DES 3063 : PRODUCT DESIGN FUNDAMENTALS
FINAL PRESENTATION
LECTURER : MR ROBERT LEE
PRODUCT : BICYCLE VEHICLE ROOF RACK
CHAPTER 1: DESIGN PROBLEM & DESIGN
TEAM
1.1: PROBLEMS DEFINITION & MISSION
STATEMENT
PRESENTER :- MOHD FAISOUL B. HASHIM
FPDM 4
Mission Statement : Bicycle Vehicle Roof Rack Product Description – put bicycle on vehicle roof
Key Business : 6 months development of beta prototype
Humanitarian Goals : 30% profit margin : initial 5 % market share : supplement to car accessories business
Primary Market : Passenger vehicle users, focusing on bicycle users
Secondary Market : bicycle user who like to travel Assumptions : durable, not too heavy, ecstatic Stakeholders : FPDM UniKL Avenues For Creative Design : Ergonomic shape, store capacity,
strength , user friendly Scope Limitations : Materials, size , weight
1.2: DESIGN TEAM MEMBERS
FPDM 6
GROUP P-TECH
Group Members :-
Mohd Azizul B. Mansur ( Group Leader )
Mohd Hafiz B. Zulkapli
Mohd Faisoul B. Hashim
Mohd Asri B. Mahmood
1.3: OVERALL OBJECTIVE FOR THE DESIGN
PROJECT
FPDM 8
To understand more about the design process
To fulfill customer requirements
To improve the design
To implement the design process
CHAPTER 2: UNDERSTANDING CUSTOMER
NEEDS
2.1: CUSTOMER REQUIREMENT
STATEMENT
PRESENTER :- MOHD AZIZUL B. MANSUR
FPDM 11
QUESTIONAIRE
1. How would you best describe your familiarity with a product like that described above? I was not aware of such a product Have investigated or researched such products Have purchased or regularly use a product like this
2. How often do you primarily use your bicycle vehicle roof rack? Always Seldom Rarely
3. Who are basically relying on this kind of product? Cyclist Teenagers Old person
FPDM 12
4. Is the appearance of the product is an important subject to you? Yes, definitely Somewhat important Not very important
5. What color do you think is/are suitable for the roof rack? Striking color (Yellow, Pink, Orange and etc) Basic color (Yellow, Red, Blue, Black) Dual color (E.g.. Black and White, Red and White, Black and Grey and etc)
6. What type of material should be the product made of? Steel Alloy Composites
7. The product should be …………… Bulky but light Light and compact Compact but heavy
FPDM 13
8. About what would you expect to pay for a new product like the one described? Less than RM 250.00 RM 251.00 – RM 350.00 RM 351.00 – RM 450.00
9. What are the safety features that should be included (Answers should be based on priorities: 1 – Weak, 3 – Medium, 9 - Strong) 9 3 1
1. lock bike with support arm clamp [ ] [ ] [ ]
2. secure bike with steel trap [ ] [ ] [ ]
10. What are the other features that should be included in the product? (Answers should be based on priorities: 1 – Weak, 3 – Medium, 9 - Strong) 1 3 9 1. Locking system [ ] [ ] [ ] 2. Easy bike loading 3. Fits all bike frame 4. Reachable height 5. Transport stability
FPDM 14
11. Special strength and resistance that you think are applicable to this product?(Answers should be based on priorities: 1 – Weak, 3 – Medium, 9 - Strong)
1 9 3
Resist bending [ ] 70 30 0 Resist tension [ ] 55 40 5 Resist corrosion [ ] 45 45 10 Resist fatigue [ ] 55 40 5 Resist impact [ ] 30 65 5
2.2: HOUSE OF QUALITY
FPDM 16
CUSTOMER REQUIREMENTS
NO. Customer Req 1/2 1/3 1/4 1/5 1/6 1/7 2/3 2/4 2/5 2/6 2/7 3/4 3/5 3/6 3/7 4/5 4/6 4/7 5/6 5/7 6/7 SUM %SUM
1 Protect Bike 0 1 1 1 1 1 5 22.7
2 No step ladder 1 0 1 0 1 1 4 18.2
3 Easy bike loading 0 1 1 1 1 0 4 18.2
4 Durable 1 0 0 1 0 1 3 13.6
5 Clear rear door 0 1 0 0 1 1 3 13.6
6 Affordable 0 0 0 1 0 1 2 9.1
7 Do not rust 0 0 1 0 0 0 1 4.5
TOTAL 22 100
FPDM 17
TECHNICAL REQUIREMENTS
NO. Technical Req 1/2 1/3 1/4 1/5 1/6 1/7 2/3 2/4 2/5 2/6 2/7 3/4 3/5 3/6 3/7 4/5 4/6 4/7 5/6 5/7 6/7 SUM %SUM
1 Yield strength 0 1 1 1 1 1 5 22.7
2 Resist bending 1 0 1 0 1 1 4 18.2
3 Fit all bike frame 0 1 1 1 1 0 4 18.2
4 Cost 1 0 0 1 0 1 3 13.6
5 Material selection 0 1 0 0 1 1 3 13.6
6 Resist Impact 0 0 0 1 0 1 2 9.1
7 Aesthetics 0 0 1 0 0 0 1 4.5
TOTAL 22 100
FPDM 18
HOUSE OF QUALITY
2.5: PRODUCT DESIGN SPECIFICATION
FPDM 20
PRODUCT DESIGN SPECIFICATIONBicycle vehicle Roof Rack
aff ordable
safe
marketable
durable
functional
easy to use
cost less then RM 800
protect user
protect bike
not eastatics
stiff
long lasting
no sharp
electrically insulated
locking system
durable material
simple shape only
resist bending
resist impact
resist static load
resist bending
resist tension
lock and secure bike
lock f rame/ tyre with switch
reachable height
easy bike loading
steady transport
on the roof
clear rear door and hatch
max allowable weight height on rest
no step ladder
tension test
bending test
static load test
impact test
bending test
resist static load
<18.0Kn bending f orce
<270Kn of impact f orce
< 4.5 kN of tension f orce
< 240 kN of bending f orce
FPDM 21
PDS FOR BICYCLE VEHICLE ROOF RACK
Objectives are :-- to design a bicycle roof rack for passenger vehicles- to design the system that allow a single person to load bikes on roof- to design the system that uses no step ladder
Size : the system should be <1.5m long
Cost : selling price < RM250.00
Quantity : Batches of 2000-5000 units for domestic market
Materials: Lightweight composite materials-resist impact and bending.
FPDM 22
PDS FOR BICYCLE VEHICLE ROOF RACK
Marketable : not aesthetics – simple shape only
Product life : 10-20 years
Customers : Cyclist , outdoor enthusiastic
Standards : to be checked
Reliability : Maximum 2 % failure over life service
Safety : no sharp edges, locking mechanism for frame , tire , folk of bike , clear door and hatch
FPDM 23
PDS FOR BICYCLE VEHICLE ROOF RACK
Ergonomics : must be user-friendly : easy to load and unload bike , one person able to load bike without using step ladder
Competition : major car accessory companies
Packing : standard car accessory for passenger vehicle :MPV, SUV, saloon cars
Market :car accessory shops/dealers
Patents : to be checked
CHAPTER 3: CONCEPT GENERATION &
SELECTION
PRESENTER :- MOHD HAFIZ B. ZULKAPLI
3.1: FUNCTIONAL STRUCTURE
FPDM 26
USER
LOAD BIKE
SUPPORT BIKE
LOCK BIKE
NO STEP LADDER
LOCKING MECHANISM
CAR
PROTECT BIKE
FPDM 27
FUNCTIONAL SEQUENCE
Bicycle Vehicle Roof Rack
Assemble partsPut the assembled
Parts on the roofMount the roof rack
On the roof of vehicle
Rise up the bicycle to the roof rack
Handle with care
Slide the bicycle on toPosition & secure it with
locking mechanism
FPDM 28
INTEGRAL OR MODULAR?
Easy to dismantled and assembled by the customers.
Flexibility in use, where as it can be configured for different uses
Easy to repair
Easy to machine and produce
Easy to upgrades where as the user needs evolve the product.
BRAINSTORMING
FPDM 30
BRAINSTORMING
Group brainstorming Rules of brainstorming
Record all ideas generated Generate and discuss as many ideas as possible Think wild Generate ideas: no judgments Focus on one specific function
FPDM 31
BICYCLE VEHICLE ROOF RACK
BICYCLE VEHICLE ROOF RACK
NO STEP LADDER
REACHABLE HEIGHT
DURABLE
LOCK AND SECURE BIKE
FPDM 32
BICYCLE LOCK
HANDLE
UPPER
FRAME
SHAFT
SEAT
WHEEL
FORK ARM
CRANK
LOWER FRAME
FPDM 33
MATERIAL FOR ROOF RACK
WOOD
ALLOY
STAINLESS STEEL
PLASTIC
COMPOSITE
FIBER
ALUMINIUM
PRODUCT DESIGN SPECIFICATIONS
FPDM 35
Bicycle vehicle Roof Rack
aff ordable
safe
marketable
durable
functional
easy to use
cost less then RM 800
protect user
protect bike
not eastatics
stiff
long lasting
no sharp
electrically insulated
locking system
durable material
simple shape only
resist bending
resist impact
resist static load
resist bending
resist tension
lock and secure bike
lock f rame/ tyre with switch
reachable height
easy bike loading
steady transport
on the roof
clear rear door and hatch
max allowable weight height on rest
no step ladder
tension test
bending test
static load test
impact test
bending test
resist static load
<18.0Kn bending f orce
<270Kn of impact f orce
< 4.5 kN of tension f orce
< 240 kN of bending f orce
3.2: CONCEPTS FOR PROJECTS
FPDM 37
CONCEPT GENERATION PROCESS
Clarify the Problem
Search Externally Search Internally
Explore systematically
Reflect on the Solutions and Process
STEP 1: CLARIFY THE PROBLEM
FPDM 39
CLARIFY THE PROBLEM
The challenge was to design a better bicycle rack. The mission statement assumptions:-
The bicycle rack will be durable The bicycle rack will be affordable The bicycle rack will be safe The bicycle rack will allow a single person to load bike The bicycle rack will not use step ladder
FPDM 40
CUSTOMER NEEDS
Based on the assumptions , we had identified the customer needs of bicycle vehicle roof rack :-
The bicycle rack will be long-lasting The bicycle rack will be cost less than current rack The bicycle rack will protect user and bike The bicycle rack will allow a single person to load bike
without using any step ladder
STEP 2: SEARCH EXTERNALLY
FPDM 42
SEARCH EXTERNALLY
Find existing solutions to overall problem and sub-problems
External Source :- Interview Lead Users – Passenger vehicle users Consult Experts - Car Accessories , bicycle user Search Patents - Search available pattern Search Published Literature – Research through published
literature Benchmark Related Product – Comparison with competitors
FPDM 43
COMPETITORS 1
THULE SUPER G YAKIMA RAPTOR
FPDM 44
COMPETITORS 2
THULE YAKIMA-SIDEWINDER
STEP 3: SEARCH INTERNALLY
FPDM 46
SEARCH INTERNALLY
Use personal knowledge to generate solution concepts Guidelines for useful improvement internal group search Suspended judgment Generate a lot of ideas – Brainstorming Process Except ideas that may seem infeasible Use graphical and physical media – Diagram, charts,
pictures
STEP 3: EXPLORE SYSTEMATICALLY
FPDM 48
EXPLORE SYSYEMATICALLY
Collected concepts from internal and external search
Organizing and synthesizing the solutions by:-
Functional Decomposition (Simplify Complicated System)
Morphological Chart (Sub function versus Concept )
Inventive Principles (TRIZ)
3.3: MORPHOLOGICAL CHART
FPDM 50
BICYCLE VEHICLE ROOF RACK MORPH CHART1 2 3 4 5
Bicycle Lock Frame Wheel Arm Shaft Shaft
Material For Rack Plastic Composite Fiber Plastic Fiber
Special Feature Fit all bike frame
Fit wheel size from 24” to 29”
Compactable with factory rack
Designed to clear rear door and hatches
Bombproof construction
User Friendly Features Protect User Transport stability
Protect Roof
Easy To Use Lightweight
Locking Mechanism Switch ratcheting wheel strap
Rack Lever Clamp Integrated Cable Lock
FPDM 51
IMPLEMENTATIONBicycle Lock Frame , Wheel , Arm , Shaft
Material For Rack Plastic, Composite, Fiber , Plastic
Special Feature Fit all bike frame, Fit wheel size from 24” to 29 , Compactable with factory rack, Designed to clear rear door and hatches , Bombproof construction
User Friendly Features Protect User ,Transport stability , Protect Roof, Easy To Use , Lightweight
Locking Mechanism Switch , ratcheting wheel strap, Rack Lever , Clamp , Integrated Cable Lock
3.4: PUGH CONCEPT EVALUATION MATRIX
FPDM 53
Evaluation MatrixConcept 1 Concept 2 Concept 3 Concept 4 Concept 5 Concept 6
Low cost
DATUM
+ - S + -
Easy to assemble + - S + -
Easy to operate + - S S S
Safety S S - S S
Light weight + - + + +
Attractive - - + - +
Multipurpose S + S S +
Long life S S S S S
Sum of + 4 1 2 3 3
Sum of - 1 5 1 1 2
Sum of ‘S’ 2 2 5 4 3
FPDM 54
Concept 1 Concept 2 Concept 3 Concept 4 Concept 5 Concept 6
Low cost S S -
DATUM
+ S
Easy to assemble - S - + -
Easy to operate - S - - S
Safety + + + + +
Light weight S S - + S
Attractive - S S + -
Multipurpose S S - S -
Long life S - + S S
Sum of + 1 1 2 5 1
Sum of - 3 1 5 1 3
Sum of ‘S’ 4 6 1 2 4
Evaluation MatrixEvaluation Matrix
FPDM 55
Concept 1 Concept 2 Concept 3 Concept 4 Concept 5 Concept 6
Low cost + + - + S
DATUM
Easy to assemble + + - + S
Easy to operate S + S + +
Safety S - S S S
Light weight - S - + -
Attractive S - + + +
Multipurpose S S - - S
Long life S S - - -
Sum of + 2 3 1 5 2
Sum of - 1 2 5 2 2
Sum of ‘S’ 5 3 2 1 4
Evaluation MatrixEvaluation Matrix
3.5: GROUP ANALYSIS OF RESULTS &
RECOMMENDATIONS
CHAPTER 4: FINAL DESIGN
PRESENTER :- MOHD ASRI B. MAHMOOD
4.1: DETAIL DESIGN
FPDM 59
ASSEMBLY MODEL
FPDM 60
EXPLODE VIEW
4.2: DFMA & SAFETY
FPDM 62
IMPORTANCE OF DFMA
REDUCE PART
REDUCE COMPONENT COST
REDUCE ASSEMBLY & MANUFACTURING COST
SIMPLIFY THE PRODUCT
EASY FOR USER TO USE THE PRODUCT
SAFETY
FPDM 64
IMPORTANCE OF SAFETY CONSIDERATION
AVOID ACCIDENCE
ENSURE SAFETY OF USER AND PRODUCT
ANALYZE THE HAZARD , RISK & POSSIBILITY OF FAILURE
MINIMIZE THE RISK
DESIGN SAFETY FEATURE FOR PRODUCT
FPDM 65
BRAINSTORMING- HAZARD
IDENTIFY ALL HAZARDS
FAILURES PROJECTILES
IMPROPER USE
FPDM 66
NO
DANGER FEATURE
AVOIDANCE PROTECTION
WARNINGFAIL-SAFE SAFE-LIFE CONTROL F.O.S PROTECT
SYSTEM
1. FRAME LOCK SLIDE ON TO THE RAIL
STOPER N/A MANUALLY CONTROL
CLAMP CAREFULLY
YES
2. SLIDING PART ARM LOCK CLOSE TOLERANCE
APPLY OIL FREGENTLY
MANUALLY CONTROL
N/A RAIL STOPPER
YES
3. BODY FRAME ABSORBER
BODY FRAMEADJUSTMENT
APPLY GREASE
MANUALLY CONTROL
N/A BEARING NO
4. TIRE CLAMP CRUSH HAND N/A N/A NO
5. BICYCLE STABILITY FALL OVER USER
BICYCLE THROUGHTLY LOCKED
N/A MANUALLY OPERATED
N/A SAFETY BAR YES
6. STORE BIKE UNSTABLE SLIDE THROUGH RACK
N/A MANUALLY OPERATED
N/A MANUAL HAND BOOK
YES
FAILURE MODE
FPDM 68
PART & FUNCTION
POTENTIAL FAILURE MODE
POTENTIAL EFFECT OF FAILURE
SEV
POTENTIAL CAUSE OF FAILURE
OCC
DETECTION METHOD & QUALITY CONTROL
DET
RPN
RECOMMENDED ACTIONS
• LOAD BICYCLE INTO RACK
•LOCK AND SECURE FRAME
•LOCK TYRES
•LOCK ARMS
•BICYCLE LOCKED AND SECURE
•STABILIZES BIKE
FRACTUTE FAILURE TO FUNCTION
8 • WEAR• FATIGUE•DEFORMATION•IMPROPER USE
6 •INCOMING PARTS INSPECTION•PRODUCT TESTING
5 240
•INITIATE RADIOGRAPHY TEST OF ALL ROOF RACK
JAMMED HAZARDOUS TO USER AND BIKE
8 •DIMENSION OUT OF SPECS•UNIT DAMAGED
5 •MEASURE & TEST PATTERN
3 120
•INTIATE PROGRAM TO MAINTAIN RACK DIMENSIONS
4.3: ERGONOMICS
FPDM 70
IMPORTANCE OF ERGONOMICS ENHANCE THE EFFECTIVENESS OF THE PRODUCT
INCREASE THE CONVINIENCE OF PRODUCT
REDUCE THE POSSIBILITY OF ERRORS
HIGHER THE PRODUCTION INPUT
INCREASE HIGH QUALITY WORK
FPDM 71
DESIGN PRINCIPLE
DESIGN FOR ADJUSTMENT
HEIGHT OF BIKE
SIZE (DIAMETER OF TYRES)
LENGTH OF SWING-ARM
SIZE OF SWING-ARM
DESIGN RANGE :- 5TH PERCENTILE FEMALE & 95TH PERCENTILE MALE
FPDM 72
ANTROPROMETRICS CALCULATIONS
FEMALE 5TH PERCENTILE :-
SHOULDER HEIGHT – KNUCKLE HEIGHT 132.3CM – 64.3 CM = 68.0 CM
MALE 95TH PERCENTILE:- SHOULDER HEIGHT – KNUCKLE HEIGHT
152.4 CM – 80.4 CM = 72.0 CM
RANGE :- 68.0 CM – 72.0 CM
4.4: ADVANTAGE & DISADVANTAGES OF
FINAL DESIGN
FPDM 74
ADVANTAGES OF FINAL DESIGN
EASY TO FIT FACTORY SPECS
EASY TO LOAD & STORE BIKE
FIRMLY PROTECTS & STABILIZES BIKE ON THE ROOF
NO ELECTRICAL & ELECTRONIC COMPONENTS
RACK CAN FIT ALMOST ALL BICYCLE FRAME
FPDM 75
DISADVANTAGES OF FINAL DESIGN
LOCK BICYCLE MANUALLY
NO AUTOMATIC FEATURE
ONLY ONE BICYCLE ROOF RACK CAN FIT TO THE ROOF
FPDM 76
CONCLUSION
Complete the design process
Applying the fundamentals of the design
Fulfill the customer need
Product is guaranteed successful in the market
THANK YOU