CONTENTS

Introduction
Survey Report
Quality Function Deployment
Design Analysis
Stress Analysis
Material Selection
Manufacturing process selection
Cost Analysis
Conclusion

1
 INTRODUCTION

“
 Fantastically useful furniture .
 Purpose is to convert chair quickly to step
ladder.
 Can be used in the kitchen and shop for
reaching high shelves.
 Can also be used in the library for reaching
books on high shelves.
 No assembly required.
 Customer Survey
Survey zone:
1. Local playground
2. School and college
3. Online survey web

More than 57 people participated

120.0%

100.0%

80.0%

60.0%

40.0%

20.0%

0.0%
Useful Helpful Multi purpose use material (wood) Low cost Safety Reliability

3
 Quality Function Deployment
QFD is a structured approach to define customer needs or requirements and translating them
into specific plans to produce products to meet those needs.

Customer Technical
requirements requirements

Acquired Customer Needs

▷ Dimension.
▷ Time to Setup.
▷ Folding Alignment.
▷ Modular Orientation.
▷ Shape and Size.
▷ Light Weight.
▷ Material.
▷ Visually Appealing.
▷ Ladder facility.
4
Quality Function Deployment

5
 Design Analysis
Main parts of the product:

6
 Design Analysis
Assembly Of The Final Product:

7
 Stress Analysis
Stress Analysis for chair base:

8
 Stress Analysis
Displacement for chair base:

9
 Stress Analysis
Factor of safety for chair base:

Factor of safety = yield strength / highest value shown

19999972
=
7.165× 10^6
= 2.7913

This is the minimum factor of safety for this part which

indicates that the design is risk free.

10
 Stress Analysis
Stress Analysis for ladder step:

11
 Stress Analysis
Displacement for ladder step:

12
 Stress Analysis
Factor of safety for ladder step:

Factor of safety = yield strength / highest value shown

19999972
=
1.113×10^7
= 1.79
For this part factor of safety is 1.79. Which indicates that
this part is safe for the load.

13
 Material and Manufacturing process
selection
Calculation of weighting factor for main body and handle material
using Digital Logic Method(DLM):

Properties Decision Number Positive Weighting

1 2 3 4 5 6 7 8 9 10 Decisions Factor

Low Cost 1 0 0 1 2 0.2

Density 0 0 1 1 2 0.2

Tensile 1 1 1 1 4 0.4

Strength

Aesthetic 1 0 0 1 2 0.2
14
 Material and Manufacturing process
selection
Properties of candidate material for making main body and
handle:
Materials Low Cost Density Tensile Aesthetic

Strength(MPa)

Wood 4 650 81 4

Steel 3 7850 520 2

Plastic 4.5 925 40(Polypropylene) 2

Aluminium 3 2700 310 2

15
 Material and Manufacturing process
selection
Scaled value of properties and performance index of material for
making main body and handle:

Materials Properties Performance

Low Density Tensile Aesthtic
Wood 80 100 15.58 80 Index
58.232
Steel Cost
60 8.28 Strength
100 20 57.656
Plastic 90 70.27 7.69 20 39.13
Aluminium 60 24.07 59.62 20 44.662

From the above calculations of the value of the performance index

has shown that we can choose WOOD for making the Body

16
 Material and Manufacturing process
selection
Qualitative analysis operation process of Ladder Chair:
Process Selection Criteria Manufacturing Process Selected
Process Considered

Cutting Cost Table Saw Table Saw

Quality Miter Saw
Operating Time Circular Saw
Finishing Wooden wounds Buffing Hand Polishing
resistor Burnishing
Surface Roughness Hand Polishing
Cost

Drilling Durability Hand Drilling Hand Drilling

Cost Radial Drilling
Safety
17
 Material and Manufacturing process
selection
Possible design combination for cutting :
Properties 1 2 3 Positive Weight
considered decision factor(α)

cost 1 0 1 0.333

Quality 0 0 0 0

Operating Time 1 1 2 0.666

Total 3 1.0

18
 Material and Manufacturing process
selection
Weight property index chart for selection of cutting process :
Cutting Process cost (0.333) Quality (0.0) Operating Time Performa
(0.666) nce
index

Table Saw 25 100 100 75

Miter Saw 75 80 60 65

Circular Saw 100 60 60 73

Table saw Process is selected for cutting selection process.

19
 Material and Manufacturing process
selection
Possible design combination for drilling :

Properties 1 2 3 Positive Weight

Considered decision factor

Durability 0 1 1 0.333

Cost 1 0 1 0.333

Safety 0 1 1 0.333

Total 3 1.0
20
 Material and Manufacturing process
selection
Weight property index chart for selection of drilling process :

Cutting Process cost Durability Safety Performanc

(0.333) (0.333) (0.333) e index

Hand Drilling 100 75 100 90.75

Radial Drill 50 100 75 74.25

So Hand Drilling Process is selected for drilling selection process.

21
 Material and Manufacturing process
selection
Possible design combination for finishing process :

Process Wooden Attractive Modular Surface Cost

Wounds Outlook orientatin roughness

resistor

Buffing 3 2 3 4 4

Burnishing 4 3 4 4 3

Hand 5 4 5 1 1

Polishing

22
 Material and Manufacturing process
selection
Weight property index chart for selection of finishing process :
Process Wooden Attractive Modular Surface Cost Performan

Wounds Outlook orientatin roughness (0.2) ce index

(0.4) (0.2)
resistor (0.1)

(0.1)

Buffing 60 50 60 33.3 25 47

Burnishing 80 75 80 25 33.3 59

Hand 100 100 100 100 100 100

Polishing

So Hand polishing is selected for finishing selection process.

23
 Cost Analysis
Bill of Material :
Component Size/Comments Unitary cost % of cost

Spline 1/4*7/8*10.75 20 1.22%

1st step 3/4*6*13.5 75 4.58%

3rd step 3/4*6*13.5 75 4.58%

2nd step 3/4*6*15 80 4.89%

top step 3/4*5.5*15 85 5.19%

piano hinge 1/2*14.5 100 6.11%

Stretcher 3/4*6*13.5 150 9.17%

Seat 3/4*8.5*15 150 9.17%

lower side Wood 300 18.34%

upper side Wood 300 18.34%

Back Wood 300 18.34%

24
 Cost Analysis
Fixed and variable costs distributed through the lifecycle of the
product :
Fixed Cost Variable Cost
1st year 2nd year 3rd year Life cycle Per unite

R&D
design 7000 0 0 7000 -
improvement 0 2000 2000 4000 -
Total R&D 7000 2000 2000 11000 -
Facilities expenses
Rent and maintenance 15000 15000 15000 45000 -

depreciation 1500 1500 1500 4500 -

Total Facilities expenses 16500 16500 16500 49500 -

production
BOM - - - - 1635
Labour cost - - - - 800
Machinery 150000 15000 15000 180000

utilities 10000 10000 10000 30000

Total production cost 160000 25000 25000 210000 2435
25
 Cost Analysis
Fixed and variable costs distributed through the lifecycle of the
product :
Fixed Cost Variable Cost
1st year 2nd 3rd year Life cycle Per unite
year
Distribution
Logistics Management and transportation 15000 15000 15000 45000 15

Total distribution cost 15000 15000 15000 45000 15

Customer services
Repairing workshop 10000 10000 10000 30000 -

Total customer ervice cost 10000 10000 10000 30000 -

End of life cycle project

decommissioning - - 10000 10000 -

Waste management 1000 1000 1000 3000 -

Total EOC cost 1000 1000 11000 13000 -

Total accumulated costs 209500 69500 79500 358500 2450

26
 Cost Analysis
Sales Scenario:
Table: Sales Scenario

Year Sales

1 700

2 500

3 600

27
 Cost Analysis
Break-even Analysis:

Break even Analysis

6000000
PROFIT
5000000
4800000
BEP 4200000 4278500
4000000
3788500
3600000
3298500
Taka

3000000 3000000
2808500
LOSS 2400000
2318500
2000000
1828500
1800000
1338500
1200000
1000000 848500
600000
358500 358500 358500 358500 358500 358500 358500 358500 358500
0 0 200 400 600 800 1000 1200 1400 1600
0 200 400 600 800 1000 1200 1400 1600
units

No of Products Sold Fixed cost Sales Total cost

28
 Conclusion
We try our best to developed our product and
reduced error.
 Followed all procedures including survey,
QFD, material selection, cost analysis,
manufacturing etc.
 Finally, we are offering a user friendly and
cost efficient product.

29