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
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
FPDM 4
1.2: DESIGN TEAM
MEMBERS
GROUP P-TECH

 Group Members :-

 Mohd Azizul B. Mansur ( Group Leader )

 Mohd Hafiz B. Zulkapli

 Mohd Faisoul B. Hashim

 Mohd Asri B. Mahmood

FPDM 6
1.3: OVERALL OBJECTIVE
FOR THE DESIGN
PROJECT
 To understand more about the design process

 To fulfill customer requirements

 To improve the design

 To implement the design process

FPDM 8
 CHAPTER 2:
UNDERSTANDING CUSTOMER
NEEDS
 2.1: CUSTOMER
REQUIREMENT
STATEMENT
PRESENTER :- MOHD AZIZUL B.
MANSUR
 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 11
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 12
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 13
 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

FPDM 14
2.2: HOUSE OF QUALITY
 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 16
 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 17
HOUSE OF QUALITY

FPDM 18
2.5: PRODUCT DESIGN
SPECIFICATION
 PRODUCT DESIGN SPECIFICATION
Bicycle vehicle Roof Rack

affordable cost less then RM 800

safe protect user no sharp

electrically insulated

protect bike durable material

locking system

marketable not eastatics simple shape only

durable stiff resist bending <18.0Kn bending force bending test

long lasting resist impact <270Kn of impact force impact test

resist bending < 240 kN of bending force bending test

resist static load resist static load static load test

resist tension < 4.5 kN of tension force tension test

functional lock and secure bike lock frame/ tyre with switch

easy to use reachable height no step ladder

easy bike loading

steady transport

on the roof

clear rear door and hatch

max allowable weight height on rest

FPDM 20
 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 21
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 22
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

FPDM 23
CHAPTER 3: CONCEPT
GENERATION &
SELECTION
PRESENTER :- MOHD HAFIZ B.
ZULKAPLI
3.1: FUNCTIONAL
STRUCTURE
 USER

LOAD BIKE NO STEP

LADDER

SUPPORT BIKE PROTECT

BIKE

LOCKING
LOCK BIKE
MECHANISM

CAR

FPDM 26
FUNCTIONAL SEQUENCE

Bicycle Vehicle Roof Rack

Put the assembled Mount the roof rack

Assemble parts
Parts on the roof On the roof of vehicle

Slide the bicycle on to

Position & secure it with Rise up the bicycle
Handle with care
locking to the roof rack
mechanism

FPDM 27
 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.

FPDM 28
BRAINSTORMING
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 30
BICYCLE VEHICLE ROOF RACK

NO STEP LADDER DURABLE

BICYCLE VEHICLE ROOF RACK

REACHABLE HEIGHT LOCK AND SECURE BIKE

FPDM 31
 LOWER FRAME UPPER
FRAME
HANDLE

SHAFT

SEAT BICYCLE LOCK

CRANK

WHEEL
FORK ARM

FPDM 32
 WOOD PLASTIC

ALLOY MATERIAL FOR ROOF RACK

COMPOSITE

FIBER
STAINLESS STEEL

ALUMINIUM
FPDM 33
PRODUCT DESIGN
SPECIFICATIONS
Bicycle vehicle Roof Rack

affordable cost less then RM 800

safe protect user no sharp

electrically insulated

protect bike durable material

locking system

marketable not eastatics simple shape only

durable stiff resist bending <18.0Kn bending force bending test

long lasting resist impact <270Kn of impact force impact test

resist bending < 240 kN of bending force bending test

resist static load resist static load static load test

resist tension < 4.5 kN of tension force tension test

functional lock and secure bike lock frame/ tyre with switch

easy to use reachable height no step ladder

easy bike loading

steady transport

on the roof

clear rear door and hatch

max allowable weight height on rest

FPDM 35
3.2: CONCEPTS FOR
PROJECTS
CONCEPT GENERATION PROCESS

Clarify the Problem

Search Externally Search Internally

Explore systematically

Reflect on the Solutions and Process

FPDM 37
STEP 1: CLARIFY THE
PROBLEM
 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 39
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

FPDM 40
STEP 2: SEARCH
EXTERNALLY
 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 42
 COMPETITORS 1
 THULE SUPER G  YAKIMA RAPTOR

FPDM 43
 COMPETITORS 2
 YAKIMA-SIDEWINDER  THULE

FPDM 44
STEP 3: SEARCH
INTERNALLY
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

FPDM 46
STEP 3: EXPLORE
SYSTEMATICALLY
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)

FPDM 48
3.3: MORPHOLOGICAL
CHART
 BICYCLE VEHICLE ROOF RACK MORPH CHART
1 2 3 4 5

Bicycle Lock Frame Wheel Arm Shaft Shaft

Material For Rack Plastic Composite Fiber Plastic Fiber

Special Feature Fit all bike Fit wheel size Compactable Designed to clear Bombproof
frame from 24” to 29” with factory rear door and construction
rack hatches

User Friendly Features Protect User Transport stability Protect Roof Easy To Use Lightweight

Locking Mechanism Switch ratcheting wheel Rack Lever Clamp Integrated Cable
strap Lock

FPDM 50
 IMPLEMENTATION
Bicycle 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

FPDM 51
 3.4: PUGH CONCEPT
EVALUATION MATRIX
 Evaluation Matrix
Concept 1 Concept 2 Concept 3 Concept 4 Concept 5 Concept 6

Low cost D + - S + -
A
Easy to assemble T + - S + -
U
M
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
FPDM 53
Sum of ‘S’ 2 2 5 4 3
 Evaluation Matrix
Concept 1 Concept 2 Concept 3 Concept 4 Concept 5 Concept 6

Low cost S S - D + S
A
Easy to assemble - S - T + -
U
M
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
FPDM 54
Sum of ‘S’ 4 6 1 2 4
 Evaluation Matrix
Concept 1 Concept 2 Concept 3 Concept 4 Concept 5 Concept 6

Low cost + + - + S D
A
Easy to assemble + + - + S T
U
M
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
FPDM 55
Sum of ‘S’ 5 3 2 1 4
3.5: GROUP ANALYSIS OF
RESULTS &
RECOMMENDATIONS
 CHAPTER 4: FINAL
DESIGN
PRESENTER :- MOHD ASRI B.
MAHMOOD
4.1: DETAIL DESIGN
ASSEMBLY MODEL

FPDM 59
EXPLODE VIEW

FPDM 60
4.2: DFMA & SAFETY
IMPORTANCE OF DFMA
 REDUCE PART

 REDUCE COMPONENT COST

 REDUCE ASSEMBLY & MANUFACTURING COST

 SIMPLIFY THE PRODUCT

 EASY FOR USER TO USE THE PRODUCT

FPDM 62
SAFETY
 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 64
BRAINSTORMING- HAZARD
IMPROPER USE

IDENTIFY ALL HAZARDS

PROJECTILES
FAILURES

FPDM 65
NO AVOIDANCE PROTECTION
WARNING
DANGER FEATURE
FAIL-SAFE SAFE-LIFE CONTROL F.O.S PROTECT
SYSTEM

1. FRAME LOCK SLIDE ON TO THE STOPER N/A MANUALLY CLAMP YES

RAIL CONTROL CAREFULLY

2. SLIDING PART ARM LOCK CLOSE APPLY OIL MANUALLY N/A RAIL STOPPER YES
TOLERANCE FREGENTLY CONTROL

3. BODY FRAME BODY FRAME APPLY GREASEMANUALLY N/A BEARING NO

ABSORBER ADJUSTMENT CONTROL

4. TIRE CLAMP CRUSH HAND N/A N/A NO

5. BICYCLE STABILITY FALL OVER USER BICYCLE N/A MANUALLY N/A SAFETY BAR YES
THROUGHTLY OPERATED
LOCKED

6. STORE BIKE UNSTABLE SLIDE THROUGH N/A MANUALLY N/A MANUAL HAND YES
RACK OPERATED BOOK

FPDM 66
FAILURE MODE
PART & POTENTIAL POTENTIAL POTENTIAL OC DETECTION METHOD & DE RPN RECOMMENDED
FUNCTION FAILURE EFFECT OF SE CAUSE OF C QUALITY CONTROL T ACTIONS
MODE FAILURE V FAILURE

• LOAD FRACTUTE FAILURE TO 8 • WEAR 6 •INCOMING PARTS 5 240 •INITIATE

BICYCLE INTO FUNCTION • FATIGUE INSPECTION RADIOGRAPHY
RACK •DEFORMATION •PRODUCT TESTING TEST OF ALL ROOF
•IMPROPER USE RACK
•LOCK AND
SECURE FRAME

•LOCK TYRES

•LOCK ARMS

•BICYCLE
LOCKED AND
SECURE JAMMED HAZARDOUS TO 8 •DIMENSION OUT 5 •MEASURE & TEST 3 120 •INTIATE PROGRAM
USER AND BIKE OF SPECS PATTERN TO MAINTAIN
•STABILIZES •UNIT DAMAGED RACK DIMENSIONS
BIKE

FPDM 68
4.3: ERGONOMICS
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 70
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 71
 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

FPDM 72
 4.4: ADVANTAGE &
DISADVANTAGES OF
FINAL DESIGN
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 74
DISADVANTAGES OF FINAL DESIGN
 LOCK BICYCLE MANUALLY

 NO AUTOMATIC FEATURE

 ONLY ONE BICYCLE ROOF RACK CAN FIT TO THE

ROOF

FPDM 75
CONCLUSION
 Complete the design process

 Applying the fundamentals of the design

 Fulfill the customer need

 Product is guaranteed successful in the market

FPDM 76
THANK YOU