DIRT DEVIL VACUUM CLEANER

TEAM 4

Justin Grates Raghava Kashyap Gujja Alban Imeri Jyothi Swaroop Reddy Yerasi

11/16/11

Purpose and Overview

To design and develop a Vacuum Cleaner. Reference product - Dirt Devil Express Quick Vacuum Cleaner.

Theory of Operation

Customer Needs

Personal Interviews. Taken reviews from Amazon and Company website.

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 presses by using heavy suction.

QFD Phase I
Weight Suction Power Force required to operate Noise level Tolerance of sealing 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 + dwn dwn + + up up up up up up dwn Engineering Metrics up dwn up dwn up Nom + + + ++ + ++ + NO INPUT IN THIS AREA

Co ++ + - -

++ +

up

Time to empty the container

Force required to operate

Tolerance of sealing

Life time of product

Customer Weights

Height adjustability

Container Volume

Energy Efficiency

Suction Power

Time to clean

Spilling Dust

Hose Length

Cord Length

Overall Size
9 0 9 0 9 0 3 3 0 3 0 9 0 1 0

Noise level

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Customer Requirements Easy to move Good dirt pick up Affordable price No dust Spill Easy to use Always works Fast Cleaning Safe to operate Lasts long Hold more dust Strong body Easy to store Consumes less power Easy to Maintain Less overheating

9 9 9 9 9 9 9 9 3 3 3 3 3 1 1

9 0 3 0 9 3 0 9 3 1 9 3 0 0 0

0 9 3 3 0 3 9 3 3 9 0 0 9 0 9

9 0 0 0 9 0 3 3 1 0 1 0 0 0 0

0 3 3 0 3 0 0 9 0 0 0 0 3 0 0

0 3 1 9 0 3 3 1 0 3 1 0 3 0 0

9 3 0 0 9 3 1 9 9 3 3 0 3 0 3

3 0 3 0 9 0 1 1 0 0 1 9 0 0 0

1 0 1 3 0 0 9 0 0 9 0 0 0 9 0

1 3 1 0 3 0 1 3 0 0 0 3 0 0 1

0 1 9 0 0 0 0 0 0 0 0 0 9 0 3

3 3 0 9 9 0 9 0 0 9 0 0 1 9 3

0 3 0 0 0 0 9 0 0 0 0 0 1 0 0

0 3 0 9 0 0 0 9 0 1 0 0 0 3 0

1 0 9 0 0 3 0 0 9 1 9 0 0 3 3

0 0 0 0 9 0 9 0 0 9 0 0 0 9 0

9 0 3 0 9 0 3 3 0 0 0 0 0 0 0

et

" x 12"

in

1 Worse

Air Flow

Balance

Weight

QFD Phase II

It relates all the engineering metrics to all the part characteristics.

Part Characteristics

Phase I Relative Weights

Engineering Metrics Weight Suction Power Force required to operate Noise level Tolerance of sealing 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

9% 9% 6% 4% 5% 9% 5% 4% 3% 3% 9% 3% 5% 5% 5% 6% 9% Raw score Relative Weight

9 9 3 9 0 3 0 0 1 9 9 9 0 9 0 0 9

3 9 0 3 1 3 3 0 9 3 9 1 1 3 0 0 0

3 0 1 0 0 0 0 0 0 3 9 0 0 1 0 9 1

3 0 3 0 0 9 9 0 0 0 1 0 0 0 0 0 3

9 3 3 0 9 1 1 9 0 0 9 0 9 1 9 0 9

3 1 1 1 0 0 0 0 0 3 9 1 1 9 0 0 1

3 3 0 3 0 3 0 0 0 3 1 0 0 9 0 0 0

1 1 0 1 1 0 0 1 0 0 3 1 3 1 0 0 0

3 1 0 3 1 1 1 0 0 3 3 1 1 0 0 0 3

9 3 3 1 3 9 3 1 1 0 0 0 0 3 0 0 9

3 1 3 1 9 3 0 1 0 0 0 0 3 3 0 0 9

1 9 0 3 1 1 0 0 3 0 9 9 3 3 0 0 3

15% 5.1

9% 3.1

6% 1.9

6% 2.1

14% 4.8

6% 1.9

5% 1.6

2% 0.8

4% 1.4

10% 3.5

7% 2.5

9% 2.9

6% 2.1

Container cover
1 0 0 0 9 1 0 9 0 0 0 0 9 1 9 0 1

Motor Housing

Rolling brush

Accessories

Container

Handle

Nozzle

Motor

Filter

Hose

Cord

Base

Belt

Functional Analysis

Costing

Motor

Filter

Cost Worth Analysis

Fishbone Diagram

Assembly Time Calculations

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:

Base Assembly Longest Time 433s

Failure Mode and Effects Analysis

Motor Over

Poor Suction

Function Based FMEA

Slip In Motor Inlet Port Clogged

Environmental Impact

Product Use

Resource Extraction

Product Packaging and Transport

Product Manufacture

Environmental Design Recommendations

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 ABS and 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

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 Drivers

Assembly
Snap-fit parts Standard components/material

Failures

Project Priority Matrix

Concept Generation
Supply Power
Create Suction Bring Vacuum to Area Loosen Particles Pickup Particles Store/Empty the Container

Concept Alternatives
Concept 1 Concept 2 Concept 3

Concept 1

Concept 2

Concept 3

Pugh Analysis Current Product

Criteria 1 Weight 2 Overall Cost 3 Manufacturing Costs 4 Easy to use 5 Suction Power 6 Safety 7 Profitability 8 Manufacturability 9 Portability 10 Environmental Impact 11 Sound Level 12 Energy Efficiency 13 Durability 14 Operating Costs 15 Reliability 16 Time to clean 17 Overall Size 18 Ergonomics 19 Ease of Maintenance 20 Quality of Cleaning Weight 9 9 3 9 9 9 3 3 9 3 1 3 3 3 9 3 3 3 3 9 Sum of +'s Sum of -'s Sum of S's 1 + + + + + + + + + + + 11 9 0 Concepts 2 + + + + + + S + S + + + + 11 7 2 3 S S + S S S + + S S S S S S + S + + + 7 1 12 Dirt Devil Express Quick

D A T U M

Pugh Analysis Top Competitor

Criteria 1 Weight 2 Overall Cost 3 Manufacturing Costs 4 Easy to use 5 Suction Power 6 Safety 7 Profitability 8 Manufacturability 9 Portability 10 Environmental Impact 11 Sound Level 12 Energy Efficiency 13 Durability 14 Operating Costs 15 Reliability 16 Time to clean 17 Overall Size 18 Ergonomics 19 Ease of Maintenance 20 Quality of Cleaning Weight 9 9 3 9 9 9 3 3 9 3 1 3 3 3 9 3 3 3 3 9 Sum of +'s Sum of -'s Sum of S's 1 + + S S S + + + + + + S + + + + + 13 3 4 Concepts 2 + + + S S S + + + S + + + + S + + + + + 15 0 5 3 S + + S S S + + + S + + + + S + + + + + 14 0 6 Dyson DC25

D A T U M

Pugh Analysis Low Competitor

Criteria 1 Weight 2 Overall Cost 3 Manufacturing Costs 4 Easy to use 5 Suction Power 6 Safety 7 Profitability 8 Manufacturability 9 Portability 10 Environmental Impact 11 Sound Level 12 Energy Efficiency 13 Durability 14 Operating Costs 15 Reliability 16 Time to clean 17 Overall Size 18 Ergonomics 19 Ease of Maintenance 20 Quality of Cleaning Weight 9 9 3 9 9 9 3 3 9 3 1 3 3 3 9 3 3 3 3 9 Sum of +'s Sum of -'s Sum of S's 1 + + + + + + + + + + 10 10 0 Concepts 2 S + + + + + + + + + + + 11 8 1 3 S + + + + + + + + + + 10 9 1 Eureka Lightweight

D A T U M

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

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

Questions?