APPLICATION 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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mengaku membenarkan tesis * 101 di simpan di Pusat Khidmat Maklumat Akadcmik, Universiti Malaysia Sarawak dengan syarat-sya rat kegwHlan seperti berikut:

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APPROVAL SHEET

This project report attached here to , entitle "Design and Development of Pepper

Harvester Ladder" prepared and subm itted 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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Aid i I AzI i Alias Date

Supervisor

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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

p

ACKNOWLEDGEMENTS

Firstly, I wo uld like to express my most gratitude to The God for givi ng me the

opportunity to finish my final year proj ect. 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 port ion of pepper

tree. The application of axiomatic concept is used in this project to facilitate the

design ing 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 des ign 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 materia l

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.

v

j-~U~~; ,u. .,,4 lV\dJr..l •.t~ .It AkaLUnH~ UNIVER.';1 fJ MALAYSIA SARAWAJ(

TABLE OF CONTENT

Page

List o fTables X

List of Figures XI

List of Abbreviation 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 Ax iomati c Product Deve lop ment Lifecyc le IS

Chapter 3 METHODOLOGY

3. I Introduction 19

3.2 Des ign Phases 19

3,3 Recognition 0 fneeds 21

3.3. 1 Customer needs 21

3.3.2 Input Con straint 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 Des ign 28

3.\0 Material Selec tion 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 ficat ion 32

4.2 .2 Constraint 32

4.2.3 Customer Requirement 32

4.3 Design spec ifi cati on 33

4.3. 1 HOllse of Quality 34

4.4 Funct ional Requirements (FRs) 36

4.5 Concept Fa [mulalion 38

4.5.\ DPs tor Concept I 38

vu

39 4.5.2 DPs for Concept 2

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 Des ign 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 of FRs 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 In fonna tion 53

4.9 Structural results 53

4.10 Material In fOlmation 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 s loped 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 decompos ition of FRs 37

4 .3 DPs decompos ition for Concept 1 39

4.4 DPs decomposition for Concept 2 40

4.5 DPs decomposition for Concept 3 41

4.6 DPs decomposit ion for Concep t 4 42

4.7 Hierarchies deco mposition of FRs 46

4.8 Hierarchies decompos ition for DPs 47

4 .9 Solid Model of Ha rvest Ladder 52

4 .10 Equiva lent stress 54

4 . 11 Maximum equi va lent stress 54

4 .12 Equivalent stress 56

4 .13 Maximum princ ipal stress 56

4. 14 Final des ign of ladeler 6 1

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 Axiomat ic 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 Electron ic Engineer

Quality Function Deployment

Malaysian Pepper Board

Pepper Marketing Board

Product Design Specification

The Occupation Safety and Health Act 1994

Xli

CHAPTER 1

INTRODUCTION

Malays ia' s production pepper produced outpu t of 4 tonnes in 1870 and made

Malaysia is the fou rth 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 wo rld 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 o f the important cash crops supporting the li velihood 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 di vision.[I ]

In 1980, pepper ind ustry in Malaysia dropped to third position in list of world

market of pepper producer to India and Ind onesia. It was because pepper fanl1ers

faced the majo r problems such as escalating cost for m,maging disease and pest

problems, increasing cost of fertili zer, pesticides and labo r inputs, lack of modem

fann knowledge among pepper farmers especial ly in rural areas and tluctuatin g

export market pri ces.[2]

1

Nowadays, the pepper industry in Malays ia has been faced w ith many problems

such as the escalating cos t for man aging disease, pest problems, poor processing

technique, the high labor requirements, low efficiency o f production and increasing

cost of fertili zer and pesticides.

Malaysian Pepper Board (M PB) is the main govemment agency has overcome

this problem by take action such as development to reduce cost of labo r 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 extens ive 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 harvest in g 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 prob lem can be

so lved, more production pepper can boosted up.

2

-

Pepper vines were nonnally brought to firs t crop at the beginning of the wet

season in the second year o f tield harvesting from March to August. Aro und 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 objecti ves of this project to design and develop a new ladder tor

pepper harvesting operation . The design of the ladder wi ll 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

-- ---------- - .

CHAPTER 2

LITERATURE REVIEW

2.1 Introduction

This chapter w ill explain about pepper backgro und and process design criteria

for Ax iomatic Design. This chapter also contain abo ut 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 Bras il is a major exporter.

At Roman times and ancient Egypt , pepper already used and supplied by Arab

sea traders and they kept secret abo ut the source of the pepper. Being a va luable

commodity, peppers are used as a paym ent. Attila the Hun reputed ly demanded

3,000 pounds in weight of pepper as part of a ranso m for til e city of Ro me.

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

"Te llichery 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 constipat ion, diarThea, earache, gangrene, heart disease, hernia, hoarseness,

indigestion, insect bites, insomnia, joint pain, li ver 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 o lel Engli sh are "pipor". In Sanskrit the wo rd pepper are "pippali"

and German are "pfeffer", French are "poi vre" 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, Malays ia 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.

va lue 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 o leoresin, 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 . Trad itionally, 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 importan t 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

des ired canopy. There have there round until the fin al pruning is done when the

terminal shoots have reached the top of the 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 o r early sign of

maturity, harvest should be done to maintain thei r 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 hil l 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 fo r managing disease and pest

contro l. On this project, only focuses on the harvest ing 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 berri es

in the bushes of pepper plan t, inju ry 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 prod uction.

10