TrekPro™ 350SDesign & Manufacture 3N Project 2013

By: Uvarajan M Velayutham; Tong Jing Kai; Benjamin Quek; Shaiful

Contents of Presentation

▪ Introduction

▪ Design Process

▪ Consumer Needs

▪ QFD

▪ Final Specifications

▪ Concepts Generations & Selection

▪ Concept Exploration

▪ Human Factors

▪ Psychology

▪ Physiology

▪ Product Differentiation

▪ Product Architecture

▪ Functional Charts & FTA

▪ Product Marketing Potential

▪ Product Material Selection

▪ Design for Environment

▪ CAD Model

▪ CAD analysis

▪ Conclusion

Introduction

▪ Sport Engineering

▪ Trekking

Generic Design Process

• Manufacturing product

Production ramp-up

• CAD Analysis

• Design for Environment

• Product testing

Testing and Refinement

• Design for manufacture

• Materials selection

• CAD Modelling

Detail Design

• Concept exploration

• Human factors

• Physiology

• Psychology

• Product architecture

• Concept testing

System level design

• Rapid concepts generation

• TRIZ Principles

• Concept screening and scoring

• Concept evaluation

Concept Development

• Market research

• Consumer needs

• QFD

• Final Specifications

Planning

Trekking▪ Trek Bag

▪ Items you carry for trekking trip includes:

▪ Clothing

▪ Sleeping Bag

▪ Medical Kit with ointments

▪ Water container

▪ Field chair

▪ Trekking pole

▪ Nesting equips

▪ Survival kits

Different item has a different function. If we can cut down items, we can make a more productive bag.

Realised Trekkers require multifunction bag.

Mission Statement

Mission Statement: Trekking Survival Bag

Product Description Storage bag for trekking equipment and trip survival necessities

Benefit Proposition Multiple functions in one bag

Bag allows trekkers to trek independently without much aid

Primary Market Mountain trekkers

Military rangers

Adventurous people venturing into inaccessible areas

Secondary Market Casual users

Assumption and

Constraints

Able to provide medical needs

Aids during emergencies and evacuation

Able to provide optimum performance in all weather

Stakeholders User

Retailer

Production team

Consumer needs

Question/Prompt Customer Statement Interpreted Need

Typical uses I need to store my personal equipment easily into the bag. The bag can store equipment easily.

I store medical equipment needed for the trip. The bag can store medical equipment.

Bag has to be comfortable and safe to use. The bag is comfortable and safe to use.

I use the same bag for trips in dangerous trails other than in

mountains.

The bag can be used in all terrains.

Likes – Existing Bag The usage of the bag is simple. The bag is easy to use.

The bag is large enough to place most of my necessities. The bag has a lot of storage space.

The bag is light and easy to carry. The bag is lightweight.

The bag has cool design. The bag has an attractive design.

Dislikes – Existing Bag Other equipment like tents are carried by porters has no space in

the bag.

The bag can be used to carry larger items.

Not comfortable when resting with bag on. The bag can be used to rest comfortably.

It has little splashproof properties. The bag is splashproof.

The bag buckles when dropped on the ground. The bag is rigid enough to hold its shape.

Internal material if the bag tends to peel off. The bag has internal material with good properties.

The zip of the bag will open itself when overloading the storage. The bag allows storage overload.

Suggested Improvements It would be good to have heating on bag. The bag can warm the user.

Incase fall into running water, good to have a lifebuoy on bag. The bag allows the user to be buoyant in water.

No easy way to signal for help, in an emergency. The bag can signal for help in an emergency.

It is good to have water filtration in bag. The bag can filter water.

Instructions on bag for beginner trekkers will be useful. The bag will have markers on it to aid user.

The shoulder straps can have more cushions. The bag will have cushions on the shoulder straps.

The price of the bag must be cheap.The bag is cheap.

The bag is easy to manufacture.

Consumer needs No. Primary Need Secondary Need

1 The bag is easy to use

The bag can store equipment easily.

The bag will have markers on it to aid user.

The bag is easy to use.

2 The bag has a lot of storage space

The bag has a lot of storage space.

The bag can be used to carry larger items.

The bag can store medical equipment.

3 The bag is comfortable to use

The bag is comfortable and safe to use.

The bag is lightweight.

The bag can be used to rest comfortably.

The bag will have cushions on the shoulder straps.

4 The bag is easy to maintain The bag is splashproof.

5 The bag is durable

The bag is rigid enough to hold its shape.

The bag has internal material with good properties.

The bag allows storage overload.

The bag can be used in all terrains.

6 The bag is lightweight The bag is lightweight.

7 The bag is multifunctional

The bag can warm the user.

The bag allows the user to be buoyant in water.

The bag can signal for help in an emergency.

The bag can filter water.

8 The bag is easy to manufacture The bag is easy to manufacture.

9 The bag is cheap The bag is cheap.

10 The bag has an attractive design The bag has an attractive design.

Hierarchy listing of Primary needs from Secondary needs

QFD –TrekPro™ 350S

Competitor Products

North Face –Patrol 24

Berghaus –Jalan II

Black Diamond –Mercury 75

Deuter –Quantum 55

Boblbee -Megalopolis

Final Specifications

Metric No. Metric Units Value

1 Time to store all equipment into bag min < 1.5

2 No. of equipment that could fit in bag No. > 15

3 Fluid volume of storage in bag L > 35

4 No. of compartments in bag No. > 2

5 Thickness of padded cushions in bag mm > 10

6 Thermal conductivity of material Wm-1K-1 < 0.33

7 Elastic modulus GPa > 100

8 Mass of bag kg < 3.0

9 Material strength MPa > 30

10 No. of functions in bag No. > 2

11 Buoyancy of bag (Weight of displaced fluid L < 3

12 Cost of manufacture S$ < 100

13 No. of colour schemes available No. > 2

Rapid Concept Generation

Rapid Concept Generation

Concept ScreeningConcept

Selection Criteria

A

Buoyant Filter

Bag

B

Air-Bag

C

Trekking Duffel Bag

D

Stretcher Bag

E

Sleeping Trek Bag

F

Boblbee Megalopolis

Bag

(REF)

Ease of Use 0 0 - - 0 0

Storage 0 - + + 0 0

Comfort + 0 0 0 + 0

Maintenance - - + - 0 0

Durability + - + + 0 0

Portability 0 - + - 0 0

Functions + + - + 0 0

Ease of manufacture 0 - + - + 0

Cost - - + - 0 0

Design + - - - 0 0

Sum +’s 4 1 6 3 2 0

Sum 0’s 4 2 1 1 8 10

Sum –‘s 2 7 3 6 0 0

Net Score 2 -6 3 -3 2 0

Rank 2 5 1 4 2 3

Continue? Combine No Combine Revise No No

TRIZ Principles

Principle 6 – UniversalityCombining a Buoyancy tube, field chair, water filter and storage functions into 1 product

Principle 11 – Beforehand CushioningBy having a buoyancy tube to aid trekker incase of water emergency situations

Principle 30 – Flexible shells and thin filmsSolid internal structure will become hollow to reduce weight

Principle 5 – Merging/ ConsolidationCombining a wardrobe door concept onto bag design

Concept ScoringConcept

C

Trekking Duffel Bag

(REF)

AC

TrekPro

D+

Fold-a-Trek

Selection Criteria

Weight (%) Rating

Weighted

Score Rating

Weighted

Score Rating

Weighted

Score

Ease of Use 14.7 2 0.294 3 0.441 3 0.441

Storage 8.8 3 0.264 3 0.264 4 0.352

Comfort 14.7 3 0.441 4 0.588 2 0.294

Maintenance 5.9 3 0.177 2 0.118 3 0.177

Durability 11.8 3 0.354 5 0.590 4 0.472

Portability 11.8 3 0.354 4 0.472 2 0.236

Functions 11.8 2 0.236 5 0.590 3 0.354

Ease of manufacture 2.9 3 0.087 2 0.058 4 0.118

Cost 8.8 3 0.264 2 0.176 4 0.352

Design 8.8 3 0.264 5 0.440 2 0.176

Total Score 2.735 3.737 2.972

Rank 3 1 2

Continue? No Develop No

Final Concept Evaluation

Mechanisms within concepts requires further exploration

Exploration will be helpful for detail designing later part of the process

Combination of Scuba Buoyancy Compensator, Field Chair, Water filter and a Backpack

Concept Exploration

Human Factors

▪ Ergonomic design considerations taken into account

▪ To make design simple so that users can use the product safely without any guidance

Anthropometrics

Male Female

Measurement

Type

(inch) 5 Percentile 50 Percentile 95 Percentile 5 Percentile 50 Percentile 95 Percentile

Measurement

Used

Mid Shoulder

Height 23.9 25.7 27.5 20.4 22.1 23.8 23.9

Hip Breadth 13.6 15.1 16.6 12.0 13.3 14.6 14.2

Shoulder 17.6 19.3 20.9 14.0 15.3 16.6 17.3

Popliteal

Height 16.0 17.5 19.0 13.6 15.1 16.5 19.0

Thigh

Clearance 5.7 6.6 7.5 4.4 5.1 5.7 5.8

5.8”

17.3” 23.9”

14.2”

Utility The human interfaces such as zipping the backpack, pumping water

to the storage tank of the backpack, folding and unfolding the chair

is easy to use and intuitive. Also these interfaces are relatively safe to

use.

Appearance The TrekPro 350S has good form, line and proportion.

Orange: it’s the color tied to fun times, happy and energetic day’s

warmth and organic product. It is also associated with ambition and a

new dawn with attitude

Green: it’s the color of balance and growth. It is also very calming and

soothes the viewers

Ease of

maintenance

Hand pump can be easily maintain as the pump assembly is snap fit

The whole backpack can be wash with water and quickly dry as the

material selected is water resistance.

Low costs As the backpack outer body shell is made from Ripstop Polyamide,

the material can be easily cut and form into the shape of the frame.

The cost of sewing into the material on the frame is relatively cheap.

Psychological

Communication The color of orange sends strong image of ambition for the trekkers.

The whole design of the backpack communicate a sense of adventure

for the user. From the shape and the contour of the backpack the

design sends a strong message of ruggedness and durability

Water Ability for backpack to pump and filter clean water

Fatigue Excellent weight distribution ensuring that the user of the TrekPro

350s will not easily suffer from fatigue and exhaustion.

Heat Air filled cushion ensure that the user will get maximum air circulation

on his back.

Physiological

Product DifferentiationLight weight With a weight of 2.5 kg it’s among the lightest trekking backpack on the market

Performance features The TrekPro 350S features an integrated filter and water pump. A foldable chair for

the user to sit on

Superior ergonomics The design allows the user to carry the backpack with maximum comfort and guaranteeing no back injury will occur. The design allows the user easy access to the items inside the bag.

Durability The TrekPro 350S was design to meet rigorous specification. It is design to be used on all-weather outdoor condition. The TrekPro 350S can also withstand temperatures extreme and humidity.

Materials The TrekPro 350S utilized several advanced materials to enhance both performance and appearance. These include CFRP frame and neoprene for maximum comfort on the shoulders.

Appearance The sleek design gave the TrekPro 350S a futuristic look associated with innovation. Because of its aesthetic appeal and highly recognizable appearance, the TrekPro 350S is expected to be a status symbol for early adopters and creates a strong feelings of pride among adopters.

Product Architecture

1. The functional elements of a product are the individual operations and transformations that contribute to the overall performance of the product

2. The physical elements of a product are the parts, components and subassemblies that ultimately implement the products functions. The physical element becomes more defined as development progresses.

3. Perhaps the most important characteristic of products architecture is its modularity.

Modularity of TrekPro 350S

In a sectional modular architecture, all interfaces are of the same type, but there is no single element to which all the other chunks attach. The assembly is built up by connecting the chunks to each other via identical interfaces

In slot modular architecture each interfaces between chunks in a slot modular architecture is of a different type from the others.

Product Architecture

Physical ElementFunctional

Element

Storage of items

Pumping of

clean filtered

water

Chair for user to

sit on

Foldable Chair

compartment

Water pump

Sternum Strap

Zippers

Bag Cushion

Area

Buoyant

Tube

Buoyancy force

Functional Flow Chart - Water PumpPlaced filter onto

water source

Used hand to

generate pressure

on Squeezer

Water will flow

through hose by

the pressure loss

generated by the

squeezer

Water will flow

into the hydration

pack

Turn knob

clockwise

Used hand to

generate pressure

on Squeezer

Dirt will flow out

through release

valve

Filter

Squeezer

Water flow to storage

Release valve

Knob

Dirt Cleaning

Functional Flow Chart - Foldable Chair

Foldable Chair in closed position Foldable Chair in open position

Placed backpack

firmly on flat

ground

Used hand to

open chair

Secure foldable

chair at 90

degree position

Function-Storage

Primary Storage

compartment,

opened and closed

by Zipper

23L

Secondary Storage

compartment,

opened and closed

by Zipper

5L Side storage

compartment,

opened and closed

by Heavy Duty

Velcro

1.5L x 2

Top storage

compartment, Quick

Access opened and closed

by Heavy Duty Velcro

5L

Bottom Storage

compartment, opened

and closed by Heavy

Duty Velcro

4L

Function-Buoyant Tube

Bouyant Tube

Implications of design on architecture

Product change Since the outer body of the bag is made of fabric, the styling of the backpack can

be easily modified for different target market segments

Product variety Different variety can be manufactured without increasing the cost of production

as the outer body shell is made soft fabric.

Component standardization Zipper, sternum straps, heavy duty velcro

Product performance -ability to hold 40kg of load

-ability to pump and store clean filtered water

-integrated foldable chair for the user to sit on

Manufacturability -internal frame of the bag made from CFRP can be easily manufactured

- the body of the bag made from RipStop Polyamide can be easily shaped and

sewed to the bag

Platform Planning (Differentiation plan)

Differentiating

Attributes

Trek Pro Trek Pro

Lite

Trek Pro

Student

Chair

Water Pump

- -

-

Fault Tree Analysis (FTA)

Material Specifications and Selection

Promotional poster of Product

TrekPro™ 350S Layout

•Fabric Covering

•Buoyant Tube

•Bag Strap

•Air Cushion

•Seat

•Internal Frames

Selected materials for TrekPro™ 350S

Fabric Covering

▪ Ripstop Polyamide 210DHD

(Outer and inner Material Fabric)

Bag Strap

▪ Ripstop Polyamide 210DHD With Neoprene

Buoyant tube

▪ Air Inflated

▪ (Outer Layer 1680 Denier Ballistic Nylon) Fused with (Inner Layer 420 Denier Nylon)

Selected materials for TrekPro™ 350S

Convertible Seat

▪ Polybutylene Terephtalate infused with 30% Carbon Fibre (PBT 30% Carbon Fibre)

Internal Structural Frames

▪ Carbon Fibre Reinforced Plastic CFRP

Lumber Pad Cushion

▪ (Outer Layer 1680 Denier Ballistic Nylon) Fused with (Inner Layer 420 Denier Nylon)

▪ Neoprene

Material Selection for Frame

CFRP vs. Aluminum Silicon Carbide

Properties to be weighted between CFRP and Aluminum Silicon Carbide:•Weight •Fracture toughness •Cost•Tensile strength •Machinability

CFRP vs. Aluminum Silicon Carbide

•Table shows that CFRP is better than Aluminum Silicon Carbide •Hence CFRP was chosen

Material Properties

CFRP (FRAME)

▪ Extremely strong and lightweight

▪ High strength and rigidity

▪ Corrosion resistance

▪ Eco friendly

▪ High damage tolerance

Material Properties

Polybutylene Terephtalate, PBT (30% carbon Fibre) (SEAT)

▪ Widely available

▪ High strength and stiffness

▪ Good creep durability under thermal stress

▪ Corrosion resistance

▪ High heat deflection temperature

▪ Eco friendly

Material Properties

Ripstop Polyamide 210DHD

▪ Recycled waste material (Eco friendly)

▪ Extremely lightweight

▪ UV radiation resistance and water resistance

▪ High resistance to ware and tear

▪ Cheap

▪ Readily available in the market

Material Properties

Sternum Strap

▪ Fast release

▪ Cheap

▪ Lightweight

▪ Readily available in the market

Material Properties

Neoprene

▪ Lightweight

▪ Excellent good impact absorber

▪ Weather and Water resistance

▪ Low friction

▪ Elastic and form-fitting

Material Properties

Brass

▪ Used for zippers

▪ Corrosion resistance

▪ Appealing

▪ High strength

Material Properties

1680 Denier Ballistic Nylon and 420 Denier Nylon

▪ Abrasion and corrosion resistance

▪ Bullet proof (Being extremely high strength)

▪ Water resistance

▪ Able to stretch

▪ Durable

▪ Eco friendly

Material Properties

Heavy Duty Velcro Tape

▪ High adhesive strength

▪ High adhesion

▪ High tensile strength

▪ Weather and temperature resistance

▪ Cheap

▪ Eco friendly

TrekPro™ 350S Layout with material

Front View

TrekPro™ 350S Layout with material

Back View

Material Pricing

Material Cost Volume Total Unit Cost

CFRP

SGD 6 – 80 / piece

Min 300 Pieces

250

500

1000

$50

$20

$12

PBT (30% Carbon Fibre)

SGD 2.30 - 4 / Kg

Min 1000Kg

250

500

1000

$4

$3

$2.50

Ripstop Polyamide 210DHD

SGD 1 – 2 / Meters

Minimum 500 Meters

250

500

1000

$2

$1.50

$1

Sternum Straps

SGD 1 – 6 / Piece

Minimum 500 pieces

250

500

1000

$8

$6

$1.50

Neoprene

SGD 6.62 – 7.28 / Kg

Minimum 250Kg

250

500

1000

$9

$7.50

$6

Material Pricing

Brass Zippers

SGD 0.01 – 1 / Piece

Minimum 100 Pieces

250

500

1000

$0.50

$0.25

$0.10

Ballistic Nylon

SGD 1.2 – 4 / Meters

Minimum 500 Meters

250

500

1000

$6

$4

$2

Denier Nylon

SGD 1 – 3 / Meters

Minimum 500 Meters

250

500

1000

$4

$3

$1.50

Self Adhesive Velcro Tape

SGD 0.01 – 1 / Meters

Min 3000 Meters

250

500

1000

$0.80

$0.50

$0.30

Brief summary of financial analysis

•Total cost of materials: $22875•Total operating expenses: $9900•Total manufacturing cost (500 units): $32775

•Cost per unit: $65.55•Expected profit margin estimated to be 200%•Expected cost per unit: SGD$199.90

Drafting for TrekPro™ 350S

Frame Draft SolidWorks Surface Modelling CATIA

CAD Drafting Frame (Close)

CAD Drafting Frame (Open)

CAD Drafting Surface

Assess energy/CO2 Over

lifespan of

Material

• Minimize raw material usage.

• Raise material recycle awareness

Manufacture

Minimize• Process energy

by selecting the correct manufacturing process for the material.

• Energy/CO2

Usage

• Material Wastage

Transport

Minimize• Distance travel

• Transportation method

Disposal

Select• Non-Toxic

materials.

• Recycle material.

Manufacture Energy Eco-Audit for Material

Component Material Process Amount processed Energy (MJ) %

Seat PBT (30% carbon fiber) Polymer molding 2.8 kg 54 48.9

SeatABS (20% carbon fiber, EMI

shielding, conductive)Polymer molding 2.8 kg 56 51.1

Total 1.1e+02 100

Component Material Process Amount processed Energy (MJ) %

FrameCFRP, epoxy matrix

(isotropic)Resin spray-up 1.8 kg 27 59.2

Frame Aluminum/Silicon carbide

compositeCasting 1.8 kg 18 40.8

Total 45 100

CO2 Eco-Audit for Material

Component Material Process Amount processedCO2

footprint (kg)

%

Seat PBT (30% carbon fiber) Polymer molding 2.8 kg 4 48.9

SeatABS (20% carbon fiber, EMI shielding,

conductive)Polymer molding 2.8 kg 4.2 51.1

Total 8.3 100

Component Material Process Amount processed Energy (MJ) %

FrameCFRP, epoxy matrix

(isotropic)Resin spray-up 1.8kg 27 59.2

Frame Aluminum/Silicon carbide composite

Casting 1.8kg 18 40.8

Total 45 100

Why TrekPro™ 350S is a Eco Design?

Drop Test Analysis (Stress)

Drop Test Analysis (Displacement)

Drop Test Analysis (Strain)

Sitting Analysis@1000N (Stress)

Video of the Sitting Analysis@1000N (Stress)

Sitting Analysis@1000N (Displacement)

Sitting Analysis@1000N (Strain)

Original LifeStraw®

Modification on LifeStraw®.

1

2

3

45

Air Traps

Volumetric Shrinkage

Weld lines

Sink Marks Shaded

Deflection, All Effect

How good is TrekPro™ 350S?

Metric No. Metric Units Target Value Actual Value Fulfilled?

1 Time to store all equipment into bag min < 1.5 Nil

2 No. of equipment that could fit in bag No. > 15 Nil

3 Fluid volume of storage in bag L > 35 40

4 No. of compartments in bag No. > 2 6

5 Thickness of padded cushions in bag mm > 10 15

6 Thermal conductivity of material Wm-1K-1 < 0.33 0.24

7 Elastic modulus GPa > 100 150

8 Mass of bag kg < 3.0 2.5

9 Material strength MPa > 30 35

10 No. of functions in bag No. > 2 4

11 Buoyancy of bag (Weight of displaced fluid) L < 3 Nil

12 Cost of manufacture S$ < 100 65.55

13 No. of colour schemes available No. > 2 5

TrekPro™ 350S has met 77% of the targeted final specifications set for it