GreenWeaver

Final PaperE/ME 105a

Caltech/Art Center/SaintgitsFall 2012

Arjun Chandar, Shobha Cherian, Yifei Huang, Majesh Tom Mani, Judy Mou

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Abstract/Summary

Currently, worldwide demand is increasing for mats made from dried screw pine leaves (see

Figure 1). However, artisans in Kerala, the leading exporter of these mats, are increasingly

reluctant to enter the profession due to the tedium and physical strain imposed during the

weaving process, resulting in a decreasing supply of

mats and other handicrafts. In particular, women must

sit in contorted positions and hold strands of leaf with

their toes as they weave. Our goal is to develop a

cheap, easy-to-use device that both facilitates the

weaving process for the workers and expedites the

production of mats to meet market demand.

The motivation for this project stemmed from a visit we made in September to the

headquarters of the Kerala Rural Development Agency (KRDA). While there we observed the

weaving process in some homes and received background information on the industry from our

contact, Salim. After deciding to tackle the weaving problem, we performed further interviews

and sought feedback from both the KRDA and artisans, and well as potential manufacturers,

before developing a prototype.

Our current solution, the second iteration of our brainstorming results, is a device which

employs a frame attached to rails. A diagonal slide, traveling along the rails, can be adjusted

with each strand of leaf laid down for a mat. Beneath the slide is a cylinder with pins which can

be rotated to lift alternating strands of leaf, allowing for interlocking of strands in each iteration.

Initial feedback from our customers has been positive. However, right now we have only

a small-scale prototype and incomplete data on costs. We are confident, though, that as we

progress further with a full-scale prototype, we will achieve a design that expedites weaving and

meets our customers’ needs.

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Table of Contents

1. Mission Statement.........................................................................4

2. Problem Statement and Background............................................4

3. Market Research...........................................................................6

4. Partners and Customers...............................................................7

5. Design Specifications....................................................................7

6. Solution..........................................................................................9

7. Design for X...................................................................................12

8. Ethical Plan....................................................................................16

9. Major Challenges...........................................................................17

10. Future Directions.........................................................................17

11. Analysis of Team Processes......................................................18

12. Appendix......................................................................................20

13. References..................................................................................20

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1. Mission Statement

Design and produce a fully functional, cheap and user friendly machine to improve and

expedite the process of weaving dry screw pine leaves into mats and other handicrafts, bringing

more artisans into the screw pine industry and increasing wages for those already in it.

2. Problem Statement and Background

Screw pine, a unique plant growing in this God’s own country, is known for its ecological

and artisanal value. Weaving of screw pine mats is one of the traditional crafts practised by

women in Kerala. The leaves for this mat are taken from the sword –shaped thorny screw pine

plant. The entire mat-making process is tough as the leaf has sharp thorns growing in both

directions. The weaving process is done crosswise, and interlacing continues as new strips are

added. Once weaving is complete, the edges are hemmed

with narrow screw-pine strips to finish the mat.

Screw pine mats are currently used ubiquitously in India.

These mats serve multiple purposes for most families,

acting as tablecloths, rugs, and mats to sleep on.

Furthermore, because of the flexible structure of screw pine

mats, many mats can be cut and sewn into other useful tools, such as baskets, handbags,

pillows and other handicrafts (see Figure 2). The usefulness of these products in daily lives

make screw pine mats high in demand not only in India but all over the world. Although mats

can be woven from other material such as coconut and palm leaves, screw pine mats are

preferred because of their softness and flexibility. In total, the Kerala Rural Development

Agency (KRDA) alone exports about 25,000 Rs. worth of mats per year to other countries like

the United States and Canada (see Table A-1).

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Despite the widespread use of screw pine mats, there is a shortage in supply and labor.

These plants are native to the Kerala area, and the large majority of the world’s supply of screw

pine mats are handmade by artisans in this region. Most of these artisans are women who

weave at home between household chores. The women are paid around Rs. 200 per mat.

Since it takes an experienced worker to weave one mat in two days, this averages to about 100

Rs. per day for the best weavers (this translates to ~1.84 U.S. Dollars).

The low pay and the tedium and strain involved in the job contribute to the unwillingness of

women to enter the profession. To weave the mats, the women sit on the floor and hold parallel

strands together with their feet. Because the mats need to be taut, it is important that the

strands are held firmly. Then, the artisans use their hands to insert perpendicular strands to

create the interlocking pattern that is the mat (see Figure 3). The process is then repeated

numerous times for each mat. Because of the interaction of

the feet and hands, the women must sit hunched-over, which

is straining for their body and back. The repetitiveness is also

tedious, and the process is slow and time-consuming. This,

together with the low pay, discourage many women from

entering the profession.

Numerous non-governmental organizations (NGOs) support community development

programs in these parts of India. One of them, the Kerala Rural Development Agency (KRDA)

supports between 500 and 800 screw pine artisans working in Thazhava and other parts of the

Karunagappally municipality. From their involvement in the screw pine industry and their sales

numbers, they have expressed concern that supply is far from meeting demand. Furthermore,

there is belief that other handicraft products could be made from screw pine to increase profits,

but because of the lack of workers, there is never enough time to create those new products.

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There have been failed attempts to create a weaving device. The KRDA has previously

worked with another manufacturing and design firm, Ostrich Mobility Instruments in Bangalore,

to develop a product for weaving screw pine. However, the product failed because screw pine

leaves are fragile and break easily under tensile stress. This is also the reason why we cannot

apply previous weaving solutions to the problem. There have been looms developed to facilitate

and expedite weaving mats from coconut and palm leaves [1], which are much tougher and

stronger than screw pine leaves. The loom clamps the leaves down, and the stress on the

strands may be too high for screw pine leaves.

The KRDA is currently asking the Caltech-Saintgits group to help them develop a device

that will both expedite weaving and make the process less strenuous for women. They are

willing to pay up to Rs. 10,000 (around $200 US), while individual artisans have expressed a

willingness to pay up to Rs. 5000 for a device. A device that will reduce the strain on the

artisans may stop discouraging women from entering the profession. More workers in addition

to a faster weaving process will increase supply of mats and allow the industry to meet more of

its demand.

3. Market Research

During our research and interviews we found out that the screw pine business is

diminishing currently due to the aforementioned lack of labor. Salim [2], our contact at KRDA,

predicted that this business may die out in 5 years if there is no device to expedite the weaving

process. Our research indicates that there are more than 7000 families in Kerala who dabble

in screw pine weaving. The problem is that with the current technique of weaving (using toes),

artisans are only able to make one mat in ten hours, or about 2 days of work. Thus, the current

production KRDA expects is very slow at approximately 600 mats per year. As a result, they

are not able to meet the demand of their customers. The most instructive point which we found

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out during our research was that there are no current weaving devices for this process, the only

previous attempt having failed with Ostrich Mobility Instruments.

As electricity is one of the major issues that Kerala is facing, the people

at KRDA prefer a device which is mechanically actuated and does not require the use of

electricity. Also, using an automatic mechanism can be a disadvantage, as it will inevitably have

a higher error rate than one made by hand. Therefore, we are trying to concentrate on a device

which is manually operated.

4. Partners and Customers

● As of now, our primary buyer is the Kerala Rural Development Agency. Our primary

contact is named Salim, and he is based in the village of Thazhava in Karunagappally.

● Our end users will be the artisans making mats. Thus far we have contacted and

interviewed six female artisans from Thazhava to receive specifications and feedback.

● For distributive and manufacturing partners, see our DFX (Section 7).

5. Design Specifications

5a: Qualitative Specs

Our device must be designed in such a way that :

● It is very cheap so that it can be affordable for everyone (for every income group).

● Women can operate it with their hands while sitting.

● Our design allows for diagonal weaving as requested by the artisans.

● It is simple enough that artisans will adapt it. If the device is too complex they will prefer

to

continue with the current technique.

● It is reliable (low error rate).

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● The most important point brought up by artisans is durability of the device. It should last

for more than 5 years.

5b: Quantitative Specs

1. Engineering Specs

● The device cannot be larger than 4 ft * 4 ft * 2.5 ft

● The customers are willing to pay up to Rs. 5000 for the device.

● Max. 10 lbs so that it can be easily handled.

● 5 years minimum use with maintenance of no more than twice a year. It should cost Rs.

200-300/maintenance.

● Error rate no greater than 1% of strands.

● Reduce at least 50% of the back pain on a 1-10 scale (as indicated by the artisans).

● Increase productivity by at least 2 folds.

2. Product Specs

● Size: 3.5 ft x 5.5 ft x 2 ft

● Weight: 8-10 lbs (3.5-4.5 kg)

● Cost: Rs. 3000-5000

● Reliability: Error rate 0.5%-1%

● Durability: 5 years of use without major breakdown

● Maintenance: During the 5 years of use, there should be maximally semi-annual

maintenance for tuning the machine. Each maintenance takes Rs. 200-300.

● Productivity: one mat in 3 hours with experience and training

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6. Solution

6a: Prototype Design

Main considerations for the design:

● Should change the artisans’ working position

● Simple actuation and operation

● Cheap materials

● Should lift one set of alternating strands, and the opposite set in the next iteration

Initial Prototype

Initial prototype: Idea was decided upon during brainstorming using Kepner-Tregoe.

Prototype components:

● Clamp

The strands of leaf are clamped side by side at one end.

● Lifting mechanism

We have two sets of holders at the other end, through which we feed the other ends of strands.

The one nearest the clamp is fixed. The far one can be lifted up or down through slots.

● Operation

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The adjustable holder will keep one set of alternating strands elevated while the fixed

holder keeps the other set fixed. Since the two sets are offset, we can just slide a perpendicular

strand into the gap between them. In the next iteration, we move the adjustable holder down,

so that set of strands is below the fixed set. Again, we slide a perpendicular strand into the gap.

Since alternating strands are at different heights in each iteration, we can achieve interlocking.

● Benefits of Design

The prototype, if properly dimensioned, should be very easy to operate, since one just

needs to lift or lower a holder to achieve interlocking. It also allows people to sit while operating

it, an improvement on crouching and weaving with the toes.

● Problems with Design

Firstly, we are still holding the strands of leaf at both ends, putting axial stress at both

ends and increasing the probability of strands breaking. This was the problem with the initial

venture between the KRDA and Ostrich Mobility Instruments. Secondly, our initial design does

not encourage the diagonal weaving process the women currently employ.

To correct these issues, a second iteration was made and is currently in India.

Current Prototype

Working position of the prototype is shown in Figure 5. Prototype components:

● Frame (Figure 6)

Wooden frame has rails attached along its length on both sides. It also has parallel

plastic strings tied to it with an offset of 8 mm (average width of a dry screw pine leaf).These

strings are inclined to the rails by an angle of 45 degrees.The strands are laid parallel to these

strings and are held by suitable clamps.

● Lifting mechanism (Figure 7)

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Strand lifting mechanism includes a flat ruler-like member that comes above the frame.

This is used to hold the strands flat and give the position about which the stands are going to

lifted. This member is positioned perpendicular to the plastic strings tied to the frame.

The lifting mechanism also consists of a rotating cylinder-like member that comes below

the frame. This has finger-like pins on it . When this cylinder is rotated these pins will lift strands

up. These pins are positioned such that they lift only a set of alternating strands.Both the ruler

and rotating members are connected by links that can easily slide on the rails.

● Operation

The ruler member is suitably placed over the laid strands and the rotating member is

rotated thereby lifting one set of alternating strands. Then one perpendicular strand is inserted

in between . Next, the lifting mechanism is slid on the rails and the ruler member is suitably

placed. When we slide the mechanism by one strand width along the diagonal, the lifting pins

will get displaced by the same distance as the strands are inclined to the rails by 45 degrees.

Then by rotating the cylinder again, the next set of alternating strands gets lifted up.

Figure 5. Working position Figure 6. Frame and rails

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Figure 7. Rotating component

● Prototype Features

This new design performs the same functions as our initial one, but it does not require

clamping at both ends and encourages diagonal weaving.

Because the pins in the cylinder are at fixed positions, this device does require that each

strand have a standard width (8 mm), something our first design did not require.

6b: Customer feedback and Interactions

● KRDA

We showed the prototype to them and demonstrated its operation. They liked the idea

and suggested standardisation of width of the screw pine leaf strands was a good thing. It

increases the finish of the final product and thereby increases the market for the mats.

● Artisans

We demonstrated the working of our prototype to some of the artisans and they also

gave positive feedback as it complies with existing weaving process

● Prof. Vinay Mathew John

We showed our prototype to Vinay. He preferred this idea as it avoids axial stresses on

both ends of the strands.

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7. DFX

7a: Suitability for the Marketplace

Through market research and interviews with partners and customers, we believe

that our product is suitable for the market both in terms of time and place.

First of all, both the artisans and distributors have expressed the need for a weaving

device. The artisans have confirmed the painful weaving process, and their desire for a device

that will ease the pain and facilitate the weaving process. Distributors, such as the Kerala Rural

Development Agency, see the same problem, in addition to issues with market supply and

demand. As seen in “Market Research,” the number of screw pine mats sold has increased

each year. However, the demand has increased more rapidly. According to Salim from the

KRDA, demand at anytime can vary from 250-2000 mats, but there are only 20-30 mats in

inventory. Therefore, both parties directly involved with the screw pine mat industry (artisans

and distributors), show the desire to purchase and use a weaving device that will both alleviate

the pain involved in weaving and expedite the process. Our product could remedy the the

inability of supply to meet demand by increasing supply, making it suitable for the marketplace.

Both the artisans and distributors have long awaited a weaving device, and all previous

attempts have failed. Therefore, our product is entering the market at a critical time, with no

major competition and a business that may die out without our help.

Our device showed initial promise for suitability in the marketplace. As we stated earlier,

upon showing the KRDA and artisans our current design, we have received positive feedback.

Their cooperation in working with us will help us further perfect the product for their needs,

which will only make the product more suitable for their use and ensure a smooth, successful

entrance into the marketplace.

7b: Cultural Sensitivity

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We have designed the product with the intention that it will be made, distributed,

and used in India. For these reasons, we have contacted local carpenters and chosen to make

our final product out of materials which they deem cheap, readily available in Kerala, and easy

to work with.

Furthermore, we are sensitive to the economic impact of our device. Because

many people in our target region live below the poverty line, we will aim to create jobs by

introducing our product. On one hand, more people may have time and willingness to enter the

mat weaving profession, increasing income for up to thousands of families. In addition, while

they give us guidance to the manufacturing process, we will be creating an opportunity for local

carpenters to make revenue by producing our device.

7c: Low Cost

We believe our frame/rails/cylinder prototype is capable of achieving low cost (Table A-

2). We found that we can use wood for the frame, as it can be cut to large sizes and will not

experience too much wear and tear given how our device operates. The rails will probably be of

the sort which are sold commercially and should be manufacturable at low cost. Other parts of

the device, such as the slide, cylinder and pins, will experience more wear and tear, and they

constantly move when the device is operated; we plan to make them from a cheap material

such as mild steel [3]. Due to the relatively simple design of all parts, wage costs for

manufacturing should not be high. Furthermore, since we plan to manufacture locally and use

local materials, transportation and importation costs will be minimized.

With all of these considerations and allowances for extra expenses, we believe we can

make a full-size prototype for Rs. 3700, well below the Rs. 5000 our customers have indicated a

willingness to pay. We should note, though, that most of our costs are estimates, and we need

to begin making our prototype to have a better idea of what our cost will be.

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7d: Human Factors

Our device considers human factors by accounting for the ease-of-use of customers.

First of all, our device is designed to maintain the same weaving process that the women

currently use. The mat is meant to be weaved starting from the corner of the device, which

is exactly the weaving process that the artisans perform by hand. Furthermore, the weaving

techniques that our device requires (moisturizing and straightening strands, elongating short

strands) are all methods that the artisans currently perform for their mats through weaving by

hand. Therefore, no complicated, new procedures are necessary, making our device easy for

our customers to use.

Other device parameters consider the convenience of the users. The device is made to

be smaller than the size of a mat. To make mats larger than the size of the device, the artisans

would slide the finished mat portion out of the way, position the side they wish to elongate along

the edge of the device, and continue weaving. This accounts for the space constraints in the

artisans’ houses.

7e: Manufacturing

For easy serviceability and maintainability, we plan to employ carpenters in

Karunagappally to manufacture and maintain the machine. We have thus far spoken to two of

them, although we are sure we can find more once we have a model to show them. If we have

trouble finding people locally, though, our best backup plan for manufacturing is Ostrich Mobility

Instruments in Bangalore, the institution suggested to us by Salim at the KRDA.

7f: Distribution

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Our current plan for distribution of our product is to do it through non-governmental

organizations. Thus far the Kerala Rural Development Agency is our only distribution channel,

but we can seek out other NGOs when we have a full-scale prototype approved by the KRDA,

manufacturers and artisans.

7g: Sustainability

1. Economic Sustainability

Our current estimate places our development cost below the maximum artisans are

willing for our product and far below what KRDA has indicated they are willing to pay. Therefore,

we expect sale of this product will generate enough revenue to cover materials, manufacturing

and marketing costs while still generating a reasonable profit for whoever produces it. Since

this is meant as more of a capital investment than a consumer item, we will need to make sure

manufacturers do not keep too many devices in inventory, lest they shy away from making

it. However, we believe demand for our device will be high enough that people will make the

investment and the product will not be mass produced without being sold.

We also anticipate making our product to last a long time (around 5 years), thus making

the investment pay for itself and then begin turning a profit for artisans and NGOs alike.

2. Environmental Sustainability

We do not anticipate using any hazardous materials in making our product, and the only

waste we anticipate will come from shaving of mild steel during production of our rails and

cylinder. However, we do not anticipate production of our device expanding to a level where

steel becomes unavailable or the levels of waste are significantly harmful to anyone beyond the

scope of their usual lives, so our device should be environmentally sustainable.

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8. Ethical Plan

We will follow high ethical principles, with emphasis on the following tenets:

● Value: we will keep costs low for customers, but ensure high quality as well.

● Health and safety: we will not use toxic materials and will design our product keeping in

mind that we want to reduce the strain imposed on weavers. We will test all designs ourselves

before showing them to potential customers.

● Integrity: we will always be honest, respectful, sensitive and accountable for our work.

● Put the customer first: our first priority is the well-being of the artisans.

● Sustainability: our product will encourage efficient use of screw pine and other materials.

9. Major challenges

The collaboration and communication between the U.S. and India team is one of the

biggest challenges we face. Since the mat weaving process is quite complex, the U.S. team had

trouble understanding it. The ability to understand the weaving process is crucial for a good

design. In order to make the U.S team understand quickly, the Indian team talked to some

artisans and filmed their weaving process, which was extremely helpful.

Another challenge we had was communicating our prototype ideas, but we have

overcome it by drawing and explaining to each other patiently during meetings. Additionally,

it was also a challenge to find artisans for interviews. Unlike other teams, our end users

- the artisans - work at home, so they are more spread out and it is hard to arrange time

for interviews. It was also a long trip for Majesh and Shobha to travel to KRDA, since

Karunagappally is about 70 km from Kottayam. For now, these challenges have not stopped us

gathering information that is beneficial for our design, but they have slowed the process.

For future challenges, we think it will require careful consideration to finalize the product

dimensions and decide on cheap and durable materials. After we have finalized the product, we

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are worried that the artisans will be reluctant to try out the product. However, we are confident

that we can make our product appealing enough so that they would like to try it out and give us

useful feedback.

10. Future directions

● Manufacturers

We would like to make CAD models to show to Ostrich Mobility Instruments in

Bangalore and local carpenters in Karunagappally. If they have any feedback on how to

redesign the parts for easier manufacturing and assembly or suggestions on alternative

materials, we would like to take them into account before finalizing the product.

● Customers

We would also like to show the artisans our prototype to receive feedback. Additionally,

we are hoping to keep them engaged in the design process. As Ken suggested in class, there

are many benefits to this. Our end product will be better, and it will be easier for the artisans to

adapt to it. Since the artisans take pride in their weaving skills, which are possibly passed down

by older generations, they might be unwilling to accept the product that changes the process.

We hope that by engaging them in the design, it will ease this tension.

● Partners

We also would like to keep our frequent contact with KRDA because they are the NGO

that can subsidize the product for our end users. If we can successfully convince them of the

benefit of our design, they can advertise and subsidize the product, reaching out to more users.

11. Analysis of Team Processes

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All things considered, our team worked very well together and everyone contributed

to the best of his or her ability. We met one to two times a week, usually through calls on

Skype. On occasion team members on the American side had trouble waking up for meetings,

but everyone held him- or herself accountable and these issues did not detract from the

overall team dynamic. We would collaborate on Google Documents and Presentations and

occasionally use instant messaging when poor connections caused us to have trouble hearing

each other. Before any deadline we would always hold a meeting to ensure each group member

read our our submission and was satisfied with it. We would email frequently to confirm or

schedule meeting times and to share documents, designs and videos using Google Drive.

Whenever someone had a conflict and was unable to make a meeting or presentation, he

or she would let other group members know far enough ahead of time that we were ready to

account for it.

Frequently, especially during brainstorming, we would have disagreements about how to

best solve the problem of weaving, mostly stemming from the big learning curve we faced when

understanding the process. However, using Kepner-Tregoe we settled on a solution reasonably

close to the group’s consensus. For our second iteration of a prototype, we held a meeting

to analyze every aspect of the design and how it improved upon the problems with our first

prototype, and each group member came away satisfied with the direction we were heading in.

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12. Appendix

Table A-1. Market Research Data from the Manager of Kerala Rural Development Agency

Table A-2. Estimated Manufacturing Costs for Current Design

13. References

[1] "Palm and Coconut Leaf Mat Weaving Machine." National Innovation Foundation India.

N.p., n.d. Web. 16 Oct. 2012. <http://www.nif.org.in/node/714>.

[2] Salim. Personal Interview. 1 Nov. 2012

[3] "Industrial Steel Products." Horizon Mercantile Associate PVT. LTD. Indiamart, n.d. Web. 12

Dec. 2012. <http://www.pipe-fitting-flanges.net/industrial-steel-products.html>.

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