Upload
others
View
12
Download
0
Embed Size (px)
Citation preview
APPLICATION OF AXIOMATIC DESIGN CONCEPT ON IMPROVING LADDER FOR PEPPER HARVESTING
Ahmad Faizal B. Zaharuddin
Bachelor of Engineering with Honours s (Mechanical and Manufacturing System Engineering) 695 2009 A286 2009
UNIVERSITI MALA YSIA SARA WAK
BORANG PENGESAHAN STATUS TESIS
Judul: DESIGN AND DEVELOPMENT OF PEPPER HARVESTER
LADDER
SESI PENGAJIAN : 200812009
Saya, ___-----'A'""H"""M""A-"D~F"'A~I_':Z":A':"Lo:::B"-.':::'Z'"'A"'H"""AC!.R'-'U"-'D~D"-I"'N-'-------(HURUF BESAR)
mengaku membenarkan tesis * 101 di simpan di Pusat Khidmat Maklumat Akadcmik, Universiti Malaysia Sarawak dengan syarat-sya rat kegwHlan seperti berikut:
1. Tesis ada lah hakmilik Universiti Malaysia Sa rawak . 2. Pusat Khidmat Maklurnat Akademik, Uni versiti Ma laysia Sarawak dibenarkan mem buat
sa linan untuk tujuan pengajian sahaja . 3. Mem bua( pendigitan lUltuk memban guankan Pangkaian Data Kandun gan Tempatan . 4. Pusa t Khidmat MakJumat Akademik, Uni versiti Malaysia Sarawak dibenarkan membuat
sa linan tesis ini sebaga i bahan pertukaran antara in stitusi pengajian tinggi. 5. .. Sil a tandakan (-IJ di ka tak yang berkenaan.
c:::J SULIT
c:::J TERHAD
T1D.AJ<. TERHAD
- I (TANDATANt ''t PENULIS)
(Mengandwlgi maklum(l.1 yand bel'LiaJ:Jah k csdarnal~!n aLau kepentingan Mal<l)' s in
sepel'l1 yang tennaklub <Ii da la ln A I( 1'A RAHS IA RASMI 1972).
(Men gandungl m(lklumat TERH AD y<l ng tdnh dileniukan ol c h org<ln l5as ilbadall d l
mana penyelidikan diJ alankan)
Disahkan o leh
Yo . d(h~QJJ (TANDATA~ PENYELlA)
Alamat tetap: 1246, Kg Padang Midin. 21400, Kuala Tcrengganu, ' [ eren gganu .
En Aidd Azli AI ias
T arikh 'l2>/ 11 /;:;.ero9 ) (
Tarikh: ;);/ . I I :Joo'i
CATATAN '" Tcs is dimaksudkan scbaga i tes is eXIgi ljazah Doktor Falsaf ah, Sarjana dan Sal]alla MlIdH ** Jika tcs is in i SU UT dan TE RH.I\D, si la ICII'npirknn Slimt da rjpad,~ pihak berkuasa/org<1nisnsi
bcrkcIHwJl ckngi.i ll Il1cll yCltil. bn sek ali se bab dan tl.:' l11poh te, is ini pcriu dikcla"kan sebagn i SLJLlT cia " TERHA D.
•
APPROVAL SHEET
This project report attached here to , entitle "Design and Development of Pepper
Harvester Ladder" prepared and subm itted by AHMAD FAIZAL B.
ZAHARUDDIN as a partial fulfilment of the requirement for the degree of Bachelor
of Engineering with Honours in Mechanical and Manufacturing is hereby read and
approve by:
_--,?:..c" /" /;> v,,,,~ :...!__
Aid i I AzI i Alias Date
Supervisor
r~L w • • ~.J. I,,"-,,"'~ ,~ ........ ~ _.L.I"' ~ ~ •.., ~ .. . ~-: ;r. ~:317: :\;'~I i' S~\ !';c.h.rlo'......K
APPLICATION OF AXIOMATIC DESIGN CONCEPT ON IMPROVING LADDER FOR PEPPER HARVESTING
AHMAD FAIZAL B. ZAHARUDDIN
This report is submitted in partial fulfillment ofthe requirements for the degree of Bachelor of Engineering with Honours
(Mechanical and Manufacturing Engineering)
Faculty of Engineering VNIVERSITI MALAYSIA SARAW AK
2009
p
ACKNOWLEDGEMENTS
Firstly, I wo uld like to express my most gratitude to The God for givi ng me the
opportunity to finish my final year proj ect. I also would like to thanks to my project
supelVisor, Mr. Aidil Azli Alias for the excellent guidance and encouragement for
me. Thanks goes to my family for always being supportive and concemed about my
work and to my friends who always help me and teaching me until I finish the
project. Last but not least, I wish to extend my thank all mechanical and
manufacturing statfthat give guidance and provide knowledge to finish my report.
til
ABSTRAK
Di Sarawak, masih banyak lagi ladang dan kebun lada hitam menggunakan
tangga sebagai alat untuk pernetikan dan penuian lada hilam. Harnpir sernua petani
tradisional rnasih menggunakan tangga buatan sendiri untuk rnenolong rnereka
mencapal bahagian-bahagian puncak pokok lada hitam. Konsep rekabentuk
aksiomatis digunakan didalarn projek rnenghasilkan tangga baru untuk kegunaan
pernetikan dan penuian hasil lada hitarn. Beberapa kebun dan ladang telah dilawati
dan beberapa ternubual telah dijalankan kepada tuan dan pekerja di ladang lada hitam
untuk rnengenalpasti rnasalah-masalah yang dihadapi ketika rnenggunakan tangga
tradisional. Rekabentuk tangga baru dapat di cipta selepas rnasalah yang dihadapi
dikenalpasti. Bermula dengan pengurnpulan rnaklurnat hinggalah ke rekabentuk
terakhir yang rnenggunakan perisian jurutera, langkah diarnbil secara berhati-hati
untuk rnernastikan setiap permasalahan dapat dikurnpul untuk rnenghasilkan
rekabentuk terbaik. Beberapa pemcriksaan telah dijalankan untuk rnenentukan
kekuatan rekabentuk tangga tersebut yang bergantung kepada bahan yang digunakan.
Tangga baru yang dicipta ini lebih senang dan sclarnat kepada pengguna dan juga
menyediakan tangga dan bahagian belakang yang bolch diubah mengikut kesesuian
tinggi untuk menjamin ianya lebih mudah dan berkesan kepada pengguna.
IV
ABSTRACT
In Sarawak, there are still many pepper fam1 and orchard using ladder as their
tool in harvesting pepper benies. Most of the traditional fanners still lise handmade
ladder in harvesting operation to assist them in reaching the higher port ion of pepper
tree. The application of axiomatic concept is used in this project to facilitate the
design ing process. Several fann and orchard was visited and interview was done to
identify the problem when using the traditional handmade ladder during harvesting
pepper berries. After problems identified, the new design of ladder was proposed to
fulfill the user needs. From gathering infonnation until the final des ign using
engineering software, the design phase was taken carefully to ensure every detail was
taking into account in order to developing the best design. Several tests have been
conducted to the design to estimate the strength of the product based on the materia l
that was used. The new ladder is more user fuendly and safety to the users and also
provide adjustab le stand and ladder to ensure it more easy and effective for the users.
v
j-~U~~; ,u. .,,4 lV\dJr..l •.t~ .It AkaLUnH~ UNIVER.';1 fJ MALAYSIA SARAWAJ(
TABLE OF CONTENT
Page
List o fTables X
List of Figures XI
List of Abbreviation Xll
Chapter 1 INTRODUCTION
1.1 Problem Statement 2
1.2 Aim and Objectives 3
Chapter 2 LITERATURE REVIEW
2.1 Introduction 4
2.2 Pepper Background 4
2.2. 1 Pepper History in Malaysia 5
2.2.2 Pepper in Sarawak 7
2.3 Pepper Cultivation 8
2.4 Problem and Constraint 10
2.5 Axiomatic Design 12
2.5. 1 Domains 13
2.5.2 Ax iomati c Product Deve lop ment Lifecyc le IS
Chapter 3 METHODOLOGY
3. I Introduction 19
3.2 Des ign Phases 19
3,3 Recognition 0 fneeds 21
3.3. 1 Customer needs 21
3.3.2 Input Con straint 22
VI
22 3.4 Product Design Specification
3.4.1 Quality Function Deployment 23
3.4.2 OSHA Standard Codes 24
3.5 Functional Reg uirement 25
3.6 Conceptualization 25
3.7 Concept Selection 26
3.8 Embodiment Design 26
3.8.1 Ergonomics 27
3.8.2 Configuration Design 27
3.8.3 Parametric Design 28
3.9 Detail Des ign 28
3.\0 Material Selec tion 29
3. I \ Cost Estimation 29
Chapter 4 RESULTS AND DISCUSSIONS
4.1 Introduction 31
4.2 Problem Identification 31
4.2.1 Objective Clari ficat ion 32
4.2 .2 Constraint 32
4.2.3 Customer Requirement 32
4.3 Design spec ifi cati on 33
4.3. 1 HOllse of Quality 34
4.4 Funct ional Requirements (FRs) 36
4.5 Concept Fa [mulalion 38
4.5.\ DPs tor Concept I 38
vu
39 4.5.2 DPs for Concept 2
4.5.3 DPs lor Concept 3 40
4.5.4 DPs for Concept 4 41
4.6 Concept Selection 42
4.6.1 Design Matrix for Concept 1 43
4.6.2 Des ign Matrix for Concept 2 43
4.6.3 Design Matrix for Concept 3 43
4.6.4 Design Matrix for Concept 4 44
4.6.5 The Best Concept 44
4.7 Concept Generation 45
4.7.1 The Second Law Hierarchy of FRs and DPs 47
4.7.2 The ThirdLaw Hierarchy of FRs and DPs 49
4.8 Embodiment Design 50
4.9 Modeling and Analyzing 51
4.9.1 So lid Model 5 1
4.9.2 Analysis and Simulation Result 52
4.10 Detailed Design 57
4.11 Material Selection 58
4.11.1 Light Nonferrous Metals and Alloy 59
4.11.2 Material Specification 59
4.12 Final Design 60
4.12.1 Design Spcci fication 61
4.1 3 Matelial Cost Estimation 62
4.14 Discussion 63
Vlll
Chapter 5 CONCLUSION AND RECOMMENDATION
5.1 SummaIY 66
5.2 Recommendation 67
REFERENCES
APPENDIX A
APPENDIX B
APPENDIX C
APPENDIX D
APPENDIX E
APPENDIX F
APPENDIX G
APPENDIX H
IX
LIST OF TABLES
Table Page
2.1 APDL Domain contents 16
4.1 List of customer requirement 33
4.2 FRs for harvest Ladder 37
43 DPs for Concept 1 38
4.4 DPs for Concept 2 39
4.5 DPs for Concept 3 40
4.6 DPs for Concept 4 41
4.7 2nd Level of FRs and DPs 48
4.8 Material In fonna tion 53
4.9 Structural results 53
4.10 Material In fOlmation 55
4.11 Structural results 55
4.12 List of Material 60
4.13 Design specification for the ladder 61
4.14 Material Cost Estim~tion 62
x
LIST OF FIGURES
Figure Page
2. 1 Pepper plant on ferti le hill s loped 9
2.2 Pepper plant 10
2.3 Handmade ladder 11
2.4 Domains 13
2.5 APDL Domains 15
3. 1 The design process phases 20
3.2 House of Quality 24
4 .1 House of Quality 35
4.2 The decompos ition of FRs 37
4 .3 DPs decompos ition for Concept 1 39
4.4 DPs decomposition for Concept 2 40
4.5 DPs decomposition for Concept 3 41
4.6 DPs decomposit ion for Concep t 4 42
4.7 Hierarchies deco mposition of FRs 46
4.8 Hierarchies decompos ition for DPs 47
4 .9 Solid Model of Ha rvest Ladder 52
4 .10 Equiva lent stress 54
4 . 11 Maximum equi va lent stress 54
4 .12 Equivalent stress 56
4 .13 Maximum princ ipal stress 56
4. 14 Final des ign of ladeler 6 1
Xl
LIST OF ABBREVIATION
ICAD
CAs
FRs
DPs
PVs
CAs
APDL
TSDL
ICs
SCs
CTCs
FTCs
DSM
AD
IEEE
QFD
MPB
PMB
PDS
OSHA
International Conference on Axiomat ic Design
Custo mer domain
Functional domain
Physical domain
Process domain
Customer domain
Axiomatic Product Development Litecycle
Transdisciplinary System Development Lifecycle
Input Constraint
System Components
Component Test Cases
Functional Test Cases
Design Structure Matrixes
Axiomatic Design
Institute of Electrical and Electron ic Engineer
Quality Function Deployment
Malaysian Pepper Board
Pepper Marketing Board
Product Design Specification
The Occupation Safety and Health Act 1994
Xli
CHAPTER 1
INTRODUCTION
Malays ia' s production pepper produced outpu t of 4 tonnes in 1870 and made
Malaysia is the fou rth largest pepper produce in the world after India, Indonesia and
Vietnam. In 2005, Malaysia pepper production was 19,099 tones [15] and the share
of the total wo rld pepper production amounted to 9.6%. In tenns of export, Malaysia
ranks third with an export volume 24,808 tonnes or 18% of the total world export.
Peppers are one o f the important cash crops supporting the li velihood of about
67,000 rural dwellers in upland areas of Sarawak. Today, there are about 40,000
smallholders invo Ived in pepper cultivation with fann sizes ranging from 0.1-0.4
hectares. In Sarawak, estimated area under pepper cultivation was at 10,200 hectares
with concentrated in Samarahan, Kuching, Sri Aman and Sarikei di vision.[I ]
In 1980, pepper ind ustry in Malaysia dropped to third position in list of world
market of pepper producer to India and Ind onesia. It was because pepper fanl1ers
faced the majo r problems such as escalating cost for m,maging disease and pest
problems, increasing cost of fertili zer, pesticides and labo r inputs, lack of modem
fann knowledge among pepper farmers especial ly in rural areas and tluctuatin g
export market pri ces.[2]
1
Nowadays, the pepper industry in Malays ia has been faced w ith many problems
such as the escalating cos t for man aging disease, pest problems, poor processing
technique, the high labor requirements, low efficiency o f production and increasing
cost of fertili zer and pesticides.
Malaysian Pepper Board (M PB) is the main govemment agency has overcome
this problem by take action such as development to reduce cost of labo r method and
analyzing pesticides residue for processed peppercoms. Apart from that, MPB has
also continued the research on the control of foot rot disease and improved
processing technique. These methods were used in order to produce a better quality.
[3]
1.1 Problem Statement
In pepper industry, there are many problems occurring in the harvesting process
and the most extens ive operation is the halvesting method of the pepper ben-res
which is not easy to implement. In Sarawak, majority of the farmers use ladder to
assist them in harvest in g operation and most it are the hand made ladder.
In harvesting operation, hand made ladder is used to assist fanners to reach the
higher pOl1ion orthe pepper tree . Farmers also need to move a ladder D'om one tree
to another. It is time consmning and in valves many workers. If this prob lem can be
so lved, more production pepper can boosted up.
2
-
Pepper vines were nonnally brought to firs t crop at the beginning of the wet
season in the second year o f tield harvesting from March to August. Aro und that
season, terrain was soft because of the moisture. Using ladder can be dangerous
because of that factor and most of them are not practical and unsecured. It wi ll
become more dangerous if harvesting operation is being done at fertile slope and
mountainous terrain . [4]
1.2 Aim and Objectives
The aim and objecti ves of this project to design and develop a new ladder tor
pepper harvesting operation . The design of the ladder wi ll be based on the fann
condition, terrain and user-friendly. This project will overcome the existing problem
related to the traditional harvesting metbod or labor extension operations. Purpose of
this project is to made ladder more suitable in harvesting in different terrain and
increase prod uction rate 0 f pepper.
3
-- ---------- - .
CHAPTER 2
LITERATURE REVIEW
2.1 Introduction
This chapter w ill explain about pepper backgro und and process design criteria
for Ax iomatic Design. This chapter also contain abo ut general principle and main
concept of the Axiomatic Design.
2.2 Pepper Background
Pepper or "Piper nigrum" is the most commonly traded spice in the world, there
are approximately 3,000 years. Pepper main producer are from Malabar Coast of
India, but Malaysia, Indonesia and Sri Lanka are also important producer. Pepper has
also been cultivated in the New World and Bras il is a major exporter.
At Roman times and ancient Egypt , pepper already used and supplied by Arab
sea traders and they kept secret abo ut the source of the pepper. Being a va luable
commodity, peppers are used as a paym ent. Attila the Hun reputed ly demanded
3,000 pounds in weight of pepper as part of a ranso m for til e city of Ro me.
4
At the point the Greeks and Roman learned of the resource of this precious
spice and battle was on. That around 2,000 years the battle tor this valuable spice and
spun-ed exp loration and discovery of the New World by Christopher Columbus and
at the end he disappointed because he did not find the "Spice Island" [4]. At last
Portuguese founded a trade to India and the Spice Islands around the Cape of Good
Hope in 1949 by Vasco Da Gama's discovery. Start from there, valuable spice has
been dominated by Portuguese until l Sth century. [5]
Pepper also known as king of all spices, India has always reigned highest in the
production and export of this exotic and sought-after spice. "Malabar Garbled" and
"Te llichery Extra Bold" are two most trade varieties of Indian. Green peppers also
one of the product from India in several process forms such as frozen, dehydrated,
freeze-dried and packed in brine. In India black peppercorns was used as a remedies
for constipat ion, diarThea, earache, gangrene, heart disease, hernia, hoarseness,
indigestion, insect bites, insomnia, joint pain, li ver problem, lung disease, oral
abscesses, sunburn , tooth decay and toothaches. [6]
2.2.1 Pepper History in Malaysia
There are many name refer to pepper or black pepper. English words for pepper
is deri ved rrom the o lel Engli sh are "pipor". In Sanskrit the wo rd pepper are "pippali"
and German are "pfeffer", French are "poi vre" and for Dutch are "peper". In the 16d,
century, "pepper" started refen'ing to the unrelated New World Chile peppers as
5
_._--
\~\,:ll III i i' I., ( Ii '" P\,.'IlP ' \I,h II' \.' 11: ,I "\ II I" .! III ( II
I h, ll],\ild :llh\ \! ,1d dE ll :-'l\11' \\,1'-,1;,1 1 d \)\\,I\ I h\,., Ilhh l ""i.~!ll ! j) "l lil d :l.,. I"i,.·:hl I' rl, 1\ 1 111 111
\ \()" Il' i.,.',lnkd 11\ r~ l\l/ il d l ;1)d O drup P I I ~ , ( If)(j [,'(1[I l.,.·" 1[1 I l)C)'? 11 \ )111 .~ \ . ',' ( )( l l,lIl11e...., I))
(lIl(I\:l1l'd .rl~d ~d pi,.·ppl'1 III \ 1 da\ .... I.1 C(llh....:!ll!.l k .1
pL'P !h: r Iltlln \ L rI<l~""'I.t \\1\:-- l.,..llkd ~I"" ..... ,Ir:l\\dk 1\'n jl\:1 j ' .. !" \,:r l',I'!'lldfIPi1 ;lIld
I' l'l I{\! 1()11 ll; d l,"!1
" , 1,· .. , \' I,
2.2.2 Pepper in Sarawak
Today, Malays ia is in fifth rank on the world largest pepper producer with 98%
of it from Sarawak and 80% pepper production from Sarawak is concentrate at
sarikei. Pepper Marketing Board (PMB) general manager Grunsim Ayom said the
projected increase was due to the effects of projects implemented under the
Productivity and Income Enhancing Programme for Pepper and Cocoa Smallholders
(SP) last year [8]. SP programme involved maintenance scheme, organized faIming
and replanting, production of value added and premium quality pepper. This
programme will involved in 7 location in Sarawak like Kuching, Sn Aman, Betong,
Sankei, Bintagor, Senan and Sungai Asap. The plant will be equipped with spiral
separator machine, blower, thresher, destoner and mechanical classifier. [9]
Currently, 67,000 farmer and workers in upland areas of Sarawak depends on
the pepper production to sllpporting their Ii velihood. They concentrate in certain
districts of Kuching, Samarahan, Sri Arnan, Betong and Sankei Divisions. In 2004.
va lue exports for Sarawak are 19,748 tOlmes and 18,824 tonnes in 2003. Today,
Malaysia ranks number five with the output 21,000 tonnes after Vietnam (87,000),
India (45,000), Brazil (35,000) and Indonesia (25,000). In export form of pepper,
about 95 'Yo pepper is in form of black and white peppcrcorns and the remaining 5% is
made up of pepper o leoresin, pepper oil , green pepper and ground pepper. [3]
7
2.3 Pepper Cultivation
In Sarawak, pepper is cultivated as a monocrop without shade mainly on gentle
to steep slope. Field drains must be provided if holding are located in low-lying
areas . Trad itionally, farmers will clean a weed around their pepper plant and walking
side can cause serious soil erosion. Pepper frumers are now encouraged to adopt the
practice using ground cover.
Between October and December is a good month and can be done the field
planting of rooted cutting. In Pre-rooted, polybag-nurseried or unrooted cUlting can
be used. One importan t thing is newly planted cutting must be shaded until they well
establish. In pruning process, vines will be pruned to encourage the formation of a
des ired canopy. There have there round until the fin al pruning is done when the
terminal shoots have reached the top of the pos and first berry production.
Application of chemical fertili zer is important to sustain high yield in fertilizing.
It is because pepper vine have high demand for nutrients. Harvesting can be done
after 2 year of field planting at the beginning of the wet season, there are between
March and August. When berries at the base start to tum red o r early sign of
maturity, harvest should be done to maintain thei r pungency. After that, green berries
will dry using direct sun-drying about a week and a half to produce a black
peppercorn. White peppercorn is processed by soaking the ben;es in clean running
water to remove their pcricarp to 110 wed by sun drying.
8
Figure 2.l : Pepper plant on fertile hil l sloped
Figure 2.2: Pepper plant
9
--- --- -- -
2.4 Problem and Constraints
In pepper industry, there are many problem fanners will face. The major
problem and constraints the farmers faced are harvesting problem, pest and disease
control, market price for pepper, fluctuating export market prices, increasing cost of
fertilizer, pesticides, labour input and escalating cost fo r managing disease and pest
contro l. On this project, only focuses on the harvest ing method.
The purposes on this project are to improve harvesting technique for better
quality and value added produce. One of the traditional methods is using a handmade
ladder to harvest pepper berries. There are dangerous to moving a heavy ladder from
tree to another tree on bumpy terrain . Moving a heavy ladder also will cause effect to
back body and muscular pain . There are also wasted many times in hatvesting pepper
bemes using handmade ladder because workers need to move the ladder.
When harvesting pepper berries, tom part from a tree bushes can injury or
scratch worker's hand. The hard part when harvesting pepper bemes are to reach a
top of pepper plant to take berries. There also when to reach hard portion like berri es
in the bushes of pepper plan t, inju ry can happen when a workers try to take certain
part of the pepper plant. Harvesting not efficient when labour can see properly
berries and try to take them, it can cause damage or crush to the pepper berries. That
can waste many pepper berries and effect their prod uction.
10