Product Design Specification
Yakima T.O.C. Load Assist
Group Members:
Haidar Al Gharash
Michael Dixon
Ben Gheliuc
Daniel Gheliuc
Fue Her
Zach McCurter
P.S.U. Advisor:
Evan A. Thomas, Ph.D., P.E.
1/30/2012
Table of Contents
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Technical Risk Management...... 6
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Yakima is a company that designs and sells rack systems. One product they have not brought to production is a system that willassist a person to load kayaks on top of a vehicle. Yakima had previously designed a system but the estimated market price for the system was too much, so they wanted to design a new system that would be efficient yet affordable. This is where they made the load assist system into a capstone project for the Portland State University students.
Yakima’s previous attempt at a load assist system had an estimated retail price of $2000, which was too expensive for the market. The system can hold up to 100 pounds of load capacity of boats, bikes, or cargo boxes. All the loading are done by the side of the car as seen in the picture below.
There are many design aspects that are need to be considered for designing the system which include: weight limit, ergonomics, safety, and the market price after completion.
The purpose of this document is to clearly define the customer requirements, lay out a project plan, set milestones, discuss risk management and create a design specification list.
The purpose of this project is to design a system that will provide load assistance for one person to load akayak on the roof ofa vehicle. The targeted price for the systemis around $500. The final prototyping is to be finished in early June.
Task / Assign Date / Finish Date / Tasks dueDiscussion of ideas and scope of project / Dec-13-11 / Jan-11-12
Internal and External Research / Jan-9-12 / Feb-3-12
Draft Design / Jan-23-12 / Feb-29-12
PDS Report / Jan-16-12 / Jan-30-12 / Jan-30-12
PDS Report Presentation / Jan-30-12 / Feb-13-12 / Feb-13-12
Evaluation Of Drafted Design / Feb-13-12 / March-5-12
Design/make Product / Feb-20-12 / March-15-12
End of the Term Progress Report / Feb-27-12 / March-12-12
Progress Report Presentation / Feb-27-12 / Feb-27-12 / Feb-27-12
Presentation design to Sponsor / March-12-12 / March-14-12
Testing and Prototyping / March-14-12 / April-4-12
Redesigning Concept And Prototype / March-21-12 / April-18-12
Repeat Testing / April-11-12 / April-25-12
Manufacture Final Product / April-25-12 / May-23-12
The internal customers are defined as any PSU affiliate that has any input to the capstone process. The following are people that are internally part of the capstone process.
The Yakima PSU team
Should demonstrate technical proficiency in the final product at the time of testing. Team members must demonstrateequal amount of effort.
Dr. Thomas and Dr. Etasami
The team must show progress of project on a weekly basis to Dr. Thomas along with the required presentations.
PSU Machine Shop
Machine shop shall be used on an as needed basis. Team members will machine parts under supervision.
External customers are those who are not affiliated with PSU. The following list identifies external customers and their input on the project.
Yakima
Chris Sautter(Mechanical Engineer); Mark Elliott(Design Engineer - Team Lead)
- Load assist must pass all Yakima Performance and Test Standards.
- Holds at least one kayak.
- Minimum number of steps to use.
- No rattling when loaded or unloaded
- Reliable
- Minimize Weight of load assist.
- Visual and/or audible confirmation that load assist is secured.
Yakima Legal Department
- Must clear existing IP (patents).
- Safe to use.
Yakima Financial Department
- Low cost (equal to competitor in features and benefits for cost)
End-User
Target Persona
- An average 45 year old 5’2” woman who paddles a sea kayak, rides a bike and drives a Subaru Outback
- Ergonomic design allows user to easily load boat on top of vehicle.
Mark Elliot and Chris Sautter of Yakima explained to the capstone group what the scope and reason for this project is. Yakima had approached this project a few years prior but decided to not release the product to the market as the price was not competitive. Mark and Chris explained the current project along with the "must-haves" and "wants". The emphasis of this project was on keeping the system relatively simple, to maintain a low cost, and that the intended end user could load her kayak on her own without causing damage to her vehicle or the kayak equipment. Feedback from Yakima thus far has helped the capstone group fine tune the requirements, scope, and expected end results of the project.
The testing of the prototype as well as the final product will be tested in Beaverton at the Yakimaheadquarters. Testing can only commence when the initial prototype is assembled. Yakima will provide any testing material such as kayaks, cross bars and boat mounts.The load assist must pass Yakima’s internal standards, specifically the forward pull at 4 times the rated carrier load and the upward pull at 2500 N.
With the complexity of this project, there are multiple risks that can cause the load assist to fail. One of the most critical components is the preloaded mechanism. Without a configured and working preloaded mechanism, the entire scope of the project may come to a halt or possibly fail. The purpose of a top of car load assist is such that the user will not feel the full load of the kayak. Failing to have a working mechanism will result in the user lifting all of the weight of the load assist as well as the kayak that he/she is loading.
Another risk of failure in the project is clearance between the side of the car and the load assist. Without calculating the proper clearances damage could occur tothe sporting equipment that is held, the car side and the windows. Things that must be taken into account are: the amount of space between lowered rack assist and side of car, deflection of the load assist due to the maximum load and clearance between the rack and the roof of the car.
One thing that must be considered heavily during the design of the final product is safety. Recognizing potential hazards such as pinch points, user misuse and sharp edgesis critical so that no one will be harmed during operation.
The cost of the final product is an important design consideration, because if the profit margin is too small or the market price too high, Yakima will not bring the load assist to market.
Applicable Codes and Standards
Customer / Requirement / Metric / Target / Basis / VerificationYakima / Adhere to fatigue standards: YS2015, ISO 11154, and DIN 75-302 / Cycle Test / 100% Design load, 30k cycles / Standard Definition / Testing
Yakima / Adhere to Durability/Road Loop standard YS2014 / Durability/Road loop test / 100% Design Load / Standard Definition / Testing
Yakima / Adhere to Pull Tests standard: YS2015 / Pull tests / Pass Yakima standard pull test (refer to appendix) / Standard Definition / Testing
Yakima / Work Place safety codes / Number of codes to be violated / Zero / Safety and legal standards / Review of the safety and legal standards
Yakima / Adhere to Pull Tests standard: ISO 11154 / Pull tests / Pass 4x Max load FWD and AFT load @ CG / ISO 11154 / Testing
Yakima / Adhere to Pull Tests standard: ISO 11154 / Pull tests / Pass 4x Max load 20 degree horizontal force @ CG / ISO 11154 / Testing
Yakima / Adhere to Pull Tests standard: ISO 11154 / Pull tests / Pass 2x max load LAT load @ CG / ISO 11154 / Testing
Yakima / Adhere to Pull Tests standard: ISO 11154 / Pull tests / Pass 4x max load (up) load @ GC / ISO 11154 / Testing
Yakima / Mount shall meet performance standards / NA / Meet all standard criteria / ISO 11154, YS2015, and DIN 75-302 / Standard Definitions
See appendix 1 for Yakima standard tests
Ergonomics
Customer / Requirement / Metric / Target / Basis / VerificationYakima / Low loading effort / Lbs. of lift assist / 60 lbs. / Customer Requirement / Measurement
Yakima / Comfortable handles or levers / Handles and levers / All / Physical testing / Customer verification
Documentation
Customer / Requirement / Metric / Target / Basis / VerificationPSU / PDS Report / Completed Report / January 30, 2012 / Course requirements / Good Grade
PSU / Progress Report / Completed Report / March 12, 2012 / Course requirements / Good Grade
PSU / Final Design Report / Completed Report / June, 2012 / Course requirements / Good Grade
Life in Service
Customer / Requirement / Metric / Target / Basis / VerificationYakima / Product should have no mechanical or structural failures for 5 years of moderate use / Product life cycle / Theoretical life cycle of 5 years. / Yakima warranty standards / Testing
Disposal
Customer / Requirement / Metric / Target / Basis / VerificationYakima / Use only recyclable plastics / Plastic recyclability / 100% recyclable / Yakima recyclability standard / Customer definition and or standards
Maintenance
Customer / Requirement / Metric / Target / Basis / VerificationYakima / Non-water soluble lubricant on moving metal parts / Lubricant type / Use only non-water soluble lubricant / Chemical composition and lubricant manufacturer specs / Test Lubricant for non-water solubility
Yakima / Plastic parts to be cleaned with soft cloth and mild detergent / Plastic type / Use only plastics that can be cleaned with cloth and mild detergent / Customer definition / Test plastic for cleaning
Performance
Customer / Requirement / Metric / Target / Basis / VerificationYakima / Ease of use / Loading time / Load and lock bike or boat in less than 5 minutes / Customer definition and physical test / Testing
Yakima / Low reach distance / Distance from ground to loading rack / 36 inches from ground to rack in loading position / Height of 2011 Subaru Outback(64 inches) / Testing
Yakima / Should be easily fitted to standard rack systems / Modular design / No removal of base rack system / Customer definition / Testing
Yakima / No rattling when loaded or unloaded / Noise or chatter during loading and unloading process / No audible sound to loader / Customer defined / Testing
Safety
Customer / Requirement / Metric / Target / Basis / VerificationYakima / No sharp edges/corners / Number of sharp corners or edges / Zero / Customer Requirement / Inspection
Yakima / No pinch points / Number of pinch points / Zero / Customer Requirement / Inspection
Timeline
Customer / Requirement / Metric / Target / Basis / VerificationPSU / PDS Report / Completed Report / January 30, 2012 / Course requirements / Good Grade
PSU / Progress Report / Completed Report / March 12, 2012 / Course requirements / Good Grade
PSU / Final Design Report / Completed Report / June, 2012 / Course requirements / Good Grade
Yakima / Final Product / Timely Completion / June 1, 2012 / Customer / Customer is Satisfied
Company Constraints and Procedures
Customer / Requirement / Metric / Target / Basis / VerificationYakima / Keep product inherently safe / N/A / Consider pinch points and potential user “misuse”. / Yakima Requirement / Inspection
Cost of production per part
Customer / Requirement / Metric / Target / Basis / VerificationYakima / Low retail price / Dollars / $1000 maximum / Customer feedback / Study of price in market
Environment
Customer / Requirement / Metric / Target / Basis / VerificationYakima / Operates in a harsh wet environment / Years of Resistance to rust and corrosion / 5 years / Group decision / Study of standards
Manufacturing facilities
Customer / Requirement / Metric / Target / Basis / VerificationProject team and Yakima / Yakima provides facilities needed / Use of Yakima’s Facilities / No need to use other facilities / Customer input / Similar system comparison
Shipping
Customer / Requirement / Metric / Target / Basis / VerificationYakima / Fit in not too large shipping container / Cubic inches / 10” X 24” X 36” / Expert opinion / Study of standards
Materials
Customer / Requirement / Metric / Target / Basis / VerificationYakima / Product components / Yes/no / Typical Yakima materials / Yakima requirement / Inspection
Yakima / Aesthetics / Yes/no / Looks sturdy &
professional / Customer input / Inspection
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Requirement / Customer / Importance / Engineering Criteria / Competitionlift capacity / cost / Materials / Size / Life Cycle / Thule / Malone
Retail Price / end user / *** / * / **** / *** / **** / ** / *** / ****
Fatigue/corrosion resistance / end user / *** / *** / ** / **** / * / **** / **** / **
ergonomics / end user / ** / **** / ** / * / *** / ** / **** / **
lift assist / end user / ***** / ***** / *** / ** / * / *** / *** / **
Installation / end user / ** / * / * / * / **** / ** / **** / *
Competition
Thule / 75 / 590 / Aluminum / 35" w / Limited lifetime
Malone / 70 / 270 / Aluminum / 35" w / 1 year
Target / 120 / 500 / Aluminum / 35" w / Limited Lifetime
House of Quality
Legend: low importance * ***** high importance
Yakima has put the most emphasis on this project to keep it simple as can be to serve its purpose. The purpose is clearly defined within this document including the main points of performance, safety, andcost. One of the main challenges the capstone team will face will be in the area of providing the load assist in a simple cost effective way. Yakima has made stated that cost is important in this project but it is not a “make or break” for them as they have lower cost sourcing options they can implement if needed.
Appendix 1
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