fall 2012- design for manufacturing
DESCRIPTION
Redesign of a canopy chair- Design, material, manufacturing process, assembly and robustnessTRANSCRIPT
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REDESIGNING A CANOPY CHAIR
Team 2: Mengshi Gao, Vibin Ilango, Tianshu Li,
Shengyu Lou , Aniruddha Srinath
University of Michigan, Ann Arbor
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Product to be Improved04/12/2023
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LOOK HOW FRUSTRATED HE IS……
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Problems & Improvements04/12/2023
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Personali-zation
Mobility
Sturdiness & Durability
Comfort
Sturdiness Of Chair Seat Back Angle Adjustment
Presence Of Phone Storage
Presence Of Cup Holder
Weight Of ChairPresence Of Canopy
Delighting Features
Customer Complaints
To design a comfortable, sturdy and economic canopy chair
which is attractive across a wide range of customers (20~75
years old) for all kinds of outdoor recreations.
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Target Groups
20-50 Age 51-75
HighSturdiness &
DurabilityGood
Good Mobility Good
Basic Comfort High
Good Personalization Good
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PRIMARY CUSTOMERS SECONDARY CUSTOMERS
Perform at BASIC Level
Perform at GOOD Level
Perform at HIGH Level
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Concepts04/12/2023
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Functional Improvements - Canopy
• A Flipping Extension can provide wider range to safeguard the customers
from rain and sunlight.
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Kelsyus Original Canopy Chair
Umich NEW Canopy Chair
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Also, it can be swiveled...!04/12/2023
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25% Shadow Area Increase
50% Side Area Increase
360° Swivel Angle
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Functional Improvements – Seat Material
• Nylon fabric is highly durable, and easy to wash and care for.
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Kelsyus Original Canopy Chair
Umich NEW Canopy Chair
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For elderly customers group, cushion is available04/12/2023
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Inserted with Polyurethane Foam cushion
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Functional Improvements - Storage
• The lightweight, easy-folding material in bellow mechanism contributes
much to the functionality and styling of this practical widget.
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Kelsyus Original Canopy Chair
Umich NEW Canopy Chair
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PP Retractable Below Cup-holder04/12/2023
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Functional Improvements - Sturdiness
• The tilting and holding brackets would both reduce stress and increase
durability.
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14Tilting Bracket Holding Bracket
Kelsyus Original Canopy Chair
Umich NEW Canopy Chair
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Hybrid concept – Tube Position Reinforcement Block04/12/2023
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Also, features an extended storage room.
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Functional Improvements – Seat Back Adjustment
• The Slot Mechanism does everything possible to achieve the tradeoff
between functionality and reliability.
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Kelsyus Original Canopy Chair
Umich NEW Canopy Chair
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Pin-Slot Mechanism04/12/2023
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Folding
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Folding
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Folding
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Folding
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Folding
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Further Functional Improvements04/12/2023
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Material Improvements – Primary Redesign04/12/2023
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24 Low Alloy Steel High Strength Polyamides
Oval-section Tube Frame Reinforcement Blocks
Tube FrameStainless Steel
ABS Plastic Gasket
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Material Improvements - Secondary Redesign04/12/2023
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25Polyurethane Foam PP HomopolymerSeat Cushion Pad Bellow
Seat Cushion PadSingle Layer Fabric
Nylon MeshBellow
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Process Improvements
• Assembly Efficiency Improved: From 25% to 42%
– Simplified mechanism
– Reduced Manual Steps
– Self-positioning Reinforcement Block
• Manufacturing Tooling Cost Reduced by: $20,000 per 100,000
units
– Better formability due to
material change from Stainless
Steel to Low Alloy Steel
(AISI 1070/4130)
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Cost Improvements (BOM and BOP)04/12/2023
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BOM I DCanopyCl oth
CarryStraps
Hol di ngCl i ps
Canopyf rame
Legsupportpl ast i cs
Canopyextensi on
fl aps
Canopysupport i ng
arms
Canopyswi velj oi nt -
top
Canopyswi vel
j oi nts -bottom
Arm rest -mobi l ehol di ng
Arm rest -dr i nk
hol di ng
End l egpl ast i cs
Sl otmechani sm
Chai rSeat i ngcl oth
Chai r Mai nFrame
Fi nal - assy CC- FA- 01
Part Name CC- CO- 02 CC- CO- 08 CC- CO- 09 CC- CO- 01 CC- CH- 06 CC- CO- 03 CC- CO- 06 CC- CO- 05 CC- CO- 04 CC- CH- 03 CC- CH- 04 CC- CH- 05 CC- CH- 06 CC- CH- 02 CC- CH- 01Cover- chai r
assy
Fasteners-Sets of bol ts,
nuts andwashers
Number ofParts
1 1 2 1 1 2 2 2 1 1 1 1 4 4 2 1 4
Materi al($/ uni t)
$0. 30 $0. 75 $0. 50 $0. 43 $0. 50 $0. 60 $0. 34 $1. 08 $1. 08 $0. 38 $0. 38 $0. 50 $0. 09 $2. 00 $1. 70 $0. 00 $2. 00
Manufacturi ng Process($/ uni t)
$0. 20 $0. 10 $0. 08 $0. 20 $0. 20 $0. 08 $0. 10 $0. 10 $0. 05 $0. 05 $0. 10 $0. 10 $0. 40 $0. 08 $0. 20
Assembl y Ti me($0. 01/ s)
10. 6 7. 9 7. 9 2. 63 16 34 3. 95 3. 95 27. 8 17. 9 10. 6 12. 6 16
CC- CO- 01 Cover Cl oth 1 $0. 30 $0. 40 10. 6 $0. 20
CC- CO- 02 Carry Straps 2 $0. 75 7. 9 $0. 00
CC- CO- 03 Hol di ng Cl i ps 2 $0. 40 $0. 20 7. 9 $0. 00
CC- CO- 04Upper Bar
Hol di ng Cl oth2 $0. 15 10. 72 $0. 26
CC- CO- 05Upper arm to
l ower arm l i nk-1
2 $1. 00 $0. 08 9. 4 $0. 41
CC- CO- 06Upper arm to
l ower arm l i nk-2
2 $1. 00 $0. 08 9. 4 $1. 17
CC- CO- 07Upper arm to
l ower arm l i nk-3
2 $1. 00 $0. 08 9. 4 $1. 17
CC- CO- 08Upper Bar
Hol di ng Cl i p2 $0. 20 $0. 08 9. 02 ($0. 16)
CC- CH- 01Arm rest - mobi l e
hol di ng1 $0. 30 $0. 10 3. 95 ($0. 03)
CC- CH- 02Arm rest - dri nk
hol di ng1 $0. 30 $0. 10 3. 95 ($0. 03)
CC- CH- 03Rear support
l i nk2 $1. 25 $0. 08 7. 9 $1. 41
CC- CH- 04Chai r Seat i ng
cl oth1 $1. 13 $0. 40 10. 6 ($0. 88)
CC- CH- 05Chai r Mai n
Frame1 $5. 00 $0. 08 12. 6 $3. 30
Fi nal - assyCover- chai r
assy1 $0. 00 18 $0. 02
CC- FA- 01Fasteners- Setsof bol ts, nuts
and washers6 $3. 00 $0. 20 $1. 00
($0. 86) ($0. 80) ($1. 18) ($1. 18) ($0. 88) ($0. 36)New Parts
Del etedParts
$2.60
Original Product
Cost$18.97
Redesigned Product
Cost$16.37
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Architecture Strategy04/12/2023
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PRIMARY CUSTOMERS SECONDARY CUSTOMERS
Price
Weight
Payload
Sturdiness
Durability
Effectiveness of Canopy
Storage
Comfort
Seat Folding Angle
Easy to Use
ORIGINAL PRODUCT
√ √ ×
MUST-BEDI HighSI Low
DELIGHTERSI HighDI Low
Phone Storage
Additional Storage
Oval-Section Tubes
W/ Seat Cushion
Light-weighted
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Modularity04/12/2023
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Modularity04/12/2023
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And… Color!04/12/2023
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MEET OUR PRODUCT FAMILY!
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And of course……Price!04/12/2023
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Umich NEW Canopy Chair
Kelsyus Original Canopy Chair
$59.99$28.97
$30.00
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ORIGINAL REDESIGN
COMPETITOR
$39.99$30.00
$59.99$28.97
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ORIGINAL REDESIGN
COMPETITOR
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ORIGINAL REDESIGN
COMPETITOR
Which of these were your motivation of buying our product?
(Check all that apply)
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Q&A
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Thank You!
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