IE 6405 Customized Chair for Playing Musical Instruments

Invent New Corporation

1. Ashvin Kulkarni (Access ID
: ft5627)

Agenda

Business Case Objective

and Mission
Under the current capacity
(4 blades
on a 5 days week

Product
Development
schedule)
we fulfil the current
production plan.
Process
2. Danilo (Access
ID :
fx6383)
Design Alternatives
S&OP states to produce 5 blades weekly from May
Development process and
with
the
3. Bhargava Saripalli (Access
Evolution of Design
actual
capacity.
ID : fq8122)
Design for Manufacturing
4. Pushkar Vyas (Access ID :
Design for
Business case is clear ifand
we are able to produce the S&OP
fs0175)
Environment
requirement
under
the
same
capacity from May 2014.
5. Pratik Kamat (Access ID :
Product Design Justification
fq6587)
Lesson Learnt and
6. Venkata Ravi (Access ID :
Conclusion
fr1188)

Business Case Objectives and Mission

Why we need a chair?
How is it different from the rest?
What

makes

customers?

Designing

it

and

special

for

fabrication

the
of

customized chair for playing musical

instruments.
Designing of the chair will be focused
on the ergonomics which will make
the artist extremely comfortable to
perform for long hours

Product Development Process

Planning

Market opportunity
Define market segment

Concept
Generation
System Level
Design
Detail Design
Testing and
Refinement
Production Ramp
Up

Who are the competitors

Planning

Definetion

Parameters

1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th 11th 12th
wee wee wee wee wee wee wee wee wee wee wee wee
k
k
k
k
k
k
k
k
k
k
k
k

Concept
developm
ent

Customer Survey

QFD

System
level
design

TRIZ formulation

Develop design
alternatives

Product architecture

Define Interactions

Product Development Process

Potential
Customers:
Music Companies
Music Professionals
Music Studios

Planning
Concept
Generation
System Level
Design

Identify Customer Needs

Define performance measures with the help of Q
Sr.
No
1

Performance measure
Weight of the chair

Chair dimensions

Detail Design

2
Design of attachment

Testing and
Refinement
Production Ramp
Up

3
Material
4
5
6
7

Sub parameters

Digital memory storage

Battery life
Color Options* (subj.)

Unit
lb

Overall Height

foot

Overall Width
Height from the
ground
Width of the
attachment
Density Rating
Indentation Load
Deflection (ILD) rating

foot
feet
feet

Range
Max. 80
lb
Max. 4
feet
Max. 2
feet
Max. 3
feet
Max. 3
feet
2.4 - 3.1
33 - 41
min 1
36 - 40

GB
Hr
subj.(in
numbers) min. 5

Product Development Process

Planning
Concept
Generation
System Level
Design
Detail Design
Testing and
Refinement
Production Ramp
Up

Develop design alternatives

Develop product architecture
Define interactions

Design Alternatives

Product Development Process

Planning
Concept
Generation
System Level
Design
Detail Design
Testing and
Refinement
Production Ramp
Up

Component Architecture

2nd Design

Development Process
Marketing How do we know our product is unique
(Customers perspective)
Planning Deciding our team approach ( Deciding on
our milestones)
Concept development ( Identifying customer needs
and how is it possible?)
Decide on type of product (in our case it is a Generic
product type)
Evolution of
Design
listen
How to decide the design?
build/revise
to
Instruments to include?

mock-up

customer

Design creativity and maintenance

Scope of future developments

customer
test-drives
mock-up

Prototyping

Manufacturing Cost
Estimation
Variabl
e
cost

Total in

1. Wood - 3mm 1/8x6x12" (6)

$15.00/piece

15*6

90

2. Cushioning material - 10kgs

$20/kg

20*10

200

$20/Gallon

20*5

100

50

50

$106/piece

106*1

106

$99.99/piece

99.99*1

99.99

$100

100

25000

$8 / Man Hour

50*8

400

50

Materia 3. Polish - 5 Gallons

ls
4. Recorder
5. Adhesives , fastners and stitching
threads(Miscellaneous)
Fixed
Cost

Cost Reduction
Initiatives

4. Wood Lathe for wood work - 1 no.

5. Stitching macine

Direct
cost

6. Miscellaneous tools

1. Shop floor construction

2. Labor cost - Total man hour target
per chair - 50
3. Power

Total Cost
Operating Cost(Excluding Fixed cost and shop floor construction
cost)

$26,246
$940

Selection of shop
floor location in the
outskirts of the city
Recruitment of shop
floor workers from
the local close by
areas resulting
reduced work
commute and hence
transportation cost
reduction
Localization of raw
materials thereby
reducing import cost
and transportation
cost
Waste reduction
initiatives by driving
5S and Continuous
Improvement(CI)
programs in the shop
thereby improving
productivity and
hence ease of
manufacturing

Total Cost Reduction Target 4- 25% -

Product Introduction
in the Market Place

Expected
Challenges

Employee and Environment

1 -Safety ISO -14001
Certification
Customer satisfaction ISO
2
9001 Certification
3 Shop floor location selection
Re-design/validation from
4 Customer survey after the first
prototype is ready
Cycle time reduction during
5
production ramp up
Technical and on job training for
6
the blue collars
Vendor and supplier selection
7 for the best quote for the raw
materials
Introduction of Enterprise
8 Resource Planning Process in
the new
organization
Incineration
followed
by land fill of

Design For Environment(DFE)

scrap product due to quality issues, resulting in reduced pollution

Production Ramp Up
First six to twelve months the product can be made to order.
Depending on the configurations, few preset configurations can be
added to the catalogue, with a unique product identification number.
This number can be used by the customer for further use, and a similar
configuration chair can be manufactured for the customer, without the
customer being physically present.
Depending on the demand and the value for the product, different
quality standards could be set, which can be helpful for determining the
price, discounts, offers and other deals to attract the customers.
High production demands can be met with outsourcing the products or
the parts, to avoid the diminishing return phase. To avoid the saturation
and customer dissatisfaction, Outsourcing is the best option.
This again depends on the customer demand.
We cannot afford to lose a customer at any given time.
Also holding the order for a longer time, reduces the value of the
product.

Product Design Justification

Competitiveness
Different than any other design, because
its ergonomically friendly
Can be used and modified according to the
need
Easy to assembly and disassemble and
carry different locations
Composite structure makes it stronger and
light in weight

Need for an Engineering

Change
Call old products in for an
engineering change and
give the customers new
improved design (modified
on old design), for free.
How will the company profit
from this
Sell accessories at high cost
Benchmark (For Ex.: i-phone)
Sell
accessories
with
autographs of different artists

LESSONS LEARNT
How to tackle real world problems like
I. Law of diminishing return,
II. Market Stagnation,
III. Inflation
. Customer satisfaction along with profit growth.
. Understanding variable cost, fixed cost , direct
cost and sunk cost

THANK YOU!