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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 + + +
19 Ease of Maintenance 3 + + +
20 Quality of Cleaning 9 + + +
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 + - +
19 Ease of Maintenance 3 + + +
20 Quality of Cleaning 9 + + +
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?