Design And Fabricationn Madular Product With The Incorprotion Of Diy Assembly Method.
SUPERVISOR DECLARATION
"I hereby declare that the quality of the dissertation written is sufficient for the award
of Bachelor of Mechanical Engineering (Design & Innovation)"
Signature
Supervisor
Date
:. . . ｷｾﾷ
'
ｾ｜＠
ﾷ＠
.
: Siti Nurhaida binti Khalil
: ......＿ＺＭＮｉＡｌｾﾷ
© Unlveralll Teknlkal Malaysia Melalal
ﾷ ﾷ＠
DESIGN AND FABRICATION MODULAR PRODUCT WITH THE
INCORPORATION OF DIY ASSEMBLY METHOD: LAZY CHAIR
NUR 'AIN BINTI AZMI
This report is submitted as a partial fulfillment of the requirements for the
award Bachelor of Mechanical Engineering (Design & Innovation)
Faculty of Mechanical Engineering
Universiti Teknikal Malaysia Melaka
JUNE 2012
© Unlverlltl Teknlkal Malaysia Melakll
11
DECLARATION
"I hereby declare that the work in this dissertation is my own except for summaries
and quotations which have been duly acknowledge"
/'
Signature
: .........ｾ＠
Author
: Nur 'A in binti Azmi
Date
':l_q
........... .
Jl!N
© Unlverlltl Teknlkal Malaysia Melakll
2.0\4...
lll
Dedicated with love,
To my parents,
Azmi bin Hj. Arshad and Roziah binti Hj. Mustapha,
To my sister,
Nur Asyikin binti Azmi.
To all my friends.
© Unlverlltl Teknlkal Malaysia Melakll
IV
ACKNOWLEDGEMENT
Apart from the efforts of myself, the success of this project depends largely
on the encouragement and guidelines of many others. I would like to take this
ｾｰｯｲｴｵｮｩｹ＠
to express my gratitude to the people who have been helping and
supporting me throughout the successful completion of this project.
First and foremost, I would like to thank my supervisor, Ms. Siti Nurhaida
binti Khalil for the valuable guidance and advice right from the beginning of this
project until the very end. Her willingness to motivate and encourage me contributed
tremendously to my project and without her, this project would not have
materialized.
I would like to express my greatest appreciation to my beloved parents, Azmi
bin Hj. Arshad and Roziah binti Hj. Mustapha. I cannot thank them enough for their
support, faith and loves towards me upon completing my project. They are the
reasons for me to complete this project.
Last but not least, special thanks to Marliati Ghazali, Myn Samsuddin, Fariha
Azmi, Nik Zubaidi and to all my friends who have been constantly helping and
supporting me throughout the completion of this project. I am grateful with their
helps and their contributions were vital for this project. Not to forget, thank you for
the friendships.
© Unlveralll Teknlkal Malaysia Melalal
v
ABSTRACT
The objective of this project is to study the activities in designed involved in
designing of a new modular product concept for ' Lazy Chair' and fabrication of a
prototype of scale 1:2 using sustainable material. The modular product also
incorporates ' DIY' assembly method. The project starts by choosing a benchmark
design and from there; ideas for concept designs were created. Morphological chart
was used as one of the method to generate concept designs. Concept selection
method was used to choose the final concept design; example is Pugh method. The
final concept design is analyzed using DFMA method to compare with the existing
design of lazy chair. DFMA is used as a tool for reducing the number of individual
parts that must be assembled and increase the ease of put the parts together. The DIY
assembly method is the most important part and the best joining method will be
determined using the concept selection method. The DIY method is implemented in
this design is to make the assembly process of the product easy to conduct with or
without the help of a user manual. The outcome of this project is a new modular
product concept for ' Lazy Chair' that overcomes several problems that encounters
with the existing design.
© Unlverlltl Teknlkal Malaysia Melakll
VI
ABSTRAK
Objektif projek ini adalah untuk mengkaji aktiviti - aktiviti yang direka
bentuk yang terlibat didalam proses mereka bentuk konsep modular produk yang
baru bagi 'Kerusi Malas' dan fabrikasi sebuah prototaip dengan skala I :2
menggunakan bahan mampan. Modular produk yang baru ini juga harus
menggabungkan konsep pemasangan 'DIY' . Projek ini bermula dengan memilih
sebuah kerusi malas sebagai penanda aras dan idea-idea untuk reka bentuk konsep
yang baru dapat dihasilkan. Carta morfologi digunakan sebagai salah satu kaedah
untuk menghasilkan beberapa konsep rekabentuk yang baru. Kaedah pemlihan
konsep yang digunakan adalah kaedah Pugh. Konsep reka bentuk yang dipilih akan
dianalisis menggunakan kaedah DFMA untuk melakukan perbandingan dengan reka
bentuk kerusi malas yang sedia ada. Analisis DFMA adalah salah satu cara atau
aplikasi yang digunakan untuk mengurangkan bilangan bahagian atau komponen
yang perlu dipasang menjadi satu produk dan meningkatkan kadar pemasangan yang
mudah. DIY adalah bahagian yang paling penting dan cara pemasangan yang terbaik
akan dipilih menggunakan kaedah pemilihan konsep yang ada di dalam Reka bentuk
Kejuruteraan. Kaedah pemasangan DIY diaplikasikan di dalam
reka bentuk ini
adalah untuk member kesenangan kepasa para pengguna untuk memasang tanpa
memerlukan bantuan manual. Hasil daripada projek ini adalah menghasilkan sebuah
konsep modular produk yang baru untuk 'Kerusi Malas' bagi mengatasi beberapa
masalah yang wujud dengan reka bentuk yang sedia ada.
© Unlverlltl Teknlkal Malaysia Melakll
Vll
TABLE OF CONTENT
CHAPTER
CHAPTER l
CHAPTER2
CONTENT
PAGE
DECLARATION
11
DEDICATION
lll
ACKNOWLEDGEMENT
lV
ABSTRACT
v
ABSTRAK
Vl
TABLE OF CONTENT
Vll
LIST OFTABLES
Xl
LIST OF FIGURES
Xll
LIST OF APPENDICES
XlV
INTRODUCTION
l
1.1
Background
1.2
Objective
2
1.3
Scope
2
1.4
Problem Statement
3
1.5
Methodology
3
1.6
Outline of Report
3
1.7
Conclusion Remarks
5
LITERATURE REVIEW
2. 1
6
Modular Product
6
2.1.1
Defmitions
7
2.1 .2
Advantages of Modular Product
8
© Unlverlltl Teknlkal Malaysia Melakll
Vlll
2.1.3
Modular Architectures
9
2.1.4 Modular Product Development
II
2.2
Do It Yourself (DIY) Method
12
2.3
Design for Manufacture and Assembly
14
(DFMA)
2.4
2.4.1
2.5
2.6
2.7
CHAPTER3
18
Chair
History of Chair
18
2.4.2 Chair Seats
19
2.4.3
19
Standards and Specifications
2.4.4 Accessories
21
Materials
22
2.5.1 Softwood
22
2.5.2
Plywood
23
2.5.3
Stainless Steel
24
2.5.4 Flexible Polymer Foam
26
Threaded Fasteners
28
2.6.1
29
Screw
2.6.2 Bolt & Nut
30
Conclusion Remarks
31
METHODOLOGY
32
3.1
Introduction
32
3.1.1
34
3.2
Benchmark
3.1.2 Ideas I Sketches
35
3.1.3 Generate Concept Design
35
3.1.4 Concept Design Selection
35
3.1.5 Product Architecture
37
3.1.6 Configuration Design
38
3. 1.7 Parametric Design
38
3.1.8 Detail Design
38
3.1.9 Prototype & Testing
39
Flow of Design Process
40
3.2.1
41
Defme Problem
© Unlveralll Teknlkal Malaysia Melalal
IX
3.3
CHAPTER4
CHAPTER 5
3.2.2
The House of Quality Configurations
41
3.2.3
Product Design Specification
43
3.2.4
Gather Information
45
3.2.5
Product Decomposition
47
3.2.6
Morphological Chart
47
Conclusion Remarks
CONCEPT GENERATION
49
4.1
Introduction
49
4.2
Concept Design 1
49
4.3
Concept Design 2
50
4.4
Concept Design 3
50
4.5
Concept Design for Join Method
51
4.6
Conclusion Remarks
52
CONCEPT DESIGN SELECTION
53
5.1
Introduction
53
5.2
Pugh M ethod
53
5.3
Pugh Method Chart
54
5.3. 1 Pugh Method: Lazy Chair Design
54
Pugh Method: Join Method
56
5.3.2
5.4
CHAPTER 6
CHAPTER 7
48
Conclusion Remarks
57
DETAIL DESIGN
58
6.1
Detail Drawing
58
6.2
Exploded Drawing
58
6.3
Prototype
58
RESULT & DISCUSSION
59
7.1
59
Result
7.1.1
DFA Analysis
59
7. 1.1.1. DFA Analysis of Existing
60
Design
© Unlverlltl Teknlkal Malaysia Melakll
X
7.1.1.2. DFA Analysis ofNew
63
Design
7.1.2
7.2
7.3
CHAPTER 8
DFM Analysis
76
Discussion
77
7.2.1
DFAAnalysis Result
77
7.2.2
Limitations and Strengths
78
7 .2.3
New Design of Lazy Chair
79
Conclusion Remarks
79
CONCLUSION & RECOMMENDATION
80
8. 1
Conclusion
80
8.2
Recommendation
81
REFERENCES
82
APPENDICES
85
© Unlverlltl Teknlkal Malaysia Melakll
xu
LIST OF FIGURES
Figure 1.1: Current Design ofLazy Chair
Figure 2.1 : Designs of a drawer (Huang 2000) ............................................................ 7
Figure 2.2: Examples of Modular Product (Holtta-Otto 2005) .................................. l 0
Figure 2.3: Examples of Integral Product (Holtta-Otto 2005) ................................... l 0
Figure 2.4: DFMA approach ...................................................................................... 14
Figure 2.5: Example of DFM Concurrent Costing Software ..................................... 15
Figure 2.6: Example of Design for Assembly software ............................................. 16
Figure 2. 7: Chair design for comfort .......................................................................... 20
Figure 2.8: Softwood description ............................................................................... 22
Figure 2.9: Plywood description ................................................................................ 23
Figure 2.10: Example's of stainless steel chair ........................................................... 24
Figure 2.11: Examples of seats made of flexible polymer foam ............................... 26
Figure 2.12: Wood screw ........................................................................................... 29
Figure 2.13: Bolt & Nut ............................................................................................. 30
Figure 3.1: Flowchart of Projek Srujana Muda .......................................................... 33
Figure 3.2: Existing design of lazy chair as benchmark ............................................ 34
Figure 3.3: Example of Pugh Method selection method for a kettle ......................... 36
Figure 3.4: An overview of product architecture methodology ................................. 37
Figure 3.5: CATIA Software...................................................................................... 39
Figure 3.6: Flow of Design Process (G. E. Dieter 2009) ........................................... 40
Figure 3.7: CES EDUPACK 2011 ............................................................................. 45
Figure 3.8: Example of Nickel alloys information from CES EduPack ................... 46
Figure 3.9: Product Decomposition of existing design of Lazy Chair.. ..................... 4 7
Figure 4.1: Concept design 1 ..................................................................................... 49
Figure 4.2: Concept design 2 ..................................................................................... 50
Figure 4.3: Concept design 3 ..................................................................................... 50
© Unlverlltl Teknlkal Malaysia Melakll
Xlll
Figure 5.1: Concept 2 as the final concept design ..................................................... 55
Figure 5.2: Final concept for join method which Concept 2 & Concept 3 ................ 56
© Unlvwaltl Telcnlkal Malayala Melalal
XIV
LIST OF APPENDICES
Appendix Al: Estimated Handling Time Table ......................................................... 86
Appendix A2: Estimated Insertion Time Table ......................................................... 87
Appendix A3: Axis of Orientation Chart ................................................................... 88
Appendix B1: Detail drawing .................................................................................... 89
Appendix B2: Exploded drawing of Lazy Chair ........................................................ 90
Appendix B3: Exploded drawing ofThreaded Fasteners .......................................... 91
Appendix C I : ISO view of Lazy Chair I ................................................................... 92
Appendix C2: ISO view of Lazy Chair 2 ................................................................... 92
Appendix C3: ISO view of Lazy Chair 3 ................................................................... 93
Appendix C4: ISO view of Lazy Chair 4 ................................................................... 93
Appendix Dl : Prototype of Lazy Chair 1 .................................................................. 94
Appendix D2: Prototype of Lazy Chair 2 .................................................................. 94
Appendix D3: Prototype of Lazy Chair 3 ........ ........................................................ .. 95
Appendix D4: Prototype of Lazy Chair 4 .......... ...................................................... .. 95
Appendix El : Flow Chart for PSM I & 2 .................................................................. 96
Appendix F l: Gantt Chart for PSM 1 ........................................................................ 97
Appendix F2: Gantt Chart for PSM 2 .......................... .............................................. 98
© Unlverlltl Teknlkal Malaysia Melakll
CHAPTER I
INTRODUCTION
1.1
Background
Figure 1.1: Current Design of Lazy Chair
Chair is created as furniture that is used to sit on normally by a single person.
Chair has been invented centuries ago and most often the chair is supported by four
legs and has a back. However, the designs are different according to the creativity of
the designers and criteria of the chair itself. There are various types of chair and one
of the chairs is lazy chair or can also be called leisure or relaxing chair. This type of
chair is for relaxing and the person that sits on it can take a nap as the back of the
© Unlverlltl Teknlkal Malaysia Melakll
2
chair is inclined and gives comfort to the user. It differs from other chairs because of
the slant angle of the back of the chair.
Lazy chair in this project is design to counter several problems from its
original design in terms of assemble the product. Using the modular product concept,
a new concept design will be produced to overcome the problems. In general,
modular product can be defined as an assembly with reduced parts, less complicated
and easy to assemble. Modularization is a concept that offers competitive advantage
to overcome complexity. Instead of manufacture a product with plenty of parts and
mechanical fasteners, design a product using simple blocks which is easy to
manufacture and use less joining method. The customers will be more satisfied and
pleased with the easiness of assemble the product (Lupton 2006).
When the customers assemble the product themselves, the terms used for that
act is Do It Yourself (DIY) method. DIY is an act of building or modifying without
the help of any expertise and instead do it independently. Usually products with DIY
assembly method will provide a manual for the customers to follow and DIY
products are easy to assemble and use low cost tools (Howell2010).
1.2
Objective
To study the activities in designed involved in designing of a new modular
product concept for " Lazy Chair" and fabrication of a prototype of scale l :2 using
sustainable material. The modular product also has to incorporate "DIY" assembly
method.
1.3
Scope
l. To propose few concept designs of modular product.
2. To produce detail design of the selected concept using CATIA V5Rl6.
3. To analyze the proposed concept design by using DFMA method.
4. To find the best joint method that meets the DIY assembly method.
© Unlverlltl Teknlkal Malaysia Melakll
3
1.4
Problem Statement
The existing design of lazy chair does not imply the DIY concept. The chair
already builds and joints completely and the buyers have to bring the chair in one
piece. The chair inclination level can be adjusted according to the user's wish. The
tricky part is that both of the rum rest must be moved simultaneously in order to
change the inclination level. New modular conceptual design of lazy chair with the
incorporation of DIY method will be produced at the end of this project to overcome
problems of existing design.
1.5
Methodology
Methodology generally is a guideline for solving problems. In this project,
there are several methods used to complete the design of new product. From the frrst
steps until the end, the methods are represents in flow chart to make it easy to
understand.
1.6
Outline of Report
Chapter 1 - Introduction
This chapter contains the background, objectives, scope and problem
statement of the project. This chapter also reviews generally about the
methods used in this project.
Chapter 2 - Literature Review
This chapter reviews the details of subjects cover in this project. The frrst
subject is modular product and followed by DIY assembly method, DFMA,
chair, materials and Screw, Bolt and Nut.
© Unlverlltl Teknlkal Malaysia Melakll
4
Chapter 3 - Methodology
This chapter contains the methods used in completing the project. The flow
chart of this project is included in this phase and the details of each methods
used is discussed.
Chapter 4 - Concept Generation
This chapter shows several of the concept designs generated from the
previous morphological chart (In Chapter 3). The descriptions of each
concept designs are also stated in this chapter.
Chapter 5 - Concept Design Selection
This chapter reviews the method used in selecting the best concept design.
There are several methods that can be used, but in this project, the author
chose Pugh Method as the concept design selection method.
Chapter 6 - Detail Design
This chapter consists of the detail drawing of the product.
© Unlverlltl Teknlkal Malaysia Melakll
5
Chapter 7 - Result & Discussion
This chapter discussed in details the results from the DFA and DFM analysis
done manuaJly and the outcomes of this project.
Chapter 8 - Conclusion
This chapter will conclude all the results and fmdings that have been
completed.
1. 7
Conclusion Remarks
In this chapter, the author reviews about the objectives, problem statements
and scopes of this project. The author also reviews the outline of this report in
general which consists of 8 chapters including this chapter. The background and
history of the lazy chair are also discussed in this chapter generally as the details will
be further discussed in the next chapter.
© Unlverlltl Teknlkal Malaysia Melakll
CHAPTER2
LITERATURE REVIEW
This chapter will discuss further on the project. The first subject to be
discussed is modular product. The topics covered are the defmitions and advantages
of modularity. This chapter also will discuss about the Do It Yourself assembly
method, Design for Manufacture and Assembly and about the chair itself
2.1
Modular Product
A product can be thought of in functional and physical terms (Ulrich and
Eppiger 1995). The physical elements of a product are the parts, components and
subassemblies. The physical elements may be presented into several major building
blocks and each of the blocks implement some functions of the product. The block
also called as the module. Modularity is an important aspect in product architecture.
As an example, the figure below shows the design of a drawer. Figure 2.1(a) shows
that the drawer and the open space are allocated to separate modules . It shows the
design of modular architecture and each module may be designed independently.
Figure 2.l(b) shows the traditional architecture design which is more complicated
and the blocks are not designed independently.
© Unlverlltl Teknlkal Malaysia Melakll
7
(a)
(b)
4 modules are used
7 blocks are used
Figure 2.1: Designs of a drawer (Huang 2000)
2.1.1
Definitions
Modularity is a common but unexplored thread among all areas of life-cycle
engineering. It has become very famous in studies recent years though it has existed
for at least 30 years. Modular products tend to have fewer components for assembly
and therefore cheaper to assemble. Modularity has no specific definitions and in fact
according to (Gershenson 2003), there is no agreement on the definition of
modularity. Modular product can be defined in many ways and shown below in
Table 2.1 are some examples of the definitions:
Table 2. 1: Definitions of Modular Product
Authors
Definitions
Pabl and Beitz
Modular products refer to products,
assemblies and components that fulfill
varwus
functions
through
the
combination of distinct building blocks
(Pahl 1988)
Ulrich and Tung
Defme modularity m terms of two
characteristics of product design (Ulrich
© Unlverlltl Teknlkal Malaysia Melakll
8
1991):
1. Similarity between the physical
and functional architecture of the
design.
2. Minimization
interactions
of
between
incidental
physical
components.
Erixson and Kusiak
Define modularity as a tool to decrease
assembly and manufacturing costs in
product
families
and
manufacturing
systems (Erixson 1996).
Chun Che Huang
The terms modularity in products is used
to describe the use of common units to
create product variants (Huang 2000).
In general, modular product is an assembly with reduced parts, less
complicated and easy to assemble. Due to the functional independence it creates,
modularization has been called the goal of good design (John K. Gershenson 1999).
2.1.2
Advantages of Modular Product
Modularity has a lot of advantages and benefits, as an example, modularity
allow the designer to control the degree to which changes in processes or
requirements affect the product. According to Ulrich and Tung (Ulrich 1991 ), they
described the benefits of modularity as:
l. Greater product variety. A modular product design can be partitioned
technically and variations in functional components can be substitutes
into modular architecture to create product variations based on
different combinations (Eggen 2003).
2. Economies of scale. Since each module will usually be produced in a
batch of large scale, natural economies of scale arise.
© Unlverlltl Teknlkal Malaysia Melakll
9
3. Ease of product updating. A modular product is decomposed into
modules; only certain modules need to be replaced. And for same
reason, upgrades, updates, maintenance and disposal are simpler.
4. Increased product variety. The use of modules means that a great
product variety can be achieved using different combination of
modules.
5. Reduced order lead-time. Since modules are manufactured in
relatively large scale, the production can be organized so as to reduce
manufacturing lead time.
6. Ease of design and testing. As the component is produced in modules,
the design is simple and for testing purpose, the components can be
tested individually.
Designing a modular product can gives the result of product cost and
development time higher or lower. If the designs are simple needs simpler
manufacturing process, the cost can be low but if the designs are complicated and
needs a lot interfaces between the modules, the cost may be higher. The development
time is often lower once the design is split into modules, where the design teams can
work in parallel on the different modules.
2.1.3
Modular Architectures
There are two types of product architecture; modular architecture and integral
architecture. An integral architecture includes a complex mapping from functional
elements to physical components (John K. Gershenson 1997). In the other hand,
modular architecture has a one-to-one mapping. Modular architecture allows a design
change to be made to one module without requiring a change to other modules for
the product function properly (Eggen 2003).
© Unlverlltl Teknlkal Malaysia Melakll
10
Typical examples for modular architecture which is close to one to one
mapping between functions are mechanical pencil, personal desktop computer and
pocket knife. The examples shown in Figure 2.2 below.
Figure 2.2: Examples of Modular Product (Ho ltUi-Otto 2005)
In the other hand, typical examples of integral architecture where it is hard to
determine what part of a product performs which function are an old fashioned
pencil, a laptop and a hunting knife. The examples shown in Figure 2.3 below.
"I hereby declare that the quality of the dissertation written is sufficient for the award
of Bachelor of Mechanical Engineering (Design & Innovation)"
Signature
Supervisor
Date
:. . . ｷｾﾷ
'
ｾ｜＠
ﾷ＠
.
: Siti Nurhaida binti Khalil
: ......＿ＺＭＮｉＡｌｾﾷ
© Unlveralll Teknlkal Malaysia Melalal
ﾷ ﾷ＠
DESIGN AND FABRICATION MODULAR PRODUCT WITH THE
INCORPORATION OF DIY ASSEMBLY METHOD: LAZY CHAIR
NUR 'AIN BINTI AZMI
This report is submitted as a partial fulfillment of the requirements for the
award Bachelor of Mechanical Engineering (Design & Innovation)
Faculty of Mechanical Engineering
Universiti Teknikal Malaysia Melaka
JUNE 2012
© Unlverlltl Teknlkal Malaysia Melakll
11
DECLARATION
"I hereby declare that the work in this dissertation is my own except for summaries
and quotations which have been duly acknowledge"
/'
Signature
: .........ｾ＠
Author
: Nur 'A in binti Azmi
Date
':l_q
........... .
Jl!N
© Unlverlltl Teknlkal Malaysia Melakll
2.0\4...
lll
Dedicated with love,
To my parents,
Azmi bin Hj. Arshad and Roziah binti Hj. Mustapha,
To my sister,
Nur Asyikin binti Azmi.
To all my friends.
© Unlverlltl Teknlkal Malaysia Melakll
IV
ACKNOWLEDGEMENT
Apart from the efforts of myself, the success of this project depends largely
on the encouragement and guidelines of many others. I would like to take this
ｾｰｯｲｴｵｮｩｹ＠
to express my gratitude to the people who have been helping and
supporting me throughout the successful completion of this project.
First and foremost, I would like to thank my supervisor, Ms. Siti Nurhaida
binti Khalil for the valuable guidance and advice right from the beginning of this
project until the very end. Her willingness to motivate and encourage me contributed
tremendously to my project and without her, this project would not have
materialized.
I would like to express my greatest appreciation to my beloved parents, Azmi
bin Hj. Arshad and Roziah binti Hj. Mustapha. I cannot thank them enough for their
support, faith and loves towards me upon completing my project. They are the
reasons for me to complete this project.
Last but not least, special thanks to Marliati Ghazali, Myn Samsuddin, Fariha
Azmi, Nik Zubaidi and to all my friends who have been constantly helping and
supporting me throughout the completion of this project. I am grateful with their
helps and their contributions were vital for this project. Not to forget, thank you for
the friendships.
© Unlveralll Teknlkal Malaysia Melalal
v
ABSTRACT
The objective of this project is to study the activities in designed involved in
designing of a new modular product concept for ' Lazy Chair' and fabrication of a
prototype of scale 1:2 using sustainable material. The modular product also
incorporates ' DIY' assembly method. The project starts by choosing a benchmark
design and from there; ideas for concept designs were created. Morphological chart
was used as one of the method to generate concept designs. Concept selection
method was used to choose the final concept design; example is Pugh method. The
final concept design is analyzed using DFMA method to compare with the existing
design of lazy chair. DFMA is used as a tool for reducing the number of individual
parts that must be assembled and increase the ease of put the parts together. The DIY
assembly method is the most important part and the best joining method will be
determined using the concept selection method. The DIY method is implemented in
this design is to make the assembly process of the product easy to conduct with or
without the help of a user manual. The outcome of this project is a new modular
product concept for ' Lazy Chair' that overcomes several problems that encounters
with the existing design.
© Unlverlltl Teknlkal Malaysia Melakll
VI
ABSTRAK
Objektif projek ini adalah untuk mengkaji aktiviti - aktiviti yang direka
bentuk yang terlibat didalam proses mereka bentuk konsep modular produk yang
baru bagi 'Kerusi Malas' dan fabrikasi sebuah prototaip dengan skala I :2
menggunakan bahan mampan. Modular produk yang baru ini juga harus
menggabungkan konsep pemasangan 'DIY' . Projek ini bermula dengan memilih
sebuah kerusi malas sebagai penanda aras dan idea-idea untuk reka bentuk konsep
yang baru dapat dihasilkan. Carta morfologi digunakan sebagai salah satu kaedah
untuk menghasilkan beberapa konsep rekabentuk yang baru. Kaedah pemlihan
konsep yang digunakan adalah kaedah Pugh. Konsep reka bentuk yang dipilih akan
dianalisis menggunakan kaedah DFMA untuk melakukan perbandingan dengan reka
bentuk kerusi malas yang sedia ada. Analisis DFMA adalah salah satu cara atau
aplikasi yang digunakan untuk mengurangkan bilangan bahagian atau komponen
yang perlu dipasang menjadi satu produk dan meningkatkan kadar pemasangan yang
mudah. DIY adalah bahagian yang paling penting dan cara pemasangan yang terbaik
akan dipilih menggunakan kaedah pemilihan konsep yang ada di dalam Reka bentuk
Kejuruteraan. Kaedah pemasangan DIY diaplikasikan di dalam
reka bentuk ini
adalah untuk member kesenangan kepasa para pengguna untuk memasang tanpa
memerlukan bantuan manual. Hasil daripada projek ini adalah menghasilkan sebuah
konsep modular produk yang baru untuk 'Kerusi Malas' bagi mengatasi beberapa
masalah yang wujud dengan reka bentuk yang sedia ada.
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TABLE OF CONTENT
CHAPTER
CHAPTER l
CHAPTER2
CONTENT
PAGE
DECLARATION
11
DEDICATION
lll
ACKNOWLEDGEMENT
lV
ABSTRACT
v
ABSTRAK
Vl
TABLE OF CONTENT
Vll
LIST OFTABLES
Xl
LIST OF FIGURES
Xll
LIST OF APPENDICES
XlV
INTRODUCTION
l
1.1
Background
1.2
Objective
2
1.3
Scope
2
1.4
Problem Statement
3
1.5
Methodology
3
1.6
Outline of Report
3
1.7
Conclusion Remarks
5
LITERATURE REVIEW
2. 1
6
Modular Product
6
2.1.1
Defmitions
7
2.1 .2
Advantages of Modular Product
8
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2.1.3
Modular Architectures
9
2.1.4 Modular Product Development
II
2.2
Do It Yourself (DIY) Method
12
2.3
Design for Manufacture and Assembly
14
(DFMA)
2.4
2.4.1
2.5
2.6
2.7
CHAPTER3
18
Chair
History of Chair
18
2.4.2 Chair Seats
19
2.4.3
19
Standards and Specifications
2.4.4 Accessories
21
Materials
22
2.5.1 Softwood
22
2.5.2
Plywood
23
2.5.3
Stainless Steel
24
2.5.4 Flexible Polymer Foam
26
Threaded Fasteners
28
2.6.1
29
Screw
2.6.2 Bolt & Nut
30
Conclusion Remarks
31
METHODOLOGY
32
3.1
Introduction
32
3.1.1
34
3.2
Benchmark
3.1.2 Ideas I Sketches
35
3.1.3 Generate Concept Design
35
3.1.4 Concept Design Selection
35
3.1.5 Product Architecture
37
3.1.6 Configuration Design
38
3. 1.7 Parametric Design
38
3.1.8 Detail Design
38
3.1.9 Prototype & Testing
39
Flow of Design Process
40
3.2.1
41
Defme Problem
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3.3
CHAPTER4
CHAPTER 5
3.2.2
The House of Quality Configurations
41
3.2.3
Product Design Specification
43
3.2.4
Gather Information
45
3.2.5
Product Decomposition
47
3.2.6
Morphological Chart
47
Conclusion Remarks
CONCEPT GENERATION
49
4.1
Introduction
49
4.2
Concept Design 1
49
4.3
Concept Design 2
50
4.4
Concept Design 3
50
4.5
Concept Design for Join Method
51
4.6
Conclusion Remarks
52
CONCEPT DESIGN SELECTION
53
5.1
Introduction
53
5.2
Pugh M ethod
53
5.3
Pugh Method Chart
54
5.3. 1 Pugh Method: Lazy Chair Design
54
Pugh Method: Join Method
56
5.3.2
5.4
CHAPTER 6
CHAPTER 7
48
Conclusion Remarks
57
DETAIL DESIGN
58
6.1
Detail Drawing
58
6.2
Exploded Drawing
58
6.3
Prototype
58
RESULT & DISCUSSION
59
7.1
59
Result
7.1.1
DFA Analysis
59
7. 1.1.1. DFA Analysis of Existing
60
Design
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7.1.1.2. DFA Analysis ofNew
63
Design
7.1.2
7.2
7.3
CHAPTER 8
DFM Analysis
76
Discussion
77
7.2.1
DFAAnalysis Result
77
7.2.2
Limitations and Strengths
78
7 .2.3
New Design of Lazy Chair
79
Conclusion Remarks
79
CONCLUSION & RECOMMENDATION
80
8. 1
Conclusion
80
8.2
Recommendation
81
REFERENCES
82
APPENDICES
85
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LIST OF FIGURES
Figure 1.1: Current Design ofLazy Chair
Figure 2.1 : Designs of a drawer (Huang 2000) ............................................................ 7
Figure 2.2: Examples of Modular Product (Holtta-Otto 2005) .................................. l 0
Figure 2.3: Examples of Integral Product (Holtta-Otto 2005) ................................... l 0
Figure 2.4: DFMA approach ...................................................................................... 14
Figure 2.5: Example of DFM Concurrent Costing Software ..................................... 15
Figure 2.6: Example of Design for Assembly software ............................................. 16
Figure 2. 7: Chair design for comfort .......................................................................... 20
Figure 2.8: Softwood description ............................................................................... 22
Figure 2.9: Plywood description ................................................................................ 23
Figure 2.10: Example's of stainless steel chair ........................................................... 24
Figure 2.11: Examples of seats made of flexible polymer foam ............................... 26
Figure 2.12: Wood screw ........................................................................................... 29
Figure 2.13: Bolt & Nut ............................................................................................. 30
Figure 3.1: Flowchart of Projek Srujana Muda .......................................................... 33
Figure 3.2: Existing design of lazy chair as benchmark ............................................ 34
Figure 3.3: Example of Pugh Method selection method for a kettle ......................... 36
Figure 3.4: An overview of product architecture methodology ................................. 37
Figure 3.5: CATIA Software...................................................................................... 39
Figure 3.6: Flow of Design Process (G. E. Dieter 2009) ........................................... 40
Figure 3.7: CES EDUPACK 2011 ............................................................................. 45
Figure 3.8: Example of Nickel alloys information from CES EduPack ................... 46
Figure 3.9: Product Decomposition of existing design of Lazy Chair.. ..................... 4 7
Figure 4.1: Concept design 1 ..................................................................................... 49
Figure 4.2: Concept design 2 ..................................................................................... 50
Figure 4.3: Concept design 3 ..................................................................................... 50
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Figure 5.1: Concept 2 as the final concept design ..................................................... 55
Figure 5.2: Final concept for join method which Concept 2 & Concept 3 ................ 56
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LIST OF APPENDICES
Appendix Al: Estimated Handling Time Table ......................................................... 86
Appendix A2: Estimated Insertion Time Table ......................................................... 87
Appendix A3: Axis of Orientation Chart ................................................................... 88
Appendix B1: Detail drawing .................................................................................... 89
Appendix B2: Exploded drawing of Lazy Chair ........................................................ 90
Appendix B3: Exploded drawing ofThreaded Fasteners .......................................... 91
Appendix C I : ISO view of Lazy Chair I ................................................................... 92
Appendix C2: ISO view of Lazy Chair 2 ................................................................... 92
Appendix C3: ISO view of Lazy Chair 3 ................................................................... 93
Appendix C4: ISO view of Lazy Chair 4 ................................................................... 93
Appendix Dl : Prototype of Lazy Chair 1 .................................................................. 94
Appendix D2: Prototype of Lazy Chair 2 .................................................................. 94
Appendix D3: Prototype of Lazy Chair 3 ........ ........................................................ .. 95
Appendix D4: Prototype of Lazy Chair 4 .......... ...................................................... .. 95
Appendix El : Flow Chart for PSM I & 2 .................................................................. 96
Appendix F l: Gantt Chart for PSM 1 ........................................................................ 97
Appendix F2: Gantt Chart for PSM 2 .......................... .............................................. 98
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CHAPTER I
INTRODUCTION
1.1
Background
Figure 1.1: Current Design of Lazy Chair
Chair is created as furniture that is used to sit on normally by a single person.
Chair has been invented centuries ago and most often the chair is supported by four
legs and has a back. However, the designs are different according to the creativity of
the designers and criteria of the chair itself. There are various types of chair and one
of the chairs is lazy chair or can also be called leisure or relaxing chair. This type of
chair is for relaxing and the person that sits on it can take a nap as the back of the
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chair is inclined and gives comfort to the user. It differs from other chairs because of
the slant angle of the back of the chair.
Lazy chair in this project is design to counter several problems from its
original design in terms of assemble the product. Using the modular product concept,
a new concept design will be produced to overcome the problems. In general,
modular product can be defined as an assembly with reduced parts, less complicated
and easy to assemble. Modularization is a concept that offers competitive advantage
to overcome complexity. Instead of manufacture a product with plenty of parts and
mechanical fasteners, design a product using simple blocks which is easy to
manufacture and use less joining method. The customers will be more satisfied and
pleased with the easiness of assemble the product (Lupton 2006).
When the customers assemble the product themselves, the terms used for that
act is Do It Yourself (DIY) method. DIY is an act of building or modifying without
the help of any expertise and instead do it independently. Usually products with DIY
assembly method will provide a manual for the customers to follow and DIY
products are easy to assemble and use low cost tools (Howell2010).
1.2
Objective
To study the activities in designed involved in designing of a new modular
product concept for " Lazy Chair" and fabrication of a prototype of scale l :2 using
sustainable material. The modular product also has to incorporate "DIY" assembly
method.
1.3
Scope
l. To propose few concept designs of modular product.
2. To produce detail design of the selected concept using CATIA V5Rl6.
3. To analyze the proposed concept design by using DFMA method.
4. To find the best joint method that meets the DIY assembly method.
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1.4
Problem Statement
The existing design of lazy chair does not imply the DIY concept. The chair
already builds and joints completely and the buyers have to bring the chair in one
piece. The chair inclination level can be adjusted according to the user's wish. The
tricky part is that both of the rum rest must be moved simultaneously in order to
change the inclination level. New modular conceptual design of lazy chair with the
incorporation of DIY method will be produced at the end of this project to overcome
problems of existing design.
1.5
Methodology
Methodology generally is a guideline for solving problems. In this project,
there are several methods used to complete the design of new product. From the frrst
steps until the end, the methods are represents in flow chart to make it easy to
understand.
1.6
Outline of Report
Chapter 1 - Introduction
This chapter contains the background, objectives, scope and problem
statement of the project. This chapter also reviews generally about the
methods used in this project.
Chapter 2 - Literature Review
This chapter reviews the details of subjects cover in this project. The frrst
subject is modular product and followed by DIY assembly method, DFMA,
chair, materials and Screw, Bolt and Nut.
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Chapter 3 - Methodology
This chapter contains the methods used in completing the project. The flow
chart of this project is included in this phase and the details of each methods
used is discussed.
Chapter 4 - Concept Generation
This chapter shows several of the concept designs generated from the
previous morphological chart (In Chapter 3). The descriptions of each
concept designs are also stated in this chapter.
Chapter 5 - Concept Design Selection
This chapter reviews the method used in selecting the best concept design.
There are several methods that can be used, but in this project, the author
chose Pugh Method as the concept design selection method.
Chapter 6 - Detail Design
This chapter consists of the detail drawing of the product.
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Chapter 7 - Result & Discussion
This chapter discussed in details the results from the DFA and DFM analysis
done manuaJly and the outcomes of this project.
Chapter 8 - Conclusion
This chapter will conclude all the results and fmdings that have been
completed.
1. 7
Conclusion Remarks
In this chapter, the author reviews about the objectives, problem statements
and scopes of this project. The author also reviews the outline of this report in
general which consists of 8 chapters including this chapter. The background and
history of the lazy chair are also discussed in this chapter generally as the details will
be further discussed in the next chapter.
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CHAPTER2
LITERATURE REVIEW
This chapter will discuss further on the project. The first subject to be
discussed is modular product. The topics covered are the defmitions and advantages
of modularity. This chapter also will discuss about the Do It Yourself assembly
method, Design for Manufacture and Assembly and about the chair itself
2.1
Modular Product
A product can be thought of in functional and physical terms (Ulrich and
Eppiger 1995). The physical elements of a product are the parts, components and
subassemblies. The physical elements may be presented into several major building
blocks and each of the blocks implement some functions of the product. The block
also called as the module. Modularity is an important aspect in product architecture.
As an example, the figure below shows the design of a drawer. Figure 2.1(a) shows
that the drawer and the open space are allocated to separate modules . It shows the
design of modular architecture and each module may be designed independently.
Figure 2.l(b) shows the traditional architecture design which is more complicated
and the blocks are not designed independently.
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(a)
(b)
4 modules are used
7 blocks are used
Figure 2.1: Designs of a drawer (Huang 2000)
2.1.1
Definitions
Modularity is a common but unexplored thread among all areas of life-cycle
engineering. It has become very famous in studies recent years though it has existed
for at least 30 years. Modular products tend to have fewer components for assembly
and therefore cheaper to assemble. Modularity has no specific definitions and in fact
according to (Gershenson 2003), there is no agreement on the definition of
modularity. Modular product can be defined in many ways and shown below in
Table 2.1 are some examples of the definitions:
Table 2. 1: Definitions of Modular Product
Authors
Definitions
Pabl and Beitz
Modular products refer to products,
assemblies and components that fulfill
varwus
functions
through
the
combination of distinct building blocks
(Pahl 1988)
Ulrich and Tung
Defme modularity m terms of two
characteristics of product design (Ulrich
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1991):
1. Similarity between the physical
and functional architecture of the
design.
2. Minimization
interactions
of
between
incidental
physical
components.
Erixson and Kusiak
Define modularity as a tool to decrease
assembly and manufacturing costs in
product
families
and
manufacturing
systems (Erixson 1996).
Chun Che Huang
The terms modularity in products is used
to describe the use of common units to
create product variants (Huang 2000).
In general, modular product is an assembly with reduced parts, less
complicated and easy to assemble. Due to the functional independence it creates,
modularization has been called the goal of good design (John K. Gershenson 1999).
2.1.2
Advantages of Modular Product
Modularity has a lot of advantages and benefits, as an example, modularity
allow the designer to control the degree to which changes in processes or
requirements affect the product. According to Ulrich and Tung (Ulrich 1991 ), they
described the benefits of modularity as:
l. Greater product variety. A modular product design can be partitioned
technically and variations in functional components can be substitutes
into modular architecture to create product variations based on
different combinations (Eggen 2003).
2. Economies of scale. Since each module will usually be produced in a
batch of large scale, natural economies of scale arise.
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3. Ease of product updating. A modular product is decomposed into
modules; only certain modules need to be replaced. And for same
reason, upgrades, updates, maintenance and disposal are simpler.
4. Increased product variety. The use of modules means that a great
product variety can be achieved using different combination of
modules.
5. Reduced order lead-time. Since modules are manufactured in
relatively large scale, the production can be organized so as to reduce
manufacturing lead time.
6. Ease of design and testing. As the component is produced in modules,
the design is simple and for testing purpose, the components can be
tested individually.
Designing a modular product can gives the result of product cost and
development time higher or lower. If the designs are simple needs simpler
manufacturing process, the cost can be low but if the designs are complicated and
needs a lot interfaces between the modules, the cost may be higher. The development
time is often lower once the design is split into modules, where the design teams can
work in parallel on the different modules.
2.1.3
Modular Architectures
There are two types of product architecture; modular architecture and integral
architecture. An integral architecture includes a complex mapping from functional
elements to physical components (John K. Gershenson 1997). In the other hand,
modular architecture has a one-to-one mapping. Modular architecture allows a design
change to be made to one module without requiring a change to other modules for
the product function properly (Eggen 2003).
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Typical examples for modular architecture which is close to one to one
mapping between functions are mechanical pencil, personal desktop computer and
pocket knife. The examples shown in Figure 2.2 below.
Figure 2.2: Examples of Modular Product (Ho ltUi-Otto 2005)
In the other hand, typical examples of integral architecture where it is hard to
determine what part of a product performs which function are an old fashioned
pencil, a laptop and a hunting knife. The examples shown in Figure 2.3 below.