product rd session3 - 4 stage model on prd and case study of ic pushcart

7/29/2019 Product RD Session3 - 4 Stage Model on PRD and Case Study of IC Pushcart

1/23

1

Product Research & Development

Session 3

4 Stage PRD Model and Case Study of

Pushcart for Vending Ice-Cream

Department of Chemical Engineering

2nd

Semester 2012-2013

V. M. Naik


2/23

RECAPITULATION OF SESSION 2

..1) WORKING DEFINITION OF PRODUCTS

UNDER OUR CONSIDERATION Consumer or Customer Centric Designer Artifacts /

Devices / Specialty Chemicals / Process Plants/

Materials

Which Are Devised to Satisfy Specific Needs of Users

Which Are More Recognized by Their Performance Than

Their Constituents

Whose Form / Functionalities Are Conceived andCreated Embodying Principles of Chemical Engineering


3/23

2) THE NEXT SET OF QUESTIONS

Who Decide, and How Do They Decide What

Product One Should Develop

Is there any Standard Structured Process

Available for Product Development

What Are the Elements of a Structured Process

(If Any) for Product Development

RECAPITULATION OF SESSION 2


4/23

Cusslers 4 Stage Model of Product Design

and Development

Opportunity or Need Identification

Idea Generation

Idea Selection

Design and Manufacture


5/23

Cusslers 4 Stage Model of Product Design

and Development

Opportunity or Need Identification

Idea Generation

Idea Selection

Design and Manufacture

Important Abstraction

However, the Process of Creation of a Product

Varies from Product to Product. It Is Far More

Complex and Non Linear, in Real Life

We Will Illustrate the Process with a Few Real-Life

Case Studies


6/23

6

Objectives of the Case Studies:

Illustrate the Steps, and Stages Involved in

Product R&D, and the Nonlinear Nature of the

Whole Process

Illustrate the Skills and Competencies Required

to MAKE AN INVENTION AND INNOVATIONHAPPEN


7/23

CASE STUDY OF ICE-CREAM VENDING

PUSH CARTSThe Background

An MNC Built an Ambitious Modern Plant for Ice-Cream, in

India, and Set up a Unique Supply Chain to Improve

Availability of Quality Ice-Cream to Consumers, in 1990s

CITY COLD

STORES

++ ++

REFRIGERATED

TRUCKS

REGIONAL

COLD

STORES

REFRIGERATED

TRUCKS

RETAIL CABINETS

VENDING PUSHCARTS

FACTORY

COLD STORE


8/23

8

Case Study Continued.

Ice-Cream Is a Delicately Structured Multiphase CompositeSystem. It Should Be Stored and Served at ~ -18Deg C forConsumers Safety and Delight

Therefore Vending Push CartsWere an Important StrategicBusiness Imperative forIncreasing the Availability ofIce-Cream to Consumers

++


9/23

CASE STUDY OF ICE-CREAM VENDING PUSH CARTSSchematic Design of the Original Push Cart, Which Was

Developed Jointly by Indian Business and Laboratory in Vlaardingen

35 Kg of 35%PG-Water Eutectic Frozen to -25 deg C

Employed as Nontoxic Coolant

Poly Urethane

(PU) Foam

Insulation

Eutectic

CoolantJacket

Freezeron

Wheel++


10/23

CASE STUDY OF ICE-CREAM VENDING PUSH CARTS

Market Response

Vendors Complained That the Push Carts Were TooHeavy and Difficult to Push

Consumers Complained That the Ice-Cream Was

Soggy When Purchased in the Afternoon

Ice-cream Sales Were Far Below Break-even Level

An Unrelated Discussion with the Business Head of

CAME Region, Regarding the MAP-DAP Eutectics

Triggered the Subsequent Events

The Needs of Both, the Customers and Consumers

Were not Met


11/23

CASE STUDY OF ICE-CREAM VENDING PUSH

CARTS Business Sent a Technical Brief to Research

Develop a Rigorous Theoretical Model of the

Pushcart and Improve the Performance of the

Non-Toxic 35%PG-Water Eutectic Coolant

System So That:

The Pushcarts Can Deliver Non-soggy Ice-

Cream for at Least 10 Hrs

AND, If Possible

The Coolant Quantity Can Be Reduced from

35 Kg to 20 Kg, to Achieve a Reduction in the

Weight of the Push Cart by 15 Kg


12/23


The First Step Was to Perform Reality Checks on the

Technical Brief from Business


13/23

CASE STUDY OF ICE-CREAM VENDING PUSH CARTSOne Must Learn to Make Quick Back of the Envelop Estimates for

Reality Checks

Next Reality Check:

Estimate the Expected Cooling

Capacity of the Eutectic

Reality Check1:

What Could Be the Maximum Extent of Heat Ingress (DH) through

PUF Insulation of the Walls of the Cabinet in 12 Hrs?

DH = A * k * DT * t / l

~ 3600kJoules

Please Note : For a liberal

estimate ofDH, one can neglect

the resistance by air films, and

use the (larger ) outer surfacearea

Tin=-200C

Tout=+300C

0.9 m

0.6m

Insulation:

k = 30 mW/m oC

l = 75 mm

CASE STUDY OF ICE CREAM VENDING PUSH CARTS


14/23

CASE STUDY OF ICE-CREAM VENDING PUSH CARTS One Must Learn to Make Quick Back of the Envelop Estimates for

Reality Checks

Reality Check 2:

What Is the Expected Latent Heat of Melting for the 35% PG-WaterEutectic System?

DH of Melting = ~ X water* l m Water

= ~ 200 k Joules/kg

Please Note : For a quick

conservative estimate ofDH for

melting, the heat ofmelting/dissolution of the solute

was neglected

Typical melting

curve of eutectics

Temperature

Enthalpy/Kg

MeltingofEuMix

TEu


15/23


Quick Back of the Envelop Reality Check

Latent Heat of Fusion of PG-Water Eutectic

Containing 65% Water~ 200 KJ/Kg

Likely Heat Ingress in to the Box, over 12 Hrs ~

3000 KJ

Therefore the Theoretically Estimated Quantity of

Eutectic Coolant Required to Counter the Heat

Ingress for 12 hrs : ~ 15 Kg Maximum (as against 35

Kg Actual)

What Was Likely to Be the Source of Discrepancies?

Next Steps : Verify Data and Assumptions


16/23


Verifying Assumptions Regarding Latent Heat of Melting of 35%PG-Water Eutectic

Using Differential Scanning Calorimetry (DSC)

Conclusions:

1. 35% PGWater Was Not an Eutectic System and Its

Cooling Capacity Was Far Short of Theoretical

Estimates/Requirements

2. There Was Definitely a Need for Improvement of the

Eutectic System.3. Was the Design of Pushcart Acceptable.? Not Sure

D H = < 30 KJ/Kg


17/23

Case Study Continued.

Next Steps :

Additional Information Gathering, and FirstPerson Observations/Discussions on the

Field, to Better Understand the Issues, as Well

as for Deciding the Way Forward


18/23

Case Study Continued..Visits to Cold Store, Vendors, and Development Department

Discussions with Customers/Fabricators/Development Team Regarding

New Ideas and Their Feedback:

(i) Electric Supply Unreliable

(ii) Refrigerants in Use Not Suitable for Cooling the Eutectic below 30 Deg C

(iii)Detachable Freezer Couplings not Reliable

(iv) There Is No Better Coolant or Insulation Available in the World (!)

(v) Dry Ice Poses Supply Chain as well as Safety Issues

Field Observations:

(i) Quick Ingress of Hot/Humid Air, When Lid Is Opened(ii) Equilibration of Air Temperature with Surroundings,

in a Short Time

(iii) Steady Ingress of Heat through Insulation,

Heating/Melting of Coolant, and Slow Rise in Ice-Cream

Temperature


19/23

Case Study Of Ice-Cream Push CartsVisits to Cold Store, Vendors, and Development Department

Learnings:

Performance of Pushcart Depends on Several Coupled

Factors and Processes. We Must Have a DependableTheoretical Modeling/Simulation Tool to Validate/Rank

Quality of New Candidate Ideas for Performance

Improvement

We Must Co-invent the New Pushcart Design, and

Eutectic System, if We Want to Succeed


20/23

Case Study Of Ice-cream Vending Push CartsNext Step :Build Theoretical Model For Predicting Heat Ingress

and Ice-Cream Melting

How Do You Build a Model for Multiple Coupled Phenomena with Vastly

Different Time-scales within a Short Time and with Limited Resource?

The Physical Model

Enthalpy Temp Diagram

for Cornetto Ice-Cream


21/23

21

Case Study Of Ice-cream Vending Push CartsBuilding Theoretical Model For Predicting Heat Ingress and

Ice-Cream Melting : The Way-forward

Simplify Model by Decoupling Modeling of the Three Processes Which

Operate at Three Distinct Time-scales, Viz. (i) Quick Ingress of Hot Air

When Lid Is Opened, (ii) Equilibration of Air Temperature with Surroundings,

(iii) Steady Ingress of Heat through Insulation, Heating/Melting of Coolant

and Slow Rise in Ice-Cream Temperature

The Physical Model

Enthalpy Temp Diagram

for Cornetto Ice-Cream


22/23

Case Study Of Ice-cream Vending Push Carts

Theoretical Model For Heat Ingress and Ice-Cream Melting

Result 1..Quick Air Ingress and Its Rapid Equilibration

C S Of C


23/23

Case Study Of Ice-cream Vending Push Carts

Theoretical Model For Heat Ingress and Ice-Cream Melting

Result 2 . Slow Heat Ingress through Walls of Container

Comparison of Result 1&2 with Field Data Confirmed That the

Modeling Methodology

The Model Was Ready for Evaluation of

Alternative Ideas

product rd session3 - 4 stage model on prd and case study of ic pushcart

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