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GROUP PROJECT

The Dinghy

MAPE WINTER 2021

Guided By : Prof. Dr.-Ing. Dirk Hecht

Prof. Dr.-Ing Maximilian Ruppert

18 January 2022

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Dinghy Project

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Agenda

1

Department Allocations

2

Timeline

3

Marketing and Costing

https://worktankwebcasts.com/productive-meeting-agendas/

4

Design and Development

5

Manufacturing and SCM

6

Costing

Technische Hochschule Ingolstadt | Dinghy Group Project

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Dinghy Project

Department Allocations

3

Ashutosh Kumbhar (Project Leader)

Marketing and Costing

1. Shweta Rege (GL)

2. Dhanesh Kulkarni

3. Nikhil Toke

4. Prakash Bhosale

5. Shrutika Mirkale

6. Hiten Mistry

Design & Development

1. Rohan Prajapati (GL)

2. Sebastian Ramirez

3. Nitin Suresh

4. Sagar Rajurkar

5. Meet Patel

6. Shiva prasad Chirala

Engineering & Simulation

All

Manufacturing and SCM

1. Brenda Rachel (GL)

2. Sumit Nalavade

3. Ashutosh Kumbhar

4. Atharva Pande

5. Rohan Sarode

6. Valeria Lopez

7. Parth Yadav

Sebastian Ramirez (Co-leader)

Technische Hochschule Ingolstadt | Dinghy Group Project

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Dinghy Project

Timeline

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Technische Hochschule Ingolstadt | Dinghy Group Project

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Marketing and Costing

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Our Approach

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How many people live in coastal areas and in areas of inland water sources?

Average 250 Million People

How many boat berths and Marine Harbors available in Europe?

1.1 Mn Boat Berths (dry berths included) and nearly 10 thousand Harbors.

What is the boat ownership in Europe?

How many people participate in marine time activities?

How many people are willing to change to our dinghy from inflatable boats?

What are the imports of the boats in Europe per year

[1]

Market Demand

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Areas of Inland water sources in sq.km

Length of coastline in kms

Target countries from Europe are Croatia, Sweden, Finland, Norway because of maximum inland water sources & long coastline length. With these target areas we expect to sell up to 10.5 K approx. dinghies in 2022

[1]

Market Demand

Technische Hochschule Ingolstadt | Dinghy Group Project

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Status of Inflatable Boat Ownership in Europe (2020) (Million Units)

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Status of Inflatable Boat Owners (0.79 Mn). These can be our target customers as our dinghy will solve the drawbacks of inflatable boats

[1]

Market Demand

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0.4 + 0.4 + 0.06 = 0.86 Mn units is the Market demand for 5 – 7 years span

50%	0.8 Mn people owe inflatable boat and are willing to change to our dinghy according to the customer reviews as we are offering what they exactly want.	0.4 Mn +	What we offer? Cost Effectiveness Non-Inflatable Easy to carry Less Weight
48 Mn	Participation in Marine time activities Considering 1% of these people will be attracted to buy our dinghy	0.4 Mn +	Who are these people? Who don’t own a dinghy Who borrow it for specific period
0.06 Mn	Imports in Europe 0.06 Mn units of inflatable boats are imported in Europe per year by various companies.	0.06 Mn	This is a part of total demand which we will fulfill
Total Market Demand		∑0.86 Mn units (+/- 0.17 Mn)

[1][2]

Market Demand

Technische Hochschule Ingolstadt | Dinghy Group Project

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Google Form Results

10

300 EUR

Plastic Dinghy

20 KG Wt. of Dinghy

Paddle Driven

10 Min. Setup Time

Fishing / Transport to Yacht

Dark Blue

5 Years Lifespan

Assembly of 2 parts

Source: google form survey

https://forms.gle/3xxUw1egAiB3QDM9A

Survey included responses from graduate students and working professionals

Customer Preferences

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Basic Boat Standard Features

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3. quickboats.com

1. loweboats.com

2. zarmini.com

Dry Storage

Grab n Go

Compact Design

Row Lock

Source

4. Portland Pudgy

Study carrying handles, Storage space for keeping fishing equipment etc., all-around durable rubber strike to prevent punctures

Customers Demand and Supply

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Note: *Market offered dinghy for 258 EUR has weight of 38kgs

*Cost can be a bit higher (till 400EUR) if ease is assembly is provided (From Customer Reviews)

*Satisfactory comfort means customer is not much concerned about comfort compared to

functionality of dinghy

[1][2]

Matrix showing our offerings and market offerings along with customer needs

https://docs.google.com/spreadsheets/d/1GS-0NATw6DII4RZwDz-ne5Bm1OO3DgkK/edit?usp=sharing&ouid=109860424102860559415&rtpof=true&sd=true

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Competitor Comparision for Plastic Materials (For Dinghy)
Sr. No.	Price (€)	Foldability	Material	Capacity�(No. of persons)	Capacity�(kgs)	Weight of Dinghy	Length�(mm)	Width�(mm)	Cavity�(mm)	Engine Power (HP)	Rudder Driven	Paddle Driven	Oarlocks availability	Integral Rear Wheel Availability	Manufacturer	Remarks
1	258.16	Rigid with 2 parts	HDPE	2	150	38	2470	1120	---	---	Yes	---	Yes	---	SeaWalker	Price mentioned applies to a lot qty of 20+ pieces; Foldable; 2 Airtubes to be attached to both sides, air tube cost additon
2	310	Rigid with 2 parts	HDPE	2	150	38	2450	1120	---	4	Yes	---	Yes	---	Oasis Industry Co. Ltd., China	Depth of inner cavity of dinghy 55 cm
3	313.5	Rigid single piece, Non Foldable	UV stable HDPE	2	150	60	2450	1150	---	---	Yes	---	Yes	---	SeaWalker	---
4	350	Yes with 3 parts	HDPE M5203	2	150	20.27	1700	950	---	---	Yes	---	--	---	THI Project	---
5	469.99	Rigid single piece, Non Foldable	HDPE Type A	2	150	18	1800	1100	2.4	---	---	Yes	---	---	Sea Walker	---
6	500	Rigid with 2 parts	UV Resistant HDPE	3	290	52	2500	1550	---	4	---	---	---	Yes	West Marine	Buoyancy 320 liters; Category D for sustaining wind Force 4 Beaufort scale; Height of waves can be sustained upto 500 mm
7	618	Rigid single piece, Non Foldable	HDPE	3	200	48	2844	1397	---	3	Yes	---	---	---	West Marine	Modified TRI Hull
8	773.5	Rigid single piece, Non Foldable	HDPE	2	200	30	2100	1300	---	---	Yes	---	---	---	Plastimo	---
9	829	Rigid single piece, Non Foldable	UV stable HDPE	2	169	19	2130	1150	---	2.2 KW	---	---	Yes	With stainlesss steel axels with screw connections	SportYak	---
10	1080	Rigid single piece, Non Foldable	HDPE	3	335	57	2850	1400	---	4	Yes	---	Yes	---	Pacer Marine	Depth of inner cavity of dinghy 40 cm

Though there is competition in the Market, specific parameters of our dinghy via Non-inflatability, Cost, Weight and Size are our strengths

[1][2]

Market Offerings

https://docs.google.com/spreadsheets/d/1GS-0NATw6DII4RZwDz-ne5Bm1OO3DgkK/edit?usp=sharing&ouid=109860424102860559415&rtpof=true&sd=true

Technische Hochschule Ingolstadt | Dinghy Group Project

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Customer Value based on comparison between what we offer and what customer needs.

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	Cost	Foldable	Weight	Size	Design & Aesthetics	Safety	Stability & Comfort	Sum	Distribution (%)
Cost		1	1	2	2	2	2	10	24
Foldable	1		1	1	2	2	2	9	21
Weight	1	1		1	2	2	2	9	21
Size	0	1	1		2	1	2	7	17
Design & Asthetics	0	0	0	0		2	1	3	8
Safety	0	0	0	1	0		2	3	5
Stability & Comfort	0	0	0	0	1	0		1	4

Cost, foldability and weight are our core competencies

Priority

#1^st Priority

#2^nd Priority

#3^rd Priority

#4^th Priority

#5^th Priority

Pairwise Comparison

https://docs.google.com/spreadsheets/d/1GS-0NATw6DII4RZwDz-ne5Bm1OO3DgkK/edit?usp=sharing&ouid=109860424102860559415&rtpof=true&sd=true

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Key factors for age group 18 - 25: Size, Aesthetics, Cost & Weight

Persona – University Student

https://docs.google.com/spreadsheets/d/1GS-0NATw6DII4RZwDz-ne5Bm1OO3DgkK/edit?usp=sharing&ouid=109860424102860559415&rtpof=true&sd=true

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Key factors for age group 25 - 50: Cost, Size & Foldability

Persona – Working Professional

https://docs.google.com/spreadsheets/d/1GS-0NATw6DII4RZwDz-ne5Bm1OO3DgkK/edit?usp=sharing&ouid=109860424102860559415&rtpof=true&sd=true

Technische Hochschule Ingolstadt | Dinghy Group Project

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Key factors for age group above 50: Foldability, Weight, Comfort & Stability

Persona – Retired Person

https://docs.google.com/spreadsheets/d/1GS-0NATw6DII4RZwDz-ne5Bm1OO3DgkK/edit?usp=sharing&ouid=109860424102860559415&rtpof=true&sd=true

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Age Group	18-25
Percentage	32.4
Concerns	Aesthetics, Cost, Size, Weight.

Age Group	25-50
Percentage	29.3
Concerns	Cost, Size, Foldability

Age Group	50 and above
Percentage	35.3
Concerns	Weight, Foldability, Comfort and Stability

To understand persona more precisely we divided age groups in percentage and their concerns (from recent expert surveys and literature reviews)

Customer statistics with functions of our Dinghy

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2024-2027

Saturation phase

Overall Demand

0.86Mn ( + / - 0.17 Mn)

Margin of volume per year

+-20% (units)

Spread of overall market demand over span of 5 years

Demand Curve

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5

4

350 €

85%

15%

52.50 €

297.50 €

142.80 €

86.28 €

32.73 €

35.70 €

100%

48%

29%

11%

12%

Target price is 350 € considering profit margin of 15% & target cost of 297,50 €

Target Costing

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We aim to target 25% Market share of whole Market demand in first 5 years of our business

Source –

https://shop.liesegang-partner.com/incorporation-german-gmbh.html

https://shop.liesegang-partner.com/trademark-registration-germany.html

https://www.companyformationgermany.com/#:~:text=Company%20formation%20fee%3A%20the%20company,from%20100%20euros%20per%20month.

https://www.nerdwallet.com/article/small-business/business-startup-costs

http://www.salaryexplorer.com/salary-survey.php?loc=81&loctype=1&job=22&jobtype=1#disabled

Business Expenses

https://docs.google.com/spreadsheets/d/1GS-0NATw6DII4RZwDz-ne5Bm1OO3DgkK/edit?usp=sharing&ouid=109860424102860559415&rtpof=true&sd=true

Technische Hochschule Ingolstadt | Dinghy Group Project

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According to forecast our turnover will reach 32.37 Mn Euro in 2026

According to expense sheet our profit will be 7.43 Mn Euro in 2026

Company Turnover and Profit Graph

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		Less Maintainence	Good buoyancy	Size	weight	Ease In assembly & disassembly	Chemical & wear resistant	Easy Manufacturing Design	Cost	Rigid Structure	Moisture Resistant	Specific strength	Setup time	Our Product	Sea Walker	Hunts Marine	Pacer Marine	West Marine
Direction of Improvement		◇	◇	◇	▼	▲	▲	◇	◇	◇	▲	▲	▼
Non Inflating	8	▽	▽		○	●		○	●	●	▽	●	●	4	5	4	4	4
Easy to carry/ No towing	5		○	●	○	●		●	○	▽			▽	3	3	3	2	3
More weight carrying capacity	6	○	●	○	○			○	○	○				4	2	3	4	4
Easy assembly & disassembly	8	●		○	▽	●		○	▽	●			●	5	4	0	2	0
Less weight	5		○	●	●			▽	○				▽	4	3	4	3	3
Can be fitted in car/ less size	9	○		●	●	○			▽	○				5	2	0	1	0
Economical	8	●		○	○	●	●	○	●	▽	○	○	○	4	2	3	3	2
Durable	7	●		▽	○	●	●	○	○	●	○	●	○	4	4	4	4	4
Relative weight %		10%	4%	10%	9%	15%	6%	7%	11%	11%	2%	7%	8%
Weight chart

Customer Priority

Customer Requirements

Technical Requirements

Customer Assessment/

Competitive Evaluation

Quality Function Deployment

Our Product Provides:

Ease in Foldability; Can be fitted in car; less weight and less cost.

QFD focuses on features of Dinghy & improvements based on needs

https://docs.google.com/spreadsheets/d/1GS-0NATw6DII4RZwDz-ne5Bm1OO3DgkK/edit?usp=sharing&ouid=109860424102860559415&rtpof=true&sd=true

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Patent Research Summary
			Parameters
Patents			Cost < 300 €	Foldability or Ease in carrying	Less Weight	Load carring capacity = 2 person	Size (Spaceous)	Safety	Design & Aesthetics	Stability and comfort	Assemble time < 5 min	Collapsible boat	Multiple hull segment	Vehicle roof mounted	Moter driven propulsion	Inflatable	Flexible canopy	Packed inside the car
1	Dinghy		✓	✓	✓	✓	✓	✓	✓	✓	✓	✓	✓	✓	✗	✗	✗	✓
2	Foldable	Scott wood, Lakewood Ranch	✗	✗	✗	✓	✓	✓	✗	✓	✗	✓	✗	✗	✓	✗	✗	✗
3		Hai Jung Lee	✗	✓	✓	✓	✓	✗	✗	✗	✗	✓	✗	✗	✓	✗	✗	✓
4		Abel St Helen�Craig A. Fleming	✓	✓	✗	✓	✓	✓	✗	✓	✗	✓	✓	✗	✗	✗	✓	✓
5		Lewis, Michael	✗	✗	✓	✓	✓	✗	✓	✗	✗	✓	✓	✓	✗	✗	✗	✓
6		Wu Shusheng	✓	✓	✓	✓	✓	✓	✓	✓	✗	✓	✓	✗	✗	✗	✗	✗
7		Zhao Xikui	✗	✓	✗	✓	✓	✗	✗	✗	✗	✓	✓	✗	✗	✗	✗	✓
8		Hinderberger, Friedel Lorenz-Wegele-Bichl	✗	✓	✗	✓	✓	✓	✗	✓	✗	✓	✓	✓	✗	✗	✗	✗
9		Roger Malcolm Scott	✗	✓	✗	✓	✓	✗	✗	✗	✗	✓	✓	✗	✓	✗	✗	✗
10		Alex R Kaye	✗	✓	✗	✓	✓	✓	✓	✓	✗	✓	✗	✗	✗	✗	✗	✗
11		ALEX Earl & Frances Kate	✗	✓	✗	✓	✓	✗	✓	✗	✗	✓	✗	✗	✓	✗	✗	✗
12		Hyun-Yoo Kim & Lee Sang-Seok	✗	✓	✗	✓	✓	✓		✓	✗	✓	✓	✗	✓	✗	✗	✗
13		Chih Yung Chen	✗	✗	✗	✓	✓	✗	✗	✗	✗	✓	✗	✗	✓	✗	✗	✗
14	Structure	Johannes Nordmar	✗	✗	✗	✓	✓	✓	✓	✓	✗	✗	✗	✗	✓	✗	✗	✗
15		Alexander Boukas	✗	✗	✗	✓	✓	✗	✓	✗	✗	✗	✗	✗	✓	✗	✗	✗
16		Vogel, Wayne A.	✗	✗	✗	✓	✓	✓	✓	✓	✗	✗	✗	✗	✓	✗	✗	✗
17		Hong Seung-gil	✗	✗	✗	✓	✓	✗	✗	✗	✗	✗	✗	✗	✓	✗	✗	✗
18	Inflatable	Steve A. Lesniak	✗	✓	✓	✓	✓	✓	✓	✓	✗	✓	✗	✗	✓	✓	✓	✗
19		Steve A. Lesniak	✗	✓	✓	✓	✓	✓	✓	✓	✗	✓	✗	✗	✓	✓	✗	✗
20		Alex R Kaye	✗	✓	✓	✓	✓	✓	✓	✓	✗	✓	✗	✗	✓	✓	✗	✗
21		Frances Kaye	✗	✓	✓	✓	✓	✓	✓	✓	✗	✓	✗	✗	✓	✓	✗	✗

We have the considered all the required parameters that a customer wants in Dinghy without harming existing pattens

Patent Research Summary

https://docs.google.com/spreadsheets/d/1GS-0NATw6DII4RZwDz-ne5Bm1OO3DgkK/edit?usp=sharing&ouid=109860424102860559415&rtpof=true&sd=true

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Key Partners

THI
The Bavarian State origination
Manufacturers of parts and components
Share Holders and Stake Holders
Material Suppliers
Deposition Tools Suppliers
Join Venture

Value Proposition

Value Packed Products
Easy to Assemble
High Performance
Safety
High Quality
Reliability
Value for money (Affordable price)
Comfortable & Enjoyable ride
Creative : A human gift to develop products that prompts better living conditions and satisfies people's needs.

Customer Segments

18 – 25 Years Old
25 – 50 Years Old
50 years + customer segment
Massive Market
Other Manufacturing around the world
Focus on brand conscious customers
Boat Manufacturer
Marine Industries

Customer �Relationship

Brand Awareness
Global Recognizances
Reputations,
Quality, Brand Awareness
Customer Loyalty
Recommendations
After Sales

Key Resource

Human Resource Production
Facilities & Tech (THI)
Distribution Networks
Partnership and Alliance
Intellectual Property
Production Output
Patent Technology
Internet Access
Furnitures & Amenities

Channels

Own Websites
Social Media , Sponsors
Content marketing
Offline promotion,
Dealers, Posters,
Exhibitions, Repair shops

Key Activity

Research and Development
Manufacturing and Distribution
Supply Chain Managements
Boat (Dinghy) assembly and Manufacturing/Machining
Injection Molding
Education and Training
Testing and Development
Quality Assurance
Branding
Develop Manufacturing Capability
Understanding of specific customer
Demand for production
Human Resource
Customer Services

Cost Structure

Parts and Components
Research and Developments
Service and Support

Manufacturing and Distributions
Maintenance of Facilities and Equipment
Production Facilities, Employs

Labor
Material
Floor Space

Revenue Streams

Sales of Dinghy Boats
Spare parts
After Sales and Services

Sales of Components
Contract Manufacturing

Our product have Value Packed Products, Easy to Assemble, High Quality, Affordable Price

The Business Model Canvas

https://docs.google.com/spreadsheets/d/1GS-0NATw6DII4RZwDz-ne5Bm1OO3DgkK/edit?usp=sharing&ouid=109860424102860559415&rtpof=true&sd=true

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Value Proposition Canvas

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Value Map

GAIN CREATOR

PRODUCT AND SERVICES

PAIN RELIVERS

Navigate your trip on map

Ability to manage all trip details on a

single platform

Automatic credit card payment

Rating system

Passenger

mobile

app

Service platform

Easy return and

pickup via

QR CODE

Flawless automatic payment

Service rating

Arrival/travel time prediction

24/7/365 availability of Dinghy

Track your dinghy

One click order/cancellation

Zero time on payment

Trusted service a products

Control cost for

the ride

Wait for the dinghy for

Some unknown

amount of time

Pay for the trip

Low dinghy availability

Need to book dinghy in

advance

Bad weather situation

Issues with payment for

the dinghy services

(cash/card)

Customer profile

The value proposition canvas framework ensure that there is a fit between the Dinghy service ideas and the market demands

Marketing Strategy

https://docs.google.com/spreadsheets/d/1GS-0NATw6DII4RZwDz-ne5Bm1OO3DgkK/edit?usp=sharing&ouid=109860424102860559415&rtpof=true&sd=true

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Strategies	Realistic approach	Addressing the questions
Executive Summary	To have an overview of the plan and discuss with the teammates.	What are the problem? What is the opportunity?
Situation Analysis	Current situation of the market and rival companies.	Where is it located? What market we compete in (regional, local, national)?
Marketing Goals and Objectives	To make an affordable Dinghy. Can be fitted easily in a car. Carry 2 person with 75 kg each�Takes less than 3 mins to install the Dinghy.	How to set a goal for the Dinghy? What are the demanded specification?
Industry and Market Analysis	Knowing the industry and the rivalries to compete with. Carrying scientific analysis like (PEST). Market segmentation.	Current situation of our industry ? How is your business unique in the market?
Target Customers	These are the customers who are likely to buy our Dinghy. Clearly identifying the target help speak the customer language.	Target customers and how do they behave? Key demographic of the customer?

Marketing strategy with limited resources can increase sales and achieve a sustainable competitive advantage

Marketing Strategy

Segmentation of Marketing Strategy

https://docs.google.com/spreadsheets/d/1GS-0NATw6DII4RZwDz-ne5Bm1OO3DgkK/edit?usp=sharing&ouid=109860424102860559415&rtpof=true&sd=true

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Segmentation of Marketing Strategy

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Strategies	Realistic approach	Addressing the questions
The Brand	A strong brand is a key to the success. Creating a Unique Selling Point	What gives our Dinghy an edge? What sets are our Dinghy different from others?
The Implementation	After assessing all the steps implementation is to be done.	When to implement ? What is the budget allocated?
Financial Projections	What expected results will be in terms of new customer sales and profits.	What is the expected sale after 5 years? What are the expenses that will be incurred?
Evaluation and Monitoring	Tracking the effectiveness of the strategies.	What target you miss/hit? What went well?

Marketing strategy with limited resources can increase sales and achieve a sustainable competitive advantage

Marketing Strategy

https://docs.google.com/spreadsheets/d/1GS-0NATw6DII4RZwDz-ne5Bm1OO3DgkK/edit?usp=sharing&ouid=109860424102860559415&rtpof=true&sd=true

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Research Patent details File

Detail QFD study File

Market Demand

Customer Preferences

Our offerings and market offerings

Market Offerings

Customer statistics with functions of our Dinghy

Demand Curve

Customer Value Vs Functions

Business Plan

Company Turnover and Profit Graph

Backup

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Design and Development

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Design Methodology

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Design Methodology

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Input from other departments

Considering customer requirements while designing increases the product-market reach better

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Design Methodology

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CONCEPT 3

CONCEPT 2

CONCEPT 1

Considering customer requirements while designing increases the product-market reach better

Rough Design Concept – Idea Generation

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Taking the essential elements and combining all the rough ideas into single design

SolidWorks- FEA

SolidWorks

Design Methodology

Final Design – THI Dinghy

https://drive.google.com/drive/folders/1h2PA73i2TqVAQ4xnMZjksr_wOKkOt7Ff?usp=sharing

https://drive.google.com/file/d/1mfiFyac9hTu7BWSaExti08vMYtFADqNT/view?usp=sharing

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1. Design of Dinghy accordingly to the customer’s need.
2.To choose go for folded one or to go with the joint boat.
3. To reduce the weight of the material.
4. Choose the materials for safety and durability.
5. To have better comfort for the customers in terms of leg room and sitting position.
6. To choose the joints for our boat.
7. To simulate the boat in software by applying different types of load.

1. Design a banana shaped dinghy as per customers requirement (Data from Marketing Team).
2. We choose one of the best joint which is called male & female joint to make it easy to assemble and dis-assemble the dinghy.
3. Created many groves on the dinghy to remove the extra weight of the boat.
4. Polyethylene is the right choice for light weight material and design stability.
5. We had design a plate section sitting bench which is attachable to the dinghy.
6. Male & Female joint are best to go with this design.
7. We had run the simulations and the factor of safety is over 1.2.

Finding out best possible solution over challenges is must for every department in every sector

Challenges and solution while designing

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Source: audia6avantreview.blogspot.com/2019/06/audi-a6-avant-cargo-space.html

Reference of a car to place our dinghy

Car Boot Reference

AUDI A6

Boot Space

Dimensions of boot A6 Avant

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Ready for the Ride Way back to home (Folded View)

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Note:- This is the final design which we made for manufacturing after having feed back from our customers.

The life span of dinghy is of about 6 years.

3D Design View of Dinghy

https://drive.google.com/drive/folders/195olhmSpqr9OeSiO9OpA0bIuG4ngPEL-?usp=sharing

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`

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Side View

Front View

Bottom View

Top View

CAD

3D different views

https://drive.google.com/file/d/1mfiFyac9hTu7BWSaExti08vMYtFADqNT/view?usp=sharing

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We have made the same 2D draft for each part

2D Design in CAD

1. Drafts of Front part of Dinghy

https://drive.google.com/file/d/1oSmQRDgjcgBwhqSxm7Na-GDzn7cJaMHK/view?usp=sharing

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Wheels and joint U Clamps on the Side walls Seat Fixture

3D Parts and Joints

https://drive.google.com/file/d/15FT7cUgBZ1lfDjROnXXAPri6vZD6jkI4/view?usp=sharing

https://drive.google.com/file/d/1-Tt5pgbJENeQ3kanM02iR6iEHJ9-x5FU/view?usp=sharing

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Silicon Seal

U clamp

Seat Fixtures

2D Draft of Parts

https://drive.google.com/file/d/1ZVbZVfF59oO3ufuSnHBSVU_lMImc2bmA/view?usp=sharing

https://drive.google.com/file/d/1oSmQRDgjcgBwhqSxm7Na-GDzn7cJaMHK/view?usp=sharing

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Packing Box

Easy carrying of Dinghy

Cardboard Packing

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Injection Mould to produced our Dinghy ( For Manufacturing Department)

Mould Design For Injection Moulding Manufacturing Process

https://drive.google.com/drive/folders/1h2PA73i2TqVAQ4xnMZjksr_wOKkOt7Ff?usp=sharing

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PRODUCT SPECIFICATIONS
Product Name	Portable Dinghy Boat
Dimension	1.70.90.35 (in meters)
Material	High density polyethylene
Target Price	€ 350
Initial Order Quantity	1
Product Function	Carry 2 persons (each one weight 75kg)
Sales Market
IP Rights

Raw Materials	High density polyethylene, Silicon sealer, Stainless steel, polypropylene and fiber glass, cardboard, graphic stickers and polyurethane (seat cushion-luxury feature)
Components	Boat, seats, hooks, side panel rod and carboard box.
Accessories	Paddles, seat cushions and graphic stickers.
Logo	Blue color

Compliance Standards
Weight	15.1 kg
Cost	€ 350
Load carry capacity	80*2 kg
Space occupancy	Fit in car (with rear folded seats)
Type of handling	Foldable

For Better Understandings to our customers

Product Specification

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Product Description:

HDPE M5203 is a natural-colored grade produced with the latest Ineos Gas Phase polymerization Technology exhibiting following features:

Very high Env. Stress Crack Resistance
Higher Impact Strength
Good Warpage resistance
Superior Processability

HDPE M5203 is recommended for following

applications:

Caps & Closures
Technical Parts
Bins

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Best Material that is suitable for production of Dinghy

Grade of Material (M5203)

High Density Polyethylene

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S. No	Part Description	Material(Grade)/ Brand	Part Weight (in SI)	Quantity (piece)	Dimension(lbh)in mm	Total Weight (in SI)
1	Boat Material	HDPE (M5203)	-	3	1700900350	15.1kg
2	Seat Material	HDPE (M5203)	1.73kg	2	-	3.46kg
3	Water proof seal	Silicone	0.045kg	2	2470	0.09kg
4	U clamp	SS (AISI4130)	0.125kg	4	-	0.5kg
5	Paddles	Polypropylene and fibre glass	-	2	1340*150	-
6	Cardboard boxes	Cardboard	1.5kg	1	950550750	1.5kg
7	Stickers	Paper	-	2	-	-
8	Nuts	SS (AISI4130)	0.07	2	M10 Hex	0.14kg
9	Bolts	SS (AISI4130)	0.07	2	M10 x 70 Hex	0.14kg
10	Nuts	SS (AISI4130)	0.023	4	M8 Hex	0.092kg
11	Bolts	SS (AISI4130)	0.023	4	M8 x 25 Hex	0.092kg
12	Washers	Rubber	0.66*10^ -3kg	8		0.00528kg
13	Wheels	Nylon PP	0.04kg	2	-	0.08kg
14	Pad	Rubber	-	-	-	-
15	Glue	UHU	0.035L	1	-	0.035L

The dinghy boat is of 16 kg of weight and with 19.76kg including the seat

Abbreviations

HDPE – High Density Polyethylene

SS – Stainless Steel

PP - Polypropylene

Bill Of Material

Complete Dinghy Boat

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S. No	Part Description	Material	Weight/part Length/part (in SI)	Quantity (piece)	Total Weight/ Total Length (in SI)
1	Boat Material	HDPE	3.17kg	1	3.17kg

Part 1 consists only the boat material

Dinghy Boat

Part 1

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S. No	Part Description	Material	Weight/part (in SI)	Quantity (piece)	Total Length (in SI)
1	Boat Material	HDPE	-	2	9.74kg
2	Water proof seal	Silicone	0.045kg	1	0.045kg
3	Seat Material	HDPE	1.73kg	1	1.73kg
4	Paddles	Polypropylene and fibre glass	-	2	-
5	Stickers	Paper	-	2	-
6	Nuts & Bolts	SS (AISI4130)	0.07kg	2	0.14kg
7	U clamp	SS (AISI4130)	0.125kg	2	0.25kg

The assemblies relate to U-clamps and locking systems for more safety

Dinghy Boat

Assembly 1 & 2

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Power BI report of BOM

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Load on Seat- Stress (FOS-1.2)

Load concentrated on the centre

Load on Floor- Middle (FOS-1.0)

Load on MF Joints (FOS-1.2)

Load on Floor- Back (FOS-1.0)

The failures where the boat can fail on extreme load

Load Analysis

https://drive.google.com/drive/folders/1h2PA73i2TqVAQ4xnMZjksr_wOKkOt7Ff?usp=sharing

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Dinghy without Person

18mm water level

> 65⁰ tilt

F_g

F_b

F_g

Stableness of dinghy by applying it’s own weight

Dinghy Roll Stability

https://drive.google.com/drive/folders/1h2PA73i2TqVAQ4xnMZjksr_wOKkOt7Ff?usp=sharing

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Dinghy with Person

150mm water level

> 15⁰ tilt

F_g

F_b

F_g

Stableness of dinghy by applying two people weight

Dinghy Roll Stability

https://drive.google.com/drive/folders/1h2PA73i2TqVAQ4xnMZjksr_wOKkOt7Ff?usp=sharing

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Possible Solutions of Major Failures

Design Failure Mode Effect Analysis

https://docs.google.com/spreadsheets/d/1k0ArTvy5a6LH0__X3vMLKI5-ZIuSVm4s/edit?usp=sharing&ouid=109860424102860559415&rtpof=true&sd=true

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The 3d printing bed at our THI for installation is of 200 mm * 220 mm * 200 mm, so we have reduce the size of our design into 1:8.5 ratio, so it can be easily printed in 3d printing.
The printer only prints the model which has minimum thickness of 2 mm, so in solution with this we gave the thickness of every side of the dinghy 2 mm.
The gaps/holes which had made in our main design is less than 0.3 mm (after designing the pretotype) but is should be gap of more than 0.3 mm, so we did that in terms of making them more apart from each other.

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Problems and Solutions while designing the Pretotype

Pretotype Design & it’s description

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The design Is made into 1:8.5 ratio.
It will easily fit into the 3d printing bed.

We had not created the whole pretotype from one mould, but instead of that we had made it in 3 different sections.
So, from that we can show the working how it will assemble and dismantle in real world.

Working Principle of our pretotype (same as actual design)

Pretotype Design 3D

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2D Draft of the Pretotype & Dimensions

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Pretotype

https://drive.google.com/file/d/1sjY9Dyslr1ErjjMrl9V1z2CODqvIzXO6/view?usp=sharing

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Part 2 front side

Part 2 back side

Part 1

The pretotype has been printed in THI Lab

Part 3

Assembly

Back side view

Left side view

Parts

Pretotype

3-D Printing Pretotype

https://drive.google.com/file/d/1vvIe3mMLozeoec1qTZOlh1bCtQZCk_rc/view?usp=sharing

3D Printer

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Manufacturing and SCM

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Technology Process Analysis

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Injection molding fits the best characteristics to produce in mass production our product

https://commons.wikimedia.org/wiki/File:RTM_process.png

https://www.iqsdirectory.com/articles/rotationally-molded-plastic/rotational-molding.html

3,070,000 EUR

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Process distribution

General process flow

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Injection molding

Hand drilling

Finishing

Silicone Assembly

Wheel Assembly

Seat Assembly

Packaging

High density Polyethylene

Process flow involves creating form and changing the form of processes

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Process	Process Specification/Tolerance	Evaluation/ Measurement Technique	Reaction Plan
Material Temperature(HDPE)	180 - 280 °C	Immersion Pyrometer	Stop Production
Injection Pressure	70-105 Mpa	Machine Pressure Sensor	Record and maintain standard values as per process specification
Shot Chamber Temperature	243 °C	Machine Sensor Machine Pressure Sensor
Clamping Pressure	2 - 6 KN/cm²
Holding Pressure	67.5 Mpa

Development of process control parameter to ensure the effectiveness of manufacturing process operating procedure for dinghy.

Crucial parameters are shown in Table

Material Temperature should not violate the range.

Sufficient Injection pressure must be attended during the process

Holding Pressure is crucial to reduce the defects.

Process Control Plan

https://docs.google.com/spreadsheets/d/11fOhiXL9YgaHziGZMDHNngrHypRQEbfq/edit?usp=sharing&ouid=109860424102860559415&rtpof=true&sd=true

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Short shots

Appreance of incomplete area	10
Injection pressure too low	6
Increase injection pressure	3
Risk Priority Number	180

Burning

Brownish discoloration	8
Improper venting	7
Increase vent size	8
Risk Priority Number	448

Sink and Void

Risk of functionality failure	9
high Temp/ Rapid Cooling	5
Decrease stock & Nozzle temp.	4
Risk Priority Number	180

Analysis of selected manufacturing process, its identifications & rating of critical failure mode

PFMEA

https://docs.google.com/spreadsheets/d/11fOhiXL9YgaHziGZMDHNngrHypRQEbfq/edit?usp=sharing&ouid=109860424102860559415&rtpof=true&sd=true

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Critical to Quality (CTQ) Defects

Grey Streaks

Void and Sink

Burn Marks

Short Shots

Entrapped Bubbles

Variation in Wall Thickness

Warpage

1

2

3

4

5

6

7

Assignment of customer centric quality parameters for achieving the product excellence

04.01.2022 _https://images.app.goo.gl/sBbzofhp2QEyqZA18

Quality Control Plan

https://docs.google.com/spreadsheets/d/11fOhiXL9YgaHziGZMDHNngrHypRQEbfq/edit?usp=sharing&ouid=109860424102860559415&rtpof=true&sd=true

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Suppliers criteria

Cost

Capacity

Delivery

Quality

Profile

CRITERIA	EXPLAINATION
Cost	Review the feasibility of the product or service and choose the reasonable one.
Capacity	Look into supplier’s current and forecasted orders and customers, along with how that impacts the ability to meet your projected requirements.
Delivery	The capacity of transporting goods from a source location to a predefined destination.
Quality	The performance of purchased material to meet or exceed the requirements and expectations in service or product that were committed to.
Profile	Certifications of the firm and type of relationship the company committed for.

For the selection of the suppliers the main criteria are quality and cost

Selection of suppliers

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Selection of final Suppliers according to criteria

List of suppliers

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Working days per year	Shifts x day	Working hours	Cycle time (sec)	Installed Capacity
250	3	7,5	150	540

For proposal process it feasible to accomplish the yearly customer demand

Year	Demand per year	Demand per day	Customer cycle time (Sec)
2022	10000	40	2025
2023	44750	179	453
2024	87500	350	231
2025	92500	370	219
2026	92500	370	219

Demand forecast and Installed Capacity�

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Detailed information for the Presentation

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PFMEA
Control Plan
Quality control
Process Cost
Capacity
Process Matrix criterio
List of tolos
Process flow

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Main Process Manufacturing Process Flow

Injection Molding

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Inspection

Rework process

OK

NG

Possible reworked?

Scrap

NO

YES

Incoming

The plastic part is cooling and solid

Eject from the opened mould

Packing

Fills Heating plastic in barrel

Start

Start motorised screw of equipment

Feed plastic granules via funnel into barrel

Heat to a molten state

Push molten plastic to mould

Screw injects molten plastic at pressure into mould cavity

Pretotype

Prototype

Mass Manufacturing

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Seat Manufacturing�

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Manufacturing Method: Injection Molding

Cycle Time: 199.108 Sec

(Note: Cycle time is higher because clamping pressure will be 2 KN/Cm2. It increases running time and cooling time for the seat manufacturing.)

Cost of Manufacturing of Seat: 3.22 Euro/ 2 Seats

Why Injection Molding Seat Manufacturing?

1. Injection Molding is Cheapest method for Plastic parts

2. Dimensions of Seat are very large

For economic and series production of Seats, Injection Molding is preferable

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Assembly�

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Manufacturing Method: Hand Drilling

Cycle Time: 100 Sec

Cost of Manufacturing : 0.85 Euro/ Dinghy

Why Hand Drilling?

Cheapest method
No Complexity in Design
Less accuracy is acceptable

Manual Operations are preferred to decrease the cost and time

Drilling Operation

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Costing

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Parts Involved	Process	Number of Direct workers	Cycle time [s]	Direct labor rate / h	Rate SOH	ROH per hour	SOH Per Hour	Sum	Hourly machine	Machine costs / pc	Defect rate (%)	Process costs / pc
Parts Involved	Process	Number of Direct workers	Cycle time [s]	Direct labor rate / h	Rate SOH	ROH per hour	SOH Per Hour	Sum	rate [€]	Machine costs / pc	Defect rate (%)	Process costs / pc
Front Part	Inj. Mold	2.5	150	20.00 €	116%	16.00 €	23.20 €	6.17 €	156,71	2,51 €	3,5	13,14 €
Middle Part	Inj. Mold	2.5	150	20.00 €	116%	16.00 €	23,20 €	6.17 €	157,31	2,53 €	3,5	13,17 €
Rear Part	Inj. Mold	2.5	150	20.00 €	116%	16.00 €	23.20 €	6.17 €	157,31	2,53 €	3,5	13,17 €
Seats	Inj. Molding Seats	2	199.1	20.00 €	116%	16.00 €	23.20 €	6.55 €	26.44	1.46 €	3	8,25 €
Assembly (front, middle and rear)	Hand Drilling	1	100	20.00 €	116%	16.00 €	23.20 €	1.64 €	-	-	3	1,75 €
Assembly (front, middle and rear)	Finishing	1	95	20.00 €	116%	16.00 €	23.20 €	1.56 €	-	-	0	1,56 €
Rear part Silicone strip	Assembly	1	60	20.00 €	116%	16.00 €	23.20 €	0.98 €	-		3	1,01 €
1st Wheel	Assembly	1	140	20.00 €	116%	16.00 €	23.20 €	1.15 €	-	-	3	1.18 €
2nd Wheel	Assembly	1	140	20.00 €	116%	16.00 €	23.20 €	2.30 €	-	-	3	1.18 €
Total												54,42 €

After the analysis of the process, the product will cost 54,42 €

Total Process Cost

https://docs.google.com/spreadsheets/d/1uS0_B_QeHgeEp1zbF7yB0petMJ7QoS4O/edit?usp=sharing&ouid=109860424102860559415&rtpof=true&sd=true

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Total Material Cost

Complete Dinghy boat

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Source –

https://www.alibaba.com/product-detail/Glass-Fiber-Polypropylene-Reinforced-Compound

https://www.alibaba.com/product-detail/Cardboard

https://www.alibaba.com/product-detail/Polyurethane-foam-sheets

https://www.alibaba.com/product-detail/Shandong-low-price-galvalume-galvanized-stainless_1600282760433.html

https://www.alibaba.com/product-detail/Faber-Castell-UHU-35ML

Source –

https://www.statista.com/statistics/1171074/price-high-density-polyethylene-forecast-globally/

https://www.aliexpress.com/item/

https://www.statista.com/statistics/214246/world-steel-prices/

https://www.alibaba.com/product-detail/Usapa10mm-13mm-16mm-Polypropylene-Core-Glass

Sr. No.	Part Description	Material	Qty/Requirements	Rate	Material Cost (€)
1	Boat Material	High density Polyethylene	15.42 Kg	€ 770 /ton	11.88
2	Seat Material	High Density Polyethylene	03.44 Kg	€ 770 /ton	02.65
3	Waterproof seal	Silicone Sealing Strip	06.40 m	25 mm = 3.08 EUR/5 m� 35 mm = 3.56 EUR/5 m	04.25
4	U Clamp	Stainless Steel	00.50 Kg	€ 760 /ton	00.54
5	Nuts and Bolts	Stainless Steel	00.28 Kg	€ 760 /ton	00.31
6	Paddles	Polypropylene and fibre glass	2 piece		10.34
7	Cardboard boxes	Cardboard	4.48 Sq.m./boat	€ 0.0901/Sq m (sample)	00.40
8	Stickers (logo & graphics)		2 Qty.	€ 0.02 /Piece	00.04
9	Glue	Adhesive UHU	1	€ 1.35/35 ml	01.35
10	Wheels	Cold-roll steel sheets Zn plating	2 (0.08 Kg)	€ 4.24 /piece	08.48
Total :					€ 40.24

Calculated Total Material Cost per Dinghy is € 40.24

https://docs.google.com/spreadsheets/d/1uS0_B_QeHgeEp1zbF7yB0petMJ7QoS4O/edit?usp=sharing&ouid=109860424102860559415&rtpof=true&sd=true

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Material Cost

Part 2

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Source –

https://www.statista.com/statistics/1171074/price-high-density-polyethylene-forecast-globally/

https://www.aliexpress.com/item/

https://www.statista.com/statistics/214246/world-steel-prices/

https://www.alibaba.com/product-detail/Glass-Fiber-Polypropylene-Reinforced-Compound

https://www.alibaba.com/product-detail/Polyurethane-foam-sheets

Sr. No.	Part Description	Material	Qty/Requirements	Rate	Material Cost In EUR
1	Boat Material	High density Polyethylene	06.98 kg	€ 770 /ton	05.38
2	Seat Material	High Density Polyethylene	01.72 kg	€ 770 /ton	01.33
3	Waterproof seal	Silicone Sealing Strip	3.2 m	25 mm = 3.08 EUR/5 m� 35 mm = 3.56 EUR/5 m	02.13
4	Paddles	Polypropylene and fibre glass	2 piece		10.34
5	Stickers (For logo & graphics)		2 stickers	€ 0.02 /Piece	00.04

Material cost for each part is calculated likewise

https://docs.google.com/spreadsheets/d/1uS0_B_QeHgeEp1zbF7yB0petMJ7QoS4O/edit?usp=sharing&ouid=109860424102860559415&rtpof=true&sd=true

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References

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The data used for the project has been uploaded in the Google Drive. The division of data has done with respect to the groups. The google drive link is attached below. Please refer it or more details.

https://drive.google.com/drive/folders/1iuC-UQQ17_xG3MdsDXERo8uS2Ey42GNF?usp=sharing

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Backup

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Material Cost

Part 1

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Source –

https://www.statista.com/statistics/1171074/price-high-density-polyethylene-forecast-globally/

https://www.aliexpress.com/item/

Sr. No.	Part Description	Material	Qty/Requirements	Rate	Material Cost In EUR
1	Boat Material	HDPE	03.17 kg	€ 770 /ton	02.44

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Material Cost

Part 3

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Source –

https://www.statista.com/statistics/1171074/price-high-density-polyethylene-forecast-globally/

https://www.aliexpress.com/item/

https://www.statista.com/statistics/214246/world-steel-prices/

https://www.alibaba.com/product-detail/Polyurethane-foam-sheets

Sr. No.	Part Description	Material	Qty/Requirements	Rate	Material Cost In EUR
1	Boat Material	HDPE	05.34 kg	€ 770 /ton	04.11
2	Seat Material	HDPE	01.72 kg	€ 770 /ton	01.32
3	Water proof seal	Silicone Sealing Strip	03.20 m	25 mm = 3.08 EUR/5 m� 35 mm = 3.56 EUR/5 m	02.13
4	Wheels	Cold-roll steel sheets	00.08 Kg (2 Qty.)	€ 4.24 /piece	08.48

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Thank you!

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