- Project Hope, a group of engineering students, has been working to improve the design of tricycles manufactured at Anandwan for elderly and disabled residents. - They have implemented improvements to the braking system and created a 3D model of the frame to analyze stresses and opportunities for weight reduction. - Time studies were conducted and a process chart created to identify how production can be increased from one to three tricycles per day without increasing worker workload. - Planned activities include improving pedal ergonomics, enabling the tricycle to be separated for transport, and developing a new design requiring fewer welds.

2. THE JOURNEY SO FAR…
• The group, named Project Hope by popular vote, did its first visit to
Anandwan in August. The idea behind the visit was to get a feel of the
task at hand, to witness the site and to interact with the workers on a
first hand basis. The group also met with senior management staff at
Anandwan and the project is known to Mr. Vikas Amte (s/o Baba
Amte). He has appreciated our efforts and the staff has pledged its
support for the project.
• The Project Hope recruited Project Assistants from Sophomore Year,
Mechanical Engineering VNIT. They are full of ideas and energy and
their support has been, and will be indispensable.
• The second visit to Anandwan happened in September with the
intention of acquiring useful data on Process Times as well as
inspection of design. The group has also procured a tricycle and is
making active changes to it.

3. PROGRESS MADE IN DESIGN
• The brakes which were used in the tricycle were
extremely rudimentary made of linkages with
drilled holes and were very difficult to apply.
• They have been replaced by wire brakes giving
it the ease of application.
• The location where it was placed is also
changed to give minimum strain to the muscle
of the hand applying it (ergonomically better).
• The cost of the brakes was inspected and it was
found out that it cost nearly the same, and will
be cheaper if bought in bulk. Thus this idea was
found to be suitable for mass production.
CHANGE IN BRAKING
SYSTEM

5. THE 3D MODEL
• We have also created a 3D model of the frame
of the tricycle. This model was made on the
software CREO. All the dimensions of the
tricycle were measured with accuracy and a
wire frame model was created. The sweep
command was then used to create a solid
model.
• The purpose of this activity is to analyse the
design for stresses. The low stress members
can then be reduced in dimension. This will give
us benefits in weight and cost reduction.
• This is currently presenting problems in
meshing and representation of welding joints.
The team is seeking the aid of experts and will
come up with solution and viable results.

6. THE 3D MODEL MADE IN CREO

7. INDUSTRIAL SOLUTION
The process times were noted and arranged in sequence. A process time
chart was created and the with the name of the process, the time
required for the processes and the number of workers required in each
of the processes.

8. PROCESS TIME CHART CONTINUED

9. INDUSTRIAL SOLUTION FINDINGS
• This process time chart was then used to
divide the processes amongst workers in such
way that all the machines and workers are
utilised to the maximum extent. The following
were the findings of the solution.
• Currently , one tricycle is produced in a day.
Using the prescribed solution, the production
per day can be increased to three.
• The pace of the workers, i.e. the time required
for a worker to complete a task is assumed to
be that observed while taking readings. The
workers need not increase/ decrease their
working speed after the application of the
solution.

10. INDUSTRIAL SOLUTION FINDINGS
• Currently, five workers are employed full time at the
factory. After implementation of the solution, we
need to have a workforce of six workers employed
full time in the plant.
• These six workers are to be divided in three teams
of two workers each. They will each work of one
tricycle. One worker in each team should be trained
in welding, should know how to use the cutting
machine , should be physically strong enough to
use the bending machine and should know the
procedures for installation of equipment like
handles, brakes, wheels etc.
• Both the workers should be able to follow the
procedure prescribed by the solution. A supervisor
may be needed in the initial days to help in the
transition from the old system of operation to the

24. ACTIVITIES ENVISIONED
• It was observed by personal testing that the rotation
of the pedal requires a substantial amount of force. It
is particularly felt when during the motion of the
pedal in the upper half of rotation.
• The team has planned to provide ease of pedal
rotation by changing the diameter of the back
freewheel. For the same diameter of the front
sprocket, if the diameter of the back freewheel is
changed, it will have fewer rotations than the pedal,
which means that a large number of pedal rotations
will have fewer back wheel rotations. This will ease
the force to be applied on the pedal.
• We have bought a large diameter freewheel and we
will get it installed. The chain length also has to be
adjusted accordingly . The complete installation and
cost analysis report will be given in the next
presentation.

25. ACTIVITIES ENVISIONED
• The tricycle has to be transported to customers in far off
locations. To cater the needs of a bigger market, it would
be profitable if we could transport a greater number of
these cycles in one batch.
• Thus we planned the idea to install a Do-it-yourself kind
of detachment system which will involve outer screw
threads on some linkages and inner screw threads on a
cuff. Once removed, the cycle will be able to be separated
in two parts, one having the handle, handle accessories,
footrest and the front arch, while the other part will have
the seat, back wheels and the chain.
• To make this happen, we will have to visit Anandwan and
suggest changes while the manufacturing is on.
EASE OF TRANSPORT

27. ACTIVITIES ENVISIONED
• It is observed that the design is very old and rudimentary.
It uses a large number of welded joints which are cost
ineffective and take a major portion of the process time.
We have planned to create a design which uses lesser
number of welded joints and more number of bends as it
is cheaper and takes less time.
• This will require a better bending equipment as the
current one requires high physical strength to operate.
• Attachments like luggage carrying system are also to be
incorporated in the tricycle.
• It was also observed that the clearance of the cycle is
very large. It is not required and creates problems for the
elderly to climb up to the seat. We will refer to a design in
which small clearances are required and use of sheet
metal for footrest will also be reduced.
A NEW DESIGN