product design and development with reverse engineering

7/29/2019 Product Design and Development With Reverse Engineering

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DIRT DEVIL VACUUMCLEANER

TEAM 4

11/16/11

Justin Grates

Raghava Kashyap GujjaAlban Imeri

Jyothi Swaroop Reddy Yerasi


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Purpose and Overview

To design and develop a Vacuum Cleaner.

Reference product - Dirt Devil Express QuickVacuum Cleaner.

Theory of Operation


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Customer Needs

Personal Interviews.

Taken reviews from Amazon and Companywebsite.


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Benchmarking

Know your enemy to know yourself and you can fight a

hundred battles without disaster. Sun Tzu, 500 BC

Compare with your competitors High performer: Dyson DC 25

Low Cost: Eureka Upright Vacuum cleaner

ex- matrix removal system used by Cary

manufacturing to remove matrix material on pressesby using heavy suction.


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QFD Phase I

Weight

Suction Power -

Force required to operate ++

Noise level --

Tolerance of sealing ++ NO INPUT IN THIS AREA

Balance - + ++

Height adjustability +

Container Volume -

Hose Length - - -

Energy Efficiency + - +

Time to clean ++ ++ + + ++ +

Air Flow ++ - + - + ++

Spilling dust ++ +

Life time of product +

Time to empty the container ++ +Cord Length -- +

Overall Size ++ + - - -

Preferred Nom up dwn dwn up up up up up up dwn up dwn up dwn up Nom

Customer Requirements CustomerWeights

Weight

SuctionPower

Forcerequiredtooperate

Noiselevel

Toleranceofsealing

Balance

Heightadjustability

ContainerVolume

HoseLength

EnergyEfficiency

Timetoclean

AirFlow

SpillingDust

Lifetimeofproduct

Timetoemptythecontainer

CordLength

OverallSize

1 Easy to move 9 9 0 9 0 0 9 3 1 1 0 3 0 0 1 0 9 92 Good dirt pick up 9 0 9 0 3 3 3 0 0 3 1 3 3 3 0 0 0 0

3 Affordable price 9 3 3 0 3 1 0 3 1 1 9 0 0 0 9 0 3 9

4 No dust Spill 9 0 3 0 0 9 0 0 3 0 0 9 0 9 0 0 0 0

5 Easy to use 9 9 0 9 3 0 9 9 0 3 0 9 0 0 0 9 9 9

6 Always works 9 3 3 0 0 3 3 0 0 0 0 0 0 0 3 0 0 0

7 Fast Cleaning 9 0 9 3 0 3 1 1 9 1 0 9 9 0 0 9 3 3

8 Safe to operate 9 9 3 3 9 1 9 1 0 3 0 0 0 9 0 0 3 3

9 Lasts long 3 3 3 1 0 0 9 0 0 0 0 0 0 0 9 0 0 0

10 Hold more dust 3 1 9 0 0 3 3 0 9 0 0 9 0 1 1 9 0 3

11 Strong body 3 9 0 1 0 1 3 1 0 0 0 0 0 0 9 0 0 0

12 Easy to store 3 3 0 0 0 0 0 9 0 3 0 0 0 0 0 0 0 9

13 Consumes less power 3 0 9 0 3 3 3 0 0 0 9 1 1 0 0 0 0 0

14 Easy to Maintain 1 0 0 0 0 0 0 0 9 0 0 9 0 3 3 9 0 1

15 Less overheating 1 0 9 0 0 0 3 0 0 1 3 3 0 0 3 0 0 0

Engineering Metrics


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QFD Phase II

It relates all the engineering metrics to all thepart characteristics.

Part Characteristics

Engineering Metrics PhaseIRelativeWeights

Motor

Hose

Cord

Handle

Container

Rollingbrush

Belt

Filter

Accessories

MotorHousing

Base

Nozzle

Containercove

r

Weight 9% 9 3 3 3 9 3 3 1 3 9 3 1 1

Suction Power 9% 9 9 0 0 3 1 3 1 1 3 1 9 0

Force required to operate 6% 3 0 1 3 3 1 0 0 0 3 3 0 0

Noise level 4% 9 3 0 0 0 1 3 1 3 1 1 3 0

Tolerance of sealing 5% 0 1 0 0 9 0 0 1 1 3 9 1 9

Balance 9% 3 3 0 9 1 0 3 0 1 9 3 1 1

Height adjustability 5% 0 3 0 9 1 0 0 0 1 3 0 0 0Container Volume 4% 0 0 0 0 9 0 0 1 0 1 1 0 9

Hose Length 3% 1 9 0 0 0 0 0 0 0 1 0 3 0

Energy Efficiency 3% 9 3 3 0 0 3 3 0 3 0 0 0 0

Time to clean 9% 9 9 9 1 9 9 1 3 3 0 0 9 0

Air Flow 3% 9 1 0 0 0 1 0 1 1 0 0 9 0

Spilling dust 5% 0 1 0 0 9 1 0 3 1 0 3 3 9

Life time of product 5% 9 3 1 0 1 9 9 1 0 3 3 3 1

Time to empty the container 5% 0 0 0 0 9 0 0 0 0 0 0 0 9

Cord Length 6% 0 0 9 0 0 0 0 0 0 0 0 0 0

Overall Size 9% 9 0 1 3 9 1 0 0 3 9 9 3 1

Raw score 5.1

3.1

1.9

2.1

4.8

1.9

1.6

0.8

1.4

3.5

2.5

2.9

2.1

Relative Weight15% 9

%6%

6%

14% 6

%5%

2%

4%

10% 7

%9%

6%


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Functional Analysis


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Costing

FilterMotor


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Cost Worth Analysis


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FishboneDiagram


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Main Assembly: 399 sec

Base Assembly: 433 sec

Handle Assembly: 108 sec

Container cover

Assembly: 37.6 sec

Filter Assembly: 46.4 sec

Container cup

Assembly:

Assembly Time Calculations


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Base Assembly Longest Time433s


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Failure Mode and EffectsAnalysis

Poor

SuctionMotor Over


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Function Based FMEA

Slip In

MotorInlet Port Clogged


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Resource Extraction

Product ManufactureProduct Packaging andTransport

Product Use

Environmental Impact


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Environmental DesignRecommendations Replace screws by snap fit mechanisms

Reduce size and use stream lined model of fan blades

Reduce the number of components being outsourced

Uncoated filters are easy to recycle

Use bio- degradable plastics like PHA, PLA, PVA instead of ABSand PP

Liquid wood as bio-polymer feels like plastic

Corn plastic caps made from degradable plant starch

Use of Ultra silencer to reduce the noise

Brushless motor consumes less power

Eliminate Poisonous Adhesives!

Distinction of Hazardous materials

No stickers! Use compatible ink for marking

Compatibility of materials may facilitate recycling


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Product Definition

Redesign should be focused on: Customer satisfaction Maneuverability

Enhanced features:

Increased suction power duration Longer power cord or Cordless

Cost: Keep cost around $45

Cost DriversAssembly Snap-fit parts Standard components/material

Failures


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Project Priority Matrix


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ConceptGeneration

Supply Power

Create Suction

Bring Vacuum to Area

Loosen Particles

Pickup Particles

Store/Empty the Container


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ConceptAlternatives

Concept 1

Concept 2

Concept 3


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Concept 1


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Concept 2


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Concept 3

C


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Pugh Analysis CurrentProduct

1 2 3

1 Weight 9 - + S

2 Overall Cost 9 - - -

3 Manufacturing Costs 3 - - S

4 Easy to use 9 + + +

5 Suction Power 9 + + S

6 Safety 9 + + S

7 Profitability 3 - + S

8 Manufacturability 3 - - +

9 Portability 9 - + +

10 Environmental Impact 3 + S S

11 Sound Level 1 + - S

12 Energy Efficiency 3 + - S

13 Durability 3 + + S

14 Operating Costs 3 + S S

15 Reliability 9 - - S

16 Time to clean 3 - + +

17 Overall Size 3 - + S

18 Ergonomics 3 + - +

19 Ease of Maintenance 3 + + +

20 Quality of Cleaning 9 + + +

Sum of +'s 11 11 7

Sum of -'s 9 7 1

Sum of S's 0 2 12

D

A

T

U

M

Criteria Weight

Concepts Dirt Devil

Express Quick


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Pugh Analysis Top Competitor

1 2 31 Weight 9 - + S

2 Overall Cost 9 + + +

3 Manufacturing Costs 3 + + +

4 Easy to use 9 S S S

5 Suction Power 9 S S S

6 Safety 9 S S S

7 Profitability 3 - + +

8 Manufacturability 3 - + +9 Portability 9 + + +

10 Environmental Impact 3 + S S

11 Sound Level 1 + + +

12 Energy Efficiency 3 + + +

13 Durability 3 + + +

14 Operating Costs 3 + + +

15 Reliability 9 S S S

16 Time to clean 3 + + +

17 Overall Size 3 + + +

18 Ergonomics 3 + + +



Sum of +'s 13 15 14

Sum of -'s 3 0 0

Sum of S's 4 5 6

D

A

T

U

M

Criteria WeightConcepts

Dyson DC25

P h A l i L


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Pugh Analysis LowCompetitor

1 2 3

1 Weight 9 - - -

2 Overall Cost 9 - - -

3 Manufacturing Costs 3 - - -

4 Easy to use 9 - S S

5 Suction Power 9 + + +

6 Safety 9 + + +

7 Profitability 3 + + +

8 Manufacturability 3 - - -

9 Portability 9 - + +

10 Environmental Impact 3 - - -

11 Sound Level 1 - - -

12 Energy Efficiency 3 + + -

13 Durability 3 + + +

14 Operating Costs 3 - + -

15 Reliability 9 + + +

16 Time to clean 3 + + +

17 Overall Size 3 - - -

18 Ergonomics 3 + - +



Sum of +'s 10 11 10

Sum of -'s 10 8 9

Sum of S's 0 1 1

D

A

T

U

M

ConceptsWeight

Eureka

LightweightCriteria


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Final Concept

Advantages: Backpack and upright vacuum

Cleaning in special areas (stairs)

Easy to move and light weight

Safety (Cordless)

Cooling fan

Fewer plastic parts

Challenges:

Ergonomics

Battery reliability

Price


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Conclusion

Advantages to Current Product:

Flexible product

It satisfies our Customer Needs

Faster assembly can create market opportunity

Green Product

Future Recommendations:

Reduce vibrations

Noise Reduction

Work with Supply Chain to lower costs of outsourced products Produce to Six Sigma Standards

Environmental Value Stream

Product Differentiation


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Questions?

product design and development with reverse engineering

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