

120

-The opening water tab hard to adjust and control. - Inspection to the attached part

- Avoid using at tight water tab and more suitable use for plastic material water tab. -Apply sufficient amount of force when press to fit the head and tab.

4 5

5

2

8

5

160

50

73

Appendix F1

74

Appendix F2

75

Appendix F3

76

Appendix F4

77

Appendix F5

78

Appendix H

79

Appendix I

Polyamides (Nylons, PA)

i. Composition (NH(CH2)5C0)n

ii. Caption Polyamides are tough, and easily colored.

iii. General properties Density 1120 - 1140 kg/m^3 Price 13.8 - 15.18 MYR/kg

iv. Mechanical properties Young's Modulus 2.62 - 3.2 GPa Shear Modulus * 0.9704 - 1.185 GPa Bulk modulus 3.7 - 3.9 GPa Poisson's Ratio 0.34 - 0.36 Hardness - Vickers 25.8 - 28.4 HV Elastic Limit 50 - 94.8 MPa Tensile Strength 90 - 165 MPa Compressive Strength 55 - 104.3 MPa Elongation 30 - 100 % Endurance Limit * 36 - 66 MPa Fracture Toughness * 2.218 - 5.617 MPa.m^1/2 Loss Coefficient * 0.0125 - 0.01527

v. Thermal properties Thermal conductor or insulator? Good insulator Thermal Conductivity 0.233 - 0.253 W/m.K Thermal Expansion 144 - 149.4 £gstrain/¢XC Specific Heat * 1601 - 1665 J/kg.K Melting Point 209.9 - 219.9 °C Glass Temperature 43.85 - 55.85 °C Maximum Service Temperature 72.85 - 86.85 °C Minimum Service Temperature * -123.2 - -73.15 °C

vi. Impact on the environment

Nylons have no known toxic effects, although they are not entirely inert biologically.

Nylons are oil-derivatives, but this will not disadvantage them in the near future. With

refinements in polyolefin catalysis, nylons face stiff competition from less expensive

polymers.

80

vii. Processability (Scale 1 = impractical to 5 = excellent)

Castability 1-2

Mouldability 4-5

Machinability 3-4

Weldability 5

viii. Durability

Flammability Average

Fresh Water Very Good

Sea Water Very Good

Weak Acid Good

Strong Acid Poor

Weak Alkalis Very Good

Strong Alkalis Good

Organic Solvents Average

UV Average

Oxidation at 500C Very Poor

ix. Supporting information

Design guidelines

Nylons are tough, strong and have a low coefficient of friction, with useful properties

over a wide range of temperature (-80 to +120 C). They are easy to injection mould,

machine and finish, can be thermally or ultrasonically bonded, or joined with epoxy,

phenol-formaldehyde or polyester adhesives. Certain grades of nylon can be electroplated

allowing metallisation, and most accept print well. A blend of PPO/Nylon is used in

fenders, exterior body parts. Nylon fibers are strong, tough, elastic and glossy, easily

spun into yarns or blended with other materials. Nylons absorb up to 4% water; to

prevent dimensional changes, they must be conditioned before molding, allowing them to

establishing equilibrium with normal atmospheric humidity. Nylons have poor resistance

to strong acids, oxidizing agents and solvents, particularly in transparent grades.

Documents

Product Design Team6