PRODUCT PLANNING AND DEVELOPMENT

REPORT

“PORTABLE STAIR” FOR ELDERS AND DISABILITIES

Created by Q5 :
 Evita Nuriya R (02411540000094)
 Fawwaz Chairon A. (02411540000122)
 Evangelica Solagratia S. (02411540000035)
 Julian Swatjez (02411748007008)
 Nik Suhaini Binti Nik Ramli (B051510168)

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 PREFACE

Gratitude to “Al Mighty Allah” who gave authors the strength,

preservation, patience and guidance to finish this financial accounting’s final
project. Authors also thankful to the assistant lab who gave writers all the guidance
and assistance in writing this final project.
This final project is made as an aptitude for learning and to give us a broad
knowledge and understanding of product planning and development by making
prototype of product. This big project also made as one of the requirement in
completing the fifth semester.
In writing this product planning and development’s final project, authors
had already done their best so that the content and purpose of this project can be
understood. Authors know that there are still many mistakes and this project is far
from perfect. So, authors hope for constructives advices and critics from various
parties, especially from the lecturer so that the mistake can be repaired for the next
time.
Hopefully this final project will be useful for others. Thanks for the
attention.

Surabaya, December 2017

Authors

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 TABLE OF CONTENTS

PREFACE ................................................................................................................ i
LIST OF TABLES .................................................................................................. v
LIST OF FIGURES .............................................................................................. vii
EXECUTIVE SUMMARY.................................................................................... ix
CHAPTER 1 ........................................................................................................... 1
PRELIMINARY ..................................................................................................... 1
1.1 Background .............................................................................................. 1
1.2 Problem Formulation ................................................................................ 2
1.3 Objective .................................................................................................. 3
1.4 Benefit ...................................................................................................... 3
1.5 Outline ...................................................................................................... 3
CHAPTER 2 ........................................................................................................... 5
LITERATURE REVIEW........................................................................................ 5
CHAPTER 3 ........................................................................................................... 7
PROJECT DESCRIPTION ..................................................................................... 7
3.1 Market Target ........................................................................................... 7
3.2 Product Competitors ................................................................................. 7
3.3 Product Explanation ................................................................................. 9
3.4 Data Collecting ....................................................................................... 10
3.5 Data Processing and Analysis ................................................................ 18
3.6 Product Concept Screening .................................................................... 31
3.7 BOM Tree and BOM Table.................................................................... 36
3.8 Design for Manufacture .......................................................................... 38
3.9 Cost of Goods Sold Calculation ............................................................. 39
CHAPTER 4 ......................................................................................................... 43
CONCLUSION AND SUGGESTION ................................................................. 43
4.1 Conclusion .............................................................................................. 43
4.2 Suggestions ............................................................................................. 43
REFERENCES...................................................................................................... 45
APPENDIX ............................................................ Error! Bookmark not defined.

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 LIST OF TABLES

Table 3. 1 Additional Functions the Customers Would Like to Add.................... 16

Table 3. 2 Suggestions for Portable Stair .............................................................. 18
Table 3. 3 Suggestions for Portable Stair .............................................................. 19
Table 3. 4 Importance Level ................................................................................. 20
Table 3. 5 Benchmarking Table ............................................................................ 21
Table 3. 6 Product Objective................................................................................. 22
Table 3. 7 Technical Response.............................................................................. 23
Table 3. 8 Assignment of Attributes to Technical Response ................................ 23
Table 3. 9 Symbols in Interaction Matrix ............................................................. 24
Table 3. 10 1st Phase of Product Specification ...................................................... 29
Table 3. 11 2nd Phase of Product Specification ..................................................... 29
Table 3. 12 2nd Phase of Product Specification (con’t) ......................................... 30
Table 3. 13 3rd Phase of Product Specification ..................................................... 30
Table 3. 14 3rd Phase of Product Specification (con’t) ......................................... 31
Table 3. 15 Morphological Chart for Portable Stair (Source: Writers, 2017)....... 32
Table 3. 16 Concept Alternatives for Portable Stair ............................................. 33
Table 3. 17 Concept Screening Table Source: Writers, 2017 ............................... 34
Table 3. 18 Concept Scoring Table ....................................................................... 35
Table 3. 19 BOM Table of Portable Stairs ............................................................ 36
Table 3. 20 BOM Table of Portable Stairs (con’t) ................................................ 37
Table 3. 21 Design for Manufacturing Portable Stairs ......................................... 39
Table 3. 22 Direct Material Cost ........................................................................... 40
Table 3. 23 Cost of Manufacturing Overhead ....................................................... 40

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 LIST OF FIGURES

Figure 2. 1 Format of House of Quality .................................................................. 5

Figure 2. 2 Toyota iBot Wheelchair (Source: www.theverge.com) ....................... 9
Figure 3. 1 Scalevo Wheelchair .............................................................................. 8
Figure 3. 2 Design of Portable Stair ...................................................................... 10
Figure 3. 3 Questionnaire Result ........................................................................... 12
Figure 3. 4 Questionnaire Result ........................................................................... 12
Figure 3. 5 Questionnaire Result ........................................................................... 13
Figure 3. 6 Questionnaire Result ........................................................................... 13
Figure 3. 7 Questionnaire Result ........................................................................... 13
Figure 3. 8 Questionnaire Result ........................................................................... 14
Figure 3. 9 Questionnaire Result ........................................................................... 14
Figure 3. 10 Questionnaire Result ......................................................................... 14
Figure 3. 11 Questionnaire Result ......................................................................... 15
Figure 3. 12 Questionnaire Result ......................................................................... 15
Figure 3. 13 Questionnaire Result ......................................................................... 15
Figure 3. 14 Questionnaire Result ......................................................................... 16
Figure 3. 15 Questionnaire Result ......................................................................... 16
Figure 3. 16 Questionnaire Result ......................................................................... 17
Figure 3. 17 Questionnaire Result ......................................................................... 17
Figure 3. 18 Questionnaire Result ......................................................................... 17
Figure 3. 19 Matrix Interaction ............................................................................. 24
Figure 3.20 Legend ............................................................................................... 25
Figure 3. 21 Matrix Interaction 2 .......................................................................... 26
Figure 3. 22 Competitive Analysis ....................................................................... 27
Figure 3. 23 Weight and Relative Weight in HOQ ............................................... 28
Figure A Product in Making Process ..................... Error! Bookmark not defined.

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 EXECUTIVE SUMMARY

Facilities is an equipment provided for a particular purpose, which is

helping society, that is why it is very important. Nowadays, government starts to
build many facilities, especially for elderly and disabilities. Elderly and disabilities
usually have difficulties in doing their daily life. That is why facilities is important
for them. One of difficulty that they usually have is taking stairs whether it is to go
up or down. But, in Indonesia the facility that can help them to take stairs is very
minim, even almost not exist. Because of those problem, writers taking initiative to
make a tools in the form of portable stair that can help them.
Portable stair is a tool that can help elderly and disabilities in taking stair. It
works like a folded fan. In this final project, a portable stair is made based on the
customer’s needs that is identified by doing VOC and make HOQ. Several technical
attributes that is corresponding to the customer’s needs are also identified.
Therefore, writers can make a product that can fully capture customer’s need and
can help them.

Keywords: Elderly, Disabilities, Portable Stairs

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 CHAPTER 1
PRELIMINARY

In this chapter, there will be some general explanation regarding this

assignment, that describes the reason of this assignment being established and the
goal of it. This chapter consists of background, objective, benefit, problem
formulation, and outline of this assignment.

1.1 Background
Accessibility of disabled people is now becoming an issue in
designing a public facilities. As a human, physical disabilities can happen
anytime whether it is less severe or severe. However, many public facilities
designed without considering the accessibility for disabled people.
Whereas, disabled people also need to use the facilities such as office
building, restaurant, or even campus. According to United Nations design
manual for a barrier-free environment, it is important to design such
facilities that is barrier-free – it can be used by anyone without having a
difficulties in using the facilities. Although it is stated by United Nations,
there are still many public places that still unequipped with such access for
disabled people.
In Indonesia, the issue is now becoming a concern in designing
public facilities. Many new buldings are now equipped with the access for
disabled people, such as parking area for disabled, ramp for wheelchair, etc.
Despite, the old buildings is unequipped with such access. This is become a
problem.

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 Figure 1. 1 Exclusive Track for Wheelchair User in a Hospital (Source: Google
Image)

Refer to the problem of the existence of access for disabled people

in old building, it is becoming a good opportunity for the developer.
Portable Stairs come up with its main feature : help disabled people,
especially people who use wheelchair to easily access public facilities that
has no permanent access. Hopefully, Portable Stairs will be a good
alternatives for disabled people to make them easily access public facilities.

1.2 Problem Formulation

Some of the issues willing to be resolved and answered through the
response of Product Design and Development are:
1. How to analyze the problems that all the disabilities have?
2. How to help the disability people to overcome their limitation in taking
stairs using the wheelchair?
3. How to analyze the performance of the existing product that being used
by the disable people to overcome their problem?
4. How to improve the performance of the existing product?
5. How are the functions and suggestion that the disability people need for
the product that can help them in taking stairs?

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1.3 Objective
The objectives that willing to be achieved by learning and doing the
product are:
1. To analyze the problems that all disability people have in their everyday
life especially in taking stairs.
2. To prepare and design the product that will help to solve the disability
problems in taking stairs.
3. To analyze all the existing product that the disability people use to help
them in taking the stairs.
4. To be able to make the prototype of the product that can help to ease
the disability people in taking stairs.

1.4 Benefit
The benefits that can be obtained by conducting this Product Design
and Development are:
1. Knowing the real problems that being faced by the disability people in
their daily life .
2. Know about all the existing product in market that is useful or not for
the disability people.
3. Know about the product development for certain product that can be
done to improve the performance of the product.

1.5 Outline
The outline of this assignment consists of:
1. The data of customer needs towards the existing problems
2. The implementation of product planning and development concept
3. The solution towards the existing problems faced by the market target
in the form of a product

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 CHAPTER 2
LITERATURE REVIEW

Product development is the set of activities beginning with the perception

of market opportunity and ending in the production, sale and delivery of a product
(Ulrich and Eppinger, 2000). A design process is the set of technical activities
within a product development process that work to meet the marketing and business
vision.
There are some processes that need to go through in making a product.
Generally, the processes are opportunity identification, concept selection and
development, and prototyping and launching (Forbes.com, 2016). In identifying
opportunity, the problem is defined and then the target market is defined by using
voice of customer (VoC). VoC contributes in gathering the information of the detail
need of the customer, and from the VoC the developer also able to select the target
market for the product. The next process will be Quality Function Deployment. In
Quality Function Deployment, the House of Quality is used as a tool to make a
matrix of relationship between VoC and technical specification that later be used
by the company as the guide to develop the product.

Figure 2. 1 Format of House of Quality

Quality Function Deployment also functions such as house of quality are

used on consumer products to identify and manage design trade-offs.

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 CHAPTER 3
PROJECT DESCRIPTION

In this chapter will be shown the explanation of the designed product, which
is Portable Stair. This chapter is divided into several explanations such as steps in
conducting the assignment, the used methods, the data results, and data analysis.

3.1 Market Target

Based on the outline of this assignment, the authors have to
determine first the steps to do in conducting this project. The first step is to
determine which market target to be chosen for the product. The authors
then chose the wheelchair users such as disabilities and elders as the market
target.
The second step is to determine the problem faced by the market
target as the topic of this assignment by conducting an observation. Through
the observation, the authors realized that there are several public places do
not have any exclusive tracks for wheelchair users. The exclusive track
means a track that could make the people with difficulties are easier in
walking through the way. In this assignment, the authors focused on the
exclusive track for stairs. Thus, the problem or the topic for this project is
decided to be creating an exclusive track for wheelchair users in taking
stairs.

3.2 Product Competitors

After that, the third step is observing the existing solution that has
been provided for this problem. In this case, the authors observed the
existing product competitor. There are 2 existing solutions which consist of:
1. Scalevo
This product is made by 10 students majored in Mechanical
Engineering and Electrical Engineering of Swiss Federal Institute
Techonolgy (ETH) in Zurich. They designed this product in order to

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 join cybathlon championship 2016. Below is the list of the
characteristics of the product. The excellence is shown by sign (+) and
the weakness is shown by sign (-).
Characteristics:
(+) Easier to be operated
(+) Can be operated without others’ support
(-) Expensive
(-) Dangerous
(-) Cannot be stored easily

Figure 3. 1 Scalevo Wheelchair (Source: www.scalevo.ch)

2. Toyota iBot Wheelchair

This product is developed by Dean Kamen in a partnership
between DEKA and Johnson and Johnson’s technology. The
development of this product started in 1990.
Characteristics:
(+) Can be operated without others’ support
(+) The height can be adjusted
(-) Expensive

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Figure 2. 2 Toyota iBot Wheelchair (Source: www.theverge.com)

3.3 Product Explanation

After observing the existing solution, the authors analyze the
weaknesses of those solutions. That is the way the authors look for another
alternative solution to cover the weaknesses of the existing ones. Due to the
expensive factor owned by both product competitors, the authors decided to
create a product as the alternative of the stair that is adjustable and suitable
for the market target. Then, the idea of portable stair is created. The list of
product description is:
1. This portable stair is easy to be carried away
2. This portable stair will overlap the existing stairs
3. The operating system of this portable stairs is just like a hand-fan
4. The length of this portable stair is adjustable

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Figure 3. 2 Design of Portable Stair (Source: Writers, 2017)

The benefits of this portable stair:

1. Can be easily carried away
2. The height is adjustable
3. Can be easily stored

This product has several innovation levels, which are the

characteristics that solve the weaknesses of the existing products. Those
innovation levels consist of:
1. It is easily carried away
2. It is not dangerous if the wheelchair is shaking when going through
downstairs
3. Can be stored and carried anywhere

3.4 Data Collecting

To develop the characteristics that the product should have, the
authors need to gain the voice of customers. The used method for collecting
the data from customers is by sharing questionnaires to several people
included in market target. The questionnaires are in the form of Google

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Docs, so the authors could input the answers online. However, the authors
asked directly to the market target (face to face). The list of questions are:
1. What is your gender?
2. How old are you?
3. How often do you usually walk?
4. Have you got any difficulties in walking?
5. How often do you use stairs?
6. Do you have any difficulties in taking stairs?
7. What is your solution so far for this walking problem?
8. Have you used any device to help you taking the stairs?
9. If you used any device, what device do you use?
10. Is your existing device helpful or not?
11. If you think your existing device is not helpful, please mention your
difficulties in operating the device!
12. What additional function do you want to add for the device?
13. What is your opinion about our Portable Stair? Will it be helpful to you?
14. Do you see any complexities of this product’s features?
15. If this Portable Stair exists, do you want to use it?
16. What is you reason related to question no.15?
17. Choose the price range of the product!
18. Can you give suggestions for this Portable Stair?

The authors are able to get 30 respondents to answer the

questionnaire. The results of the questionnaire are described in some circle
diagrams below.

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 Gender

Male

Female

45.20%
54.80%

Figure 3. 3 Questionnaire Result (Source: Writers, 2017)

Age

35-45 45-55

29% >55
35.50%

35.50%

Figure 3. 4 Questionnaire Result (Source: Writers, 2017)

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 How often you usually walk
Everyday
Once a week
16.10% Not always
12.90%
71%

Figure 3. 5 Questionnaire Result (Source: Writers, 2017)

Have difficulties in walking

Yes
No
38.70%
61.30%

Figure 3. 6 Questionnaire Result (Source: Writers, 2017)

How often use stairs

Everyday
Once a week
32.30% Not always
48.40%

19.40%

Figure 3. 7 Questionnaire Result (Source: Writers, 2017)

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 Have difficulties in taking stairs
Yes
No
41.90%
58.10%

Figure 3. 8 Questionnaire Result (Source: Writers, 2017)

Solution for walking problems

3.20% See doctor
9.70% 3.20%
38.70%
9.70% Ongoing
physiotherapy
Use wheelchair

35.50%

Figure 3. 9 Questionnaire Result (Source: Writers, 2017)

Use device in taking stairs

Yes
No
51.60%
48.80%

Figure 3. 10 Questionnaire Result (Source: Writers, 2017)

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 Device that being use
70.00% 60%
60.00%
50.00%
40.00%
30.00%
20.00% 13.40% 13.40% 13.30%
10.00%
0.00%
Have a companion Use lift Walking stick Use wheelchair

Figure 3. 11 Questionnaire Result (Source: Writers, 2017)

Existing device helpful or not

No
Yes
36.40%
63.60%

Figure 3. 12 Questionnaire Result (Source: Writers, 2017)

Any difficulties in the device

35.00%
28.60% 28.60%
30.00%
25.00%
20.00%
14.30% 14.30% 14.30%
15.00%
10.00%
5.00%
0.00%
Difficult to walk Cant goin down Complex Hard to go Still need
fast stairs easily anywhere companion

Figure 3. 13 Questionnaire Result (Source: Writers, 2017)

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Table 3. 1 Additional Functions the Customers Would Like to Add

Portable

Easy to carry

Can help lead a way

List of additional function they want to
Can reduce the pain in the legs
add for the device
Make it easy t walk faster

The comfort holder

Can easily help going down the stairs

Source: Writers, 2017

Will the product be helpful to customers?

Yes
No
9.70%

90.30%

Figure 3. 14 Questionnaire Result (Source: Writers, 2017)

Any complexities in our product

Yes
22.60% No

77.40%

Figure 3. 15 Questionnaire Result (Source: Writers, 2017)

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 They want to use the device or not

Yes
19.40% No

80.60%

Figure 3. 16 Questionnaire Result (Source: Writers, 2017)

Reason they want to use our product

30.00% 26.00%
25.00% 21.50%
20.00% 17%
15.00%
10.00%
4.30% 4.30% 4.30% 4.30% 4.30%
5.00%
0.00%
Portable Can help Easy to use Can rest Can help useful No need to To ease my
taking my feet people use stairs way
stairs

Figure 3. 17 Questionnaire Result (Source: Writers, 2017)

Price range
175-275
275-375
16.10% >375
41.90%
41.90%

Figure 3. 18 Questionnaire Result (Source: Writers, 2017)

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Table 3. 2 Suggestions for Portable Stair

Easy to operate

Should be lightweight
Suggestion for our portable
stairs
Less complexity

Strong

Source: Writers, 2017

3.5 Data Processing and Analysis

After the results of the observation are obtained, then they are being
processed in order to obtain the characteristics of the product. To determine
those characteristics, the authors should find the attributes based on VOC
(Voice of Customers) in the form of questionnaires that are explained in the
previous section. However, the authors did not directly ask the customers to
mention the product attributes and rank them in terms of importance level.
It is implied in several questions such as the 6th, 11th, 16th, and 18th questions.
Therefore, the authors conclude the customer needs based on the
respondents’ answers. Then, the authors transform those needs into primary
needs to be specific. After that, they are transformed again into secondary
needs to be more specific. List of secondary needs is the list of product
attributes as well. The attributes transformation is shown in Table 3.3 below.

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Table 3. 3 Suggestions for Portable Stair
Customer Needs Primary Needs Secondary Needs
Can be used for a long Not easily damaged
Endurance (lifespan)
time
Safe using Ergonomic Safety (safe using)
Can be carried Moveable
Design
everywhere
Economical Moderate Price Moderate Price
Size Dimension Dimension
Adjustable Can be used for any sizes
Suitable for different
of wheelchair (small,
wheelchair
medium, or big)
Easy to be stored Storable Storable
Source: Writers, 2017

After that, the authors create importance level of those attributes

based on the mode of how many times the respondents state one of those
attributes in each question related to the attribute. Then, the mode of each
attribute determines the rank of importance level. The result of importance
level could be seen from Table 3.4.

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Table 3. 4 Importance Level

Respondents
Attributes 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 3 3 Mo
1 2 3 4 5 6 7 8 9
0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 de
Endurance
3.0
(lifespan) 4 3 3 4 3 4 3 4 4 3 3 3 4 3 3 3 3 3 4 3 3 3 4 4 4 3 3 4 3 4 3
Safety (safe using) 5 5 5 5 5 5 4 4 4 5 4 5 4 4 4 5 5 5 5 5 5 5 4 4 5 5 5 5 5 5 5 5.0
Design 5 5 4 5 5 4 4 5 4 4 4 4 4 5 4 4 4 3 3 3 3 4 4 3 3 4 4 4 4 4 4 4.0
Moderate Price 3 5 5 3 4 4 3 5 3 4 5 5 4 3 4 5 3 4 3 5 3 5 3 5 5 4 4 3 4 4 4 4.0
Dimension 3 2 3 2 2 2 3 3 4 3 2 3 3 2 2 3 3 2 3 2 2 2 4 3 3 2 2 2 2 3 2 2.0
Suitable for
different 5.0
wheelchair 5 5 5 4 4 4 5 4 5 5 5 4 5 4 5 5 5 4 4 5 4 5 4 5 5 4 4 4 5 5 4
Storable 3 4 3 2 4 4 2 3 4 2 4 1 3 2 3 3 2 3 2 2 2 3 2 3 2 3 2 3 2 2 2 2.0
Source: Writers, 2017

After that, the authors create the benchmarking or product evaluation. In benchmarking, the authors tried to compare their
product with product competitors in order to know in what aspects the product could be evaluated. The authors put evaluation
score which is the relative position of product competitors, and target value which is the position that will be achieved by the
authors’ product. The position rank of those attributes is in the range of 1-5. Determining the target value of each attribute is from
the perspective of the product creator considering many aspects.

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 Yellow-shaded column shows the author’s product position, blue-
shaded column shows the benchmarking towards the first product
competitor, and red-shaded column shows the benchmarking towards the
second product competitor. The benchmarking table could be seen from
Table 3.5.

Table 3. 5 Benchmarking Table

Attributes 1 2 3 4 5

Endurance

Safety

Design

Moderate Price

Dimension

Suitable for different wheelchair

Storable

Source: Writers, 2017

The next step is determining the product objective that consists of RI

(Improvement Ratio), RII (Relative Important Index), and weight of each attribute.
The formula of IR could be seen below:

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 𝑇𝑎𝑟𝑔𝑒𝑡 𝑉𝑎𝑙𝑢𝑒
IR (𝐼𝑚𝑝𝑟𝑜𝑣𝑒𝑚𝑒𝑛𝑡 𝑅𝑎𝑡𝑖𝑜) = 𝐸𝑣𝑎𝑙𝑢𝑎𝑡𝑖𝑜𝑛 𝑆𝑐𝑜𝑟𝑒 (3.1)

While the RII is the mode of attribute importance level. To obtain

weight of each attribute, the formula is:

Weight = 𝐼𝑅 × 𝑅𝐼𝐼 (3.2)

𝑊𝑒𝑖𝑔ℎ𝑡
Weight % = 𝑇𝑜𝑡𝑎𝑙 𝑊𝑒𝑖𝑔ℎ𝑡 × 100% (3.3)

Therefore, the result of calculation of IR, weight, and percentage of

weight could be seen from Table 3.6.

Table 3. 6 Product Objective

Attributes Evaluation Target IR RII Weight %
Score Value Weight
Endurance 3 4 1.333333 3 4 14

Safety 4 5 1.25 5 6.3 22

Design 4 5 1.25 4 5 17

Moderate Price 4 4 1 4 4 14

Dimension 2 3 1.5 2 3 10

Suitable for different 5 5 1 5 5 17

wheelchair
Storable 5 5 1 2 2 7

Source: Writers, 2017

After that, the authors could determine some technical responses

based on attributes that are obtained. 1 technical response is able to represent
minimum 2 attributes. The list of technical response could be seen from
Table 3.7, while the assignment of attributes into technical responses could
be seen from Table 3.8.

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Table 3. 7 Technical Response
No. Technical Response
1. Product dimension
2. Product features
3. Strength of material
4. Foldable
5. Number of adjustable parts
6. Cheap price
Source: Writers, 2017

Table 3. 8 Assignment of Attributes to Technical Response

Attribute Technical Response
Endurance 3
Safety 2, 3, 4
Design 1, 2, 4, 5
Moderate Price 3, 6
Dimension 1, 2
Suitable for different wheelchair 1, 3, 5
Storable 1, 2, 4
Source: Writers, 2017

Finally, the authors could build HOQ (House of Quality) to show the
relationship between quality characteristic of the product with the demanded
quality by customers. The first step in making an HOQ is creating the
interaction matrix between quality characteristics with demanded quality.
There are several symbols in matrix interaction that consist of:

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Table 3. 9 Symbols in Interaction Matrix
Symbol Description Score
 strong relation 9
 medium relation 3
∆ weak relation 1
Source: Innovative Product Design and Development Module, 2017/2018

Quality characteristic means the technical response, while

demanded quality means the attribute of the product. In this matrix, the
authors also include the relative weight which is the weight percentage, and
weight/importance which is the weight value. Therefore, the matrix
interaction of Portable Stair could be seen from Figure 3.19
.

Figure 3. 19 Matrix Interaction,(Source: Writers, 2017)

Then, the authors created the roof of the HOQ, which is assigning
the correlation between each quality characteristic. Below the roof, the
authors also assigned the direction of improvement for each quality

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 characteristic, whether it is better to minimize it, maximize it, or make it
to hit target. The legends or symbols of the correlation could be seen from
Figure 3.20 below.

Figure 3.20 Legend (Source: Innovative Product Design and Development Module,
2017/2018)

Therefore, the interaction matrix of the roof could be seen in Figure

3.21 below.

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Figure 3. 21 Matrix Interaction 2 (Source: Writers, 2017)

In HOQ, there is also competitive analysis that shows the

comparison chart between Portable Stair and the product competitors related
to the attributes of the product. The competitive analysis chart could be seen
from Figure 3.22.

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Figure 3. 22 Competitive Analysis (Source: Writers, 2017)

At the bottom of HOQ, there is some calculations regarding the total

of weight/importance and relative weight. First, the weight/importance for
each quality characteristic should be obtained by sum all the percentage of
weight that is multiplied by the score of relationship.
For example, the relationship score for product dimension could be
seen from Figure 3.19. Then, the calculation of the weight/importance of
product dimension is:

Weight = ∑(𝑟𝑒𝑙𝑎𝑡𝑖𝑣𝑒 𝑤𝑒𝑖𝑔ℎ𝑡 𝑖 × 𝑟𝑒𝑙𝑎𝑡𝑖𝑜𝑛𝑠ℎ𝑖𝑝 𝑠𝑐𝑜𝑟𝑒) (3.4)

Weight = (19,4 × 3) + (15,5 × 1) + (9,3 × 9) + (15,5 × 3)

+ (15,5 × 1)
= 219,4

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 After the authors have the weight/importance for each quality
characteristic, the authors sum all the weights in order to get the total weight.
Then, the authors obtain relative weight for each quality characteristic by
using this formula:
:
𝑤𝑒𝑖𝑔ℎ𝑡
Relative weight = (𝑇𝑜𝑡𝑎𝑙 𝑤𝑒𝑖𝑔ℎ𝑡) × 100% (3.5)

Use the example for product dimension quality characteristic in

order to show how the authors obtain the relative weight:

231,6
Relative weight = ( ) × 100% = 14,0%
1.363,2

Therefore, the authors could obtain the weight/importance and

relative weight of each quality characteristic as they are shown in Figure
3.23.

Figure 3. 23 Weight and Relative Weight in HOQ (Source: Writers, 2017)

The next step to do is determining the product specification. There

are several phases in determining it, which consist of:
1. Preparing the metrics, which is a detailed measurement created from
the technical response
2. Gathering the information of the competitors for benchmarking

28
 3. Setting the target value for each metric

Metric means the measurement that has numerical value. The table
of the first phase is shown in Table 3.10.

Table 3. 10 1st Phase of Product Specification

Technical Importance
No Metrics Units
Response level
Maximum length to be
adjusted
Minimum length to be
adjusted
1 Product Dimension 1 m
Maximum width to be
adjusted
Minimum width to be
adjusted
2 Product Features Number of safety features 4 List
Strength of material Mpa
3 Type of Material 3
Weight of material kg
4 Foldable Number of foldable parts 5 List
Number of
5 Number of adjustable parts 4 List
adjustable parts
6 Cheap Price Price 3 Rp
Source: Writers, 2017

After determining the metrics along with the unit for each metric, the
second phase could be conducted as it could be seen from Table 3.11 below.

Table 3. 11 2nd Phase of Product Specification

Technical Importance 1st 2nd
No Metrics Units
Response level Competitor Competitor
Maximum
length to be 0,2 0,4
Product adjusted
1 1 m
Dimension Minimum
length to be - -
adjusted
Source: Writers, 2017

29
Table 3. 12 2nd Phase of Product Specification (con’t)
Technical Importance 1st 2nd
No Metrics Units
Response level Competitor Competitor
Maximum
width to be - -
Product adjusted
1 1 m
Dimension Minimum
width to be - -
adjusted
Product Number of
2 4 List 6 3
Features safety features
Strength of
Mpa - -
Type of material
3 3
Material Weight of
Kg 95 131
material
Number of
4 Foldable 5 List - -
foldable parts
Number of
Number of
5 adjustable 4 List 2 2
adjustable parts
parts
Cheap
6 Price 3 Rp 67.800.000 81.363.000
Price
Source: Writers, 2017

In the second phase, the metric information for each product

competitor are explained. After that, the third phase could be conducted as
it could be seen from Table 3.12 below. There is comparison between
marginal value and ideal value for each technical response.
Ideal value means the ideal measurement that the technical response
supposes to have, while marginal value is the value that customer could still
tolerance. If the value of a metric is getting better when it has higher value,
then the marginal value is lower than ideal value, and vice versa.

Table 3. 13 3rd Phase of Product Specification

Technical Importance Marginal Ideal
No Metrics
Response level Value Value
Product Maximal length to be
1 1 2 3
Dimension adjusted
Source: Writers, 2017

30
Table 3. 14 3rd Phase of Product Specification (con’t)
Technical Importance Marginal Ideal
No Metrics
Response level Value Value
Minimum length to
2 0.3
be adjusted
1
Product Maximum width to
1 1 2
Dimension adjusted
Minimum width to
1 0.5
be adjusted
Product Number of safety
2 4 2 2
Features features
Strength of material 3 7 11
Type of
3
material
Weight of material 3 1.5 0.6
Number of foldable
4 Foldable 5 1 1
parts
Number of
Number of
5 adjustable 4 1 2
adjustable parts
parts

6 Cheap price Price 3 275,000 375,000

Source: Writers, 2017

3.6 Product Concept Screening

In this section, there will be concept selection process that consist of
morphological chart, concept generation, and concept screening.
The first thing to do in concept selection process is to make the
component alternatives for the product so the feasible combination of the
components of the product can be determined. This alternatives can be
represented by morphological chart. The morphological chart for Portable
Stair is shown in the table below.

31
Table 3. 15 Morphological Chart for Portable Stair (Source: Writers, 2017)

N Compone
Alternative 1 Alternative 2 Alternative 3
o. nt

Hinge
1 none
Joint

Aluminium
Steel
Light Steel
Carbon Fiber

2 Board

Aluminium

3 Board pad none

Rubber

Threshold
4
ramp

Rubber
Aluminium

5 Bar Joint

Aluminium rod Steel

32
 After that, the feasible combination from morphological chart of a
product is generated into a concept alternatives table. The concept
alternatives for Portable Stair is shown in the table below.

Table 3. 16 Concept Alternatives for Portable Stair

Source: Writers, 2017

Next, the concept alternatives are screened and selected using

concept screening table. The concept screening table for Portable Stair is
shown in the table 3.15 in the next page.

33
Table 3. 17 Concept Screening Table Source: Writers, 2017
Concept 7
No. Criteria Concept 1 Concept 2 Concept 3 Concept 4 Concept 5 Concept 6 (Concept Concept 8
Reference)
1 Endurance 0 + + -- + 0 0 0
2 Safety 0 0 0 0 - - 0 0
3 Design + + + + + + 0 +
4 Price 0 0 - -- - 0 0 --
5 Dimension ++ ++ ++ ++ ++ + 0 0
6 Suitable for different wheelchair + + + + + + 0 0
7 Storable ++ + + ++ + + 0 +
Sum of + 6 6 6 6 6 4 0 2
Sum of 0 3 2 1 1 0 2 7 4
Sum of - 0 0 1 4 2 1 0 2
Net Score 6 6 5 2 4 3 0 0
Rank 1 1 2 5 3 4 6 6
Continue? Yes Yes Yes No Yes No No No

Source: Writers, 2017

34
Table 3. 18 Concept Scoring Table
Concept 1 Concept 2 Concept 3 Concept 5
No. Criteria Weight
Rating Score Rating Score Rating Score Rating Score
1 Endurance 13,7 3 41,1 5 68,5 5 68,5 3 41,1
2 Safety 21,4 2 27,4 2 27,4 5 68,5 2 27,4
3 Design 17,1 3 41,1 4 54,8 4 54,8 3 41,1
4 Moderate price 13,7 4 54,8 3 41,1 2 27,4 4 54,8
5 Dimension 10,3 2 27,4 3 41,1 3 41,1 2 27,4
6 Suitable for different wheelchair 17,1 4 54,8 4 54,8 4 54,8 1 13,7
7 Storable 6,8 4 54,8 3 41,1 3 41,1 4 54,8
Total Sum 301,4 328,8 356,2 260,3
Rank 3 2 1 4
Develop no no yes no
Source: Writers, 2017

In the table above, the concept alternatives is scored. The score is represented in matrix table which is obtained by times the
rating that is given by writers to the weight of each criteria that is resulted from the HOQ. Based on the rating, the concept 3 is selected
for the product. So, the product will have the hinge joint that is made from steel, board material from alumunium, board pad from rubber,
threshold ramp from alumunium and bar jpint from steel.

35
3.7 BOM Tree and BOM Table
Bill of material is a comprehensive list of parts, items, assemblies
and other materials required to create a product. In this chapter, the bill of
material will be represented in the form of tree and table to make it easier to
be understood. The bill of material that will be shown is adjusted to the
concept that has been selected in the previous subchapter. The bill of
material is as follows.

Portable
Stairs

Safety
Track
Features

Treshold
Pad Board Hinge Joint Bar Joint Barrier
Ramp

Nuts and Nuts and

Bolts Bolts

Figure 3. 24 BOM Tree of Portable Stairs (source: writers, 2017)

In order to understand the product and the material that construct it

better, the BOM table is given below.

Table 3. 19 BOM Table of Portable Stairs

Name of
No Material Quantity Description Dimension
Component
1 Portable Stairs 1 Make
200 cm (length)
Aluminum 1 Make
1.1 Track 60 cm (width)
200 cm (length)
Rubber 1 Buy
1.1.1 Pad 60 cm (width
Source: Writers, 2017

36
Table 3. 20 BOM Table of Portable Stairs (con’t)
Name of
No Material Quantity Description Dimension
Component
200 cm (length)
Aluminum 1 Buy
1.1.2 Board 60 cm (width
188 cm (length)
Steel 3 Buy
1.1.3 Hinge Joint 58 cm (width)
10 mm (bottom
Steel 20 Buy diameter)
1.1.3.1 Screw 17 mm (top diameter)
45 cm (length)
Steel 6 Buy
1.1.4 Bar Joint 5 cm (width)
10 mm (bottom
Steel 10 Buy diameter)
1.1.4.1 Screw 17 mm (top diameter)
1.2 Safety Features Aluminum 2 Make
10 cm (length)
Rubber 1 Make
1.2.1 Treshold Ramp 60 cm (width)
200 cm (length)
Aluminum 2 Buy
1.2.2 Barrier 12 cm (height)
Source: Writers, 2017

The prototype of portable stairs can be seen in the figures below.

37
Figure 3. 25 Fusion 3D Prototype Side View (Source: Writers, 2017)

Figure 3. 26 Fusion 3D Prototype Top View (Source: Writers, 2017)

3.8 Design for Manufacture

In order to make manufacturing process of portable stair is more
effective and efficient, writers use design for manufacturing first. Design for
manufacture is the method to design for ease of manufacturing of the
assortment of parts that will form the product after assembly. It is primarily

38
 concerned with reducing overall part production cost and minimizing the
complexity of manufacturing operations. The design for manufacturing for
this product is as follows.

Table 3. 21 Design for Manufacturing Portable Stairs

Part Manufacturing process Alternative Process

Track Cutting -

Safety features Cutting and joining Drilling

Threshold ramp Cutting and joining Drilling

Source: Writers, 2017

The parts that will be manufactured in the product are track, safety
features and threshold ramp. Manufacturing process that later used to build
these parts influence the precision of each part. It can be seen above that the
manufacturing process that is done is only cutting and joining. It is because
those two process does not need complex machine and only tools that can
be found everywhere. The process is also quite simple. The alternative
process below is used as the replacement to make the existing manufacturing
process easier, in terms of joining 2 or more parts together. Drilling is used
to create a hole for bolts and nuts for joining the track and safety features.

3.9 Cost of Goods Sold Calculation

In order to know the price of the product, writers will calculate the
Cost of Goods Sold (COGS) in this subchapter. Cost of goods sold is the
cost to produce a product before it is added by profit margin. It can be
obtained by sum the cost of direct materials, direct labors and manufacturing
overhead. The calculation is as follows.

39
Table 3. 22 Direct Material Cost
Name of
No Quantity Unit Price Total Price Material Cost
Component
Rp Rp
1.1.1 Board 8
19.125,00 153.000,00
Rp Rp
1.1.2 Joint 8
10.000,00 80.000,00
Rp Rp Rp
1.1.3 Joint 6
10.000,00 60.000,00 393.000,00
Rp Rp
1.2.1 Treshold Ramp 2
12.500,00 25.000,00
Rp Rp
1.2.2 Barrier 6
12.500,00 75.000,00
Source: Writers, 2017

Table 3. 23 Cost of Manufacturing Overhead

No Type Cost

1 Indirect material Rp 22.000,00

2 Utilitiy cost Rp 15.000,00

3 Depreciation Rp 250,00

Overhead Cost Rp 37.250,00

Source: Writers, 2017

In order the make the product, a total of three days is needed. When
making the product, there are several manufacturing overhead that incur.
Manufacturing overhead is the cost that does not give valye added directly
to the product but also contributes in making the product. The first overhead
is indirect material. Indirect material that is meant is screw and nuts because
they only used as connector in the product. The second overhead is utility

40
cost. It includes the cost of electricity to make the product for three days.
Last, depreciation cost. It is the cost that is caused by the decreasing life
value of the tools that are used to make the ptoduct.
In order to make the product, writers hire a worker to do it. The
worder make the product for three days and the cost of the direct labor is
Rp200.000. So, the calculation of cost of goods sold for portable stair is as
follows.

Direct Material Cost+Direct Labor Cost+Manufacturing OverheadCost

COGS = (3.6)
Number of Production in one job

Rp393.000 + Rp200.000 + Rp37.250

COGS =
1
COGS = Rp630.250

So, the total cost that is needed to make one portable stair is Rp630.250

41
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42
 CHAPTER 4
CONCLUSION AND SUGGESTION

In this chapter, the conclusion is shown to answers the objectives of this

assignment which is explained in chapter 1. There is also suggestion for the
observed object and also the next observer to create better assignment.

4.1 Conclusion
The conclusions that can be obtained from this assignment consist
of:
1. Writer’s product is portable stairs to help elderly and disabilities taking
stairs by overlapped on the actual stairs
2. Writer’s market targets are elderly and disabilities
3. Writers do the survey by asking people directly and put the data in the
online google form which can helps us to identify the customer needs
4. Based on our survey, it shows that the existing device that our market
target only uses lift, walking stick, and wheelchair
5. The attribute that we get from our questionnaire are endurance, safety,
movable, price , size , speed , storable and suitable for different
wheelchair
6. Writers make the comparison of our product and the existing product to
evaluate our product performance

4.2 Suggestions
The suggestions for the next respondents in order to conduct the
better project consist of:
1. More information should be given to help us produce our product
2. More explanation should be done for us to help us do our questionnaire

43
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44
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