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Report
Report
Report
IE -6405
INTEGRATED PRODUCT DEVELOPMENT
Invent New Corporation
Title: Customized Chair for Playing Musical Instruments
Team 3
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1. Introduction
A product is anything that can be offered to a market that might
satisfy a want or need. Any product at a particular point of time
reaches a point where in the demand for the product starts
decreasing. At that particular point of time the product should be either
innovated or upgraded to maintain the presence in the market. The
process of translating an idea or invention into a good or service that
creates value or for which customers will pay is innovation.
Innovation can be a catalyst for the growth and success of your
business, and help you adapt and grow in the marketplace. The
innovation of a random product is a tough task as there are many
genres of products which can be innovated.
There are many different types of chairs. There is a chair for
almost every purpose but there has never been a chair for the
musicians. This basic need has made us think about a chair for the
musicians.
A customized chair with attachments/extenders for an artist to sit and place the
musical instruments and perform in a most comfortable manner for a longer duration
without getting exhausted.
Benefit proposition
Primary market
Secondary market
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Assumptions
constraints
Stakeholders
and
1. Music companies and studios who will buy the product in huge volume
2. Investors and employees who will work in the shop for manufacturing
3. Music teachers and students who will buy the product in a small volume
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Innovatio
n
Evolutio
n
Design
Four
Legged
Chairs
Comfor
t
Cotton
In
Built
Cushions/
Foam
Pillows
Feature
s
Hand
Rest
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FLC/CWW
Hand Rest
and Leg
support
2006-2010
2011-2015
FLC/CWW/C
also
FLC/CWW/C FLC/CWW/C/R convertible
various
positions
Combinations
Foam
and Foam/Spring/Ai
of
all
us
Spring
r Filled
before
Hand Rest, Leg Hand
Re
Hand Rest,
Support,
Leg Suppo
Leg Support,
Laptop/Writing
Laptop/Writin
Glass
Support, Glass Support, Gla
Holders
Holders
Holders
Four Legge
Chairs - FLC
Chairs
wi
wheels
CWW
Couch -C
Recliners - R
Planning phase also includes project scheduling. The project
scheduling is a method or a tool that communicates what work needs
to be performed and at what time frame it has to be performed. The
project scheduling reflects all the tasks with the associates delivery
time in the project timeline. For this project, we used Gantt chart as a
tool to define the project schedule. The Gantt chart is shown in the
figure below.
PROJECT SCHEDULE
Planning
Definition
Parameters
Concept
Customer Survey
development
QFD
System level
TRIZ formulation
design
Develop
design
alternatives
Product architecture
Define Interactions
CAD
modeling
and
Detail design
assembly
Prototype development
Detail
drawings
of
mechanical parts
Design
specification
Testing
verification
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Week
1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th 11th 12th
Customer
validation
Production
ramp up
need
Product launch
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After
Dec
Unit
Range
lb
Max. 80
lb
Chair dimensions
2
Overall Width
Design of attachment
3
4
Overall Height
Material
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Height
ground
from
Width
of
attachment
Density Rating
foot
Max. 4
feet
foot
Max. 2
feet
feet
Max. 3
feet
feet
Max. 3
feet
the
the
2.4
3.1
, Weak(1) -
Cushion thickness
Battery life
10
11
16
17
Ground clearance
18
19
20
21
22
Color Options*
1.2 0.48
1.2 0.52
1.2 0.51
1.5 0.59
Total
Total
1 0.61 4.5
4.5
154 209 183 235 181 128 128 108 122 120 69 11981.9 54 50.7 258 155 165 104 125 40.567.52855
15
Material of cushion
14
3
Weight of attachment
13
2
Design of attachment
12
1
DQ composite imporance
, Medium (3) -
7.92
9.74
6.53
7.10
6.82
11.06
7.32
Ratio of improvement
Strong(9) ,none(0) -
9.64
6.22
Degree of tilt
10.49
5 Recorder/Metronome/mic/etc support attachment
6 Glass/Mug/Bottle Holder
7 I-pad/music note stand - attachment
8 Ground wheels: Moveable
9 Arm rest
11Pushback seat
% Importance
Weighted Importance
Sales point
This phase
includes
the
definition
of product
Chair dimensions
min 1
System
Level
Design:
Weight of the chair
subj.(in
numbers
)
min. 5
Color Options* (subj.)
33 41
10Height Adjustment
Target
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36 40
Hr
Battery life
GB
memory
Digital
storage
5
Load
(ILD)
Indentation
Deflection
rating
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Concept #2: This design concept was generated using TRIZ method.
Out of 40 TRIZ innovative principles, combination and nesting
principle was used to generate this concept. The concept involves a
regular chair with 2 attachments to it. The improvement of this concept
over the first concept was to decrease the number of components and
hence ease of manufacturing and ease of assembly. This eventually
will reduce the cost of manufacturing. This design consists of a 360
degrees rotator and foldable attachment to place and fix the
instruments and a foldable stand to hold music notes or iPad. The
chair has a hydraulic sphere at the bottom which has an infinite
degree of freedom in the XY plane which can be used to move the
chair. And whenever the chair needs to be fixed at one place there is a
one degree freedom in the z plane; sphere can be moved up with the
help of the hydraulics and the chair can be fixed at a particular place.
The chair also has the pocket to hold miscellaneous things. In addition
to this it also fulfils the customer requirement of having audio box for
connecting microphones and other audio requirements.
So this design helps the artist to adjust the attachment vertically,
horizontally just by sliding with great ease.
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Concept #3
This design concept was generated keeping in mind the unicomponent approach. In simple words, this design was made for
simplicity, to reduce complexity but at the same time keeping its
optimum functionality. It also consists of foot rest which was not in the
earlier concepts.
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Planning
Concept Generation
System Level
Design
Detail
Design
Testing and
Refinement
Production Ramp
Up
Brass family
Strings family
Woodwind family
Percussion Family
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changes were not yet made. However, it was predicted well before
from the beginning which eventually occurred. The main change in
plan came into action after the customers review through customer
survey. This was part of our marketing strategy that will be discussed
in detail on the next page.
Our Marketing Strategy:
The first question we had to ask ourselves was, how unique is our
product? This was one of the most important phase during our product
development process. The way of approach for this was dependent on
the following factors:
1. Who are our targeted customers?
2. What are the customers expectations?
3. How can we collaborate with all the furniture companies to
establish our grounds in the market?
4. Who are our competitors?
5. How can we compete with our competitors in the long run?
6. What will be our plan of action to launch the product?
To decide on the above factors we had conducted a customer survey
where we had few selected questions in our mind that could help the
customer understand the type of product we are trying to introduce to
them. Further we were open to their suggestions that could emphasize
on key factors that our chair needs according to the customers.
Even after taking surveys from professional and non- professional
musicians, it was very important to know the industrys perspective
regarding our product since they have good experience with what a
customer expects in these kind of scenarios. Hence we created a
survey form and asked some musicians to comment on what they feel
about our product. Table shown below is a survey form that we
presented to our potential customers from different backgrounds;
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Sr.
No
1
2
3
4
5
6
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Customer Rating
out of 5
(5
being
extremely
desirable and 1
being not at all
desirable)
7
8
9
10
11
12
13
15
16
Glass holder
Attachment to keep an i-pad
Chair with wheels
Chair without wheels
Adjustable arm rest
Without arm rest
Height adjustment
Pushback(Like a car seat)
Without pushback(Like an office chair)
Air blower attachment to the chair for
17
hands
After one week of collecting the reviews, few surprisingly new
suggestions were made that were never part of our design plan. This
was a main turnover in our project. Eventually House of Quality was
made as shown in this report where we decided on the importance to
be given to the features that are needed in the design of chair.
A product concept is an approximate description of the technology,
working principles, and form of the product. It is a concise description
of how the product will satisfy the customer needs. A concept is
usually expressed as a sketch or as a rough three-dimensional model
and is often accompanied by a brief textual description. The degree to
which a product satisfies customers and can be successfully
commercialized depends to a large measure on the quality of the
underlying concept.
House of quality revealed the demanded key factors by our customers
that can satisfy the engineering needs of our design. This gave us a
clear picture of what ideas should be implemented in our design to
make it a success when introduced to the customers in the market
after manufacturing. It was a clear lesson learned that all the demands
of the customer cannot be fulfilled, however it is very important to
listen to the customers perspective before making a decision on the
product design.
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build/revise
mock-up
customer
test-drives
mock-up
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4. EVOLUTION OF DESIGN
Target Instruments:
Once the idea was formed, the main question to ask ourselves was,
what instruments we are going to accommodate for our design. Our
product was designed with an intent to held/accommodate at least 3
instruments. In order to do that we had to categorize all the possible
instruments which need a stand/support for its player while
performing. The motto of the design was to make the ease of playing
the instrument possible even though the player has to perform for
hours continuously. Hence it was clear to say that ergonomics was
one of the main criteria. After the customer survey was taken, we
realized that only specific musicians require a product that we intent to
manufacture. For example, a flutist preferred to perform standing and
was neutral about sitting and playing his instrument, meanwhile a
tabla player insisted on having such a chair that we want to
manufacture. Hence it was clear that even in variety of musicians, only
70% of them were our target. This helped us a lot in concluding that
instruments like Table, Guitar, Veena, Trumpet etc. need a product
that we are building.
Design Creativity:
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Now it was clear on how to target the instruments. After reaching this
phase of product development, our team started coming up with ideas
that could make this product possible. Our main criteria was to make
an ergonomically feasible chair that is very robust when a musician is
playing his instrument. This will not only make our product a success
but also a reliable product for our customers.
cost reduction initiatives right from the facility location selection stage
to the shop floor improvements without altering quality and safety of
the final product. Economically successful design is therefore about
ensuring high product quality while minimizing manufacturing cost.
Effective DFM practice leads to low manufacturing costs without
sacrificing product quality.
Material
s
Total in
$
1.
Wood
3mm
1/8x6x12" (6)
2. Cushioning material 10kgs
3. Polish - 5 Gallons
4. Recorder
5. Adhesives , fasteners
and
stitching
threads(Miscellaneous)
$15.00/piec
e
15*6
90
$20/kg
20*10
200
$20/Gallon
_
20*5
_
100
50
50
106*1
106
Fixed
Cost
4. Wood Lathe for wood
$106/piece
work - 1 no.
$99.99/piec
5. Stitching machine
e
$100
6. Miscellaneous tools
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99.99*
1
_
99.99
100
Direct
cost
1.
Shop
floor
_
_
construction
2. Labor cost - Total man
hour target per chair - $8 / Man
50
Hour
50*8
3. Power
_
_
Total Cost
Operating Cost(Excluding Fixed cost and
shop floor construction cost)
Total Cost Reduction Target - 25% - $6,561.50
25000
400
50
$26,246
$940
So, we have taken certain cost reduction initiatives to cut the cost of
manufacturing by 25%.Following are the cost reduction initiatives
which we have set as a major KPIs (Key performance Indicators) to
achieve the cost reduction target ;
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So, labor workforce should be recruited from the nearby areas so that
they can commute very easily and also the supervisors can call them
in case of emergency.
3. Localization of raw materials is another important factor for cost
reduction. Defined & developed supplier network in line with strategic
plan is a must. Defined procedure should be set up for vendor
qualification to meet supplier expertise & capabilities. We will have to
implement strategic action plans to develop local suppliers to reduce
lead time and cost. It becomes very much important to consider
sufficient supply of raw materials and the quality of raw materials. And
also the cost of raw materials is an important element of the total cost
of production. If the supply chain of raw materials is not regular, it may
lead to frequent stoppages and breakages in production line. The time
and the cost of the transportation of raw materials are also important.
So it is best if the manufacturing facility is located close to raw
materials suppliers/vendors or vice-versa.
Closeness to market is important to have control over the market. In
industries where raw materials are obtained from different sources,
closeness to the sources of raw materials is to as important as
nearness to the market. Closeness to the market is important for
supplying goods to customer in the minimum period of time. So
speedy transport facilities are needed for regular and timely supply of
raw materials at low cost. Transport facilities are important for getting
control over foreign markets.
4. Power is another important factor and is necessary for production
and for transporting finishing goods and raw materials. Power may be
electrical, diesel and atomic energy. All types of power should be
localized and mobile. Power shortages lead to tremendous losses due
to the stoppage of machinery. Therefore, industries must have a
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Traini
ng
Theory
Class
based
Work
Instructi
on
Practic
al
Tests and
Examinati
on
Real time
manufacturing
Training
Equipme
nt
Trainings
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7. Lessons Learnt:
How to tackle real world problems like law of diminishing return,
Market Stagnation, Inflation
Getting the customers feedback on the product into impact.
Developing an innovative design taking all the uncertainties into
consideration
Customer satisfaction along with profit growth.
Design for Manufacturing
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THANK YOU!
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