The Cordless Drill - Assignment Example

rdlеss Drill Student Name: Student ID: Instructor Name: Date of Submission: Task 3: QFD Diagram 3.1 Documentation of the customer requirements for the QFD, and their importance When competition for new customers and markets increases, customer satisfaction becomes an important factor for long-term organisational success. A satisfied customer or client will turn into a loyal customer and this will make the business to have future cash flow (Akao, 2003). In their article “Zero Defections: Quality Comes to Services”, Reichfeld and Sasser (1990) report that a 6 per cent increase in customer loyalty can increase revenue/profit by 90 per cent due to the fact that satisfied clients or customers buy the organisation’s products more often and in greater quantities (Clausing, 2006). In general, a satisfied customer will be inclined to spend more on proven products and is also less price-sensitive. Customer requirements with regard to safety have been considered during the development process of cordless drills. The drilling tool amaze end user with their minimum weight and maximum power (Todd, Allen and Alting,2005). As part of the development process, our cordless drill will be continuously be developed to ensure that the drill always meet the high safety requirement. Various customer requirements have be identified from the product research study. According to the survey, most customer require safety, which can be divided into two. 1). General Usage, and 2). Ergonomy. General usage is further divided into loss of control; brand reliability; design of safety; and maintenance (Paris, 2005). While Ergonomy will be concern with Brand design which further divinded into material and price of the cordless drill. Brand reliability is a choice and not an accident of furtune. Our cordless drill will have high equipment reliability by ensuring the chance of failure to the drill are low. The componets of our drill will have less stess (Peigné, 2009). At same time, our drills will be made in such a way that they are versatile, and the drill will offer multifunctional power in both compact and lightweight designs. A customer should be able to perform variety of tasks quickly, with both ease and power. One common specification that end user have stated in the study when buying a cordless drill is the torque (Todd, Allen and Alting,2005). Many user have stated torque to be an important actor when buying a drill. Therefore our drills will be developed in such a way it will have good balance between speed, torque and speed ranges. In normal use, our drill will design in such a way that will need little maintenance, after a considerable use (Bralla, 2006). To prevemt problems from occurring from time to time, the cordless drill will be developed to be dust or water proof. Dirt can be trapped in the cordless drill mechanism either and this will slow the drill down or stopping it altogether. While too much moisture can cause rust, which can destroy the cordless drill. This is true when the battery is not protected from water or moisture. Consumers frequency overlook part replacement and maintenance costs when buying a cordless drill. As time goes by, the cordless drill will be worn out, some part will be needed to be replaced. This can become costly to the end user. To minimize such cost, our cordless drill will be designed to be serviced (Peigné, 2009). For example, our two-piece motor that consists of the armature and the filed as separate parts, and will have brushes that will be externally accessible. This will allow each individual piece to be replaced individually (Paris, 2005). Other models of cordless drill use motors that consist of the field and armature as one piece (Hurst, 2006). The cost to replace the brushes on out tow piece motor would be less than 10 dollars. However, the cost to replace the brushes on a cam moror could cost more than 50 dollars because there is need to replace the cam-motor at the same time. While the material that will be used to develop the cordless drill will be kept at a minimum. Loss of control can cause harm to end user or damage to the cordless equipement itself. Therefore, the developed cordless drill will come packaged with secondary or auxiliary handle. Auxillary handle will make heavier, larger and more powerfull cordless drill easier to manage, easier to balance, and easier to control (Peigné, 2009). In addition, the auxiliary handles will provide end user with comfort, and this will increase end user safety. Because two handles often make powerful drills more controllable (Hurst, 2006). UL-rated drills can still cause injuries to end users, but for our cordless drill, the force on the hand due to stastic torque will not be excessive. Ergonomics is important consideration in the design process of our cordless drill. Cordless drill is probably a tool that is used most. It should be designed to be comfortable; that means cordless drill that has a low weight, feels great in end user hand, and can be used left or right handed (Hurst, 2006). Not to mention other small details that we integrated to make the cordless drill a pleasure to use (Bralla, 2006). To reduce the weight of the cordless drill, our design will integrate the use of Lithium Ion Battery technology. Further we will use brushless motor technology which, which among the benefit of this technology will reduce weight (Hurst, 2006). Our Centrotec chuck will reduce the weight of the drill by a quarter of a kilogram or more versus our rival’s drills. If the end user spend long period of time driving and drilling, this weight difference will make a difference thus prevent fatigue among the end users (Bralla, 2006). C-handle cordless drill will offer better balance and put the end user arm inline with the drill transmission, which will provide comfort. A drill that has an oversized trigger will allow the end user to operate the cordless drill with more than one finger. A rubberized coating will be integrated in the design of the cordless drill handle to provide a non-slip surface and also cushions the end-user grip. Water resistance is also another factor that was identified by customers as important when buying a cordless drill (Paris, 2005). This single most product requirement is grouped under the product performance requirement. This aspect of water resistant is important because water will affect the engine of the wireless drill. 3.2. Translation of the customer requirements into technical requirements The above requirement by customers in the research survery will be transformed inot technical requirements that will be used to develop cordless drills. The customer requirements identified include: water resistant, battey life, speed, reliability and power. While marketable attributes include size, style, comfort and price. The QFD diagram below shows how custoemer requirements has been mapped into technical requirements. The technical requirements include materials that have been used for the cordless drill, size, cost of the material, battery life. Customer Importance Cost of manufactuing and assembly Stand alone Device Long life components Simplistic design with minimal components Requirements Durability 5 4 4 Water Resistant 4 5 Power 5 Battery Life 5 Style 5 4 Reliability 4 Comfort 5 Minimum Price 5 Fig: QFD diagram for the cordless drill The QFD diagram illustrates the correlationship between the technical requirements and customer requirements. The customer requirements has been rated from 1 to 5, whereby 5 indicated the most important customer requirement and one indicate the least important customer requirement. The weight of the technical requirements is shown and the value of technical requirement is found by multiplying customer requirements with the importance of the customer requirements. The found result is then used to determined the percetange weight of the requirements. The comfort of the TASK 4: Generate Concepts to Addrss the Identified SOR 4.1 documentation of Brainstorming Diagrams Fig: Brainstorming diagram with design concepts illustrated 4.2 Prior art search and documentation There are a lot of different models of cordless drills that are currently avaialbe in the market. This section will examine two cordless drills models that are similar to our desing and illustrate important things that are associated with those models. However, our product use similar features with the two models. These concepts have been included in our final design to produce cordless that are marketable. Bosch is one of the similar model that is availbe in the market. This product has a range of $150 to $450 depend with size and function. Borsch cordless drills are geared to the contractor market and are available in multiple weights, sizes, and power. According Bosch design, the product is heat and water resistant. This product has a charging docket which the battery first need to be removed in order to chage the battery. However, on average Bosh cordless drill is expensive, also the product cannot be used in multiple functions. The above disdvantages indicates that there is need for cheap product thtt can serve the same purpose. Skil is another cordless drill which is geared to the consumer market and is available in multiple weights, sizes and voltage. Skill cordless drill cost approximately $150, most of the home consumers are satisfied with the price of this product, which a reason that our model will be pocket friendly. Despite skill being cost effective, this model has it shortcoming that dissatisfy the consumers. The available survery study indicates that this model does not keep charge for long. In addition, this model spoilt very easy when in contact with water. Task 5: Evaluation of Design Concept 5.1 Identification of Preferred concept using a Structured Decision Making Technique This part will use structured decision making tool to identify the preferred model. The decision matrix is illustrated below: User Interface Shape Engine Part Automatic Mixed Manual Small Large Smart Electric Hybrid Cost 1 1 0 1 0 1 0 1 Size 1 0 1 1 0 1 0 1 Speed 1 1 0 1 1 1 1 1 Torques 1 1 0 1 1 0 1 0 Voltage 1 0 1 0 1 1 1 1 Style 1 1 1 1 0 1 0 1 Total 6 4 3 5 2 5 3 5 The key to cordless drill performance is being able to deliver the required torque at the highest speed. A common misconception from the many customers is that the higher the towque rating, the faster the drill will complete the task (Paris, 2005). Torque is the force the cordless drill will produce in order to turn an object, not how fast an objected will be turned. Torque is controlled by clutch button. In simple terms, a clutch is a mechanical device that provides for the transmission of power from one component to another. In most cases, a clutch is used by end user to control the amount of power being transmitted. The clutch setting is the amount of torque that the motor will pass through to the bit. When the clutch is set at 1, little power will be passed, while at the maximum setting, power will be passed the most (Paris, 2005). The design of a cordless drill will have a numerical scale, 1-4 and then a symbol for a drill bit. In our case, if the drill bit is completely disengages the drill’s clutch, maximum amount of power will be passed. The design of our cordless drill will integrate clutches, where the customer will be required to select the level of torque and this will be done through the adjustable torque control ring (Peigné, 2009). The highest the level of torque ( level 4 ) the customer select, the more turning force the cordless drill driver will deliver the force, and the more resistance the cordless drill will overcome before stopping. The adjustable torque ring will be numbered, and this will depend on how many torque levels of the cordless drill. Adjustment of torque level will give customer greater control when driving bits or screws. For example, when the end user put their cordless drill on maximum torque and drive ther drill bits all the way in (Paris, 2005). When the screw reaches the depth they want. One, they may over-drvie the drill bit. And second, they might start stripping the head if it’s hard wood as the drill bit cams out of the head. However, if the end user put the drill it on the lower settings, the clutch will not transmit any more power to the drill bit once the optimum power that is needed to turn the drill bit is found to be more than the drill bit settings. The design of our drill will have a variable speed feature. The more the end user will squeeze the cordless drill trigger, the faster the drill spins will be made. This feature will allow the end user to get a drill or a screw bit started, and will also help to prevent over-torquing, and will also be nice for delicate task (Paris, 2005). Voltage is an important marketed feature that is associated with cordless drills. The higher the voltage is, the bigger the battery pack and motor must be, resulting in a heavier tool. At 14.4 volt or 12 volt driver weights around 3 pounds, whereas most 16 volters are more than 5 pounds (Peigné, 2009). Big votage will be necessary if end user are doing lot of boring or if they want extra power to put down screw. For longer or tougher jobs, a lot of voltage will means the cordless drill doesn’t have to work as hard as a lower voltage cordless drill doing the same work. Decision have to be made on the shape of the cordless drill. There are two chooses: large or small. We found that the the two cordless drills in the market are basically large in desing. Therefore small design was preferred. It is clear that most consumers in the survey preferred cordless drills that were smaller in size. While other consumer prefer comfort and quality of the cordless drills to be a factor in the design of the cordless drills. The other consideration is the weight of the drill (Peigné, 2009). The wight of the cordless drill and the battery combined are important factor. Even if customers are used to handle power tools. By the end of the day their body and arms will be tired if they are using a heavy cordless drills (Paris, 2005). According to most consumers in the survey, their efficiency on the task and possibly their usage of the cordless drill will depend on the investing in a cordless drill that will extend their energy a little further. In addition, people in the survey stated that they prefer drills that have multiple usage. In ideal world, a drill should be used for multiple usage. Another factor that relate to size of the drill is space, half of the customers did not worry about how much they are willing to spend to buy a cordless drill. Among the important factor that people in the survey considered is how much space consumers are willing to reserver for the cordless drill (Peigné, 2009). Space, as stated by half of respondent in the survey is the deciding factor. From the space consideration, the cordless drill be will be designed to occupy small space. All the cordless drills have 3/8 inch which are too small for havier work and larger bits. While the hammer drill don’t come with side handle, which is not great for heavier work and controlling large bits. Our cordless drill will have a ½ inch chuck which is a new standard. In addition, it will come with a removable side handles that will give customers great controlling large bits and heavier work. Both skill and Borsch cordless drills have not been fitted with aoutomatic brakes. Our cordless drill will be featured with automatic brake tht activates the moment the user release the trigger. This great feature will speed production because a user can start the next screw or immediately change drilling bits instead of waiting for the drill chuck to stop spinning. Another feature that will be included in our cordless drill is the automatic locking spindle, which will allow the user to tighten or lossen the chuck with one hand. Another design concept of concern among the consumer is to feature an onboard task light. This will be great for consumers who work in dark spaces and they need to accurately drill a hole or place a screw head on the hole. This light will be activated by pulling the trigger and will be remained lit for about 20 seconds after the release button is pressed. Another concept that has been really overlooked by other manufactures ins the onboard bit storage (Peigné, 2009). A person suing a drill will need at least two different drilling bits, and it will be convenient to have them right on the tool and ready to change without looking through the pockets or pouches. According to the survey, the concept will save a lot of time and frustration by having drilling bits situated where the end user can grap the bits and use them. According to the survey, batteries is an important factor whe purchasing a cordless drill. But higher voltage batteries are not the best (Paris, 2005). While low cost batteries will guarantee the consumer disappointment. Lithium-Ion batteries will be integrated into the cordless drill. Although, comfort is not the first thing customer think of when purchasing a cordless drill, the concept of comfort is a primary factor in our cordless drill. A drill that do not fit in a end-user hand well can bring painful moments when used for long hours, while a comfortable cordless drill will allow task to be carried more competently. The material that will be used to developed the outer cover of the cordless drill will be made up of rubber and will consist of const effective material that are similar to shoe used for other product in the market. The basic marial will be rubber with a glossy surface finish since it will bring out an appeling effect and enhanced the concept of water resistance. Soft elastomer will also be incorporated into the desing because it is water resistant , and can be comfortably be used for the button. TASK 6: Detailed Design 6.1 Development of specifid (detailed)Embodiment for the Concept The user interface From the customer survey, it is evident that most of the cordless drill customer indicated that they use their cordless drill to do light works but customers use their drills for commercial purposes such as drilling, screwing, holling etc. Therefore, the design for our cordless drill will take into consideration all those aspects in order to suit the needs of end users. Three control functions will be integrated into the cordless drill. Slow speed, fast speed and torch. All this will be achieved through the use of buttons that will be placed at the side of the cordless drill. The control buttons will be placed on left side of the drill because it is assumed that most our end user will be right handed, thus their right hand is more committed than the left hand. Rechargeble Battery Battery From our survey, cost of the te cordless drill is one of the most important factor that consumers consider when purchasing a cordless drill. Therefore, our recharable batteries will be made using the Lithium-Ion batteries. This type of battery has low maintenance and no cycling is required to prolong the battery’s life. In addition, to high energy density and lightweight, the self-discharge is less than half compared to other types of batteries. The interference for the battery wire will be limited because the use of wire have been made in such a way to be limited. The main reason for the use of limited wire is to reduce the size of the cordless drill, and thus increase the comfort of using the equipment. The battery will be inserted and removed below the handle. This is because it will eliminate the need ot have the batteries take lot of space in the design, and it will enhance comfort and reduce the cost of the cordless drill. Adjstable Design Overheadint was one of the aspects that was identified to cause dissastifaction among the cordless drill custoemers (Peigné, 2009) The drills will over heat when used for a long time, also during charging the battey will overheat. The design of the cordless drill will be made with material that absorbe heat fast. Our design will make it easy to work for long hours without the drill emitting smoke. This is a unique desing that will provide end users with a drill that cannot overheat after few minutes. This concept has not been used by any of the cordless drills that have been previously in the market. 6.2 Morphological Analysis The cordless drill market has produced different model and desings over the past five decade, which has led to the development of new functions and features. The morphological analysis shown below schematically arranges all the possibilities that have been used to select and assess variants of our design embodiment. Considering the market requirments, innovative concept, available tehcnologies, and future tendencies. The following are features and functions of the cordless drills that we have selected. Morphological Chart Table 2: Morphological Chat Means 1 2 3 4 User interface Place buttons on the below the handle Being controlled the amount of speed Shape Small-size Medium-size Large size Material for water resistance Mylar Polypropylene Plasticdip Power of cordless drills Docking station Container with charger Only a charger that plug into an outlet Battery Removable battery Permanent battery Flexibily Light work Mix work (both light and heavy work). 6.3 Design Strategies for Added Value There are numerous design strategies that will be used to add value to our cordless drills without incurring additional cost. These are the values that are not expected by our customers but their presence will increase customer satisfaction in the market. For example, the consumer do not expect the cordless drill to used may drill bits. Therefore, making the adjustable will be a desing value for added value.The glossy finish on the drill body is also a desing strategy that is aimed at addint value and comfort to our cordless drills. Reference Todd, Robert H, Allen, Dell K and Alting, Leo (2005), Manufacturing Processes Reference Guide, Industrial Press Inc., pp. 43–48. Bralla, James G. (2006). Design for manufacturability handbook. New York: McGraw-Hill. p. 4‐56. Paris, Henri (2005). Modelling the Vibratory Drilling Process to Foresee Cutting Parameters. CIRP Annals – Manufacturing Technologies. pp. 367–370. Peigné, Grégoire (2009). Axial machining device. WO/2011/061678 (patent). Hurst, Bryan (2006), The Journeyman's Guide to CNC Machines, Lulu.com, p. 82, Read More

One common specification that end user have stated in the study when buying a cordless drill is the torque (Todd, Allen and Alting,2005). Many user have stated torque to be an important actor when buying a drill. Therefore our drills will be developed in such a way it will have good balance between speed, torque and speed ranges. In normal use, our drill will design in such a way that will need little maintenance, after a considerable use (Bralla, 2006). To prevemt problems from occurring from time to time, the cordless drill will be developed to be dust or water proof.

Dirt can be trapped in the cordless drill mechanism either and this will slow the drill down or stopping it altogether. While too much moisture can cause rust, which can destroy the cordless drill. This is true when the battery is not protected from water or moisture. Consumers frequency overlook part replacement and maintenance costs when buying a cordless drill. As time goes by, the cordless drill will be worn out, some part will be needed to be replaced. This can become costly to the end user.

To minimize such cost, our cordless drill will be designed to be serviced (Peigné, 2009). For example, our two-piece motor that consists of the armature and the filed as separate parts, and will have brushes that will be externally accessible. This will allow each individual piece to be replaced individually (Paris, 2005). Other models of cordless drill use motors that consist of the field and armature as one piece (Hurst, 2006). The cost to replace the brushes on out tow piece motor would be less than 10 dollars.

However, the cost to replace the brushes on a cam moror could cost more than 50 dollars because there is need to replace the cam-motor at the same time. While the material that will be used to develop the cordless drill will be kept at a minimum. Loss of control can cause harm to end user or damage to the cordless equipement itself. Therefore, the developed cordless drill will come packaged with secondary or auxiliary handle. Auxillary handle will make heavier, larger and more powerfull cordless drill easier to manage, easier to balance, and easier to control (Peigné, 2009).

In addition, the auxiliary handles will provide end user with comfort, and this will increase end user safety. Because two handles often make powerful drills more controllable (Hurst, 2006). UL-rated drills can still cause injuries to end users, but for our cordless drill, the force on the hand due to stastic torque will not be excessive. Ergonomics is important consideration in the design process of our cordless drill. Cordless drill is probably a tool that is used most. It should be designed to be comfortable; that means cordless drill that has a low weight, feels great in end user hand, and can be used left or right handed (Hurst, 2006).

Not to mention other small details that we integrated to make the cordless drill a pleasure to use (Bralla, 2006). To reduce the weight of the cordless drill, our design will integrate the use of Lithium Ion Battery technology. Further we will use brushless motor technology which, which among the benefit of this technology will reduce weight (Hurst, 2006). Our Centrotec chuck will reduce the weight of the drill by a quarter of a kilogram or more versus our rival’s drills. If the end user spend long period of time driving and drilling, this weight difference will make a difference thus prevent fatigue among the end users (Bralla, 2006).

C-handle cordless drill will offer better balance and put the end user arm inline with the drill transmission, which will provide comfort. A drill that has an oversized trigger will allow the end user to operate the cordless drill with more than one finger. A rubberized coating will be integrated in the design of the cordless drill handle to provide a non-slip surface and also cushions the end-user grip. Water resistance is also another factor that was identified by customers as important when buying a cordless drill (Paris, 2005).

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