Exercise Device

Peak Performance Engineering

Problem Statement

Create Compact Total Body Workout Equipment That Provides Both:

• Cardiovascular Workout» Weight Loss / Fat Burning

• Strength Training» Muscle Toning / Muscle Building


Problem Statement (Redefined)

Create Compact Total Body Workout Equipment That Provides Both:

• Upper Body Strength Training Capabilities» Muscle Toning / Muscle Building

• Lower Body Strength Training Capabilities» Muscle Toning / Muscle Building


Market ResearchProduct Type Retail Sales Percentage of Sales

Aerobic Riders $25,000,000 0.66%

Aerobic Steps $5,000,000 0.13%

Cross-Country Ski Machines $50,000,000 1.34%

Elliptical Trainers $600,000,000 16.04%

Free Weights $130,000,000 3.48%

Home Gyms $540,000,000 14.44%

Rowing Machines $5,000,000 0.13%

Stair-Climbing Machines $180,000,000 4.81%

Stationary Exercise Bicycles $360,000,000 9.63%

Treadmills $1,650,000,000 44.12%

Weight Benches $195,000,000 5.21%

Total $3,740,000,000 100%


Market Research


Sales Quantity of Home Gyms

0

200

400

600

800

1000

1200

1400

1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010

Year

Qu

an

ity (

in t

ho

usan

ds)

Market Research


0

20

40

60

80

100

120

140

160

Av

era

ge

A

rea

(s

qu

are

fe

et)

Aerobic riders

Cross-country ski machines

Elliptical cross-tra

iners

Free weights

Home gyms

Rowing machines

Single-station gym

Stair-clim

bing machine

Stationary cycles

Treadmills

Type of Equipmnt

Average Area Required for Fitness Equipment

Customer Requirements


HOQ

Engineering Requirements


HOQ

Operational Description














Individual Parts

• ½” plywood cut to size• Padding & cover• Polypropylene straps

• Aluminum sheet metal bent to desired shape• Locating guides for pulleys welded to inside of box, with pulleys on• Cable tie-off welded to outside of box• Positioning hanger with locating hole welded to top of box


Individual Parts

• Nylon 6/6 reinforced with glass fibers• Material injection molded to create part

• Nylon 6/6 reinforced with glass fibers• Material injection molded to create part• Rubber attached at end for sealing purposes


Individual Parts

• Square aluminum tubing• Holes drilled and ends bent for attachment to Resistance Box

• Aluminum sheet metal• Bent to desired shape• Slots machined on sides for cable• Holes machined on end for buttons• Holes drilled for attachments


Bill of Materials

Performance Analysis

• Engineering Models–Piston-Cylinder Model–Pulley-Weight System–Spring System–Exercise Wheel Design

Piston-Cylinder Model

• Resistance generated by vacuum.• Force is constant at absolute vacuum.• Vacuum maintained by vacuum seal.• Maximum force corresponds to diameter

of piston. F=P*π*r2

• Several cylinders used for resistance skill level.


Assembly

Parameter Variation


hi ≈ 0

di = 1.32”

F = 20lb

Vi ≈ 0 F = P * A A = π * r2 r = di / 2

Assumptions: Pressure inside piston starts at 1 atm, and density is 1.18 kg/m

3. Dynamic Vacuum seal on piston Constant room temperature

Piston/Cylinder Model


Comparison Benchmarks

Benchmark - Cap Barbell Home Gym System

- Model outperformed or met customer requirements the same as the Cap Home Gym. (150 lbs vs. 180lbs)

- Reparability, the only issue for customer requirements.


Pulley System Model

F F

F

mg

• Elaborate Pulley System

● Basic Configuration: Force-driven cable connected at one end to external surface, with the cable being wrapped around a pulley linked to a mass.

● Assumptions: Frictionless pulley, constant gravitational acceleration (9.81m/s^2), massless cables, massless pulley.


Basic Calculations: (2 pulley configuration)

Fx = 0 Ax = 0Fy = 2F – mg = 0 F = (mg) / 2 (m)Ay = 2F – mg

Ay = ((2F) / m ) – g

For

ce

mg

Pulley System Model



Assembly

Comparison Benchmarks

Benchmark - Cap Barbell Home Gym System● Net weight of concept exercise device lower than Cap Barbell Home Gym. (170 lbs vs. 300lbs)● The ability of foldable bench legs helps in storage under beds or other furniture.


Assembly Efficiency

• Goal: Maximize production efficiency, Minimize cost.

• Solution: Design for Assembly worksheet– Pinpoint faults, areas for improvement.– Obtain a DFA score


First DFA Worksheet

46

01610128


DFA Evaluation

• Improvements in overall assembly, part retrieval and part mating.

• Steps to implementation– Single pulley sizes– Lighter materials– Chamfers, round edges– Hinged legs


3612

66

20

16

Second DFA Worksheet


Assembly Efficiency

• Simple assembly for consumer.– Leg Hinges– Leg Extension Bar– Exterior Pulleys– Rail and Box Assembly


Economic Analysis

• Purpose: Evaluate financial effectiveness of our product.

• Established Financial Analysis Diagram.





Other Calculations

• Net Return on Investment: 55.6%• Net Rate of Return: 76.9%• Break-even Thresholds:

– Quarter 7– 4,488 units (assuming interest)


Conclusions

• Unparallel total body workout in a compact design.– Strong niche in current market.

• Met or surpassed customer needs• Very profitable, low risk, investment• Conservative sales assumptions, great

entry opportunity


Documents

Exercise Device