Laptop Holder Report

8/2/2019 Laptop Holder Report

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Sultan Qaboos University

College of Engineering

Department of Mechanical and Industrial Engineering

Industrial Engineering Design

Project on

Laptop Holder

Students Name:

Abeer Al-Barram 82313

Reem Al-Kharusi 82351

Salma AL-Masrouri 82349

Zumuruda Al-Hashli 82356

Supervised by: Dr. Ibrahim Garbie


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ABSTRACT

This project studies the process of designing and making a new product from

an interdisciplinary standpoint (business, engineering, and industrial design).

Covers modern tools and methods for product design and development and

assembly line and layout. In brief, this project is the entire set of activities

required to bring a new concept to a state of market readiness. Topics

include identifying customer needs, concept generation, product

architecture, industrial design, design-for-manufacturing, assembly line,

costs, and final layout and location.

CHAPTER (1): Introduction(Salma)

The aim of Industrial engineering design is to study both

function and form of the product, and the connection

between product, the user and the environment. We, as

Industrial designers in this course, do not design the gears ormotors that make machines move, or the circuits that

control the movement, but we can affect technical aspects

through usability design and form relationships. And we

partner a whole of other professionals like marketers, to

identify and fulfill needs, want and expectations.

In the current work, a whole study is made to design a high-quality laptop holder thats light and travel friendly and also

suitable for different uses.


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In this project, we first present a general discussion on our

product A Laptop Holder. We then offer our view on the

Identifying Customer Needs, Product Specifications, Concept

Generation and Concept Selection.

We then examine the product development practices of a

few representative companies and compare this examination

with our philosophies. Studies are conducted to choose the

right manufacturing site and set the proper assembly line

and factory layout. In simple words: we design the product

and the production process from A-Z to come up with the

best system, with the lowest cost and time, and

manufacturing time. Finally, we discuss the products effects

on the society, environment and the market.

3-4 pages

Product , manufacturing , economic , explain the phases u will go thru

CHAPTER (2): Phase I(Salma)Analysis of product

Design architecture

Product design

Product complexity

2.1 IDENTYFYING COSTUMER NEEDS

Table 1 shows the mission statement of the design team.


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Table 1: Mission Statement

A device that holds the laptop at all

positions and ergonomically designed for

all postures.

Product Description

Introduced in May 2011.

20%

Key Business Goals

Share market

Students Primary Market

Employees

Designers

Gamers

Traveler

House Keeper

Secondary Markets

Foldable

Portable

Easy to store

Assumptions

Users

Schools

Universities

laptop companies

production

retailers

Stakeholders


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2.2 Survey

A survey consists of twelve questions was conducted to thirty persons (Mostly student as

they are the primary market):

1.What type of computers do you use ?

a.Normal computers (i.e. one that normally stays in one place) Desktop

b.laptop (i.e. one that is normally carried around)

c. Both

Figure 1: Survey results: what type of computers do you use?

2. In what posture you use your lab top ?

a. Sitting on chair or sofa

b. Sitting t on the floor

c .sitting on the bed

Figure 2: Survey Results: What postue?

3. If you use your laptop on the floor, describe your posture:

a. Sitting on floor extending your legs

b. sitting on your legs

c. sitting on pillow or anything with a height cm high

4. If you choose laying on bed, describe your posture:


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a. Laying on your back b. Laying on your stomach

5. do you suffer from the heating problem when putting the laptop on your legs?

a. YES b. NO

6. Do you want it foldable?

A.YES b. NO

7. Do you want it portable?

A.YES b. NO

8. Do you want it easy to store?

a. YES b. NO

9. Where will you use it?

a. Indoors b. outdoors

10. Are you willing to use it for any additional purposes?

a. Children table

b. Patient table

c. Room TV table d. else

11. what other functions you want to perform ?

12. what other problems you want it to solve?

2.3 Gathering Raw Data:


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In order to reach to the ideal product that customer would find their needs satisfied in it,

customers statements were taken and noted as follows:

1- Ummmm, if it's only a laptop holder, a cooling fan in it will be great !!

2- It will be good if it comes with cans holder to place the drink

3- I wanna the heating problem to be solved4- I guess it should be rotatable, so we can adjust it to avoid the sunlight if it's

behind us.

5- Locks into place quickly and efficiently Height adjustments

6- Being able to give extra angles of view especially while using in bed or floor

7- I'll use it as a drawing table while sitting on the bed!!! Ooh, That will be

fantastic

8- Well, I might put my books on, especially during lectures, and use it as snack

holder

9- Contain Foldable legs or something else

10- variety of colors and styles that will suet every taste11- Want an edge which can provide comfortable support for my hands while

typing (leather will be a good material).

12-Most holders nowadays dont have a place for mouse so plz offer this feature.

13- Mainly just the heating problem

14- documents or paper holder adjacent to the screen

15- Changeable colors/style

16- I want it to contain a light fan for cooling

17- Place to hold/put some papers or pen

18- it should contain USB slots

19- a pocket-like area to keep the flash drives and the mouse in20- A cup holder to hold drinks in place

These customer needs are translated into need statements that will be implemented in the

product itself.

The following table shows the customer statement with its Professional need as follows:

Table 2: Customer Statement and Proffessional needs

# Customer statement Need statement

1 Ummmm, if it's only a laptop holder, acooling fan in it will be great !!

The device allows better cooling

2 It will be good if it comes with cans

holder to place the drink

The device can hold cups

3 I wanna the heating problem to be The device allows better cooling


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solved

4 I guess it should be rotatable, so we

can adjust it to avoid the sunlight if it's

behind us.

The device is adjustable to avoid the

sunlight

5 Locks into place quickly and

efficiently Height adjustments

The device Can be adjustable and

orientation

6 Being able to give extra angles of

view especially while using in bed or

floor

The device Can be set to different

angles.

7 I'll use it as a drawing table while

sitting on the bed!!! Ooh, That will be

fantastic

The device can be used for drawing

8 Well, I might put my books on,especially during lectures, and use it

as snack holder

The device Can be used formultipurpose

9 Contain Foldable legs or something

else

The device easy to store and carry

10 variety of colors and styles that will

suet every taste

The device is attractive

11 I want an edge which can provide

comfortable support for my handswhile typing (leather will be a good

material).

The device is comfortable

12 Most holders nowadays dont have a

place for mouse so plz offer this

feature.

The device can hold papers ,mouse,

key board..etc

13 Mainly just the heating problem The allows better cooling

14 documents or paper holder adjacent to

the screen

The device can hold mouse, key

board..etc

15 Changeable colors/style The device is attractive

16 I want it to contain a light fan for

cooling

The device allows better cooling

17 Place to hold/put some papers or pen The device can hold papers, mouse,

key board..etc


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18 it should contain USB slots The device contain USB slots

19 a pocket-like area to keep the flash

drives and the mouse in

The device can hold mouse, key

board..etc

20 A cup holder to hold drinks in place The device can hold cups

2.2 PRODUCT SPECIFICATION

The work team responsible for developing this product established target

specifications (metrics) of the product and agreed on giving these specifications an

index that reflects its importance and their units as illustrated by the following table:

Table 3: Metrics of the Product

Metric No. Needs Nos. Metric Importance Units

1 1,2,9 Time to fold 3 sec

2 4,6,7,8,12,13 Stability 5 subj

3 1,2,7,8,9,11,1

2,13

Minimum total mass 3 kg

4 1,4,6,7,8,9,12

,13

Volume 3 M3-

5 1,3,5,9,12,13 Unit manufacturing cost 4 OMR

6 2,5,9,10,12,1

3

Attractive style 4 subj

7 1,6,12,13 Folded volume 3 M3

8 1,7,8,9,11,12.

13

Area of the laptop holder 5 in

9 2,4,5 Power needed to fold 3 Watt

10 1,7,8 vibration 3 m/s2

(metrics with no engineering unit is given a -):

A table that shows the relation between the metrics and the needs is given; this table

relates the specifications and needs in a form of a matrix:


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Can be used for study and eat

(multi use)


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Table 4: Metrics and Needs

2.5 Concept Selection (Screening):

This process was held to evaluate the concepts with respect to customer needs,

Comparing the relative strengths and weaknesses of the concepts and selecting one or

more concept for further investigation and development.

Here you can see the concept screening matrix. The selection criteria are listed along the

left-hand side of the screening matrix. These criteria are chosen based on the customer

needs.

Concept (B) was chosen to be the benchmark or as a reference concept to evaluate

concept variants against selection criteria. It was an obvious solution. The concept that

we select are:

Concept A: A Pug flat a mini table.

Concept B: Adjustable legs.

Concept C: A USB-powered fan.

Concept D: A cup holder.

Concept E: A felt mouse pad surface.

Selection Criteria Concept

A B

(reference

)

C D E

Ease of handling 0 0 - 0 0

Ease of use - 0 - 0 0

Ease of manufacture 0 0 - - +


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portability 0 0 0 0 +

Fold ability - 0 - - +

Ease to store + 0 0 0 0

Sum+s

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Table 5: Screening

2.6 Concept Selection (Scoring):

Concept scoring uses weighted selection criteria and a finer rating scale. The concept

scores are determined by the weighted sum of the ratings.

The below table illustrates the scoring matrix used in this stage.

Selection

criteria

Weight Concept

B E

(reference)

AD

Rating Weight

score

Rating Weight

score

Rating Weight

score

Ease of

handling

10% 3 0.3 2 0.2 2 0.2

Ease of use 20% 2 0.4 2 0.4 3 0.6

Ease of 25% 3 0.75 2 0.5 3 0.75


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manufacture

portability 15% 3 0.45 2 0.3 3 0.45

Fold ability 15% 1 0.15 2 0.3 5 0.75

Ease to store 15% 2 0.3 2 0.3 1 0.15

Net score

Rank

2.35 2.0 2.9

Continue? No No Develop

Table 6: Scoring

2.7 PRODUCT ARCHITECTURE AND COMPLEXITY

Product architecture is the scheme by which the functional elements of the product arearranged into physical chunks. The architecture is established during the system-leveldesign phase of development.

Physical chunks:

Base

Legs

Cup holder


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Pen holder

Paper holder

Mouse holder

Table 7: Components

Figure 3 The Leg of The Laptop Holder

The leg


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Figure 4 The Base with The Cup, Mouse and Book Holders

Functional chunks:

Mechanism of folding

Adjustability

Mechanism of ejecting out drawers


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Figure 5 Succession of Pictures Showing The Mechanism of Folding

To maintain adjustability and make the legs fixed at certain height and the base fixed at

certain orientation a self locking system was used and is shown in the figure below:


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Figure 6 Self-Locking system for Adjustability

To eject the drawers out, a spring was attached to the drawers using a push button

mechanism.

Figure 7 Spring Attached to Push Button


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2.8 HOW THE PRODUCT WORKS

- When you hold the laptop holder and Position it at an ergonomically correct

height by Folding the legs.

- To maintain adjustability and make the legs fixed at certain height and the

base fixed at certain orientation a self locking system was used .

- To eject the drawers out, a spring was attached to the drawers using a push

button mechanism.

2.9 DIFFERENT USES OF THE PRODUCT

- It has a Cup Holder, Paper Holder, Pen Holder and Keyboard Holder.

- Can b used as Drawing Table for Architecture s

- Can be used as TV Table.

- Can be used as a table for patients

- Can be used by moms as a table to feed their children

2.10 THE PROCESS OF MANUFACTURING

The process is designed as shown in Figure 8


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Figure 8: The Manufacturing Process Flow

The process requirements are as follows:

- Standard Requirements: such as screws.

- Custom Requirements: Rubber, Anodized Aluminum.

- The custom requirements are either shaped and processed in the factory or

purchased from an external seller.

Market studies were conducted and demands for this product were forecasted to be 20000

CHAPTER(3): Phase II

3.1 Factory Operations Model

We Calculated the following:

Total number of parts produced (NPF):

NPF= PQNP


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NPF=(1000product units ) (5part/unit)

= 5000 Parts

Total number of operations (NOF):

NOF= PQNPNO

NOF=(10050product)(5parts/unit)(5operation /part)

= 25000 Operations

Production Rate( Rp) :

Rp= 1/Tc

Rp=( 1 unit/26min)(60min/hr)=2.307unit/hr

Cycle time( Tc) :

Tc = To+ Th+ Tth

Which are:

To= processing time for the operation=15min

Th= handling time=5min

Tth= tool handling time =6min

So the Cycle Time :

Tc = 15+5+6= 26 min=0.4333hr

weekly plant capacity (PCW):

PCw= n SwHs Rp

n= number of work centers working in parallel producing in the facility

Sw= number of shifts per period (shift/week)

Hs= number of hours/shifts = 8hrs

Rp= hourly production rate (output units/hr).


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So :

PCw=(1)(5)(8)(2.307)=92.307 unit /week

Manufacturing Lead Time (MLT):

MLT= no(Tsu+ QTc+ Tno)

Which are :

no= number of operations = 5 operation

Tsu= setup time,

Q= batch quantity

,Tc=cycle time per part

Tno= non-operation time

So MLT= 5(4 + 100(4.5/60) + 12) = 5(23.5) =117.5 hr

3.2 Part Analysis and Complexity

The Table below shows our product parts name which are 8 parts (Leg, Base,

Screws, Cup Holder, Mouse Holder, Springs, Self Locking System and

Rubber tube) and their number, quantity, material , make or buy decision

and their manufacturing process:


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Table 1 Part Details of the Product

The Machines required for injection molding are three machines which are:

material hopper

Injection ram or screw-type plunger

Heating unit

CNC machine to make the mold

And one Machine required for rubber tube which is Rubber tube shapingmachine.

And this Table shows the relationship between the machines and the Parts:

Table 2 Focused Cells

So from the table it shows that 2 machine cells and 2 part families.


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The Efficiency =100% , Grouping Efficiency T=100%,Grouping Capability

Index GCI=100% and Machine Utilization Mu=100%.

The following figures show the machines to produce the laptop holder and their

costs :

Injection Molding Process:

The figure below shows the steps of injection molding process.

Figure 1 Injection Molding Process


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Figure 2 Material Hopper Machine


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Figure 3 CNC Machine

Figure 4 Heating Unit Machine


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Figure 5 Rubber Tube Shaping machine

Table 3 Machines Cost

Machine Cost

Material hopper RO 212

Injection RAM RO 48

Heating unit RO 29

CNC Machine RO 231

Total for Injection Molding RO 520

Rubber Shaping machine RO 519

Total machine cost RO 1039

3.3 Operations Data:

The Figure shows the Operations Features in our product.

Figure 6 laptop holder Operations


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And this table shows the Features description from the above figure and

their Operation and Operation ID.

Table 4 Operations Features of the Laptop holder

Since this is a simple product, single station is used.

CHAPTER (4): Phase III

4.1 Assembly Line

After manufacturing the product, the parts proceed to the assembly area to

be assembled and form the product. Products are usually assembled on a

manual assembly line.

A manual assembly line is a production line that consists of a sequence of

workstations where assembly tasks are performed by human workers. An

assembly line consists of workstations. A workstation on a manual assembly

line is a designated location along the work flow path at which one or more

work elements are performed by one or more workers. The work elements


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represent small portions of the total work that must be accomplished to

assemble the product. Below is the precedence table of the assembly tasks of

the laptop holder:

Table 5 Assembly Task Precedence Table

Task Task number Te Precedence

Molding of legs 1 6 -

Molding of base 2 6 -

Shaping rubber

tube

3 2 -

Assemble

rubber tube

with base

4 1 2

Molding of

mouse holder

5 4 -

Molding of cup

holder

6 4 -

Assembling

mouse holder

with base

7 0.5 2,4,5

Assembling cup

holder with

base

8 0.5 2,4,6

Assembling the

legs with the

self locking

system and

screws

9 2 1

Assembling legs 10 0.5 9


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to the base

Total 26.5

Figure 7 Precedence Diagram

Since, forecasted demand is 20000 unit/year and the factory operates 2

shifts/day for 5 day/week for 52 week/year and each shift is 8 hours.

Production rate ( Rp) is:

Rp = 20000 / ( 2*5*8*50) = 5 unit/hr

Hence, cycle time ( Tc) = 1/Rp = 1 / 5 = 0.2 hr = 12.0 mins

According to positional ranked technique the tasks are rearranged in the

following table:

Table 6 Positional Ranked Techniqe

Task RPW Te Precedence

1 8.5 6 -


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2 8 6 -

5 4.5 4 -

6 4.5 4 -

9 2.5 2 13 2 2 -

4 2 1 2

7 0.5 0.5 2,4,5

8 0.5 0.5 2,4,6

10 0.5 0.5 9

The following table shows the workstations for different task:

Table 7 Number of Workstations

Station Task Te Te

1 1 6 6

2 6 12

2 4 1 1

5 4 5

6 4 9

9 2 11

3 3 2 2

7 0.5 2.5

8 0.5 3

10 0.5 3.5

From Table 2:

Number of stations =3


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Utilization:

1. Station 1: 12/12= 100 %

2. Station 2: 11/12=91.2 %

3. Station 3: 3.5/12 = 29.2 %

Figure 2 Workstation Utilization

Theoretical minimum number of workers Twc/ Ts = 26.5/ 12=2.2 = 3

workers

Assembly line efficiency E= 26.5/(3*12)=73.611%

Balance delay=1-0.73611=0.26389

Length L= nVT= (3station) (7.5ft/min)(1.467 min)= 33 ft

Tolerance Time Tt= = 1.467 min

Elapsed Time ET= 3(1.467) = 4.401 min

Figure 3 Flow of Assembly Line

4.2 Plant Layout

For each department dimensions were estimated as shown in the figure

below:


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Figure 4 Plant Layout

CHAPTER (5): Phase IV

5.1 Economical Justification

5.1.1 Machines and assembly cost

10 m7 m 35 m 33


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Figure 1 Machines and Assembly Cost

5.1.2 Raw Material Cost

These Raw material with its cost are listed in table below.

Table 8 Raw material Cost

(anodized aluminum)

(Cost per piece)

(O.R)

Cold rolled

(Cost per kilo)

(O.R)

Screw

(Cost per kilo)

(O.R)

Rubber

(Cost per

piece)

(O.R)

30 0.950 2.300 1.100

Facility Location Cost :

Table 2 Facility Location Cost

Type Cost After 10

years

Land RO 45000

Building RO 60,000 -

Total 105000 40500


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Initial investment = Raw material cost + land and building cost +

Machines Cost

= 133400+105000+1586= 239986

Salaries :

Table 3 Employees Salaries

Annual Cost :Table 4 Annual Cost

Type Annual Cost

Total Salaries 72600

Cold rolled 3800

anodized aluminum 120000

Screw 9200

Rubber 400

Operation & maintenance cost 2900

Taxes 1300

Insurance 14000


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Contingency cost 1400

Total cost 225600

Interest rate = 7%, MARR=15

Demand = 20,000 multi mechanical wrench

Annual Expenses =225600

Unit cost =11.28 R.O

Unit Price = 14.664 RO

Annual Revenues = 14.664* 20, 000 = 293280

Annual Profit = Annual revenues Annual expenses = 293280-

225600=67680.

PW= - 239986+67680*(P/A,7%,10)+41033*(P/F,7%,10)

PW= -1842172+(67680*7.0236)+(41033*0.5083)

PW=256230.4

FW=41033-239986*(F/P,7%,10)+67680*(F/A,7%,10)

FW=41033-(239986*1.9672)+(67680*13.8164)FW=504026.5

Figure 1 Cash Flow Diagram


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Payback Time :

By the end of the third year= -36946 O.R is left to cover of the

total cost

The company will cover the costs and starts making profit by the

end of the fourth year. (30730 OMR).

Hence, its feasible to produce this product.

5.2 Environmental Effect :

The laptop holder is a hazard free product. It doesnt include any

dangerous material, chemicals and no radioactive emissions.

Manufacturing of the laptop holder also doesnt involve the use

of any hazardous materials.

There were high safety issues for ID to consider on the laptop

holder. It is safety because it is not sharp and it is proper for

eyes and arms.

Ease of use high level of important because it is adjustable and it

can be used for multiple purposes.

Simple, there is very little maintenance required.


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5.3 Society Effect :

Our project (laptop Holder) has many impacts on Students

,Mothers ,Travelers ..etc .

Students for example spend hours on their laptop. It allows them

to adjust the monitor to the right height so there will be a low

risk of back pain

As for others this laptop holder can cause no or minimal effects.

They will experience low risk body postures while working on a

laptop, reading, editing, or entering the document data.

It helps in minimizing neck pain, back pain and shoulder stress

by creating low monitor position and repetitive twisting.

CHAPTER (6): Results and Conclusion

Laptop holder product was studies and investigated form the very

basic stages of raw material to manufacturing and assembling. As

mentioned in the previous chapter, the product will start making profit

after the third year. Hence, the laptop holder is feasible to produce.

Documents

Laptop Holder Report