PRODUCT DESIGN CASE STUDIES Sahil Karkhanis Copyright ©2010
List of Case Studies
1
ZeeSaw Oscillator
4
Cybernetyx Manta Ray
7
ErgoFit CTS Diagnostic Tool
Product specification & design for an India based manufacturer of surgical equipment.
Portable, multi-touch interactive surface. Grounds-up design and development for a technology start-up.
Design, engineering and patentability research for a Texas-based technology start-up.
2
Accumax ‘Smart’ Micropipette
5
Andslite AA LED Torch
8
Nomad Vacuum Flask
Design & development of an all-new mechanical micropipette for the American & European markets. Grounds-up design, engineering & patentability research.
Design and engineering of a low-cost LED torch light for the urban Indian market.
Self-initiated concept product- an insulated vacuum flask for hikers, trekkers & other outdoors people.
3
Quickshaw
6
Boutique Microbrewery
9
Teaching Design
Design & development of a low-cost, human-powered waste transport solution for the Ahmedabad Municipal Corporation.
Design, styling & engineering of a boutique microbrewery for a global category leader looking to enter India.
A look into my methodology, experiences and learnings, teaching design to post-graduate students.
PRODUCT DESIGN CASE STUDIES ©2010 Sahil Karkhanis
Role Freelance Designer (Solo)
Responsibility Project planning, research, design, testing, prototyping supervision
CASE STUDY 1 ZeeSaw Oscillator
Sagittal Saw for Orthopedic Surgery
CASE STUDY 1 ZeeSaw Oscillator
PROCESS OVERVIEW Brief
Research
Insights
Ideation
Observation
Documentation
Prelim Engg
Conversation
Detailing
CAD + Engg
Prototyping
Prototype
Evaluation
PRODUCT DESIGN CASE STUDIES Š2010 Sahil Karkhanis
CASE STUDY 1 ZeeSaw Oscillator
BRIEF › BEGINNINGS Client Expectations Foreign competition is getting cheaper & better; How do we maintain our edge? Primarily a mechanical design issue which may be addressed by smart engineering. Looking at user needs may provide a key to product differentiation.
Market Imperatives Better feature set required Wrench-less chuck Wrench-less drive connector Two-way trigger action
User Needs Frequent complaints of wrist fatigue from long-time users of product.
PRODUCT DESIGN CASE STUDIES ©2010 Sahil Karkhanis
CASE STUDY 1 ZeeSaw Oscillator
RESEARCH › INSIGHT Observation Direct observation of various types of joint replacement surgeries and different scenarios where the sagittal saw is used.
Key Insight | Two Handed Use Consistently, it was observed that most surgeons used a two-handed grip when using a sagittal saw. It is an awkward grip since the instrument is designed to be compact and meant to be held in a pistol-grip.
Documentation Meticulous video & photo documentation of relevant surgical procedures, preparatory procedures & points of note.
Conversation Rigorous follow-ups with surgeons using documentary evidence as conversation starters.
PRODUCT DESIGN CASE STUDIES Š2010 Sahil Karkhanis
CASE STUDY 1 ZeeSaw Oscillator
IDEATION
Problem Redefined | Physical demands of task should drive design
Observing Parallel Tasks Observing similar tasks with other hand tools showed a similar two-handed grip. One hand provides the precision to locate the tool and the other provides power to make the cuts.
Rapid Ideation A number of different product configurations were explored that could provide the vital, two-handed grip. This would also differentiate the products from the competition, almost all of which utilise the one-handed pistol grip.
PRODUCT DESIGN CASE STUDIES Š2010 Sahil Karkhanis
CASE STUDY 1 ZeeSaw Oscillator
PROTOTYPE › EVALUATION Prototype Early; Prototype Often Quick prototypes were created using thermocol with steel inserts that effectively simulated various grips, configurations and mimicked weight distribution of the actual product.
Concept Evaluation The prototypes were tested extensively by volunteer surgeons who provided realtime feedback. This was useful in creating rapid iterations that incorporated the feedback elements and could be tested again.
PRODUCT DESIGN CASE STUDIES ©2010 Sahil Karkhanis
CASE STUDY 1 ZeeSaw Oscillator
DETAILING › ENGINEERING Ergonomic Issues Tackled Physical Dimensions & Configuration Weight & Weight Distribution Criticality of Interface Elements (Trigger, Lock, Mounts, Chuck)
Mechanical Issues Tackled Wrench-less Chuck (Quicker, Faster Blade Changing) 360° Chuck Rotation (Flexible Cutting Angle) Body Incorporates a Muffler (Silent Operation)
SLS Prototypes To Validate Form & Fit PRODUCT DESIGN CASE STUDIES ©2010 Sahil Karkhanis
CASE STUDY 1 ZeeSaw Oscillator
FINISHED PRODUCT
Key Differentiator Product configuration is better suited to the physical demands of the task. Rather than aiming to be compact, it aims to be usable. The new configuration also aims to be physiologically more comfortable over longer times.
PRODUCT DESIGN CASE STUDIES Š2010 Sahil Karkhanis
Role Product Development Team Lead
Responsibility Project planning, research, design, testing, engineering & prototyping supervision
CASE STUDY 2 Accumax Smart
Professional Mechanical Micropipette
CASE STUDY 2 Accumax Smart Micropipette
PROCESS OVERVIEW Brief
Research
Insights
Ideation
Product Audit/ Patentability
Benchmarking
Prelim Engg
User Observation
Detailing
Prototype
CAD + Engg
Prototyping
Patent Audit
Evaluation
PRODUCT DESIGN CASE STUDIES Š2010 Sahil Karkhanis
CASE STUDY 2 Accumax Smart Micropipette
BRIEF › BEGINNINGS Client Expectations Patentable design. Not the next generation of his existing product, but an entirely new product grounds-up. Client expectations & market imperatives are very much in tune with each other. Usability is a key to product success in a market of many variants & many promises.
Market Imperatives Cost competitive and feature competitive in an over-crowded marketplace.
User Needs Professional product needs to be ergonomically comfortable and should allow one-handed use over long periods of time.
PRODUCT DESIGN CASE STUDIES Š2010 Sahil Karkhanis
CASE STUDY 2 Accumax Smart Micropipette
RESEARCH Product Audit + Benchmarking Comprehensive, component level audit of existing product, SWOT analysis and benchmarking with the most important competitors internationally.
Forces & Angles
Pipetting Geometry
Benchmarked Attributes
Grip Geometry
Pipetting Force & Angle Blowout Force & Angle Ejection Force & Angle Adjust-Pipette-Eject Geometry Counter Adjust Action Pipetting & Ejecting Action Physical Dimensions Weight & Weight Distributions Counter Readability
PRODUCT DESIGN CASE STUDIES Š2010 Sahil Karkhanis
CASE STUDY 2 Accumax Smart Micropipette
USER › INSIGHT
Key Insight | Optimise Thumb & Wrist Movement
User Observation Detailed observation & documentation of lab technicians in India, Germany & Finland. Close to 400 data points collected & analysed.
PRODUCT DESIGN CASE STUDIES ©2010 Sahil Karkhanis
CASE STUDY 2 Accumax Smart Micropipette
PRELIM ENGG › PHYSIOLOGY Prelim CAD Template A preliminary CAD template was created based on collected insights, established benchmarks and patentability requirements. This served as the basic iterative model.
Physiological Data Points Physiological data points were collected to establish criticality of product dimensions, weight, weight distribution and sizes of various interface elements (trigger, knob, buttons). Plasticine grip models & fingertap prints allowed quick collection of data.
PRODUCT DESIGN CASE STUDIES Š2010 Sahil Karkhanis
CASE STUDY 2 Accumax Smart Micropipette
IDEATION
Concept Sketches A number of directions were explored as sketches and the most promising of these were validated in CAD and as foam mock-ups. Production & ergonomic feasibility were prime considerations.
PRODUCT DESIGN CASE STUDIES Š2010 Sahil Karkhanis
CASE STUDY 2 Accumax Smart Micropipette
DETAILING › ENGINEERING Outer Body
Counter Adjust Knob
Plunger Assembly Tip Eject Button Inner Body
Counter Lock Button Counter
Tip Eject Assembly PRODUCT DESIGN CASE STUDIES ©2010 Sahil Karkhanis
CASE STUDY 2 Accumax Smart Micropipette
FINISHED PRODUCT
Key Differentiators Ergonomically more comfortable. Patented mechanisms make it more accurate and reliable. Smart engineering also ensures it’s cheaper to make and assemble.
PRODUCT DESIGN CASE STUDIES ©2010 Sahil Karkhanis
Role Freelance Designer (Solo)
Responsibility Project planning, research, design, testing, prototyping supervision
CASE STUDY 3 Quickshaw
Waste Transport Solution for Ahmedabad Municipal Corporation
CASE STUDY 3 Quickshaw Waste Transport
PROCESS OVERVIEW Brief
Research
User Observation
Insights
Ideation
Prototype
Detailing
CAD + Engg
Prototyping
Evaluation
Environment Observation
PRODUCT DESIGN CASE STUDIES Š2010 Sahil Karkhanis
CASE STUDY 3 Quickshaw Waste Transport
BRIEF › BEGINNINGS Client Expectations Client expectations & market imperatives are very much in tune with each other.
A viable, cheap to produce, manual waste transport solution for high-density urban areas. Capable of transporting 500 liters of garbage in one go.
User needs are NOT a high priority for the client. To accommodate the user, cost must be kept to a minimum.
Market Imperatives Very low cost and extremely easy to manufacture at a local level.
User Needs Make it physically less demanding for the target user- the daily-wage unskilled labourer.
PRODUCT DESIGN CASE STUDIES Š2010 Sahil Karkhanis
CASE STUDY 3 Quickshaw Waste Transport
RESEARCH
Key Insight | Women Work Through Their Pregnancy
Women Garbage Collectors Majority of the workers are women who work throughout their pregnancy since a day spent absent means a day without wage for them.
PRODUCT DESIGN CASE STUDIES Š2010 Sahil Karkhanis
CASE STUDY 3 Quickshaw Waste Transport
RESEARCH › ENVIRONMENT
Narrow Lanes + High Population Density The area to be serviced is characterised by narrow lanes and an extremely high population density. Most parts of old Ahmedabad are home to narrow lanes that do not admit anything larger than a three-wheeler. This needed to be part of the solution.
PRODUCT DESIGN CASE STUDIES ©2010 Sahil Karkhanis
CASE STUDY 3 Quickshaw Waste Transport
IDEATION
Problem Redefined | Human powered, 3-wheeler, 500 liter capacity, pregnant-women-friendly
Concept Sketches Rapid exploration of possible solutions in sketch form. The first prototype was built directly from concept sketches with improvements and modifications being made on the fly. This helped us cut down the development time considerably.
PRODUCT DESIGN CASE STUDIES Š2010 Sahil Karkhanis
CASE STUDY 3 Quickshaw Waste Transport
PROTOTYPE › EVALUATION Prototypes A total of three iterative prototypes were made on a modified cycle-rickshaw chassis. All three featured twin tilt-bins of 250 liter capacity each but each employed a different tilt mechanism. All three were extensively tested with the targeted user group as well as with test rig hacks.
Concept Evaluation Three different tilt mechanisms were tested- pneumatic, worm & worm gear, winch and pulley. Mock scenarios were created and target users were asked to evaluate each of the three. The tilt bins were mocked up in plywood and FRP to keep costs low. The product was created on a standard cycle rickshaw chassis with minimum modifications.
PRODUCT DESIGN CASE STUDIES ©2010 Sahil Karkhanis
CASE STUDY 3 Quickshaw Waste Transport
FINISHED PRODUCT
Key Differentiators Narrow track width allows the Quickshaw to be maneuvered in narrow lanes. Low-cost steel fabrication on a standard cycle-rickshaw chassis. Low-cost rotomoulded tilt bins. Design can be easily copied and fabricated at a local level using minimally skilled labour. Winch & pulley tilt mechanism makes it easy to load and unload the tilt bins.
PRODUCT DESIGN CASE STUDIES Š2010 Sahil Karkhanis
More Case Studies To be shown in person
Cybernetyx Manta Ray
Andslite AA LED Torch
Boutique Microbrewery
Portable, multi-touch interactive surface. Grounds-up design and development for a technology start-up.
Design and engineering of a low-cost LED torch light for the urban Indian market.
Design, styling & engineering of a boutique microbrewery for a global category leader looking to enter India.
ErgoFit CTS Diagnostic Tool
Nomad Vacuum Flask
Teaching Design
Design, engineering and patentability research for a Texasbased technology start-up.
Self-initiated concept product- an insulated vacuum flask for hikers, trekkers & other outdoors people.
A look into my methodology, experiences and learnings, teaching design to post-graduate students.
PRODUCT DESIGN CASE STUDIES Š2010 Sahil Karkhanis