APPLICA TION OF AXIOMATIC DESIGN CONCEPT ON IMPROVING LADDER FOR PEPPER HARVESTING
Ahmad Faizal B. Zaharuddin
Bachelor of Engineering with Honours
s
(Mechanical and Manufacturing System Engineering)695 2009
A286
2009
UNIVERSITI MALA YSIA SARA WAK
BORANG PENGESAHAN STATUS TESIS
Judul: DESIGN AND DEVELOPMENT OF PEPPER HARVESTER LADDER
SESI PENGAJIAN : 200812009
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1. Tesis adalah hakmilik Universiti Malaysia Sarawak.
2. Pusat Khidmat Maklurnat Akademik, Uni versiti Malaysia Sarawak dibenarkan membuat salinan untuk tujuan pengajian sahaja.
3. Membua( pendigitan lUltuk membanguankan Pangkaian Data Kandungan Tempatan .
4. Pusat Khidmat MakJumat Akademik, Uni versiti Malaysia Sarawak dibenarkan membuat salinan tesis ini sebagai bahan pertukaran antara institusi pengajian tinggi.
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APPROVAL SHEET
This project report attached here to, entitle "Design and Development of Pepper Harvester Ladder" prepared and submitted by AHMAD FAIZAL B.
ZAHARUDDIN as a partial fulfilment of the requirement for the degree of Bachelor of Engineering with Honours in Mechanical and Manufacturing is hereby read and approve by:
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APPLICATION OF AXIOMATIC DESIGN CONCEPT ON IMPROVING LADDER FOR PEPPER HARVESTING
AHMAD FAIZAL B. ZAHARUDDIN
This report is submitted in partial fulfillment ofthe requirements for the degree of Bachelor of Engineering with Honours
(Mechanical and Manufacturing Engineering)
Faculty of Engineering
VNIVERSITI MALAYSIA SARAW AK 2009
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ACKNOWLE DGEMENTS
Firstly, I would like to express my most gratitude to The God for giving me the opportunity to finish my final year project. I also would like to thanks to my project supelVisor, Mr. Aidil Azli Alias for the excellent guidance and encouragement for me. Thanks goes to my family for always being supportive and concemed about my work and to my friends who always help me and teaching me until I finish the project. Last but not least, I wish to extend my thank all mechanical and manufacturing statfthat give guidance and provide knowledge to finish my report.
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ABSTRAK
Di Sarawak, masih banyak lagi ladang dan kebun lada hitam menggunakan tangga sebagai alat untuk pernetikan dan penuian lada hilam. Harnpir sernua petani tradisional rnasih menggunakan tangga buatan sendiri untuk rnenolong rnereka mencapal bahagian-bahagian puncak pokok lada hitam. Konsep rekabentuk aksiomatis digunakan didalarn projek rnenghasilkan tangga baru untuk kegunaan pernetikan dan penuian hasil lada hitarn. Beberapa kebun dan ladang telah dilawati dan beberapa ternubual telah dijalankan kepada tuan dan pekerja di ladang lada hitam untuk rnengenalpasti rnasalah-masalah yang dihadapi ketika rnenggunakan tangga tradisional. Rekabentuk tangga baru dapat di cipta selepas rnasalah yang dihadapi dikenalpasti. Bermula dengan pengurnpulan rnaklurnat hinggalah ke rekabentuk terakhir yang rnenggunakan perisian jurutera, langkah diarnbil secara berhati-hati untuk rnernastikan setiap permasalahan dapat dikurnpul untuk rnenghasilkan rekabentuk terbaik. Beberapa pemcriksaan telah dijalankan untuk rnenentukan kekuatan rekabentuk tangga tersebut yang bergantung kepada bahan yang digunakan.
Tangga baru yang dicipta ini lebih senang dan sclarnat kepada pengguna dan juga menyediakan tangga dan bahagian belakang yang bolch diubah mengikut kesesuian tinggi untuk menjamin ianya lebih mudah dan berkesan kepada pengguna.
IV
ABSTRACT
In Sarawak, there are still many pepper fam1 and orchard using ladder as their tool in harvesting pepper benies. Most of the traditional fanners still lise handmade ladder in harvesting operation to assist them in reaching the higher portion of pepper tree. The application of axiomatic concept is used in this project to facilitate the designing process. Several fann and orchard was visited and interview was done to identify the problem when using the traditional handmade ladder during harvesting pepper berries. After problems identified, the new design of ladder was proposed to fulfill the user needs. From gathering infonnation until the final design using engineering software, the design phase was taken carefully to ensure every detail was taking into account in order to developing the best design. Several tests have been conducted to the design to estimate the strength of the product based on the material that was used. The new ladder is more user fuendly and safety to the users and also provide adjustab le stand and ladder to ensure it more easy and effective for the users.
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UNIVER.';1 fJ MALAYSIA SARAWAJ(
TABLE OF CONTENT
Page
List ofTables X
List of Figures XI
List ofAbbreviation Xll
Chapter 1 INTRODUCTION
1.1 Problem Statement 2
1.2 Aim and Objectives 3
Chapter 2 LITERATURE REVIEW
2.1 Introduction 4
2.2 Pepper Background 4
2.2. 1 Pepper History in Malaysia 5
2.2.2 Pepper in Sarawak 7
2.3 Pepper Cultivation 8
2.4 Problem and Constraint 10
2.5 Axiomatic Design 12
2.5.1 Domains 13
2.5.2 Axiomatic Product Development Lifecycle IS
Chapter 3 METHODOLOGY
3. I Introduction 19
3.2 Design Phases 19
3,3 Recognition 0 fneeds 21
3.3. 1 Customer needs 21
3.3.2 Input Constraint 22
VI
22 3.4 Product Design Specification
3.4.1 Quality Function Deployment 23
3.4.2 OSHA Standard Codes 24
3.5 Functional Reg uirement 25
3.6 Conceptualization 25
3.7 Concept Selection 26
3.8 Embodiment Design 26
3.8.1 Ergonomics 27
3.8.2 Configuration Design 27
3.8.3 Parametric Design 28
3.9 Detail Design 28
3.\0 Material Selection 29
3. I \ Cost Estimation 29
Chapter 4 RESULTS AND DISCUSSIONS
4.1 Introduction 31
4.2 Problem Identification 31
4.2.1 Objective Clari fication 32
4.2.2 Constraint 32
4.2.3 Customer Requirement 32
4.3 Design specification 33
4.3.1 HOllse ofQuality 34
4.4 Functional Requirements (FRs) 36
4.5 Concept Fa [mulalion 38
4.5.\ DPs tor Concept I 38
vu
4.5.2 DPs for Concept 2 39
4.5.3 DPs lor Concept 3 40
4.5.4 DPs for Concept 4 41
4.6 Concept Selection 42
4.6.1 Design Matrix for Concept 1 43
4.6.2 Design Matrix for Concept 2 43
4.6.3 Design Matrix for Concept 3 43
4.6.4 Design Matrix for Concept 4 44
4.6.5 The Best Concept 44
4.7 Concept Generation 45
4.7.1 The Second Law Hierarchy of FRs and DPs 47 4.7.2 The ThirdLaw Hierarchy ofFRs and DPs 49
4.8 Embodiment Design 50
4.9 Modeling and Analyzing 51
4.9.1 So lid Model 5 1
4.9.2 Analysis and Simulation Result 52
4.10 Detailed Design 57
4.11 Material Selection 58
4.11.1 Light Nonferrous Metals and Alloy 59
4.11.2 Material Specification 59
4.12 Final Design 60
4.12.1 Design Spcci fication 61
4.1 3 Matelial Cost Estimation 62
4.14 Discussion 63
Vlll
Chapter 5 CONCLUSION AND RECOMMENDATION
5.1 SummaIY 66
5.2 Recommendation 67
REFERENCES
APPENDIX A APPENDIX B APPENDIX C APPENDIX D APPENDIX E APPENDIX F APPENDIX G APPENDIX H
IX
LIST OF TABLES
Table Page
2.1 APDL Domain contents 16
4.1 List of customer requirement 33
4.2 FRs for harvest Ladder 37
43 DPs for Concept 1 38
4.4 DPs for Concept 2 39
4.5 DPs for Concept 3 40
4.6 DPs for Concept 4 41
4.7 2nd Level of FRs and DPs 48
4.8 Material Infonnation 53
4.9 Structural results 53
4.10 Material InfOlmation 55
4.11 Structural results 55
4.12 List of Material 60
4.13 Design specification for the ladder 61
4.14 Material Cost Estim~tion 62
x
LIST OF FIGURES
Figure Page
2.1 Pepper plant on ferti le hill sloped 9
2.2 Pepper plant 10
2.3 Handmade ladder 11
2.4 Domains 13
2.5 APDL Domains 15
3.1 The design process phases 20
3.2 House of Quality 24
4.1 House of Quality 35
4.2 The decomposition of FRs 37
4.3 DPs decomposition for Concept 1 39
4.4 DPs decomposition for Concept 2 40
4.5 DPs decomposition for Concept 3 41
4.6 DPs decomposition for Concept 4 42
4.7 Hierarchies decomposition of FRs 46
4.8 Hierarchies decomposition for DPs 47
4.9 Solid Model ofHarvest Ladder 52
4.10 Equivalent stress 54
4.11 Maximum equivalent stress 54
4.12 Equivalent stress 56
4.13 Maximum principal stress 56
4.14 Final design ofladeler 61
Xl
LIST OF ABBREVIATION
ICAD CAs FRs DPs PVs CAs APDL TSDL ICs
SCs CTCs FTCs DSM AD IEEE QFD MPB PMB PDS OSHA
International Conference on Axiomatic Design Custo mer domain
Functional domain Physical domain Process domain Customer domain
Axiomatic Product Development Litecycle Transdisciplinary System Development Lifecycle Input Constraint
System Components Component Test Cases Functional Test Cases Design Structure Matrixes Axiomatic Design
Institute of Electrical and Electronic Engineer Quality Function Deployment
Malaysian Pepper Board Pepper Marketing Board Product Design Specification
The Occupation Safety and Health Act 1994
Xli
CHAPTER 1
INTRODUCTION
Malaysia's production pepper produced output of 4 tonnes in 1870 and made Malaysia is the fourth largest pepper produce in the world after India, Indonesia and Vietnam. In 2005, Malaysia pepper production was 19,099 tones [15] and the share of the total world pepper production amounted to 9.6%. In tenns of export, Malaysia ranks third with an export volume 24,808 tonnes or 18% of the total world export.
Peppers are one of the important cash crops supporting the livelihood of about 67,000 rural dwellers in upland areas of Sarawak. Today, there are about 40,000 smallholders invo Ived in pepper cultivation with fann sizes ranging from 0.1-0.4 hectares. In Sarawak, estimated area under pepper cultivation was at 10,200 hectares with concentrated in Samarahan, Kuching, Sri Aman and Sarikei division.[I]
In 1980, pepper industry in Malaysia dropped to third position in list of world market of pepper producer to India and Indonesia. It was because pepper fanl1ers faced the major problems such as escalating cost for m,maging disease and pest problems, increasing cost of fertilizer, pesticides and labor inputs, lack of modem fann knowledge among pepper farmers especially in rural areas and tluctuating export market prices.[2]
1
Nowadays, the pepper industry in Malaysia has been faced with many problems such as the escalating cost for managing disease, pest problems, poor processing technique, the high labor requirements, low efficiency of production and increasing cost of fertilizer and pesticides.
Malaysian Pepper Board (MPB) is the main govemment agency has overcome this problem by take action such as development to reduce cost of labor method and analyzing pesticides residue for processed peppercoms. Apart from that, MPB has also continued the research on the control of foot rot disease and improved processing technique. These methods were used in order to produce a better quality.
[3]
1.1 Problem Statement
In pepper industry, there are many problems occurring in the harvesting process and the most extensive operation is the halvesting method of the pepper ben-res which is not easy to implement. In Sarawak, majority of the farmers use ladder to assist them in harvesting operation and most it are the hand made ladder.
In harvesting operation, hand made ladder is used to assist fanners to reach the higher pOl1ion orthe pepper tree. Farmers also need to move a ladder D'om one tree to another. It is time consmning and in valves many workers. If this problem can be solved, more production pepper can boosted up.
2
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Pepper vines were nonnally brought to first crop at the beginning of the wet season in the second year of tield harvesting from March to August. Around that season, terrain was soft because of the moisture. Using ladder can be dangerous because of that factor and most of them are not practical and unsecured. It wi ll become more dangerous if harvesting operation is being done at fertile slope and mountainous terrain. [4]
1.2 Aim and Objectives
The aim and objectives of this project to design and develop a new ladder tor pepper harvesting operation. The design of the ladder will be based on the fann condition, terrain and user-friendly. This project will overcome the existing problem related to the traditional harvesting metbod or labor extension operations. Purpose of this project is to made ladder more suitable in harvesting in different terrain and increase prod uction rate 0 f pepper.
3
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- .CHAPTER 2
LITERATURE REVIEW
2.1 Introduction
This chapter will explain about pepper background and process design criteria for Axiomatic Design. This chapter also contain about general principle and main concept of the Axiomatic Design.
2.2 Pepper Background
Pepper or "Piper nigrum" is the most commonly traded spice in the world, there are approximately 3,000 years. Pepper main producer are from Malabar Coast of India, but Malaysia, Indonesia and Sri Lanka are also important producer. Pepper has also been cultivated in the New World and Brasil is a major exporter.
At Roman times and ancient Egypt, pepper already used and supplied by Arab sea traders and they kept secret about the source of the pepper. Being a valuable commodity, peppers are used as a payment. Attila the Hun reputedly demanded
3,000 pounds in weight of pepper as part of a ransom for tile city of Rome.
4
At the point the Greeks and Roman learned of the resource of this precious spice and battle was on. That around 2,000 years the battle tor this valuable spice and spun-ed exp loration and discovery of the New World by Christopher Columbus and at the end he disappointed because he did not find the "Spice Island" [4]. At last Portuguese founded a trade to India and the Spice Islands around the Cape of Good Hope in 1949 by Vasco Da Gama's discovery. Start from there, valuable spice has been dominated by Portuguese until l Sth century. [5]
Pepper also known as king of all spices, India has always reigned highest in the production and export of this exotic and sought-after spice. "Malabar Garbled" and
"Tellichery Extra Bold" are two most trade varieties of Indian. Green peppers also one of the product from India in several process forms such as frozen, dehydrated, freeze-dried and packed in brine. In India black peppercorns was used as a remedies for constipation, diarThea, earache, gangrene, heart disease, hernia, hoarseness, indigestion, insect bites, insomnia, joint pain, liver problem, lung disease, oral abscesses, sunburn, tooth decay and toothaches. [6]
2.2.1 Pepper History in Malaysia
There are many name refer to pepper or black pepper. English words for pepper
is deri ved rrom the olel English are "pipor". In Sanskrit the word pepper are "pippali"
and German are "pfeffer", French are "poivre" and for Dutch are "peper". In the 16d, century, "pepper" started refen'ing to the unrelated New World Chile peppers as
5
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2.2.2 Pepper in Sarawak
Today, Malaysia is in fifth rank on the world largest pepper producer with 98%
of it from Sarawak and 80% pepper production from Sarawak is concentrate at sarikei. Pepper Marketing Board (PMB) general manager Grunsim Ayom said the projected increase was due to the effects of projects implemented under the Productivity and Income Enhancing Programme for Pepper and Cocoa Smallholders (SP) last year [8]. SP programme involved maintenance scheme, organized faIming and replanting, production of value added and premium quality pepper. This programme will involved in 7 location in Sarawak like Kuching, Sn Aman, Betong, Sankei, Bintagor, Senan and Sungai Asap. The plant will be equipped with spiral separator machine, blower, thresher, destoner and mechanical classifier. [9]
Currently, 67,000 farmer and workers in upland areas of Sarawak depends on the pepper production to sllpporting their Ii velihood. They concentrate in certain districts of Kuching, Samarahan, Sri Arnan, Betong and Sankei Divisions. In 2004. value exports for Sarawak are 19,748 tOlmes and 18,824 tonnes in 2003. Today, Malaysia ranks number five with the output 21,000 tonnes after Vietnam (87,000), India (45,000), Brazil (35,000) and Indonesia (25,000). In export form of pepper, about 95 'Yo pepper is in form of black and white peppcrcorns and the remaining 5% is made up of pepper oleoresin, pepper oil, green pepper and ground pepper. [3]
7
2.3 Pepper Cultivation
In Sarawak, pepper is cultivated as a monocrop without shade mainly on gentle to steep slope. Field drains must be provided if holding are located in low-lying areas. Traditionally, farmers will clean a weed around their pepper plant and walking side can cause serious soil erosion. Pepper frumers are now encouraged to adopt the practice using ground cover.
Between October and December is a good month and can be done the field planting of rooted cutting. In Pre-rooted, polybag-nurseried or unrooted cUlting can be used. One important thing is newly planted cutting must be shaded until they well establish. In pruning process, vines will be pruned to encourage the formation of a desired canopy. There have there round until the final pruning is done when the terminal shoots have reached the top ofthe pos and first berry production.
Application of chemical fertili zer is important to sustain high yield in fertilizing. It is because pepper vine have high demand for nutrients. Harvesting can be done after 2 year of field planting at the beginning of the wet season, there are between March and August. When berries at the base start to tum red or early sign of maturity, harvest should be done to maintain their pungency. After that, green berries will dry using direct sun-drying about a week and a half to produce a black peppercorn. White peppercorn is processed by soaking the ben;es in clean running water to remove their pcricarp to 110 wed by sun drying.
8
Figure 2.l : Pepper plant on fertile hill sloped
Figure 2.2: Pepper plant
9
- - - - - -
-- -2.4 Problem and Constraints
In pepper industry, there are many problem fanners will face. The major problem and constraints the farmers faced are harvesting problem, pest and disease control, market price for pepper, fluctuating export market prices, increasing cost of fertilizer, pesticides, labour input and escalating cost for managing disease and pest control. On this project, only focuses on the harvesting method.
The purposes on this project are to improve harvesting technique for better quality and value added produce. One of the traditional methods is using a handmade ladder to harvest pepper berries. There are dangerous to moving a heavy ladder from tree to another tree on bumpy terrain. Moving a heavy ladder also will cause effect to back body and muscular pain. There are also wasted many times in hatvesting pepper bemes using handmade ladder because workers need to move the ladder.
When harvesting pepper berries, tom part from a tree bushes can injury or scratch worker's hand. The hard part when harvesting pepper bemes are to reach a top of pepper plant to take berries. There also when to reach hard portion like berries in the bushes of pepper plant, injury can happen when a workers try to take certain part of the pepper plant. Harvesting not efficient when labour can see properly berries and try to take them, it can cause damage or crush to the pepper berries. That can waste many pepper berries and effect their production.
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