Return On Failure

Name : Gabriel Hii Jia Enn

Student ID : 0321318
Discipline : Mechanical Engineering
Project : Energy And Resources Savings On Laundry Washings

Describe the failure or mistake that you are analysing.

Our concept of group project is conservation of energy and related resources in performing
laundry washing, in which our purposed solution is the creation of immediate laundry
cleaning solution through trial and error formulation involving existing active cleaning
agents found in most cleaning products, such as sodium carbonate (washing soda) and
MES (methyl ester sulphonate). The details for process of formulating immediate laundry
cleaning solution is illustrated in diagram 1.0.1 as shown below.

soda)
Production of fundamental cleaning agent - sodium carbonate (washing
Enquiry on sponsorship of chemical agents - MES
formulation Research on its most effective cleaning agents - MES, Na 2CO3
Detergency Commercial detergency products test
Phase 1:

Formulation of suitable ratio between concentrated softener and frangrance

Accqusition of frangrance sample from fabric shop
removal performance
formulation Selection of stain with strong odour as benchmark for measuring odour
Phase 2: Fragrance

Installation of pacakging label

Selection of existing container design as packaging preference
Packaging Design Nomination of ergonomic feature to improve mechanical agitation
Phase 3:

Diagram 1.0.1 Formulation process of immediate laundry cleaning solution

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The flowchart for 1st phase formulation process is illustrated as below:

Preparation Identify
Preparation Division of Cleaning
of best
of stain region on action
detergent detergency
solution cloth fabric performed
solution solution

Diagram 1.0.2 Flowchart for 1st phase formulation process

During 1st phase of formulation process, our team has performed commercial detergency
test across all five major detergent brands, which they are Breeze and Top in form of liquid
detergent together with Kuat Harimau, Attack and Daia in form of powder detergent. Both
liquid and powder detergent were mixed with water in ratio of 1:4 in terms of mass to
ensure consistency in measuring performance of each distinct detergency solution, despite
they have been found to have different solubility in water that might influence the
performance in bleaching the stains from the fabric cloth shown in diagram 1.0.5 & 1.0.6.
In 1st commercial detergency test, there were three stains being prepared for performing the
detergency test, which they were flavouring bags representing different flavouring products
and derived from single instant noodle product. The details for type of stains are labelled as
below in diagram 1.0.4. As the flavouring bags were presented in powder form as shown in
diagram 1.0.3, the stains were prepared through dilution with distilled water in ratio of 1:10
to form solution that would allow greater penetration of fabrics in order to challenge
effectiveness of active cleaning agents from detergency products. However, we had soon
realized our mistake in missing facts of water insolubility of oil based products during
meeting with project supervisor. Furthermore, the dissolving action of stain powders had
reduced visibility of dirt presence on fabric cloth, in which it eventually affects the
accuracy of determination for the stain presence after performing the cleaning action using
each detergency product in their respective region, as demonstrated in diagram 1.0.6.

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 Diagram 1.0.3 Label of stains used in commercial detergency test

Milk Seasoning
Powder Powder
Solution
Oil
flavouring

Diagram 1.0.4 Label of stains used in commercial detergency test

Diagrams 1.0.5 & 1.0.6 Demonstration of detergency test (left pic) and result
outcome (right pic)

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Examine what was the root cause of failure.

Unable to measure the detergency

performance during 1st attempt of
detergency test Why?

The colour of shirt has outperformed the

colour of stain solution even before
performing cleaning action Why?

The stain solution does not provide adequate

visible feedback on its presence above fabric
surface Why?

Dilution occur on intensity / odour of stain

while dissolving stain powder in distilled
water Why?
The ratio of 1:10 between stain powder and

Why?
water promotes further dilution due to
greater volume of water in comparison to
stain powder

The stain is found to lose its intensity

drastically while dissolving in water as the
ratio difference rises.

The 1st attempt on performing commercial detergency test was unsuccessful. The testing
phase on commercial detergency brands failed due to incapable of measuring detergency
performance after performing cleaning action on its respective regions shown in diagram

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1.0.6. The intensity of stain should be adequate enough to allow its visibility on fabric
surface in order for enabling accurate comparison of stain presence before and after
cleaning action performs on distinct fabric regions separated according to different
detergent brands. Nevertheless, the colour of shirt has outperformed the colour of stain
solution due to lack of visual feedback capabilities as a result of low stain intensity. The
intensity factor of stain has missed out as considering factors of commercial detergency
test completely besides focusing on its penetration abilities inside fabric layers. Hence, the
stain solution was prepared by dissolving stain powder in distilled water with ratio of 1:10,
thus promote dilution of stain and further reducing its concentration the important key
factor of contributing both intensity and odour of stain while react with fabrics.

Are there any other ways that you could have failed to achieve your objectives?

Another great obstacle that our group faced that could cause failure in completion of
prototype formulation was trial and error process during 2nd phase of formulating fragrance
test. At the initial progress of formulating suitable fragrance for immediate laundry
cleaning solution, our team has found out that the substitution of softener alone does not
improve the overall odour removal performance of immediate laundry cleaning solution,
regardless of whatever ratio between cleaning agents and softener. Before seeking existing
fabric fragrance solution from outside sources, our group decided on trial and error method
by applying alternative methods of producing natural fragrance through heat extraction of
cellulose fibers. Based on brief research of producing natural fragrance from website
sources such as Fragrantica and Eden Botanicals, our group has decided to apply heat
extraction method on celery and pandan leaves as shown in diagram 3.0.1 and 3.0.2, which
they are one of the most common materials used in production of herbal essence and other
plant based essential oils. The heat extraction method involves ratio of 1g plant mass to
100ml of distilled water for temperature in range between 95C to 105 C and
approximately 10 minutes of heating period depends on the intensity of lignin smell
presence in water solution. After obtaining the water solution with adequate lignin smell
presence, it is then separated into different partitions to test its best composition with
cleaning solution (mixture of sodium carbonate and MES solution) in order to deliver
optimum performance in removing stain odour. Unfortunately, the outcome of heat
extraction method turned out to be similar with substitution efforts of softener, in which
none of the ratio combination enables the odour removal feature for the cleaning solution.

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The failure of such method was then discussed among group members to seek its root
cause and possible improvements.

Diagram 3.0.1 & 3.0.2 Heat extraction for celery (left) and pandan leaves (right)

Diagram 3.0.3 Plant extract with aid of softener substitution still unable to mask the
odour presence despite great cleaning performance

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 Cleaning solution contains plant extract incapable of
mask stain odour on cloth fabric. Why?

Plant extract (ligin molecules) can't subsitute the

odour from cloth stain Why?

Plant extract had not trigger any significant chemical

reaction with the stain residues Why?

Chemical properties of plant extract unable to be

retained as it mixes with cleaning agents Why?

Cleaning agents have triggered reaction with plant

extract (linen) to produce by-products Why?

Cleaning agents would need to mix with plant extract

as a single product with frangrance feature addition
for end users' convenience

In short, the plant extract does not appeal to be the suitable fragrance material for our
existing cleaning solution. As we began to reflect our 1 st attempt in self-manufacturing
fragrance solution, our team members in discipline of chemical engineering had pointed
out a possibility to conclude that the chemical properties of plant extract in related to its
production of smell might be altered by undesired breakdown of calcium ions on cell wall
of plant membrane with freely hydroxide ions released upon contact between sodium
carbonate and water. The possible chemical reactions that responsible on such failure is

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listed as below:
2+
Na 2 CO 3 + Ca CO3 + 2NaOH
Ca + 2O H

The second failure that our group encountered in 2 nd phase of formulating fragrance is the
substitution of fragrance beads. After encountering 1st failure of masking stain odour by
addition of plant extract, our group decided to attempt on second method in which a simple
fragrance solution is produced by extracting the scent of fragrance beds. The flowchart of
scent extraction is shown on diagram 3.0.4 while the extraction process is demonstrated
further on diagram 3.0.5. While the fragrance solution is proved to be capable of masking
odour at volume exceed 80ml, the downside soon revealed on hitting the volume beyond
50ml of fragrance solution, in which the cleaning performance dropped as the odour
masking ability grew over increasing volume of fragrance solution. Since there was no
balance point in methods of fragrance bead substitution, the method has considered to be a
failure and its root cause was discussed among team members.

Heating process at
Fragrance solution
controlled
Soaking fragrance poured on cleaning
temperature range of
beads on 100ml of solution by 10ml
70C to 80C for
distilled water increment every trial
approximately 20
until masking occurs
minutes

Diagram 3.0.4 Flowchart Of Fragrance Bead Extraction To Formulate Fragrance

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Diagram 3.0.5 Heat extraction process on fragrance beads using hot plate

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 Fragrance beads subsitution does not compatible with
the fragrance addition solution on existing cleaning
solution
Why?

There is absence of balancing point between

fragrance masking feature and cleaning performance
through current method
Why?

The addition of fragrance solution compromises the

cleaning performance of solution beyond 50ml
volume point
Why?

The addition of fragrance solution dilutes the

concentration of cleaning agents per volume Why?

The majority content of fragrance solution are pure

water molecules with subsitution of frangrance smell Why?

Pure water is used as solvent for engraving the smell

of fragrance beds in form of liquid state

Describe how you will use the insight above so that you eliminate or minimise the
possibility of failure in the future.

The failures mentioned previously can be eliminated or minimised through greater

implementation of design thinking. Our design thinking is considered not comprehensive
enough to accelerate the project progress for innovation ideas that fall on unknown
territory. Instead, the understand phase in design thinking should be more focus on areas of
possible measures to make improvements on existing cleaning formulations besides the
marketing value of detergency. The identification of areas for improvements helps to

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narrow the scope of background research while ensuring most information obtained are
beneficial to accelerate the formulation process of prototype, especially when most of the
progress requires trial and error method in order to identify the right amount of
composition for all chemical agents to suit entirely new cleaning functionalities.

For the main failure, our group have improved the preparation method of stain in order to
provide strong pointers on measuring the detergency performance in terms of visual and
smell. In our 2nd attempt of commercial detergency test, the addition of colourant into three
stains has enabled visual feedback for allowing the determination of efficiency for each
detergency brands in two different types of fabrics: linen and cotton as shown on diagram
4.0.1 and 4.0.2. Moving on, our team has decided to introduce more consistency on
measuring the detergency of our prototype by replacing the existing three stains with black
pepper sauce stain that provides greater visual, odour and texture feedback as shown on
diagram 4.0.3.

Diagram 4.0.1 & 4.0.2 Commercial detergency test on cotton fabric (left) and linen
fabric (right) using stain samples with colourant as visual benchmark

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 Diagram 4.0.3 Application of black pepper sauce as stain sample to provide great
visual, odour and texture benchmark in measuring detergency of prototype
For alternative failures, the fragrance test should be done systematically as similar to
detergency phase on early prototyping progress, in which a commercial fragrance test to
research on effective fragrance pigments that would mask the stain odour effectively in
comparison with others. By acquiring the suitable range of fragrance selections, their
compatibility with cleaning solution can be tested further to be integrated as additional
feature upon our final prototype, which is masking the stain odour. The acquisition of right
fragrance agents could bring greater time and effort savings on prototyping progress by
minimising potential failures due to trial and error method.
What are the other key learnings from this failure?

The failure indicates the importance of having reflection session for each prototyping
progress in order to learn its root cause and respective measures on avoiding the repetition
of similar mistakes on next prototyping phase. In other words, the chances or risks of
failure can be reduced by investing more time on managing implementation efforts of
future prototyping phases. The integration of reflection sessions is one of the great
improvements in project management as it benefits team communication as well as
introducing greater time savings by minimising losses due to prototyping failures.

In addition, the failure also brought a realisation of importance for taking initiative in
seeking advices or suggestions from industrial experts. In previous projects of constructing
chassis for human powered vehicle, we had achieved prototype completion in shorter time
than projected schedule thanks to our initiative on seeking opinions from manufacturing
expert who had decades of industrial workshop experience, especially on evaluating the
feasibility of design based on observing three dimensional model of chassis. Likewise, we
felt that our prototyping progress could be more successful if we consult opinions or

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seeking other forms of assistance from experts in oleochemical industrial field. A complete
familiarisation of production for oleochemical based solutions could provide huge hints on
alternative techniques that would innovate our prototype in a more systematic behaviour
rather than pure trial and error method. Nevertheless, our group felt blessed in acquiring
design thinking knowledge in order for us to validate the business value of such project
innovation. Thus, we able to seek sponsorship interest from other companies due to their
value of interest in our initiative on solving the project challenge.

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