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Contents 1.0 EXECUTIVE SUMMARY ................................................................................................................ 1

2.0 LIST OF TABLE AND FIGURE ......................................................................................................... 2

3.0 ACKNOWLEDGEMENT ................................................................................................................. 7

4.0 INTRODUCTION ........................................................................................................................... 8

5.0 LITERATURE REVIEW .................................................................................................................. 10

5.1 BENCHMARK .............................................................................................................................. 10

5.2 BACKGROUND OF THE FOLD-IT & GO PORTABLE WAGON ........................................................ 11

6.0 MAIN CONTENT DESIGN ............................................................................................................ 13

6.1 BILL OF MATERIALS .................................................................................................................... 13

6.2 PUGH MATRIX ............................................................................................................................ 14

7.0 RESULTS & DISCUSSION ............................................................................................................. 16

8.0 CONCLUSION & RECOMMENDATION ........................................................................................ 18

9.0 REFFERENCES .................................................................................................................................. 19

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1.0 EXECUTIVE SUMMARY

This report is about design project. All semester one student have been given a project to

design a product. The product to be design is either can in form of invention or innovation.

Therefore, we have chosen portable trolley to be designed for this project. The objectives of

the project are to learn about the design process of the trolley and designed a trolley. The

design scope of the trolley is to design a trolley that are medium size, portable and foldable,

that can be used in supermarket and fit in car trunk. The design is accomplished by first

referring to the other portable trolley design that existed. Then, each of our members

produces a design of a portable trolley. The designs criteria are based on portable wagon and

baby stroller. The designs were than be discussed for their specification. The best

specification aspects from all the design are than be choose and compile together. Then, the

best portable trolley design was make. In here, we consider our portable trolley design is

successful. The benefit of our portable trolley are it is portable, lightweight, strong, durable,

easy to carry, easy to assemble and most important easy to operate.

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2.0 LIST OF TABLE AND FIGURE

The specifications of our portable trolley as shown in table 2.1 below. The figure 2.1 shows

the model final design of our portable trolley. The idea was generated from the concept of baby

stroller as shown in figure 2.2, wagon shown in figure 2.3 and standard portable trolley shown in

figure 2.4. Figure 2.5, 2.6, 2.7, 2.8, 2.9, 2.10, 2.11 & 2.12 present the sample of parts and materials of

the trolley. Figure 2.13, 2.14, 2.15 & 2.16 show our portable trolley drawing design.

Dimension 60cm x 40cm x 50cm (length, width &

height)

Weight Approx 5.0kg

Max Weight Capacity Approx 30.0kg

Material Stainless steel, plastic (washer & cover),

rubber (wheels) & nylon (net)

Table 2.1

Figure 2.1

Figure 2.2

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Figure 2.3

Figure 2.5 : Wheel

Figure 2.7 : Braided nylon rope & net

Figure 2.6 : Handle

Figure 2.4

4

Figure 2.8 : Metal washer

Figure 2.10 : Rivet

Figure 2.9 : Plastic washer

Figure 2.11: Square pole

Figure 2.12: Plate bar

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Square Pole

Wheel

Arm

Edge cover

Handle

Arm joint

Figure 2.13 : Schematic diagram with label

Figure 2.14: Orthographic projection

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Figure 2.15: Isometric projection

Figure 2.16: Exploded view

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3.0 ACKNOWLEDGEMENT

After few months learning about design process and do this project there are many

thing that we have accomplish. More knowledge and skills that we have learn from it. Thus

we want to acknowledge all people that have help finish the project.

Firstly, we would to say thank to our lecturer that have taught us about design process

and give lot of guidance for us to complete the project.

We would also like to thank the entire classmates that help us in this project. They

give a lot of guidance, share idea and information on how to accomplish this project.

We also would like to acknowledge worker at Maria Stationary Shop, at seksyen 2,

Shah Alam, for helping us to select material to build our model.

Lastly, we would like to thank to all people that have help us directly or non-directly

for finishing this product. Thank you.

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4.0 INTRODUCTION

Every Saturday is considered as ‘No Plastic Bag Day’. In Malaysia, many of

supermarket has practicing it by not given plastic bag in every Saturday to their customer.

Some provide the plastic bag upon request and the customer will be charge 20 cent for each

plastic they ask. Instead of selling or giving a plastic bag, some supermarket will offer their

customer with some fancy shopping bag that cost RM 4 the cheapest. If they do not buy it

they have to carry all the groceries barehanded themselves. This situation troubles the old

folks and person that do the shopping alone. If they use the supermarket trolley or cart, the far

most they can go is to the car park.

In conjunction with this matter, our group have decided to design portable trolley that

will become handy for the supermarket customer. This trolley is not own by supermarket and

consider as public but it is vice versa, public own it and consider as personal trolley. They

can store the trolley in their house, car trunk or elsewhere. They can bring the trolley, to the

supermarket as substitution to the supermarket trolley. Most important they do not have to

carry all their groceries barehanded every Saturday. The generation of the idea on the

portable trolley design of our group is based on baby stroller, portable wagon and standard

portable trolley that being use today. The basic criteria and specification for all the product

are small, light, durable, strong, easy to carry and easy to assemble.

Our group have choose to design a medium size portable trolley. The dimension for

the trolley is 40cm X 60cm X 50cm for its width, length and height. We find this dimension

fit in all car trunks even in small and compact car. The main reason for we choose medium

size trolley is it allow customer to easily fold the trolley, keep it inside the car trunk along

with their groceries or they can just put the trolley inside the car with the groceries in the car

trunk without unloading the groceries. The trolley is foldable, lightweight and easy to store

just like conventional baby stroller that available in supermarket. The trolley can be

considered easy to be assemble as it cost you less than 30 seconds to be assemble. All you

need to do is pull and stretch to the trolley, make sure all parts are correctly secure and then

put the trolley handle socket.

For compartment part, we use braided nylon net that then be form into a box shape so

it hold all the groceries. The net is durable and can support heavy load. The net is secure to

each 4 pole of the trolley. The net usage allow the trolley to be fold rather than standard

trolley that use steel cage for their compartment frame. 4 wheels also be place beneath each

pole. All the wheels are free to move to all direction. This makes this trolley easy to handle

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and use less energy. We use rubberize wheel trolley to provide smoothness as the trolley

being pull in the gravel or hard surface.

Most part of the trolley is made from materials that can be recycled except for the

pole cover and net part. It suits the green concepts, which reduce, reuse and recycle.

Therefore, our hope that the consumption of plastic can be reduces by using our portable

trolley design.

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5.0 LITERATURE REVIEW

5.1 BENCHMARK

We use Fold-it & Go Portable Wagon as our benchmark. It simple design, durability

and strength are the main criteria to be point out and compare with our product. Figure 5.1

shows the sample of Fold-it & Go Portable Wagon, sourced from

http://www.foldingwagon.com. The simulation of fold and unfold of Fold-it &Go Portable

Wagon as shown in the figure 4.2 and figure 4.3, sourced from http://www.sears.com.

Specification of the Fold-it & Go portable wagon

Dimension (88.9x50.8x104.1) cm

Weight 8.6 kg

Max Weight Capacity 57.0 kg

Material Composition Steel, rubber & polyester fabric

Tires Solid polyfoam

Figure 5.2

Figure 5.1

Figure 5.3

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5.2 BACKGROUND OF THE FOLD-IT & GO PORTABLE WAGON

The Folding Wagon concept was designed by Tamara Galt (Tami) in 1997. It began

when Tami and her husband Tom had been shopping at farmers’ market and had bought more

than could carry. She tried to bring a conventional wagon in the next week to help her to

carry her things when shopping. However the wagon would not fit in her car. She tried to find

the way to solve her problem by surfing internet in long hours, but she failed to find it and

she concluded that no such product existed. After she got the first child, the amount of stuff

she had to bring everywhere increased. Tami thought that she needed the wagon which could

easily fit in the car for transport. The new wagon should have strength and utility of

conventional wagon, but it can be fold and transport of a folding chair-in-a bag. It also can be

completely assembled.

Tami convinced Tom to work with her to develop a design and produce

prototypes in 1999. The basic mechanism for Folding Wagon became reality after many

month of work and countless prototypes. The design of Folding Wagon was achieved all of

their objectives. It can fold and unfold easily. For the patent protection of the concept, Tami

and Tom filed their innovation. The Galt’s Folding Wagon became one of thousands of

prototypes presented to a startup toy company in year 2000 which was conducting a national

research for new product ideas. Tami and Tom were happy when their design was choose by

small toy company and they asked to license the concept for the right to produce and

distribute a Folding Wagon product. But in year 2002, the toy company was bankrupt and

could not sell even a single wagon. Tami and Tom entered the innovation contest, “Not so

Crazy Idea” organized by “the Early Show” on CBS and the United Inventor Association.

Their product was evaluated and was chosen from thousands product as one of five product

to be featured on “The Early Show”. They appeared on the TV show that was held at New

York hosted by Bryant Gumble on 2/15/02. Their patent was granted in December 2002.

Although they worked with other companies on the Folding Wagon concept, but all company

failed to manufacture the product.

Tami and Tom got call by a representative of TriGen Group, LLC in October 2005.

The company emphasized the quality of the design that created by Tami and Tom. 9 month

later, a licensing agreement was finalized between Folding Wagon LLC and TriGen Group

LLC. As the result, TriGen Group LLS became the exclusive manufacturer of product based

on the Folding Wagon concept. They named the product as Fold-it & Go Portable Wagon and

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became available in the market in mid-2007. Many famous retailers and chain retailers

showed their interest to market Fold-it & Go Portable Wagon. Lastly, the product was well

received in the market.

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6.0 MAIN CONTENT DESIGN

6.1 BILL OF MATERIALS

Bill of material is a list of each individual component in the product. Bill off material

consists of part description, quantity of parts needed and part material. For the wheel parts,

we used vulcanized rubber and steel for it build materials. It is because vulcanized rubber is

cheap, absorbs shock, not skidding and produces less sound in operation. Steel is used to

connect the rubber wheel with the body of the trolley because steel is strong enough to

withstand a high load. For the parts of square pole, arm, handle, arm joint and handle

connector, we used stainless steel. It is because stainless steel is can withstand heat, non-

corrode, durable and easy to work with. For the net part, we used breaded nylon rope. Nylon

has high resistant to water and also to insects, fungi, molds, mildew, rot and many chemicals.

So, that show nylon has high durability. Besides, it has flexibility, impervious to sunlight and

work as an excellent shock absorber. Parts of edge cover and plastic washer are made of

plastic material. Plastic is used because it has lightweight, high wear resistance, not rough so

it would not cut the nylon rope, easily processed and corrosion resistance. Lastly, for the part

of metal washer made of metal because metal is suitable with the part to joint which is

stainless steel. Table 6.1 below show the bill of materials of the product.

No. Parts Materials Quantity

1. Wheel Rubber / Steel 4

2. Square Pole Stainless Steel 4

3. Arm Stainless Steel 7

4. Handle Stainless Steel 1

5. Arm Joint Stainless Steel 1

6. Net Braided Nylon Rope 1

7. Edge Cover Plastic 4

8. Handle Connector Stainless Steel 2

9. Rivet Aluminium 37

10. Plastic Washer Plastic 16

11. Metal Washer Metal 21

Table 6.1: Bill of Materials

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6.2 PUGH MATRIX

The Pugh Matrix is a criteria-based decision matrix which uses criteria scoring to

determine which of several potential solutions or alternatives should be selected. Today, the

first problem of the existing trolley is not easy to handle. The customer need to use both

hands to control the handle of a trolley. Besides, the trolley is too big in size and does not fit

with a boot of a car. The customer need to transfer the groceries after shopping to the boot

from the trolley and it is just waste of time. The price of a trolley also expensive and the

people do not interest to buy the trolley. Therefore, there are some criteria that we considered

in design of a trolley. First criteria that we choose are easy to handle. It is because, this

criteria is very important to make sure the customer could operate the trolley easily. They

could operate the trolley by single hand only. Secondly, light trolley. We considered on the

weight of the trolley because the customer could lift the trolley to go any supermarket

without facing any problem to bring the trolley and suitable to carry around as less energy

(human power) consume to pull it. Thirdly, the size of the trolley in medium because to fit

the trolley with the boot of a car. The customers do not have to transfer the groceries into the

boot from the trolley as the trolley could fit into the boot of a car. It could save the time of a

customer. Besides, low cost production also is one of the criteria that we considered. It is

because to make sure the price of a trolley not too expensive and everybody afford to buy it.

The production of this trolley requires low manufacturing cost as it involve simple assembly

process that a few parts to be cut, rivet and screw. The only part to be weld is handle. Thus, it

is low cost and save time. Foldable also is an important criteria for saving the space to store.

The criteria in durability, the trolley is long lasting. The materials of the trolley is very good

and strong. Table 6.2 shows the Pugh Matrix of the trolley. From the Pugh Matrix of this

design, the highest criteria scoring are member D. The design of member D was chosen as

there are improvements to this design.

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No. Criteria A B C D

1. Easy to handle 1 1 1 1

2. Light 1 1 1 1

3. Low cost (production) 1 1 1 1

4. Easy to store 1 1 1 1

5. Easy to assemble 1 1 1 1

6. Not skidding 1 1 1 1

7. Strength 1 1 1 1

8. Using less energy to operate (human power)

1 1 1 1

9. Good stability 1 1 1 1

10. Low cost in maintenance 0 1 1 1

11. Automatic movement 0 0 0 0

12. Multi-purpose function 0 0 1 1

13. Suitable size/shape 0 1 1 1

14. Environmental friendly 1 1 1 1

15. Long lasting (durability) 1 1 1 1

16. Foldable 0 0 0 1

Total 11 13 14 15

Table 6.2: Pugh Matrix

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7.0 RESULTS & DISCUSSION

The trolley can be considered strong based on its design and materials used. Still there

are still many to be improved from it. For the manufacturing cost, most part of the trolley

does not require welding. Most of the part is being joint by rivet and screw. The only part to

weld is the handle. All the stainless steel plate and hollow bar require no bending. Therefore

all the metal part is just need to be cut to size and some stamping for the metal plate to shape

it, remove excess part and make hole. Some of the part can be manufacture from other

supplier, like the wheels. This entire factor can reduce the price of the trolley.

The type of material use and thickness need to be change to increase the strength of

trolley, become lighter and durable. The stainless steel part can be change with aluminium.

This is because aluminium is 1/3 the weight of steel. Furthermore its not corrode. The

substitution of aluminium with stainless steel would not change the making process of the

trolley. So, it is consume no additional cost for process but consume more cost on material.

The shape of the trolley is ergonomic. Its does not require the operator to bend their

body to pull the trolley. This trolley can fit into most of Asian people as they are not too tall.

For tall people that have height more than 1.8 metre the trolley is not ergonomic with them.

Maybe the handle can be design as an adjustable handle that allow the handle to be stretched

even more. For the handle no padding was place on it. Some padding should be added to the

handle to improve grip and comfort to user. Rubber or plastic padding can be put to the

handle.

For the net compartment part there was no base supports bellow it. The load force is

transfer to all the nylon rope that attach to each pole. Addition of metal base support below

the trolley can reinforce the compartment part as the load is transfer to base support as well as

the rope. Therefore, more weight can be load into the trolley. Few adjustment on the design

can be done so base support can be added as trolley part.

The net was made from the braided nylon rope. It is strong, durable and shock absorb.

It is useful because the net does not have rigid structure like steel cage. So, it can be fold and

shape, making the trolley foldable and easy to store. The braided nylon rope can be change

with nylon Kermantle rope. The woven exterior sheath called mantle protect the core called

kern from being torn or scratch. Nylon Kermantle rope can increase the strength and

durability of the net. Figure 6.1 shows the example of Kermantle rope, sourced from

http://www.nrs.com/tech_talk/know_the_ropes.asp.

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For the wheel use is suitable enough to be use on supermarket cement floor and tile.

Also can be use on tar paved road. But it will be produce high vibration and noise due to the

wheel. Therefore, bigger wheel needed to overcome the problem. Bigger wheel allow the

trolley to be use on more coarse ground. It would not easily get stuck due to gravels, hole and

can overcame many terrain easily.

There is no grease put on the movable joint parts. Grease should be put to those part

to ensure it operate smoothly and reduce wear. Not only for assembly, grease or lubricating

oil should be put on the movable joint for the maintenance purposes.

Figure 7.1: Kermantle rope

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8.0 CONCLUSION & RECOMMENDATION

In conclusion, by doing this project we have able to learn and get to know about

design process and successfully design a product which is a portable trolley. Although only a

model was made, but we have gain much knowledge by doing it. We, learn about material,

type of material, it strength and weaknesses. We also learn about parts involve in trolley, its

mechanism mostly on the foldable mechanism and wheel mechanism. There is still many

room to be improvise mostly on the product itself. We can change the product material by

using lighter and stronger material. The design also needs some alteration to make it stronger

like adding supportive bases to the net. Product design mechanism also can be change so

simple system can be apply to the product and less part required for the portable trolley. The

most important to be remember is the purpose of design which we must create a product that

satisfied need and constraint. Therefore, we really hope that we can continue to improvise the

trolley, make prototype of it and make it available in market. We hope by doing this portable

trolley we can create a better and greener world together.

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9.0 REFFERENCES

1. Story of Folding Wagon. Retrieved from http://www.foldingwagon.com/about.htm on 5

NOV2013.

2. Trolley, Wikipedia. Retrieved from http://en.wikipedia.org/wiki/Trolley on 5 NOV2013.

3. Trolley Offers Super Market Workout (April 2004). Retrieved from

http://news.bbc.co.uk/2/hi/3665777.stm on 5/11/2013 on 7 NOV 2013

4. Santa Ana Shopping Cart Law Shows Extent of Mayor’s Business Dealings, Adam Elmahrek (Jun

2011). Retrieved from http://www.voiceofocc.org on 7 NOV 2013.

5. Folding Wagon, Mac Sport. Retrieved from http://www.samsclub.com/sams/folding-

wagon/prod3080161.ip on 9 NOV2013.

6. Wheeling Food Product Around the Store… and away, Wilmington (2006). Retrieved from

http://www.csi.ensmp.fr/working-papers/WP/WP_CSI_006.pdf on 9 NOV 2013.

7. Pugh Method or Decision-matrix Method. Retrieved from http://www.enge.vt.edu on 12 NOV

2013.

8. Wheel of Fortune, Silicon Valley (1999). Retrieved from http://www.metroactive.com on 20 NOV

2013.

9. Know the ropes, NRS. Retrieved from http://www.nrs.com/tech_talk/know_the_ropes.asp on 1

JAN 2014