SYSTEM

DESIGN
STO RAGE OF
GROUP
MEMBERS B OBB IN
SAUFI RASMAN

(GROUP 6)

AIMAN ALIAS
AMIRSUFIAN

NOORFARAHAIN
NUR NABILAH
NURUL FAZIERA

OUTLINE
S

INTRODUCTION

BACKGROUND OF STUDY
DESIGN PROCESS
PRODUCT DESIGN SPECIFICATION (PDS)
MORPHOLOGY CHART
CONCEPTS SELECTION
SCORING OF CONCEPTS
FINAL CONCEPT
DFMA
FMEA
ENGINEERING ANALYSIS
SOLIDWORK

INTRODUCTI
ON
KISWIRE (client) company which company produced
wire rope.
Having problems at three phases of production line of
wire rope which is :
Wire rope coating (Design 1)
Bobbin transfer (Design 2)
Storage of wire rope (Design 3)
All production line have their own specification.
Task: Required to design one of the process based on
KISWIRE specification and objectives.

E NGINEE RING
D ESIGN PR OCESS

BACKGROUND OF
STUDY
KISWIRE is the
company that located
based on South Korea
and establish since
1945
Wire rope is
made up of single
wire where they
are stranded to
become a strand.
To be a complete
wire rope, All the
strands are
twisted and they
will become wire
rope.

OVERVIEW OF
STUDY

Wire Rope application:

crane application, tower
crane, crane industries
and offshore industries.
Each of this type of wire
rope has their own design
and formation.

KISWIRE factory
has their own
product and
manufacturing
process. One of
this company
produce is Wire
Rope.

M A N U FA C T U R I N G O F
WIRE ROPE

Wire Rope

Stranding

Closing

Surface
Treatment

2nd
Drawing

Wire Rope

1st
Drawing

Patenting

STORAGE OF
BOBBIN WIRE
ROPE
(DESIGN 3)

LAYOUT DESIGN
3
Storage room

Trolle
y

From
previous
process

new
bobbin
g

in
Storage space

Rail

out

To next
process

ROOM DIMENSION

New
bobbing

Level 1

Level 2

1 2
1

Difference wire
specification

4
Floor

Parameters

PR OD UCT D ESIG N
SPECIF ICATIO N (PD
S)
Design
Description

To create bobbin storage

mechanism

Kiswire Company has a

problem about arranging
bobbin in their factory .
They give us the dimension
of the storage to minimize
the space and require to
use mechanical
mechanism.

The bobbin can store in two

levels and the system is
first in ,first out.

Karakuri concept and Pulley

mechanism are applied to
the bobbin storage .

Karakuri concept is the

system that moves
automatically without any
work from the human while
pulley mechanism is used
to lift the platform up and

1.Problem

2.Performance

The storage can store the

bobbin with four different
types of wire rope.

3.Size of Design

Storage
Height : 2000mm
Length : 4275mm
Width : 1090mm

Platform
Width : 885mm
Length : 870mm
Thickness : 50mm

Bobbin
525mm
760mm
435mm

435m
m

Solid bar

50x50mm

525m
m

760mm


4.Cost of Design

RM 500,000.00

5.Finishing

Coated

6. Material

1.
2.
3.
4.
5.
6.
7.

7.Aesthetic

Toughness
Strengths
Hardness
Corrosion resistance
Formability
Weldability
Ductility

Robust , firm , reliable

Our selection of the

material for this product is
alloy steel.

Coated to avoid corrosion

problem.


8.Customer

KISWIRE SDN BHD Company

9.Product life span

10 years

10.Standard /
Specification

11.Reliability

( 1 probability of failure) x
Will be evaluated in FMEA
100%
analysis

The ability of the system to

function understated condition
under a specific period of time.

Max 3% failure rate over service

life

According to the usage with

the proper techniques.

To be checked


12. Safety

13.Environment

14. Testing

Should not have sharp

projection.

Bobbin must move follow the

path/platform

The movement of the bobbin

must not effect people at the
surrounding

Factory environment

Solidwork software:
Motion analysis
Simulation ( Max. stress, factor of safety, displacement,
materials, cost)

CONCEPT
GENERATION
MORPHOLOGICAL
CHART

CONCEPT
SELECTION
CONCEPT 1

CONCEPT 2

CONCEPT 3

CONCEPT 4

CONCEPT 5

CONCEPT 6

SCORING OF
CONCEPTS

FINAL CONCEPT

Final design after improvement from selection of concept

based on scoring of concepts
Improve at parts which have low scoring

DFMA
Stands for Design for Manufacturing and Assembly
(DFMA)
Technique which used to minimize product
through design and process improvements

cost

Concerned with reducing overall part production cost

Design of products that will transition to production:
At minimum cost
Focus on the numbers of parts
Handling and ease of assembly

FUNCTIONAL ASSESSMENT

To eliminates or combine of functional

components which have low function
Start to choosing the a functional components that
critical to the system

FUNCTIONAL ASSESSMENT
Number
Of
component
1
2
3
4
5
6
7
8
9
10
11
12
13
14

Component

Back plate
Vertical pole
Main horizontal pole
Plate blocker pole
Plate blocker
Vertical pole hollow
Horizontal pole left
Horizontal pole right
Horizontal pole right(below)
Horizontal pole left(below)
Horizontal pole below
Horizontal pole below(below)
Roof
Roller

Type of
component
(A=Essential)
(B=NonEssential
A
B
B
A
A
A
A
A
A
A
B
B
B
A

CONTINUE..
15

Roller case

16

Blocker

17

Weightage 1

18

Spring

19

Spring cover

20

Spring plate

21

Weightage 2

22

Spring pole

23

Pulley

24

Weight blocker

25

blocker

26

Bolt & nut

27

Lock

28

Door

29

Bearing

30

Screw

IM PR OVE ME NT
1) Vertical pole + Main horizontal pole + Roof = (one part)

2) Horizontal pole below + Blocker + Weight Blocker = (one

part)

DESIGN EFFECIENCY

Design efficiency based on overall parts

Design efficiency above 60 % can be consider as
the system can works well.

FMEA

No Function Affected Potential

Failure
Modes

Potential
Failure
Effects

Potential
Causes of
Failure

Recommen
ded Actions

Move the bobbin

High friction

Roller do not
move

Bobbin failure

Smooth
surface of
roller

Wall

Platform
number (4)
does not
function
properly

Movement not
smooth

Adjustment
on the wall
surface

Shaft

Shaft not
smooth

Bobbin failure

Adjust the
smoothness
of the shaft

Stop the bobbin

Elongation
Rope do not
work
properly

Out from the

pulley

Cannot block
the bobbin .The
bobbin will fall

Use suitable
measuremen
t of rope for
the
elongation

Spring do
not function
properly

Expansion and Platform not

compression
complete the
downward
movement

Use suitable
stiffness of
spring

ENGINEERING
ANALYSIS

SOLIDWORK
Overall Design
Motion Study
Simulation :
Maximum stress
Factor of safety
Materials
Displacement
Motion Analysis

THANK
YOU,FOR
YOUR FULL
ATTENTION
Q & A