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PRODUCT DESIGN E-PORTFOLIO – MYP E-Assessment 2019

Global Context Fairness and Development

Key Concept Systems
Related Concept Function
Statement of Inquiry Designs that effectively synthesize structure and creativity can improve productivity
Inquiry Questions What are some different types of desktop toys that increase productivity?
How do distractions during work hours increase productivity?
Factual: What causes lack of productivity?
What are the positive and negative impacts of an environment?
How does relaxation and play improve creativity?
Conceptual: How can your environment impact the way you think?
How can a designer influence productivity?
Debatable: Should work places, schools, and/or communities promote creativity, relaxation and play?

Introduction:
Lack of productivity has always been a matter of great concern in emerging industries, especially those that involve more
practical work like the textile industry. The director of the company that my father works in, Mr. Gaurav Sareen (client for
this project) has always been involved in the textile industry from the very beginning because he sees this industry as a
place where cultures and ideals are brought together to produce a unique piece. The lack of productivity is something that
many offices and firms face, and one of the main reasons for it, is due to work-related stress or because of an unappealing
work environment. Sometimes employees get caught up in so much work that they don’t have time to rest or take a break,
also these employees end up losing interest in the work they are doing which results in them getting extremely fidgety and
restless. This condition directly effects the firm more economically and socially, by affecting the output that a firm
produces, also lack of productivity impacts the social environment of the firm, if one employee shows any sign of low
productivity, other employees feel the same resulting in a less productive workforce.
Further analysis for the above is as below.

Criteria A: Inquiring and Analyzing

Strand (i): The Situation
I am extremely fortunate to find that my client also shares a similar opinion as me and believes that his firm is always
open to any ideas or solutions that can help increase productivity of the employees. This industry requires an extremely
open-minded work environment wherein all employees communicate and make sure that everything is going in the right
direction because communication here helps in identifying what went wrong in a particular piece, this also plays a huge
part for customer satisfaction because an industry like this is all for the customers in the end. The best way to tackle the
problem of productivity that these firms are facing currently is by introducing a more comfortable and relaxed workplace
to reduce the stress endured by the employees themselves. This can also be done by engaging the employees in toys and
stress busters that they can use during their breaks, allowing them to refocus when they continue working.
In an email to Mr. Gaurav (see pg. 3. Fig 2) I learned my client’s company has already been implementing ideas that may
increase productivity in the workplace, for example, the company has introduced ideas like standing desks and chairs
without a back rest. A standing desk increases productivity because standing burns more calories than sitting due to
increased muscular activity, “according to a study conducted by O’Sullivan, also Texas A&M University found that
productivity could be boosted by as much as 46% when workers switch to standing desks”1. The company’s decision to
introduce chairs that do not have a back rest is another step that they have taken to increase productivity, because an

1
To see link for study, see page 41

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employee sitting in a chair like this will have to sit upright and sitting upright is considered the best way to sit because by
doing so the employees tend have a greater urge to complete the task in front of them so that they may rest in some time
and they are more concentrated on the work they are doing.
Also, these firms can introduce the employees to small desktop toys on their desks that can keep them engaged and avoid
laid back attitude in the workplace. Such desktop toys help distract you from all the workload that you had before, they
help you relax and refocus. Toys that display a continuous pattern (perpetual motion) can often help employees more than
other conventional toys. These toys help the mind pay attention more often and more effectively, which can be further
applied to the workplace itself.
My client has always felt the need for a way to increase productivity in his
workplace, which is why he would like a product that helps him and maybe
in the time to come, the other employees also understand the need for a
product like this. However, he feels the product shouldn’t be too childish,
and it must have a modern look to it, and must be an office product and not
something that is from the kid’s room. In addition, my client wants a product
that is simple looking with not too many bright colors since his room is not
that vibrant and colorful but more greyscale (see Fig.1). In addition, the
^Fig. 1 (self-clicked) client also believes that the product must have some sort of connection to the textile industry, either
from the pattern of the product or the structure of the product. He also would like a product that is
made from either fabric, wood, or metal since he thinks these materials give a very simplistic look and feel to the product.
Plastic is to be avoided at all times since the office by itself is an eco-friendly office with minimal usage of plastic
products.

Strand (ii): Identify Primary and Secondary Sources

The research plan will enable me to add significant information to the making of the product from valid sources,
and helping design the specifications based on subtle elements that collect and interpret through the entire
research process
Primary Sources:
Priority Task Explanation How it will help?

1 Taking a This interview will include questions Such information will help me to
detailed about likes, dislikes, important features incorporate it into my product and
interview of and personal views on the topic. successfully satisfying my client’s
client needs.
2 Conducting a The survey will include questions A survey regarding the following topic
survey with regarding productivity and how some will help me understand what my target
employees toys will help them in the office along audience thinks and some preferences
(Part 1) with some samples. by the employees themselves.

3 Learning I shall be visiting my father’s office, and
about textiles this session will be from my father who
is in the textiles himself. The session will
include information like different types
of fabrics, how to use it, etc.
A session about textiles will introduce
me to a completely new field. This
session will also teach on how to use
fabrics so that I can merge both
materials in my desktop toy.

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4 Brainstorming This will be in the form of a mind map
on possible or any other visual thinking process and
ideas it will include the materials, type of toy,
ergonomics, structure etc.
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A mind map or any other visual
thinking process will help me to
organize my thoughts and all the
information collected from the past
surveys and interviews.

5 Conducting a This survey will include questions on After finding already existing desktop
survey with what employees think about existing toys in the internet, a survey on them
the employees products on the internet based on the will help me understand my target
(Part 2) previous survey. audience’s preferences in more detail
and depth. Also, this help me choose
between products, making the final
decision easier for me.
Take detailed interview of client

^Fig. 2 The above picture is a screenshot of the mail sent to my client to

understand his opinions and his likes and dislikes

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Survey 1(see Appendix A, for full survey)
The first survey taken is only to gain a perspective on what my target audience thinks about the productivity in
the workplace. The questions in this survey were primarily on their thoughts on productivity, solutions for
increased productivity, possible desktop toys that might increase productivity etc.
The below pictures are sample graphs for a few questions. For a detailed analysis of the full survey, refer to
Appendix

In the graph above, it is clearly shown

that majority of the respondents
believe that the main causes for lack
of productivity is due to either heavy
work load or long continuous work
hours. This result supports my point,
since my product is being made to
reduce heavy work load by allowing
the employees to play with these toys
during their short breaks.

The graph above shows that half of the respondents believe that a desktop
toy will definitely help increase productivity in the work place, with 35.7%
saying that it would help to some extent. This result also supports my
product, since it shows that my target audience believes that a toy like this
will accelerate change in the firm.

The following graph shows that my target

audience want either a continuous motion toy
or an arcade game. This is extremely
important for this process since it will help me
narrow down to a product rather than having
a lot of options. So with this information, I
know that my target audience wants a
continuous motion toy or an arcade game.

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Learning about textiles:
The textile industry is a growing industry especially in India, and I extremely fortunate to see that I my father is so deeply
involved in such a growing industry. To learn more about fabrics and how I want to use it, I visited my father’s office so
that he could show me around and tell me about the industry and a lot more about fabrics. Also, I was lucky enough to
find that my father’s office already has a piece wherein the structure is metal, and it is covered in fabric.

The picture below (see Fig. 3) is a jewelry box made from handcrafted brass tin. The fabric on the jewelry box is a hand
tie and dye effect with organic colors, and for additional decoration they used sea shells, multicolor beads and threads
to give it a vintage look. Now when it comes to using fabrics, it must always be used in a productive way so that minimal
fabric is wasted. Also, when working with fabrics, one must always be careful with needles and even some of the colors
since they could contain various chemicals in them. Apart from the fabric, my father even gave an insight on how they
made the box. They used small chisels and hammers to carve the design. While doing this, one should wear eye
protection and gloves to avoid getting hurt from the sharp pieces of the
metal itself.

Now although this isn’t the product that I will be making, it still serves
as a good foundation for metal working and even fabrics. Based on this
session, I can apply the knowledge that I received, to my toy.

Fig. 3 (self-clicked)

Secondary Research (see Appendix B for screenshot of sources used)

Priority Task Explanation
1 Understanding Here I will be referring to various
what causes websites and articles wherein they
lack of explain why some industries are
productivity facing lack of productivity today
2 Understanding Once I have understood the problem,
what the I will begin researching on how
solutions are productivity can be increased by
to increase simple products that I can make for
productivity this project. This will be done with
the help of more websites.
3 Research Since I am already comfortable with
about metal wood, I will need to research on
various types of metals that I can us e
with the help of
TechnologyStudent.com. This phase
will include understanding some
properties of these materials and even
some of the equipment that I will
need while working with these
materials
4 Understanding After learning about the types of
joints with metal and its properties, I must begin
metal. researching about the different metal
How it will help
This will help me understand the problem
in more depth so that I able to find a more
applicable solution to it as well.
By doing so, I will have a base foundation
upon which I will be able to come up with
creative and unique ideas to help decrease
lack of productivity in the workplace.
This will help in technical application
during the process of making the product.
By researching about the materials, I will
be using, I may be able to find some
unique properties and materials that I can
use in my toy. By doing so I won’t have
any problems while I am making the
product and can help me complete it
faster.
This will also help me in technical
application, because metal joints and
finishing is something that I have never
tried before and learning about it now will

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joints and finishing techniques that I
will use in my toy.
5 Analyze Here I will find already existing
existing desktop toys made from wood and
desktop toys metal and analyze at least 6 ideas,
wherein I will find the positives and
negatives of each product.
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help the manufacturing of the product run
smoothly.
This is another key part of the research
process, since it will help gain a
perspective on what a desktop toy should
look like and also what I must avoid in my
toy to make it better.

Understanding the concept of stress and productivity

Work-life balance aside, workers often invest a ton of energy at work. With a wide range of identities, it’s
outlandish for everybody to get along constantly, however a positive company culture can make the workplace
condition all the more comfortable. Positive company culture likewise enables you representatives to feel
increasingly engaged with their fellow employees and more associated with the organization and their work.
“Often overlooked in organizations, especially large ones, is the fact that productivity, happiness, and
engagement are all related,” according to Regain Your Time. “Employees who are happier and more satisfied at
work are more productive and more engaged in the mission of the organization.” 2
While some may think distractions are the biggest productivity killers, recent study says otherwise. “Among HR
professionals surveyed, 55 percent called cellphones the biggest productivity killer for employees. While
employers may think their workers are busy texting and scrolling through social media, employees tell a
different story about cellphone use. Among the 3,031 employees surveyed in the same study, only 10 percent of
those who own smartphones said it decreased their productivity at work. In fact, 66 percent said they use it at
least several times a day for work.”3
Recent studies has shown that minor distraction can help boost productivity by giving the mind a break, making
it easier to focus on a task. However there are two types of distraction. A fidget toy and a iPhone game. The key
is make sure that the distraction is used for the enjoyment of the experience itself and not to achieve any sort of
goal.

^Fig. 4

^Fig. 5

*CITATIONS FOR ALL FIGURES ARE

GIVEN IN THE BIBLIOGRAPHY. PLEASE
REFER TO PAGE 40

^Fig. 6

2
See citations on page 41
3
See citations on page 41

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Strand (iii): Research and Analyze Existing Products

ANALYSIS 1
This toy shown is a
miniature bowling set
made from wood and
metal. This looks like
something that can be used
in a desktop toy for office
workers as a stress-buster.
As shown, the balls and
pins are made from metal
and the base is entirely
wood
This product holds many positive aspects,
for example, the toy does not look like a
child’s toy, in fact it looks like something
that one would see on an office desk.
Also, the product looks aesthetically
pleasing due to the polished finish.
Another positive aspect is the size, since
this is a miniature product, it does not take
a lot of space on a desk and can be placed
^Fig. 7
inside a drawer without damaging the
product itself.

The product shown above does hold a few
negative aspects, the main one being that,
since the pins are made of metal, when the
pins drop they will create a lot of noise and
may disrupt the office environment.
The materials required for this are simply wood and metal.
As shown in the picture above, the wood that is used for
the base looks like pine and the sheet used at the back
looks like some flexible plywood board. The pins and
balls can be made from any metal for example, aluminum,
copper, brass based on requirements

ANALYSIS 2
The product shown holds a lot of
The product shown on the right positives for example, the toy looks
is called a kinetic compass. It is extremely pleasing to the eye with its
made from wood with a few minimalistic look, also the star looks like
hidden magnets in the piece it is hovering on thin air at first glance,
itself. This is something that but if you were to look at it closely you
does not require any external see the thin string that the start is
force. It also mesmerizing to suspended by. When in motion, the
watch and helps anybody to rotation of the star is extremely soothing
relax which makes a great office to watch and can help anyone relax
^Fig. 8
toy. making it an excellent office product

Apart from the positives of the product, it also has a few negatives. The product uses only wood
Firstly, such a product would require extreme precision while making that is precisely cut and
because even the slightest weight difference may spoil the entire polished. Apart from the
product rendering it useless. Also, the product is also very fragile, and wooden components, it also
the parts are hard to repair or replace, for example, if the string snapped has a few magnets hidden in
replacing it will be difficult and may take some time and if the star were the product itself.
to chip off, it would cause a weight change spoiling the whole product.

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ANALYSIS 3
The product shown is called
a Soma Cube, which is a
puzzle wherein you have 7
wooden pieces and you
must arrange all 7 pieces to
get a complete 3x3 cube. It
comes in various colors and
materials and is great fun to
play with. It is a good brain
teaser because you have
use your brains to arrange
the pieces in the right way ^Fig. 9
Despite the positive features, puzzles like this often
have one very persistent problem, that once solved it
becomes very easy and people tend to get bored of it
very soon. Also, if one of the pieces were to get
damaged, it ruins the structure of the entire cube.
ANALYSIS 4
The product shown to the right is
called a Helicone, it is an extremely
popular product and is seen on many
office desks around the world. When
you spin the axle 180 degrees the
petals above form the pattern shown
in the picture. When the axle is spun
again it forms a different DNA pattern.
It is extremely satisfying to watch and ^Fig. 10
is great to break the stress and relax in
offices.
One of the negatives of this product is that is extremely
fragile and if it were to fall, the pieces would either fall
apart or get disorientated which ruins the entire product.
Also, when you rotate more than required there are
chances of it getting disoriented.
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Some of the positive aspects of
this toy/puzzle is that is compact
and can be carried around
without any problem making this
a great office toy. Also, it comes
in a case which is even better to
store the pieces without losing
them. Also, at first glance, the
product looks very simply but
once it is taken apart, it becomes
a challenge and is great to refocus
when you are bored or sleepy at
work.
The materials required for this puzzle are
primarily wood, however some may use metal
instead or even plastic for this. Some cubes
are both wood and metal combined as well.
The product looks very aesthetically pleasing
and is a treat for the eye when it is turned. It is
a great office product and watching it change
forms helps the mind relax and refocus, which
is extremely important in the work life.
Another interesting feature about this is that
looks very complicated but in reality, it is just
identical pieces arranged in a specific order.
Also, the product is made out of simple
materials without any electronics making it
extremely pleasing to watch.
The materials for this product are
extremely common, the only two
materials used for this are wood for the
petals and the base and a metal rod for
the axle of Helicone.
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ANALYSIS 5
The product shown here holds many
The product shown is called
positives, for example, the sound that
an Amish Marble Machine,
the marbles make when they drop into
where the marble keeps
the components is extremely soothing
going into middle component
and helps the person relax. Another
and then into box below. The
positive aspect is that this product is
process continues as long as
compact in size, so the product will fit
there are marbles. This is
perfect on an office desk. Also,
extremely pleasing to watch
product is extremely easy to make and
and the sound of the marbles
^Fig.11 if it broke, it can easily be fixed.
dropping into each
component.
The materials that are being used to make this
The negatives that come with this product are product is wood. However, the same product
simply that this product does make a lot of noise can be made in metal and that may give a
which may disrupt an office environment. Also, the classier look to the product.
product does not look that good, although this can
be modified to a metal toy, it will end up making
more noise than the wood

The toy on the looks very aesthetically

ANALYSIS 6
The product shown on the right
is a marble run tower wherein,
the marbles on the top are
released and from there, the
marbles go down a set of
ramps and then into the
buckets, from the buckets the
marbles fall out onto another
set of ramps and the process
continues until the marble
reach the bottom.
pleasing and it also seems like it would be a
desktop toy because it will help relax the
mind with the help of the sound that it
makes. Also, another point being that, this
toy can be created in a lot of different ways
and still be the basic function of the product.
For example, this product does not require
the bucket. A tower with only ramps will also
have the same impact as a tower with the
bucket and the ramp.
^Fig. 12

One of the drawbacks of this product is that, it would create a lot of noise This product is made entirely
which may distract other employees in the work place since the marble is from wood that is polished
heavy and when it falls into the bucket, it would make some noise. Also, and finished extremely well.
this product requires a lot of precision while making it because the ramps Also, if you look closely, the
and buckets have to perfectly aligned and the weight balance must be ramps are engraved which is
perfect. This makes the toy extremely fragile and replacement of any parts another useful technique. Also
isn’t easily accessible. Another point to keep in mind is that, if the marbles creating a bucket like that out
fall out of place, there is a high risk of losing them. Although these can be of wood seems quite
bought anywhere, it still counts as a possible negative. A toy like this will challenging but very pleasing
only work if it were made from wood or plastic, because if it were made in as well.
metal it would simply create more noise.

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Summary of analysis:
After researching already existing desktop toys, I listed all positives and negative aspects of all products
alongside a brief description and a possible materials list. After self-analysis, I came up with the conclusion that
all products chosen would make great desktop toys however some of them were either too fragile or would
make some noise that could possibly disturb the work environment. Another possible drawback that was there
in a few products, was that there were too many smaller components, which the user may lose by mistake.
However, if we look at the positives we see that, many of the toys shown above would be great to relax the
mind in some way or the other, with the help of the satisfying sound they make or just its aesthetics.

^The above pictures are sample results of the top 2 selected designs from the survey. (see Appendix C
for full survey)

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Apart from my individual analysis, I even conducted a survey for all the employees in my client’s firm. I sent
this survey to 30 employees but unfortunately got only 15 responses. This was to collect general feedback on
these existing products so that I may gain some perspective on what my target audience likes and dislikes. The
questions for each product were the same. The employees were asked to rate the product out of 5 on 3
parameters, Material choice, Overall Design, and Functionality. The highest rating any product could get was 5
or 225 marks. The closest to that was the Miniature bowling alley and the Helicone (201/225 and 199/225
respectively). The miniature bowling alley and the Helicone were appreciated a lot as a lot of respondents found
this very interesting. Even my client found both these toys the most interesting and he even gave both of them
three 5s each.

Strand (iv): Design Brief

The following design brief is written while considering all necessary information obtained from past surveys,
interviews and other means of research.
I am going to design and make a desktop toy for my client (Mr. Gaurav Sareen) who is the director of Orange
International. Orange International is a garment export company and the employees that are working here are
my target audience. The toy’s primary motive is to be used as a product that an employee can play with whilst
he/she is taking their short break in the office. This will be a small and portable toy that my client can take
wherever he is working. It must also be strong and must be able to withstand small drops and damages as per
my client’s requirements. The toy will be placed on my client’s desk where he has quick access to it. The toy
must incorporate fabrics in some way since my client wants the product to have a strong connection to the
textile industry. The product must avoid any use of plastic since my client’s firm aims on minimizing plastic
usage in the firm itself. Apart from the fabrics, the product will be made from wood and metal with a slight tint
of orange on both the wood and the metal parts of the toy since orange is my client’s favorite color. It must not
include any vibrant colors other than orange since my client’s room has a very subtle color scheme (Black,
White, Grey). The product must not make a lot of noise and must be something that one can simply play with
without disturbing the other employees as inferred from analyzing existing products. The toy must not contain
too many smaller components since it may add a risk of losing them rendering the entire product useless.

Criteria B: Developing Ideas

Strand (i): Design Specifications

Sr. Aspect Details

no
1. Client/Target My client for this product is the director of Orange International, which is a textile industry that
Audience does garment exporting. The employees in this firm who have formal desk jobs like accounting,
web developers, and managers are my target audience.
2. Target My target market is mainly employees that have desk jobs, since this product is meant to be
Market kept on an office desk.
3. Function The main function of this product is to help in relieving stress and is meant to be used during
short office breaks. The product is a toy/game that workers can use for some time and then
continue working. The product serves the purpose of holding a few small office supplies as it has
a drawer as well.
4. Location As previously mentioned, this product is for office employees and the product will be placed on
an employee’s desk. The product must not take too much space either. The product will be

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placed in my client’s room which is very greyscale therefore the product is able to match its
surrounding well.
5. Contents While the product is mainly for recreational purposes, the product also has a drawer which
holds a few small office supplies like paperclips, pencils, pushpins, binder clips etc. The drawer
will also hold a small part of the game like the ball, the pegs, etc.
6. Ergonomics The product must be big enough so that my client can use without any problems but small
and size enough that it does not take too much space on my client’s desk. The product should not be
more than 30cm is length, height or width.
7. Finishing The product must be well finished. This will be done by staining wood and polishing the metal.
The fabric must also be well finished and cleaned with minimal defects.
8. Shape The product will have a geometric shape (rectangular or square) so that it matches well with my
client’s room.
9. Standout Apart from the game itself, the product will also a drawer that holds office supplies and a small
feature – part of the game itself.
drawers
10. Colors As mentioned earlier, the product must not be too colorful and but have more subtle colors like
grey, black, white, etc. However, the product must also have some orange color since orange is
my client’s favorite color.
11. Form The product should be self-standing and must be well balanced on all four corners that the client
is able to use the product effectively. The game must also be single player and the game should
not make too much noise while being played with.
12. Materials The materials used for this product are wood, metal, and fabric. Wood must be cheap, strong,
and long lasting. The metal must also be cheap, malleable, strong and easy to work with. The
fabric must be easily available and strong. It must also be cheap.
13. Tools The tools that will be used for this product are easily available in the workshop, however any
textile work that needs to done will be done with tools like color dye, block prints etc. Some of
the tools required in the workshop include hacksaws, band saw, files, hammers, belt sanders,
welding machines, etc.
14. Health and The product must not contain any dangerous and sharp pieces that may hurt the user. The
safety edges and corners must be rounded off to avoid getting hurt. Safety measures must also be
measures followed during the manufacturing of the product.
15. Environment The product must be environmentally sustainable. For example, the product must use minimal
and plastic since my client’s firm follows minimal plastic use due to some of plastic dangerous side
sustainable effects.
design
16. Cost The product must not be too expensive in terms of materials required. All metal, wood, and
fabric components must be cheap and easily accessible.
17. Quality The product must be quality assured before being sent to the client so that the client is able to
assurance use the problem effectively. Some of the tests for the same include:
and control The product must be stable on all corners.
The product must be checked for any uneven painting or staining.
The product must also be tested on the game itself, the game must functional and all parts must
be working perfectly.

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Strand (ii): Design Ideas

Initial Ideas:

1. This is a small desktop dart game which can

also be hidden with the help of calendar. The main
function of this product is as a calendar, but when
my client is bored or is taking a break, the calendar
can be put back (which is on a spiral at the top) and
he can play a few rounds of dart. The dart board is
etched on a metal plate with is placed on a wooden
base. As a part of the product, there is also a drawer
that can hold a variety of office supplies according
to my client' needs, however, this drawer will also
hold a small magnetic dart with which my client
can play dart. The horizontal side of this product is
a wooden base, it will be decorated by a lot of
fabric around the base itself. On top of the base,
there will be a thicker fabric that that if the dart
does not stick and falls, then the fabric will help in
reducing the noise created. Once my client has used
the dart board, he can flip the calendar back in place, so that it is not distracting.

2. This is small desktop game of marble

solitaire, only in this case, instead of the
marbles, I have used metal pegs. The game
uses the simple rules of marble solitaire. The
aim of the game is to leave the board empty.
The game starts off with 32 pegs in each of
the holes on the board with the center hole
empty. To remove a peg, simply use one peg
to jump over another into an empty slot,
then the peg which was jumped over will be
put out. However, you can only move
vertically or horizontally, diagonal
movement is not allowed. The same
continues until all pegs are removed from
the board. There will 33 holes drilled in a
specific pattern. The product will be in the
shape of a box which is made of wood. This
will also hold a drawer which has a
compartment that holds 32 metal pegs. The
drawer also holds a few office supplies. To
hide the solitaire board, there is a slider
made of wood. The box will be covered
with fabric to decorate the product.

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3. This is a small desktop toy in which

the aim is to keep the wooden wheel on
the ramp. The ramp is made of metal and
it is held by a thick U-shaped metal strip.
The base is wooden box like structure
with a thin fabric. The ramp is not
attached to the base, because it can be
removed and put in the drawer. The ramp
can be moved sideways with the help of
your finger. You can slide your finger in
the direction you want the ramp to go.
The wooden box is wrapped by a
decorated fabric. Also there will be a
small drawer on the main wooden body
of the product that keeps the wooden
wheel, however the drawer is big enough
to keep small office supplies like erasers,
paperclips, etc.

4. This is a miniature air hockey game which is

primarily made of wood and has a metal puck.
This game will a single player game wherein
there is no aim. The motive behind this product is
to simply play with during breaks so that it
relieves my client from all the work. The main
surface of the game is made of wood that is
polished extremely well, so that the metal puck
can easily bounce around the board with minimal
friction. The metal puck will also be polished
well so that the game runs smoothly. The sides of
the board will also be made of wood but will have
a thin fabric around it. This is to minimize the
sound that is made while my client uses this
product. Some fabric will also be used outside the
board itself for decorating. The product will also
have a small drawer that is made to hold the
metal puck and a few small office supplies like
pushpins, binder clips, and rubber bands.

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5. This is a miniature basketball arcade game

wherein the main aim of this game is to shoot a mini
basketball into the basket without a bounce. The
product is mainly made from wood, however the front
side of the vertical and horizontal pieces of wood is
covered in fabric. This is mainly for noise reduction
and also for decoration purposes. The product has
barriers around it to stop the ball from getting lost.
There are also a few mesh barriers made of metal
below the basket. The bottom part of the mesh will
have a small opening directly under the basket and the
base of this is declined towards the opening. There are
also a few mesh barriers on the sides to stop the ball
from going off board. Once the ball goes into the
basket, it will directly drop into the opening and will
reach the bottom base. There is also a small drawer to
keep the ball and a few small office supplies like
paperclips, and pushpins.

6. This is a miniature foosball game;

however, this game is a single player game
unlike the original foosball game. This game
has one metal rod and one player on that rod.
The aim of the game is to try scoring a goal
but also to defend and avoid getting scored
on. The ball will be a small wooden ball and
the ball will bounce around inside the board
and the user must move the rod horizontally
and twist the rod to stop the ball and/or score
a goal. The base of this game is made of wood
and a thin fabric is put on top of it, so that the
ball does not make too much noise. There is
also a drawer on one of the sides of this
board, this is to hold the ball and even some
small office supplies.

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Analysis of Initial Ideas with Design Specification

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
Design 1
Design 2
Design 3
Design 4
Design 5
Design 6

Green cells: Design specification is met

Yellow cells: Design specification is partially met.

Research and Analysis of Materials

Research on metal

The picture below is a list of commonly used metals. Since my client wants a metal that is easy to find, light, and
easy to use for this toy. Based on this information and the information found on the source, I have chosen
Aluminum for this project.
Aluminum is a very commonly used metal, that is often used in soda cans, kitchen utensils, foil, window frames
and many more. One of the main properties of aluminum is that it is extremely malleable and ductile, which
means that it can be shaped to numerous shapes and sizes by will. Another interesting fact about aluminum is
that, it is a non-corrosive metal, which helps the product last longer without sustaining too much damage. Also,
aluminum is very strong despite its malleability and ductility.
Aluminum has a relatively low melting point (660.2 Celsius) when compared to other metals like copper, brass,
or stainless steel. This is a very useful aspect while manufacturing because, aluminum can easily be melted for
casting without using too much heat or any fancy machineries.4

4
To see link for source, see page 41

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Mirror Finishing
Mirror finishing is a process wherein a piece of metal is polished to such an extent that the metal becomes so
lustrous that it exhibits properties of a mirror and begins to reflect off surfaces. To achieve a mirror, finish on
any metal surface, the first step is to use a scotch pad and scrub the surface, this helps any further polishing run
smoothly. Once the scrubbing is done, the next step is to use Acetone and some high grit sandpaper. This is
done by starting off with rubbing with the scotch pad and then rubbing the surface with Acetone, then rub with
an 800-grit sandpaper and then cleaning it with Acetone again. You keep repeating this process, clean the
surface with Acetone and then rub the surface with a higher grit sandpaper than before. 5
The Buffing Machine
The Polishing Machine (also called the Buffing Machine) is used to polish soft metals including copper and
brass as well as plastics such as Perspex. The two ‘mops’ spin at high speed when the ‘on’ switch is pressed. If
the material is carefully pressed against the mop and moved backwards and forwards it will be polished. The
material must be filed to removed scratches and then wet and dry paper or emery cloth is used to further smooth
the surfaces. Only then can it be polished on the buffing machine. 6
Metal Casting
A mold is formed into the geometric shape of a desired part. Molten metal is then poured into the mold, the
mold holds this material in shape as it solidifies. A metal casting is created. Molds can be classified as either
open or closed. An open mold is a container, like a cup, that has only the shape of the desired part. The molten
material is poured directly into the mold cavity which is exposed to the open environment. The other type of
mold is a closed mold, it contains a delivery system for the molten material to reach the mold cavity, where the
part will harden within the mold.
Varnishing Wood
To varnish a piece of wood, you will need a piece of cloth, varnish, wood, a nice thick brush, a newspaper, and
fine grit sandpaper. Also, before applying varnish, make sure that your workspace is clean and dust free to
avoid any dust from sticking to the piece of wood. To start the process, give the wood a light sanding with a fine
grit sandpaper, make sure to sand with the grain as well. Once sanded, clean the wood with a piece of cloth and
then begin applying the varnish with a brush. Start by applying the varnish against the grains of the wood. Once
dried, reapply the varnish with a brush, but this time, with the grains of the wood. Once the piece has dried,
sand the piece again with a fine grit sandpaper, and then wipe the surface with a piece of cloth. Make sure the
varnish is painted in thin and even coats for best results. 7
Butt Joint
One of the most common joints in woodworking. A butt joint is used to join two pieces of wood, however in
this technique, the ends of each piece of wood are joint together. This joint does not include any fancy cuts or
extra materials. This joint can be done with wood glue and a few nails. The nails and the wood glue help join
the two pieces firmly.

5
To see link for source, see page 41
6
To see link for source, see page 41
7
To see link for source, see page 41 17
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Improved Designs
Design 1:

*ALL DIMENSIONS IN
CENTIMETERS (CM)

In this design, I have changed a few minor details that were not there in the initial drawings. For example, in the
initial drawing, the main body of the game was a perfect square. But in this design the main base is a rectangle
and the added component in this new design is a place for the drawer itself. Here I have shown a sample of how
the game will look when being played. This will give a clear understanding of how the game works. I have also
shown some of the contents of the drawer.
Another important detail that is changed in this design is that previously the pegs were made out of metal, but in
this design the pegs will be 3D printed on the 3D printer. This is mainly because making 32 pegs that look
identical to each other is very tedious and may result in a few abnormalities. With the help of the 3D printer, I
will be able to print all 32 pegs in absolute precision. These pegs will be printed with a yellow filament since
orange would not go well with the product itself. Also, the type of wood used in the main body of the game is
pinewood that is stained with walnut. This is because a dark colored wood is difficult to find and very
expensive. However, there will be a variation in the stain color between the slider on top of the game and the
main body so that they look a different to each other.

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Design 2:

In this design, I have tried to avoid changing any major details since my client was very pleased with this idea.
This design is a dartboard made out of an aluminum sheet which is stuck on a block of wood, while the
dartboard is vertical, there is another block of wood which is the base of the product. The fabric on the top of
the base is slightly thicker than the fabric on the sides. This is because the top of the base acts as a cushion for
the magnetic dart to fall on so that the dart does not make any loud noises, which may disturb the other
employees.
In this design, I have also made a sample of how the calendar will look. The reason the calendar is like this, is
simply because this format saves a lot of space, by doing so I will only need 3 more sheets like this. The
calendar is made out slightly hard paper so that it does not tear while my client is using it. The thickness of the
vertical side of the product is also very important because, if it were too thick then the calendar would have
more chances of tear and the calendar would not be able to turn as efficiently, and if it were too thin then the
force of the dart being thrown at the board would damage the product itself.

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The entire product is made out of pinewood and the places where the grain of the wood is shown is well
polished so that the product looks aesthetically pleasing. The sides are mostly covered in fabric, mainly for
decoration purposes. The magnetic dart is also made of a light wood and has a magnetic tip at the very end. The
dart must be precisely made since any abnormalities will result in a weight misbalance, which would in turn
spoil the entire game itself.
Justification of Improved Designs
After talking with my client, we were able to come to a consensus that the top 2 designs that need to be taken
forward are the dartboard design and the solitaire design. Although all designs followed all the design
specifications precisely, it all came down to personal choice. My client personally liked these 2 designs simply
because these designs hide the fact that they are games meant to be played. For example, the dartboard design
also had a calendar which could be useful to hide the dartboard itself. Even for the solitaire design, the top
sliding board of wood hides the holes made for the game and gives the product an extremely minimalistic look.
Another reason why my client chose these designs is because these were the one of the very promising in terms
of low noise levels. These products were the kind that didn't make too much noise and was considered ideal for
office purposes. However, my client did mention that he wanted to change the pattern on fabric, and the color
choices have to be reconsidered. Since orange would not go well with all colors, my client and I were able to
narrow down to shades of orange or the colors that looked like orange.

^ The picture above is the screenshot of the reply I got from my client after I showed him all my design ideas and the
design specifications as well

Strand (iii): Chosen Design

Justification of Final Design:
After narrowing down to 2 designs, it was time to finalize on 1 product that I shall be making. To do so, my
client and I had to go through the pros and cons of both designs, and after doing so, we were able to narrow
down to one final idea, the peg solitaire game. One of the main reasons behind choosing this design was that
this design was one of the few designs that did not make any noise while in use. This was a major plus point and
this also played an imperative role in being able to decide between the 2 designs. Another reason for why we
chose this design is because the dartboard design had one minor flaw. The dartboard was not strong enough for
the magnetic dart to attracted to. So, this meant that the dart might not stick on the dartboard. This was one flaw
that was highly overlooked.
Apart from these, my client also really liked the idea of the solitaire game. He strongly believed that this would
help him increase productivity the most and was also extremely pleased about the fact that the game could be
hidden when not in use. My client believed that the product would look very minimalistic and aesthetically
pleasing when covered, and it would also be a lot of fun trying to solve the puzzle itself.

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Also, my client was extremely pleased with the use of the drawers since the product now has multiple purposes,
which helps my client immensely. This context of the drawers will help my client in being more organized and
being organized also helps increasing productivity.
Thus, my client and I were able to narrow down this idea.

Strand (iv): Planning

Final Design Isometric

Final Design – Orthographic Drawing (First Angle Projection)

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Final Design –Working Drawing

Analysis of Final Design

After talking with my client, we were able to narrow down to one final design idea. This is the peg solitaire
game with 3D printed pegs and the wooden base. In this design, a variety of techniques are being used. The
entire product requires extreme precision while manufacturing, and the fabric work also needs to be done
carefully as I will be working with colored dye which is a harmful chemical.
Firstly, I will be using few very common types of joints that are used in woodworking. One of the most used
ones is the butt joint. This joint will be used while making the drawer and the slot for the drawer. The butt joint
is simply two pieces of wood joined together at each other’s end with no extra cutting. The pieces will be held
in place with glue and a few nails for extra strength. I will also be using the bench drill to drill the holes on the
main body since this machine is far more precise when compared to a hand drill. However, this task must also
be done carefully since any small mistake will cost me greatly.

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Exploded Drawing of Final Design

Criteria C: Creating the Solution

Strand (i): Manufacturing Plan
Step by Step Process

Step Process, Tools, and Materials

1. Sourcing and collecting all materials:
1m of white linen cloth, pinewood, yellow 3D printing filament, and metal drawer handle
2. Marking the portion of the pinewood block Tools and Materials:
needed for the main body Pinewood, pencil, Steel rule, Tri square, marking
gauge
3. Cutting the pinewood block to marked Band saw, hacksaw, scroll saw
dimensions
4. Marking 33 2cm radii holes in exact pattern Pencil, pinewood, steel rule, tri square, marking
gauge
5. Drill 33 holes precisely. Make sure all holes Bench drill, dot punch, drill bit (2cm)
are drilled to a depth of 2cm only.
6. File all edges of main body Hand files, vertical belt sander, horizontal belt sander
7. Marking pieces of pine to exact dimensions of Pinewood, pencil, steel rule, tri square, marking
drawer slot gauge
8. Cutting all pieces of pine to marked Band saw, coping saw, scroll saw
dimensions
9. File all edges of drawer slot Hand files, belt sanders

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10. Join all pieces of drawer slot PVA glue, nails, hammer, spirit level
11. Join drawer slot to main body PVA glue, nail gun

12. File all edges of main body + drawer slot Hand files, belt sander
13. Mark all pieces of pine to exact dimensions of Pinewood, pencil, steel rule, tri square, marking
drawer gauge
14. Cutting all pieces to marked dimensions Band saw, coping saw
15. File all edges of drawer pieces Hand files, belt sanders
16. Join all pieces of drawer PVA glue, nails, hammer, spirit level
17. File all edges of drawer Hand files, vertical belt sander, horizontal belt sander
18. Mark all pieces of pine to exact dimensions of Pinewood, pencil, steel rule, tri square, marking
slider gauge
19. Cutting all pieces of pine for slider to marked Band saw, coping saw
dimensions
20. Preparing clothes dye Blue and black clothes dye, 2 plastic tubs, hot water
21. Coloring linen cloth in dye. Leave the linen Linen cloth, tub with hot water and 1 teaspoon of
cloth in the tub for 5 minutes. Dip only half of blue dye
the cloth in one color. Once dipped leave to
dry
22. Once dried. Color linen cloth in dye. Leave Linen cloth, tub with hot water and 1 teaspoon of
the linen cloth in the tub for 5 minutes. Dip black dye
only other half of the cloth in other color.
Once dipped leave to dry.
23 Marking dimensions of main body on linen Pencil, steel rule, tri square
cloth
24. Cutting linen cloth on marked dimensions Scissors, steel rule, cutter
25. Draw the design for the peg on Fusion 360 for Laptop
3D printing. Make sure all dimensions are
precise
26. 3D print 32 identical pegs 3D printer, Laptop
27. Creating model of drawer from clay. Once Terracotta clay, modelling needles and scalpels.
made, let it dry.
28. Create mold out of silicone from the clay Two-part silicone, acrylic sheets, and clay model
model with the model inside. Let it to cure.
Make sure there is an opening to pour the
aluminum.
29. Cut open the mold to remove the clay model. Cutter, Silicone mold, Clay model.
Make sure the mold is untouched.
30. Melt scrap aluminum pieces in metal melting Metal furnace, scrap aluminum pieces, propane
furnace torches
31. Pour melted aluminum into silicone mold Crucible, metal furnace, silicone mold,
from the crucible. Once poured, seal the
silicone mold firmly to avoid any leakage.
32. Open the mold to remove the aluminum Tub of cold water, aluminum casting, silicone mold,
casting. Place the casting in cold water for cutter, thick gloves (safety)
some time.
33. Clean the drawer handle casting. Wire brush, water, and metal wool.
34. Stain main body and drawer (light coat) with Walnut wood stain, and a spare cloth
a spare cloth

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35. Apply varnish on main body and drawer with Varnish, and spare cloth
a spare cloth
36. Stain slider (heavy coat) with a spare cloth Walnut wood stain, and spare cloth
37. Apply varnish on slider with a spare cloth Varnish, and spare cloth
Gantt Chart

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Flow Chart

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Strand (ii): Manufacturing Process

Step Photograph Process

1. To mark my pieces of MDF, I used a tri square, steel rule,
pencil, and my laptop for referencing. Firstly, I marked the
datum of my piece of MDF so that it is easier and more
accurate when I continue marking. I marked the dimensions
of the main body of my product. I used 1cm thick MDF for
all the woodworking processes.

2. To cut the pieces, I used a band saw for cutting the MDF
pieces. I made sure to cut roughly 1 or 2mm away from the
line to make sure I get accurate pieces. Once cut on the band
saw, I used a belt sander to sand to the line marked
previously. This process was fairly easier since I knew
exactly where to stop sanding, and this gave me accurate
dimensions for all pieces.

3. Once all the pieces were joined, it was time to start painting
all the components of my product. The main body of the
product was painted brown in order to give the product a
woody look, and the drawer itself was painted with a mixture
of brown and gold making a bronze shade. This will help
give the product a different look and provide some contrast
as well. I made sure that the paint was done well, in order to
do so, I used the paint and made sure to dip the tip of the
brush in water so that the paint isn’t too thick. Also, I made
sure to make even strokes so that once the paint has dried,
the surface looks smooth.
4. Once the main body was joint and painted, it was time for
me to make the slider. In order to do so, I had to first make
the grooves that will hold the slider itself. To make the
grooves, I used a 1cm by 1cm strip of MDF and used the
circular saw to make a groove of 4mm height. This was done
by lower the circular saw so that the saw cuts halfway
through the wood. After the grooves were made, I joined
them on the main body with PVA glue. The grooves would
go on the sides of the main body and the far end side. Once
this was done, I used a 4mm thick MDF piece of wood and
marked it to the correct dimensions, and then cut it. Once cut
I also painted it with the same brown color.

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5. Once the drawer was made, I bought a drawer handle from a

local hardware store for Rs. 90 only. This handle was made
entirely from metal. The body of the handle was made from
cast iron and the handle itself was made out of stainless steel.
The handle was 4in long and 3in wide. To join the handle, I
used a simple nut and bolt since I was not able to find the
perfect kind of screws. Before joining the handle, I marked
the center of the drawer face with respect to the dimensions
of the handle. I used a screwdriver to screw the handle in
place and then used a saw to cut off excess screw.

6. Once all the woodworking was complete, I started working

on the fabric. I bought 1m linen-cotton cloth from a nearby
textiles shop, where I got it for Rs. 285 only. I got the dye
from my father’s office since he too is involved in the
textiles industry, I got a orange color dye and a grey color
dye since that was the color combination that I decided on.
To prepare the dye for the process, firstly, I poured some
water into a kettle and heated the water. For the process to
go successfully I had to make sure that the water is
extremely hot. I then poured the water into a mug and poured
very little of my orange dye into the water. I stirred it for a
while to make sure that the color is well mixed
7. Once the dye was prepared, I stacked the fabric together so
that the fabric catches the dye evenly, then I tied the other
end of the fabric with a rubber band and then dipped the
fabric into the dye. I let the fabric sit in the dye for roughly 2
minutes so that the fabric absorbs the color well. Once that
was done, I lifted the fabric out of the dye and let it drip for a
while until the fabric stops dripping. Once that was done, I
used the heat gun to dry the fabric a little bit, and then
repeated the same process with the grey color. I made sure
that both colors are making significant contact and are
mixing to some extent.
8. Once the fabric was dried, I decided to use paper fusing so
that the fabric is stiff and doesn’t wrinkle when I stick it onto
my wooden main body. To start paper fusing, firstly I took
some fuse paper and placed it on my fabric. I made sure that
the sticky side of the fuse paper on my fabric, and I began
ironing the non-sticky side of the paper. The iron was set to
maximum heat and I ironed the entire fabric. I also had to
make sure that there were no air bubbles as well. To remove
the air bubbles, I kept ironing over the bubbles. I stopped
once the fabric was completely stuck to the paper, and the
fabric was stiff.

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10. While the product is being 3D printed, I began to apply some
varnish on each of the components to protect the paint and
also to give the product a glossy effect. This was a fairly
easy process and didn’t take too much time either. I made
sure that the varnish was applied in even coats avoiding any
unnecessary drips that may spoil the entire look of the
product.

11. Once all the components were made, it was time to start
making the pegs for the game. I used Fusion 360 for the
design of the pegs itself. I changed the dimensions of the peg
from 5cm to 3cm so that all the pegs can fit inside the drawer
and since a 5cm peg would take relatively more time than
the 3cm one. I made sure that there were exactly 32 pegs,
and I arranged them in rectangle so that it is easier to 3D
print. Once the design was done, I sent the file for 3D
printing.
12. Once the design was made, I sent the file for 3D printing.
However, I had to change the layout for all my pegs and
change it to smaller groups, this way the process will take
minimal time. I had to make sure that the pegs were arranged
in a circular layout as well. Once the layouts were finalized,
I decided to make the pegs out of white filament, simply
because I can later spray paint the color of my choice.

13. Once the fabric had dried completely, I had to mark the
fabric according to the dimensions of the sides of the main
body of my product. I made sure that the area I was marking
had a perfect blend of both colors. The dimensions had to be
accurate as well. I made sure that the fabric was 5cm tall and
would go along the base of the main body. Once I marked
the dimensions for the main strip onto the fabric, I drew
another line roughly 2cm above each of two lines previously
drawn. This was to help me understand where I must fold the
fabric. This was an imperative part of the process since this
helped me give the fabric a clean finish. To stick the fabric
onto the main body, I used some Spray Adhesive and let the
fabric to dry

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Strand (iii): Solution

Strand (iv): Changes made to my solution

During the manufacturing process, I had to make a few changes to my product. One of the biggest changes
made in the process was the switch from pinewood to MDF. This was inevitable since I was not able to find a
sufficient number of pieces of pinewood. The initial plan was to make the entire product out of pine and then
stain it to emphasize on features like the grains of the wood itself, but due to availability issues, I had to switch
to MDF. I decided to paint the wood brown so that I can still keep the color of wood and brown would also look
subtle in my client’s room. Another noticeable change is the drawer handle. I has previously planned that I
would make my own handle with aluminum, but due to lack of time and experience in the field, I decided to
buy a handle from a local hardware store. I made sure that the handle was economic, which meant that it would
have to be strong/durable and cheap. I finally bought the handle shown in the pictures above, I chose this handle
simply because it matched my products colors and I was told that it was extremely durable, hence I bought this
for Rs. 90 only. Another change that I made to my initial idea was the use of the fabric. I had initially decided
that I would completely wrap the fabric around the sides of the product, however, after giving it some thought I
realized that if I were to wrap it entirely, I would be hiding a large portion of the wood like aesthetic of the
product. Which is why I finally decided to only cut a short strip of the fabric and stick to the lower half of the
main body.

Criteria D: Evaluating
Strand (i):
Reflection
For this project, I started off with the idea of making a desktop game that my client could when he was taking a short
break during his office hours. I aimed to make this product as ergonomically friendly as possible and made sure that my
client use it without any difficulties or complications. Both my client and I were really happy with how the product turned
out to be, since it is exactly how we imagined it to during the design stage of this project. While the product looks finished
and clean, I had to make several changes during the manufacturing process due to various factors. One of the main factors
for such changes was the fact that I was not able to source all the right materials due to availability, time constraints and
lack of experience in the process. However, I have displayed various skills while manufacturing my product, and this

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helped me achieve the desired result. For example, I have been able work on fabric and learnt a plethora of skills that I can
use in future projects, some of those skills include paper fusing and dip dying. Apart from working with fabric, I was also
fortunate enough to use the 3D printer for the first time. Although my 3D model isn’t as complex, I was still able to learn
about using software like Fusion 360. With this newly found skill, I can now make even more models that can be printed
in future projects. Apart from learning new skills, I was also able work on my woodworking techniques that I learnt in my
previous years of doing this subject. As I worked on this project, I got better in woodworking and now I am able to
manufacture more quality products in a limited amount of time.

Testing Methods
In order to check whether the product functions properly without any complications, I have come up with a variety of
testing methods that ensure the product’s functionality. This is an imperative stage in the design cycle since it gives the
client a sense of guarantee and he/she can use the product without any hesitations. To test the product effectively, I will
require evaluation by myself, my client, and the target audience. By doing so, I will get multiple perspectives on my
product and I will also be to understand what my client feels about my product.

Questionnaire Results (see Appendix D for full survey)

Analysis of Testing
After conducting the survey, I was able to
identify few possible changes that could have
been made in the product. For example, some
pointed out the overall size of the product
could have been bigger, whereas some said
that the colour scheme could have been
better. Some also mentioned that the fabric
work could have been more clean and could
have used different colours. Apart from the
changes, the survey also showed that such a
concept would increase productivity
according to the respondents of the survey.
The overall rating for the product itself, is
pretty good with 6 people of 15 giving the
product a 8, 9 or 10. Some people did not like
the fabric work done on the product since we
have a few 5s and one 4.

Strand (ii)

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Changes made to my solution

During this process of manufacturing, I aimed to keep as much of my original design as possible. However,
some changes had to be made due to various factors like availability and lack of time. One of the main changes
made to the solution was the base material itself. I had initially planned to make the entire product out of
pinewood since it would look more natural with the grains, however, pinewood was hard to find in such great
quantity. Mainly because my solution required a lot of different parts of pine to joined together. Also, another
problem I encountered with a big pine slab was that this wood tends to bend a lot. One of the reasons behind
this is because when it is cut into big slabs of pine, the wood is relatively wet, and once it is stored, the wood
begins to warp along the grains as the wood dries out. This meant that I could not use pine and I had to switch
to using MDF. MDF was cheap, very accessible and easy to work with. Hence, I decided to make the entire
product out of MDF. Once the materials were sorted out, I had to find a big block of MDF. Unfortunately, I was
unable to find the block, and I had to resort to making a box out of 1cm thick MDF. I used simple butt joints
with PVA glue and nails for the same. This in turn meant that the box would be hollow, hence I had to drill all
the way through the top piece of wood for the main body. This was also a change since I previously thought of
drill only a 2cm deep hole into the block of wood. Another change I made to my solution was the drawer
handle. Initially, I had planned to make my own handle out of aluminium via casting with silicone, but due to
the shortage of time and resources, I had to resort to buying a handle from a local hardware store. One of the
main reasons as to why I was not able to make my own handle was because finding scrap aluminium was
extremely difficult and the silicone casting would take a lot of time. This was fair more easier since now I only
had to screw the handle into the drawer. Apart from all of this, I also had to change the size of my pegs. Simply
because a 5cm tall peg was too big to fit in the drawer itself and also because 32 pegs and 5cm each would take
a lot of time in 3D printing. Hence, I ended up with a 3cm peg. Since the height of the peg was changed, the
other parts of it would also have to change, for example, the upper surface of my peg had to changed from a
diameter of 5cm to a diameter of 3cm and the lower part of my peg which goes into the holes also changed from
2cm to 1cm. This was also done because a 2cm diameter hole would not be able to fit properly with sufficient
spacing the top of the main body. Hence the holes drilled were also changed to 1cm diameter holes. Towards
the end of my project, I made one final change to the final product. Instead of wrapping all sides of my product
I decided to cut a thin strip of the fabric that shows a balance mix of both colours and stuck it to the lower half
of the three sides of the body of the product. This decision was taken entirely for aesthetics. This was to bring
the features of the wood colour and the fabric work equally.
Analysis of Success of Product

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Strand (iii)
Revised Gantt Chart After Manufacturing (Timeline Comparison)

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Timeframe Changes Justified

When comparing both Gantt charts, there are some areas where I had spent more time than required and that
resulted in an extension of the number of hours previously decided. In my first Gantt chart (see page 25), I had
planned to make my product in a total of 8 hours in the manufacturing, however due to various factors, I ended
up finishing the product in 9 working hours. One of the main reasons for this extension, is because of the fact
that I had to create a box like structure which was made using butt joints for my main body whereas during the
planning stages I had decided to use a solid 10cm tall box and then drill holes in them. This process took more
time than anticipated since I now had to cut individual pieces for the sides and join them together. However, by
doing so, I was able to cut down the overall weight of the product significantly, hence making my product more
ergonomically friendly. Another stage of the manufacturing process that took most of my time was creating the
drawer and the drawer slot. The main reason for as to why this took so much time, was simply because I faced a
lot of problem making the drawer fit into the drawer slot. After creating the drawer and the drawer slot, I had to
sand the sides of the drawer multiple times to make sure it fits smoothly into the slot. I also had to keep
repeating this step since I also had to make that the drawer can go in and out smoothly without any difficulties.
Apart from the woodworking, another stage that took more time than expected was the 3D printing process.
Although my design was simple, I needed 32 identical pieces, this took a few extra hours. However, I was able
to multitask, so while the pegs were being 3D printed, I began working on the fabric. Fortunately, the fabric
work did not take any extra time and came out well.
Improvements Justified
Improvements made during manufacturing
As mentioned earlier, during the manufacturing process, certain changes were made. Most of these changes
were made as improvements to the initial design idea. Various components of the product have been improved,
however, I tried to keep the changes as subtle as possible and as close to the initial design as well. For example,
one of the key improvements made to the product is the fabric itself. In my initial design, I decided to wrap the
fabric completely across the sides of the product. However, while working on the fabric I had realised that it
would be better to only cut out a short strip of the fabric in order to highlight the colour of the main body. This
way, there is a clear contrast between the bright colours of the fabric and the subtle colour of the main body.
Another key improvement made to the product is the size of the peg itself. I had previously decided that the peg
would be 5cm tall and the wide part of the peg would also be 5cm in diameter. However, I soon realized that,
the width of my drawer is not as much, and hence I will have to decrease the overall height of the peg itself.
This was an improvement since by doing so, I can now save much more space for office supplies as well.
Possible improvements after manufacturing and testing
After testing the product via a variety of methods like questionnaires, interviews, self-evaluation etc. There
were a few components of the product which could have been better. These components could have been
finished better or perhaps made in a different way as well. One such area of improvement is the colour of the
product. Although my specifications asked for a subtle colour scheme, I could have used a larger variety of
subtle colours since the product currently looks slightly monotonous. This was also pointed out during the
questionnaire, as a large number of the respondents said they would have wanted a better colour scheme.
Perhaps even using a different type of wood could have also solved this problem. Using a wood like pine,
would bring a natural tone to the product which looks extremely aesthetically pleasing. Another possible
improvement pointed out during the questionnaire and by my client the overall size of the product, more
specifically the drawer itself. My client’s only problem with the product was the size of the drawer, my client
pointed out that the drawer has very limited space and may not be able to hold most of his office supplies.

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Perhaps a possible improvement which I could make to the drawer, is that I could make compartments within
the drawer itself so that it looks more organized.

Strand (iv)
Solution Impact on Client/TA
After showing the product to my client, I was able to get an insight on what my client feels about this project. In
previous stages I had only shared the pictures of the product with him, but now I have given the product with a
all 32 pegs and all components of the product. I gave my client 1 week to test the product, and use the product,
so that both my client and I are clear on the impact that it is creating. After 1 week, I spoke to my client to talk
about his experience using the product, and I was glad to hear that my client did not have too much of a
problem while using the product. My client was able to use the product in multiple occasions and said that it
was a great stress buster. He also said that “I usually don’t take too many breaks, but thanks to this product, I
am encouraged to take casual breaks and by doing so I am much more relaxed and stress-free during work
hours”. I was extremely glad to hear such comments since my aim behind creating this product was to
encourage my client to take casual breaks and to help him work without too much stress. My client also shared
that his colleagues were also highly impressed by the product and often he would have some of his employees
come to his table during lunch to play the game. The game itself was also appreciated by my client, as he
mentioned that the game was the perfect type because it was not too distracting, yet it was a good brain booster.
Playing the game helped the workers and my client to be more focused during work hours. Also, my client had
told me that the he was able to solve the game a few times, and he believes he knows the trick to it, however, he
said that it still is just as exciting when you solve it every time. My client also appreciated the fabric work on
the product, and he too believed that putting a short strip was a better idea than wrapping it completely. He was
also able to tell about the few things that could have been done better in the fabric work and told me that I will
have to create more unique patterns and show it to him in the near future. In conclusion, I am very happy to
know that the product has worked and is helping my client in such ways. Also, I am also happy to hear that my
client being an expert in the fashion industry, appreciated my effort in dip-dying, and says he would like to see
more patterns from me in the future.

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Appendices
Appendix A

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Appendix B

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Appendix C

*The other questions are similar to ones above,

with only a different picture in each question.

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Appendix D

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