The document provides details of a project to design a lifting device for DIY workers and builders. It includes sections on research conducted, concept generation and evaluation, development of top concepts, and planned inclusion of technical drawings and manufacturing details. Two concepts were evaluated in more depth through a scoring matrix where Concept 3 was found to better meet criteria such as mobility, cost, and space usage while Concept 2 had strengths in ease of use, efficiency, and load handling. The team then identified ways to improve the weaker areas of each concept through synthesis and combination of ideas to evaluate in a second scoring round.

1. 1
Kranes lifting device
Team Members: James Slee, Patrick Vega, Luke Rumming and Mijan Uddin.

2. 2
CONTENTS
Heading: Page Number:
1 Introduction, 3
2 Research, 4-7
2.1 Survey, 4
2.2 Mind-Mapping, 5
2.3 Existing Product Research, 6-7
2.4 Material Research, 8-10
3 Generating Ideas & Concept Sketches, 11-12
4 Concept Evaluation, 13-14
4.1 Development, 15-17
5 Conclusion, 18
6 Final Design, 19
6.1 Finite Element Analysis, 20-22
6.2 Manufacturing Process, 22
7 Reference, 23

3. 3
Introduction
There isan increasingproblemof DIYworkerssustaininginjuriesdue toheavylifting.This
has beenaconcern as injurycanmake theirjobsharderor impossible tocomplete.Asa
groupof designerswe have seena niche inthe marketandbelieveithasbeenworth
developingideasthatwill resolve theircurrentsituation. We will designandevaluatea
liftingapparatusthatwill hoisttheir products,move itindefinitely andstow away
comfortablyintheirvehiclewhilstbeingportable.
The final design will have threeviews;fullyassembledview,packedview andexplodedview.
Documentation willbe included onhow eachof the parts workswhenitis beingassembled.
Researchof current designs anddesignconcepts are alsoincluded.Aswellas,material
researchusedto determinewhatthe device will be made of, whythese materialshave been
chosenandcost implications thatneedtobe takenintoaccount. Alsothere will be
discussionof howthisideameetsthe criteriagiveninour designbrief.Thisdevice will be
the solution tobuilders,DIYenthusiastsandgeneral peopletoavoidinginjurydue toheavy
lifting.

4. 4
Research
Survey
Doesa liftingdevice benefityourbusiness?
How muchwouldyoupay forthe device?
Data collected:
There wasa total of twentybusinessesthatparticpatedinthe surveyabove.The datahas
beencollectedandisrepresentedbelow.
The twentybusinesseswere selectedrandomlytorepresentthe industrialsector.The
benefitdatashowsthat70% of businessessaw fitpurpose of the liftingdeviceand30% saw
no needof sucha device.Regardlesswhetherthe businesseswouldhave foundit beneficial
or not theyneededtorespondwiththeirviewsonthe productspricing.The final datafor
purchasingshowedthat40% wouldpay£50 - £99.99, 50% wouldpay£100 - £149.99 andthe
last10% wouldbe happyto spendover£150 for the device.
Yes
No
£50 – £99.99
£100 – £149.99
£150 +
How much would you pay for the
device?
Numberof
businesses
Does a lifting device benefit your
business?
Numberof
businesses

5. 5
Mind Mapping
Thismindmap wascreatedto aid the researchthat wasconducted.Certainareassuchas
materials,methodof lifting,existingproductsandmobilityetc.were settoconductresearch
on.Material is an importantpart of the designprocess. There are manymaterialsthatcan
be usedsuch as metals,alloysandpolymers.Whenlookingatthese groupsfurtheritcanbe
seenthatfor polymersthere are manytypesof polymerssuchas;acrylics,HIPSand PVC.
Anotherareathat came upwas the target market.There are a few targetmarketssuch as
the elderly,DIYworkersandmiddle agedmen.

6. 6
Existing Product Research
Whenthinkingaboutconceptsandfeaturestoaddto the lift, we will be developingnew
concepts butalso redesigningdesignscurrentlyusedforothertasksandcritically analyzing
currentmodelstofindflawsinthe marketand lookat individual aspectsof eachof the
liftingdevices.
Clarke ½ ton foldingworkshop crane
Thiscrane isan engine winchandseemstobe well suited
for the designbrief thatwe have created.Notonlycanit lift
weightsof upto ½ a tonbut itis collapsible.Unfortunately
evencollapseditisunwieldyandhasn’tbeendesignedtofit
fullyextendedintothe bootof a car. (1)
Tiger premiummobile lifttable
On a differenttrackthisalsoseemssuitable liftingasensible
150lbs, it couldliftgoodseasilytothe heightof acar boot.
Unlike the crane it addsanotherissue thatafterliftingitisat
the car level.Itstill needstobe pushedintothe car
heighteningthe riskof snagsandtears. (2)
Manual crate wizard
As a device formovingcratesaroundthishas a simple
designandisprovento workinmany environments.The
cars ‘lip’couldprove trickyforthe device to maneuver
unlike the crane.(3)

7. 7
The PacificPorta Lift Trolley
Althoughsmallerthanthe otherdevicesresearched
it can liftupto 100kg whichisa respectable weight
for itssize.It’sa soliddesignandlooksdurable
howeverthe same issuesremainsinthatitdoesn’t
directlyplace the objectinthe arealike a crane
would. (4)
Portable Ergonomic Lifting Devices
Thisdesignissimilartothe othersrunningona basic forklift
ideahoweverthisisbatterypowered; italsohas an aluminium
frame whichwouldbalance outthe weight. (5)
Conclusion(Research):
What we can see fromthese currentdesignsisthattheyare successful designs thathave
gottento and beyondproductionstage tobecome successful productsof theirown. All of
these deviceshave beencateredtodeal with specificsituations.Whilstnone of these are
specificallycateredforoursituationwe cantake elementsfromtheseto inspire concepts
and designs.Asateamwe have usedthe researchto analyze partsof the current products
that we believetobe successful andthinkmakesagoodproduct toincorporate intoour first
setof conceptsketches.

8. 8
Materials Research
8500 SeriesSky Hooks with Tool Holder Base:
Thisis an example of awinchsystemthatwe feel is
successful, itisworthanalyzingthe materialsandprocess
usedso we can design similarorbetterdesignand
materials.
 Steel rollermechanismforthe cable.
 2000 lbs.tensile strengthrollerchain.
 Aluminiumhandwheel(8”giving11:1 liftingadvantage)
 Load limitof 500 lbs.>>> 226.796 kg.
 4:1 ratio gearbox
 Structural ‘DOM’ (drawnovermandrel) tubing,lightweightsteelframework
 DOM tube beingconstructed,startingasERW andthenbeingdrawnovera mandrel.
The manufacturingprocessforDOM tubingbeginswithcoilsof steel,whichare slit
to the properwidthforthe desiredtube size.The stripiscoldformedandpassed
throughan electricresistance welderwhichjoinsthe edgestogether,under
pressure,tocomplete the tubularshape.Aftertestingthe weld'sintegrity,the
tubingiscut to lengthforfurtherprocessing.
 Strongand well-finishedDOMisan electricresistance weldedtube testedfor
soundnessof weldanddrawnthrougha die andovera mandrel.Thisprocess
impartssignificantlyimprovedmechanical propertiestothe tube,due tothe cold
workingprocess.Itisconsideredahighqualitytube,andisnormallyconstructed
fromSAE 1020 or 1026 steel.Note that,technicallyDOMreferstothe processby
whichthe tube isfinishedafterhavingstartedasanERW tube.Technically,DOMis
not a type of steel tube,butrathera process. ((6) refersto everythingon thispage)
The two graphsabove are stressvs.straingraphs. The one on the leftshowsa comparison
betweenfibermaterials,composite materialsandmatrix materials.

9. 9
Facts and figuresfor Fiber-glassandCarbon-fiber:
(8)
Large
carbon fibre
tubes.
This is a sample of fiber glass
tubing that can be purchased from
a supplier.
Below are figures relating to its
mechanical properties.
This is a sample of carbon fiber
tubing that can also be purchased
from a supplier.
Below are figures relating to its
mechanical properties.
Carbon fiber is an alternative to
fiber glass but the disadvantage
compared to fiber glass is the price
as it is very expensive.
(8)
(8)
(8)
(8)

10. 10
Conclusion(MaterialsResearch):
Fibreglasshasbeenchosenasthe primarymaterial due toitsexcellentmechanical
properties.Thismaterialwillbe usedtoconstructthe majorityof the structure such as the
cylindrical middle section.
The sample of fibreglassinspectedhasanultimate tensile strengthof 170 MPa whichis fairly
highthusmakingit suitable asitmay needtowithstandaheavyload.Thissample alsohada
young’smodulusof 17 GPa at 90°, thisis fairlyimpressive asasimilarsample of carbonfibre
has a young’smodulusof 19 GPa at 90°. Thispropertymakesitsuitable asitisfairlyelastic
inthe formof deformationthusmakingitlessbrittle,thiseliminatesbrittle fractures.Thisis
importantas itis unsafe if there isa brittle fracture duringaheavyload.The chancesof
seeingthe defectordamage issmall therefore makingitsudden.If the partdoesfail inthe
formof elasticdeformationitcanbe noticedat an earlierstage,thisallowsthe parttobe
markedunsuitable foruse.Thismaterial hasaflexural strengthof 170 MPa whichgivesit
the same benefitsasfromhavinga highyoung’smodulus.The densityof thisspecimenis1.8
g/cc whichis higherthan the alternative carbonfibre whichis1.6g/cc.
Fibreglasswillalsobe usedforthe liftingarmatthe topof the machine.Thispartmust be
designedverywell tohandle aload.Thisisbecause the otherpartsmade out of fibreglass
are ina cylindrical formwhichisverystrongforitsapplication.
Fibreglasstubescanbe purchasedata verylow price especiallyif boughtinbulk.Thisisa
much betteroptionthanmanufacturingacylindrical shape asthisisfairlycomplex,time
consumingandexpensive.
Highcarbon steel will be usedforthe base due toits highstrength.Steel isfairlyheavyso
the designof the base is importanttomaintainstructural strengthwhile tryingtoreduce
weight.
The heaviermaterial willbe strategicallyusedforthe lower partsto counterbalance the
weightthe machine maylift.
The castors will be made of polyurethane onaluminiumwheels.Polyurethane hasbeen
chosenas itis extremelydurableanddoesnotmark the floor.These castorscan be liquid
cast, therefore allowingcolourtobe addedenhancingthe aesthetics.
The advantagesof aluminiumare asfollows;
 Doesnot easilycorrode
 Easy to workwith
 Lightweight
 Strong
The advantagesof fiberglassare asfollows;
 Corrosionresistance
 Lightweight
 Low maintenance
 Strong
All above factorsallowthe device tocomplywiththe PDS.

11. 11
Generating Ideas and concept sketches
Initiallybefore comingupwithdesignideas,researchingall existingproducts wasnecessary
whichcan be seeninthe researchsegment.A unique conceptneededtobe generated to
fulfillthe designrequirements.The key pointsthatneededtobe consideredwhen
researchingexistingproductswere;mustbe able tolift the consumersrequiredweightand
it neededto be manuallyoperated.There are variousexistingdesignsalreadyonthe market
and none fulfill ourPDScriteria.
Generatinginitialdesignswasthe nextstepforward,mostof the ideas have beenderived
fromexistingproductssolelybecausetheywere goodtoadaptto the criteriathat hasbeen
outlined. Here are the eightconceptsthatwere generated:
ConceptOne: Concept Two:
ConceptThree: ConceptFour:

12. 12
ConceptFive: ConceptSix:
ConceptSeven: Concept Eight:

13. 13
Concept Evaluation
Feasibilityevaluation:
Eightconceptshave beendesignedtomeetcustomer needs.Toquicklyeliminateany
conceptsthat don’tmeetthe criteria,the use of a FeasibilityEvaluationTable wascreated.
The FeasibilityEvaluationTable allowsthe designteamtoquicklydiscardanyconceptthat
isn’teither;anoriginal concept,meetscustomerrequirementsortechnologicallyfeasible.
Feasibility Evaluation Table
In thiscase,as a group, itwas decidedthat:Conceptfive,six,sevenandeightwere not
worthconsideringbecause theydon’tmeetthe criteriaspecifications.
Conceptevaluation(screening):
The nextstage is to evaluate the conceptsfurther;the Pughconceptselectionmethodisa
commonstructural technique usedtonarrow the choice of designconcepts,whichusesa
matricesfilledwithcriteriafromthe designbrief andPDS.Foreach criterionthe team
markedwhetherthe conceptisworse (-),better(+) oreven(s) asthe datum.
Concept Screening
Concept
Number
Is the ideaoriginal? Doesit meetcustomer's
requirements?
Is ittechnologically
feasible?
Worth
considering?
1 YES YES YES YES
2 YES YES YES YES
3 YES YES YES YES
4 YES YES YES YES
5 YES NO YES NO
6 YES NO YES NO
7 YES NO YES NO
8 YES NO YES NO

14. 14
Conceptone waschosento be the datum, as the designteamproposed ittobe the weakest
link.The teamthenselected aconcepttobe evaluated.Analysingthe datashowed:
 Concept2 scored the highest,withitsmainstrengthbeingthe use of space and
weaknessbeingthe difficultyinhandlingload.
 Concept3 scoredthe secondhighest,withitsmainstrengthinefficiencyand
weaknessinmanufacturingof the product.
 Concept1 scored the lowest,withnomainstrengths.
The designteamdecidednottoconsiderthe datum and conceptone for furtherevaluation
because of the lowscoresit achievedinthe ConceptScreeningEvaluationstage.
ConceptEvaluation Scoring (round one):
Once all conceptshave beenevaluated,amore accurate matrix isimplemented.Concept
Scoringis a detailedweightedratingmethod,withthe criteriaratedasa percentage chosen
by the designteam.Forthe criteria,the designteamgradedthe costat 20% as specifiedin
the designbrief.Also,mobility,ease of use,loadhandling,use of space andinstallationwere
gradedat 10%, withmaintenance,efficiencyandmanufacturinggradedata respectable 5%.
Each concept wasthenratedfrom 0 to 5, 0 beingpoor and5 beingexcellent.Eachconceptis
thenmultipliedbyitsrespective weight;thisproducesanoverall ratingforeachconcept.
Concept Scoring Table (Round One)
Concept 3
Selection Criteria Weight Rating Weighted score Rating Weighted Score
Mobility 10% 1 0.1 3 0.3
Ease of use 10% 3 0.3 1 0.1
Manufacturing 5% 1 0.05 5 0.25
Cost 20% 1 0.2 5 1
Maintenance 5% 1 0.05 4 0.2
Efficency 5% 4 0.2 1 0.05
Load Handling 10% 5 0.5 1 0.1
Max Load 15% 5 0.75 1 0.15
Use of Space 10% 1 0.1 5 0.5
Installation 10% 1 0.1 5 0.5
Total Score
Rank 2 1
Concepts
Concepts 2
2.35 3.15

15. 15
Development
Once the firstround of the conceptscoringwascompleted,the designteamhighlighted and
discussedeachcriterion.Then strengthenedthe positivesand reducedthe negativesof each
conceptthroughsynthesisandnewideas,forevaluationinroundtwo.
For concept2 these were:
1. Ease of use.
2. Efficiency.
3. Load handing.
4. Max load.
For concept3 these were
1. Mobility.
2. Manufacturing.
3. Cost.
4. Maintenance.
5. Use of space.
6. Installation.
ConceptTwo:
‘Ease of Use’was discussedandideas were developed thatcan
helpimprove the score itachievedinthe firstroundof
EvaluationScoring.The Designteamdecidedtotake the ideaof
a wrenchtype liftfromconcept3 and implementitintoconcept
2. This will make itmucheasierforthe userbecause the motion
isvertical,unlike the turningwheelthatishorizontal,whichcan
be difficultwithheavyload. Furtherresearchidentifiedauseful
device thatworkslike apulleysystemcalledaskyhook,which
worksto an 11:1 ratio.
‘Efficiency’,‘LoadHanding’and‘Max Load’ all come underthe same criteria,as theyare all
to do withbalance.If the machinescentroidisinthe centerthenmax weightcanbe
achievedwithout favoringone side.If not,thiscanbe
dangerousasthe machine wouldleantoone side and
topple over,causingdamage tothe machine and its
load.In the worstcase,the machine topplesover,
crushingthe userand anyone inthe same area. The
designgroupcame up withmanysolutions,suchas;
havingthe centerpole angled,sowhenthe loadis
liftedthe weightwill be atitscentroid.Thiswill give
the machine more balance.Anothersolutionwasto
have three extendable legsthatthe usercan change
decidingonthe weightof the loadthatneedsto be
lifted.The designteamthendecidedtoinclude
extendable legsintothe design,asthere are many
benefitsforchoosingthissolution;thisisasuccessful
solutionasthe usercan leave the legsonone settingforquickerandeasieruse.

16. 16
ConceptThree:
‘Use of Space’and ‘Installation’wasdiscussedasone
criteriaandthe teamthoughtup ideasthatcan be
improvedforthisconcept.The whole machine is
complex,due toa large numberof nutsand bolts
neededtobe insertedbefore use.Therefore,getting
the machine readyforuse will take the usera long
periodof time,andthiswon’tbe productive forour
target market.The designteamtackledthisproblem
by removingnuts&boltsthat are notdeemed
necessary.Thisthenmade the machine mucheasier
and quickertoinstall.Therefore ‘Manufacturing’,
‘Cost’and ‘Maintenance’will be reducedasthere
aren’t as many holesandparts neededtobe drilled
and manufacturedprovidingamuchmore simple
manufacturingprocess.
‘Mobility’wasdiscussedasa groupand a member
was assignedtoresearchdifferentsolutionstotackle
thisproblem.A three leggeddesignisguaranteedto
be stable,because the endsof itslegsalwaysforma
plan,and a fourleggeddesignwill due toitscenter
of gravitybeingfurtherinside its base.Itwasthen
decidedtoimplementthe legdesignfromconcept2
intoconcept3, givingthe designamuchmore steady
foundationandincreasingitsmobility.
ConceptTwo & Three:
Here you can see the evolutionof ourchosenarmfor concept
twoand three,as itcan be seeninpicture 1 the arm startedas a
collapsiblewire baseddesignwhichhadseveral removablepins
to helpitto go as flatas possible.Howeverafterdiscussionit
was decidedthatkeepingitasa single piece wouldkeepthe
productstrongeras a whole.
From figure 2 and3 you can
see a designsimilartothat
of the final howeveritismore roundedandislarger
than necessary.Itisalsoopento the elementsunlike
the final meaningthatitispossible andlikelyforthe
wire andthe rollerstogetrusty.
The final designforthe toparm isfigure 4 thisusesa
chaininsteadof wire sothat the device hasa better
control and gripovera weightedchain.Itisangularand
completelycoveredalongwithbeingthinneritamore
aestheticallypleasingdesign.

17. 17
Conceptevaluationscoring (round two):
The designgroupthensketchedeachconceptwithitsnew solutionsandappliedthe Pugh
conceptwithconcept2 beingthe datum.The resultswere then analyzedandconcept2
beingthe datum(asIt receivedthe highestscore inroundone) wasscoredhigherthen
concept3. The designgroupthendecidedtogowithconcept2 forfurtherdevelopment.
Concept Scoring (Round Two)
Conclusionof evaluation:
By choosingconcept2 the designteambelievesthatthe productsucceedsonpointssuchas
space and ease of use.All teammembersunderstandwhythissolutionisthe best,andall
are committedtothisconceptwhichisnow readyfor prototyping
Concept 3
Selection Criteria Weight Rating Weighted score Rating Weighted Score
Mobility 10% 3 0.3 3 0.3
Ease of use 10% 3 0.3 4 0.4
Manufacturing 5% 3 0.15 5 0.25
Cost 20% 3 0.6 5 1
Maintenance 5% 3 0.15 4 0.2
Efficency 5% 4 0.2 4 0.2
Load Handling 10% 5 0.5 4 0.4
Max Load 15% 5 0.75 4 0.6
Use of Space 10% 4 0.4 5 0.5
Installation 10% 3 0.3 5 0.5
Total Score
Rank
Continue
2 1
No Develop
Concepts
Concepts 2
3.65 4.35

18. 18
Conclusion
The aim wasto come upwitha designthatwill liftarequiredamountthatisportable from
pointA to pointB andto stow awayinto the user’svehicle.Inthisreport,adevice forDIY
workerstoliftwhattheyneedhasbeendesignedandthe followingoccurred:There was
hesitance whendecidingbetweenthe twoideas.Concept2was ideal forthe consumers’
needsandcome to score higherthanthe otherideabecause itwasnoticedtobe more
adaptable tocomplywiththe PDS.Concept3 wasseento be close to beingacomplete
designbutissue arose suchas: size,weightof the equipmentandcostof manufacture.
Therefore Concept3was eliminateddue tothose reasons.Concept2was modifiedto
become smallersoitcan be stowedawayand a three wheeledbase came tobe more stable
than four.The wrenchcomponentfromConcept3 was transferredtoConcept2 because it
was showntobe veryeasyto use andefficient.Fiberglasswaschosenasthe primary
material followedbyaluminiumasthe secondarymaterial.Fiberglasswaschosenasthe
primarymaterial asit has excellentmechanical propertieswhichare suitable forour
purpose.Fiberglasscanalsobe boughtin bulkina tubularshape therefore lowering
expensesandreducingmanufacturing.Ease of use andergonomicshasalwaysbeen
consideredthroughoutthe designprocess.The designthatwasselectedmeetsouraimsand
has gone throughdevelopmentnow complieswiththe criteriaof the PDS.

19. 19
The Final Design
This is the culmination of the
analysis and decision
processes, it is a collapsible
and multi directional lifting
device with a gear based
winch.
The device can lift up to 200
kilos carry it around easily and
lower it on a chain based
winch from 0m to 2m in the
air.
The gear based winch makes it
easy and reliable to lift heavy
objects with minimal effort to
the user.
The handles also make it easy
to move a loaded device
about and rotate the top arm
these both are at convenient
heights and can be adjusted
with whichever height was
chosen in the lower tube.
The body handle is attached
to the bolt that holds the
upper and lower tubes
together.
The three retractable legs
make it easy to get objects
close to the lifting arms body.
The legs can also be shortened
if the object carried needs to
be closer to where it needs to
be lowered.
The device can be seen folded
up on the left, the inner tube
slides down into the outer and
the legs retract into
themselves making the device
considerably more compact
for either storage or moving
objects in smaller spaces.

20. 20
Finite analysis
Finite elementanalysiswascarriedouttoprove that the machine can liftthe requiredloadif
a safe manor. Itwas alsodone to ensure thatthe machine can withstandthe loadthatmay
be appliedwithoutanydamage occurring.Throughoutthe analysis(see picturesabove)itis
clearlyvisiblethatthere verylittlepartsthatundergoveryhighstressandstrain.Highlevels
of thiscan be seenbythe color red.The onlyredpart isthe base where there mainlifting
arm connectsto. Thisisprone to experience highlevelsof stressandstrainisthisis the part
that connectsthe mainliftingarmto the restof the body.The rest of the body colored in
purple isexperiencingverylittle stressandstrain.Thisisdue tothe structure and shape of
design.
The arm ismade of aluminium,whichtakesthe maximumloadthatneedstobe lifted.
Throughfinite analysisitshowsthatthe armwill be able totake the loadwithoutbreaking
but,it doesshowdeformationcausedbythe load.The jointisusedtoattach the arm to the
beamwhichisalsomade outof aluminium.Itundertakesa momentcausedbythe loadon
the arm the analysisshowsthatthere isnobreakage onthe holes.Fiberglassisusedtomake
the beam.Analysiswasundertakenoneachof the holes;Top,Middle andBottomandit
showedthatthe beamwill be able totake the maximumload.
Arm, Stress Maximum Principle
Load

21. 21
Arm joint to beam, Stress Maximum Principle
Beam, Load acting
at the top, Stress
Maximum Principle
Beam, Load acting in
the middle, Stress
Maximum Principle

22. 22
Manufacturing process
As explainedearlierthe bulkof the designwillbe constructedout of fiberglassand
aluminiuminaneffort tominimizeweight.The majorityof the designhasbeenpre
manufacturedsothat the manufacturingprocessisasquickas possible.The mainbodyof
the device ismade outof fiberglasstubeswhichwouldbe boughtinandhave the holes
drilledintothem. The bolts,handlesandwheelswouldalsobe boughtinalongwiththe
chainas these are mass producedandto standard soit wouldbe unnecessaryandexpensive
to produce ourselves.
The top arm and the legswouldhave tobe producedourselvesbyusingamillingprocess.
Whilstthisisa slightlywasteful methoditwill resultinagenuinelystrongerproductwhich
can handle the repetitive stressstrainplaceduponit.
Firstlyitwouldbe inour bestintereststobuildaprototype before goingintomass
production,we wouldgoaboutthisbybuyingall the mass producedpartsneededfromthe
appropriate sources. Inthe future we will be buyingthemfromwholesalersorfromthe
source so that we have smallercostsforbuyingingoodsinbulk.For the aluminiumbarswe
wouldalsodothe same takingthe upfrontcostson ourselves.Howeverwe wouldonlybe
rentinga CNCmachine fora small time fromeitherasmall businessora universitysowe can
have a workingprototype.The nextstepwouldbe torenta factoryspace andall the devices
neededtohitour firstproductiontargets.
Beam, Load acting at
the bottom, Stress
Maximum Principle

23. 23
References
1. http://www.clarketooling.co.uk/tools/Workshop_Cranes___Engine_Stands.html
2. http://www.midlandpallettrucks.com/midland-pallet-trucks-products.asp?c=2107
3. http://www.simpro.net.nz/products/manual-crate-wizard,2012
4. http://www.pacifichoists.com.au/our-products/categories/materials-handling-
equipment/trolleys-trucks/pacific-porta-lift-trolley/,2013
5. http://www.ergonomicpartners.com/Portable-Ergonomic-Lifters.aspx,2013
6. http://www.skyhook.cc/model8500.html,Sycloneattcoservice,2012
7. http://www.ecfibreglasssupplies.co.uk/p-659-polyester-glassfibre-tube-254mm-x-
194mm.aspx
8. http://www.ecfibreglasssupplies.co.uk/p-659-polyester-glassfibre-tube-254mm-x-
194mm.aspx

24. 24
Design Brief
Businessname: JPLM
Contact number: +1 650 253 0000
Due date for completion:4/12/2013
Reviewdate/s: 3/12/2013
Budget: £20,000.
Product/service/brandname: Kranes.
Key objectives:
 Innovative idea.
 Low manufacturingcost.
 Quickand cheapto mass-produce.
 Low maintenance.
 Easy installation.
 Highlymobile.
 Aestheticallypleasing.
 Highmax load.
 Highlyefficient.
Marketing objectivesandtarget audience:
The target audience will be aimedatmalesaveraginganage of 20-50. Withan occupation
such as: builder,self-employed,painter,engineerorcarpenter.A surveywasconstructedto
see whetherlocal buildersandpainterswouldfindaproductlike thisusefulfortheir
business.The resultswereunanimous;everypersonthattookthe surveybelievedthata
productlike thiswouldbe useful fortheirbusinesstakingthe strainoff theirworkers.
The main advertisingtoolswillbe the InternetandLocal Newspapers.Internetwill be the
mainadvertisingtool because of itsgreatcosteffectivewayof advertisingaproduct
worldwide.Whenanalyzingthe resultsfromthe survey,itrevealedthatalarge percentage
of the targetmarketuse sitessuchas YouTube and Facebookto promote theirbusinessin
some way.So byusingthe same sitestoadvertise ourproductwill thenensure the right
marketingmethodsare beingappliedforoptimumpromotions.
Local Newspaperswill be agreatwayto advertise asthe target marketwill alsobe
advertisingtheirbusinessthroughthe same method.

25. 25
Salespromotional plans such as:
 Frequentshoppercard- offerthe customerdiscountaftertheyhave made aspecific
numberof purchases.
 Have a sale- givingdiscounttoall customers.
 Holda contest- offertoautomaticallyenteringintoacontest.
 Offerfree shipping- if the customeriswithinthe UnitedKingdom.
 Discountto targetmarket- enablingthe targetmarketdiscount.
Direct Marketing/advertisingplanssuch as:
 Posters,bannersandsigns- place these inretail storesanddisplaytheminprivate
businesswhere people gather.
 Brochures
 Newsletters-enablethe businesstocommunicate regularwithpotential customers.
 Hiringof ad agencyor marketingfirm
 Outdooradvertising- billboardsandsigns.
Publicityplans such as:
 Sponsoran event
 Put onan in-house event
 Attendtrade shows
 Create a blog
 Host an event
Distributionwill be achievedbythe use of Lorriesforinternal deliversand shipping
containersforexternal delivers.
Scope:
Thisspecificationwill deliveraspectssuchas:
 Portable- allowingthe usertotravel withthe design.
 Takesup minimal amountof space- givingthe customermaximumroomforthe
goods.
 Low maintenance- longpartlifetime
 Easy installation- easilyinstalledandeasilydismantled
 Highmax lift- beingable toliftheavybulkygoods.
 Aestheticallypleasing- uniquedesignsmakesthe Productstandoutfromother
competition.
Purpose and function:
The purpose of thisdesignisto enable easyliftingof heavybulkygoods.The designneedsto
be portable,fitintoa domesticvehicle andstill be able toliftseveral objectsatone time.
The target marketisaimedat builders,paintersandself-employedthatare fromthe agesof
20-50 whoare hopingtotake the strain of heavyliftingoff theirbody,realizingtheyneeda
solution,butdon’twant/cannotaffordto employaworker.Thisiswhere amachine would
be the bestsolutionasit’sa one-off-paymentbutalso performingmostof the workers
needs.Unlike employingsomeonethatyouhave to paya respectable dailywage,allocate
lunchtimes,sicknessesandholidays.

26. 26
Regulatory issues:
 Article 69 of EU BPR.
 Regulation31 of UK BPR.
 Supplyof Machinery(Safety) Regulations2008.
 CE Marking.
 Instructions.
 Declarationof Conformity.
Format:
 Pro EngineerCreoParametric2.0
 Sketches
DesignProject plan:
Task Number Task Team leader
1. Target Market Research Luke
2. Existing Product
Research
Mijan
3. Material Research James
4. Generating Ideas &
Concepts
Patrick
5. Concept Evaluation Luke
6. Conclusion Mijan
7. Finite Analysis James
8. Manufacturing Process Patrick
9. Design Brief Luke
10. PDS Mijan
Measuresof success:
The way inwhichthisdesign will be successful ischoosingthe righttargetmarket.As
mentionedearlierthe surveysuggeststhatthe productswouldbe helpful anduseful for
theirbusinesses.Thisinformationclarifiesthatthe designbrief meetsthe correcttarget
market.
A detaileddrawingwillbe constructedtoshow the designinathree dimensional view.Finite
Analysiswillbe runtoprove that the designcan liftitsmaximumweight,withoutcausing
any majorstressto the weakerpoints.

27. 27
Product Design Specification
Contents
1 Introduction
2 Scope
3 Standardsand specificationsadheredto
Main
4 Performance
5 Environment
6 Ergonomics
7 Aesthetics
8 Size & weight
9 Restrictions/limits
10 Qualityandreliability
11 Manufacturing
12 Testing
13 Companyconstraints
14 Process
15 Packaging
16 Shipping
17 Installation/fitting/setup
18 Maintenance
19 Service life
20 Productlife span
21 Shelf life
22 Safety
23 Legal
24 Documentation
25 Disposal
26 Target audience
27 Marketing
28 Competition
29 Costs
30 Quantity
31 Bibliography

28. 28
1 Introduction
To designa general andmulti-purposeliftingdevice tosell inthe trade of construction,DIY
and possiblythe automotive repairsector.
2 Scope
 The specificationwill deliveraspectssuchas:portable,easytostore,takesup
minimal amountof space,low maintenance,pleasingtothe eye,fashionable,easy
installationandhighmax lift.
3 Standards and specificationsadheredto
 Article 69 of EU BPR.
 Regulation31 of UK BPR.
 Supplyof Machinery(safety) Regulations2008.
 CE Marketing.
 Instructions.
 Declarationof Conformity.
4 Performance
 Liftand lowera loadof 200kg (+/- 10%).
 Wrenchcomponentmustnot liftif the loadexceeds10% of the specifiedload.
 Wrenchcomponentmuststoploweringwhenonly1metre of the cable remainson
the winchdrum.
 Wrenchcomponentmustoperate withwindandunwind.
 The product mustlift 2.0m in the air.
 The product mustbe portable.
 The product mustbe manpowered.
 The weightof the product mustbe sufficienttoaidthe stabilityof the product.
 The drum musthold5m of cable.
5 Environment
 Temperature ranges; -25degree C – Europe,10-45 degree C – Far East.
 The product will experience all weatherconditions.
 Corrosionresistance mustbe consideredbyuse of special materialsorsurface
protectionmethods.
6 Ergonomics
 Controlstobe mountedinanaccessible position,relativetothe operatori.e.waist
height- around1m, toaccommodate 95% of the workingpopulation.
 All controlsshouldbe handoperated.
 One man shouldbe able to operate the product.
7 Aesthetics
 The form can followfunction.
8 Size & weight
 Weightmustnot exceed20kg.
 Widthmustnot exceed900mm.
 Heightmustnot exceed1800mm

29. 29
9 Restrictions/ limits
 Liftand lowera loadof 200kg (+/- 10%).
10 Quality and reliability
 Qualitymustbe such that the wrenchcomponentmustnotgenerallyfailwithina
periodof three yearsandonly1 in50 shouldfail withinthe firstyear.
 The wrenchcomponentmustnotfail inthe areaof the safetyoverloaddevice.
11 Manufacturing
 Capacityisavailable forcurrentmarketdemandwithinscope toincrease production
to 200 peryearwithoutinvestment/expansion.
12 Testing
 Testingisto be carriedout on 20% of units.
13 Company constraints
 These include constraints/limits outlinedinthe manufacturingprocess.
14 Process
 All componentstobe of metricformand complywithBS4500 (1)
for limitsandfits.
15 Packaging
 Packaging/ transportcost shouldbe kepttoa minimumandpreferablybelow 5% of
the unitcost.
16 Shipping
 Distributionwill be achievedbythe use of lorriesandshippingcontainersfor
internal deliveries.
 Productwill be shippedbyroadwithinEurope.
 Productwill be shippedbyseatoFar Eastern markets.
17 Installation/ fitting/ setup
 The product will be verysimple tosetupas there will be minimalseparable parts.
These partsconsistof the base,the centre section,the winchmechanismandthe
lever.
18 Maintenance
 To be maintenance freesexceptforlightlubricationonce amonthanda
recommendedservice everytwoyears.
 Parts requiringlubricationshouldbe accessible within15minuteswithoutthe use of
special toolsorequipment.
 All fastenersusedshouldcomplywithBS6105(2)

30. 30
 Sparesshouldbe available for5yearsafterthe product is replacedwithanew
model.
 No special toolsshouldbe requiredformaintenance.
19 Service life
 Shouldwithstandanoperatingperiodof 1houruninterrupteduse perdayfor5
years.
 Life inservice shouldbe assessedagainstthe criteriaoutlinedinthe Performance
and Environmentcategories.
20 Product life span
 The product will be onthe marketfor 10 years.
 Spare parts will be availableforanadditional 5years.
21 Shelflife
 The product will be storedon-site forupto1 monthbefore dispatched.
 Our Far East distributormaystore the productfor several months.
22 Safety
 The wrenchcomponentmustnotfail inthe areaof the safetyoverloaddevice.
 The wrenchcomponentmustnotoperate whenmaintenance isbeingcarriedout.
23 Legal
 Possible litigationliesinthe userinjuringthemselvesbyhavingaccesstomoving
parts duringwinchoperation.
24 Documentation
 Productmust be suppliedwithausermanual coveringwinchoperationand
maintenance.
 Suppliersrequire maintenanceandrepairmanual.
25 Disposal
 Plasticpartsmust be separable andmarkedtoaid disposal.
26 Target audience
 The target audience will mainlybe aimedatmalesaveraginganage of 30, withan
occupationsuchas and builder,self-employed,painter,engineerorcarpenter.
27 Marketing
 The main advertisementtoolsare the internet,newspapers,buildingeventsandDIY
programmes.The internetwill be the mainadvertisingtool becauseof itsgreatcost
effectivewayof advertisingaproductinternationally.A greatpromotional plan
wouldbe to joinforceswithalarge suppliersuchasB&Q. This wouldboostour

31. 31
sales,astheyhave thousandsof storesworldwideandare knownas a reliable
company.
 Initiallytobe manufacturedforthe EuropeanmarketbutourFar Eastern
distributorsinSingapore,HongKongandAustraliawill be able tofindamarketfor
the product.
 Applicable markets:Telecom - Cable laying,GasandElectricityoperators,Pipelaying
services,CivilEngineeringOperations.
 Summaryof marketrequirements:Portable product,Tobe usedinall weather,To
allowone manoperation,Tohave at least10m of cable,To pull 200kg.
28 Competition
 The competitionwillbe againstequivalentmodelsfromcountriessuch:USA and
Germanyetc. Othercompetitionmaypossiblyarise inthe UKfromcompaniessuch
as B&Q and Wickesas these companiesare knowntocreate theirownequivalent
model orwhateverthe marketalreadyhas.These companiesusuallyrebrandthe
productby usingitsgenericname.
29 Costs
 The product shouldhave anend-usercostof lessthan£150 withinBritain.
 The cost of manufacture shouldbe lessthan£500.
 The cost of packagingand shippingshouldbe nomore than15% of the
manufacturingcost.
A single prototype
Material cost for prototype:£290
Manufacturinglabourforprototype:£200
Overheadcosts(8 weekschedulefor1 prototype):£4,320
Rent:500 p/w
Utilitybills:40p/w
Salaryfor 4 membersover8weeks(CADengineer,researcher,designer,leaddesigner):
£15,500
Miscellaneouscosts:£100
Grand total for produce a single prototype over8weeks:£20,410
Expenditure over1 year
(thisisby assumingthat3 unitswill be made a day andalso consideringadecrease in
material andmanufacturinglabourcostsas bulkmaterial willbe purchasedandworkload
doesnotincrease withunitsmade)
Material cost: £71,000 p/a (£19 per unit)
Manufacturinglabour:£54,000 p/a (£200 perday for10 units)
Packagingandshipping:£37,000 p/a(£10 per unit)
Overheadcosts:£29,160 p/a
Salaryfor 4 members:£105,000 p/a
Grand total to manufacture anddistribute 10 unitsa day over1 year: £296,160

32. 32
Each unitcosts £78 throughoutthe whole process,sellingitfor£128 per unitgives£50
profitperunittotalling£189,000 profitperyear.
30 Quantity
 3780 unitsinthe first year,increasingto7560 withinthree years
31 Bibliography
1
http://www.bath.ac.uk/idmrc/themes/projects/delores/co-design-
website/dpg/tol/tol2.html2011
2
http://www.bssa.org.uk/topics.php?article=1(Home/Technical Help/Technical Library
/Standards,Specifications&Grades/BS/BSEN Grades CompositionsProperties)