GreenWeaver
E/ME 105Caltech/Art Center/Saintgits
December 10th, 2012
Arjun Chandar, Shobha Cherian, Yifei Huang, Majesh Tom Mani, Judy Mou
Problem Statement
● Screw pine mats are used ubiquitously ● PROBLEM:
○ Shortage of labor in making mats○ Strain and tedium of weaving process
● Suggested by non-governmental organization Kerala Rural Development Agency (KRDA) in Karunagappally
Mission Statement
Design and produce a cheap and user friendly weaving machine to improve and expedite production of screw pine mats and other handicrafts.
Partners and Customers● Customers
○ KRDA (contact Salim)○ Female artisans- Interviewed
with 6 artisans in Karunagappally
● Distribution Channels○ NGOs- Have met with KRDA
● Construction Partners○ Met with two local carpenters in Karunagappally○ Ostrich Mobility Instruments in Bangalore- suggested by
Salim● Entrepreneurs
○ Carpenters and machinists could make wages from the product- need to explore further
Market Research
● The screwpine business is diminishing○ May die out in 5 yrs
● Demand is high, but supply is low○ KRDA: 600 mats per year ○ Process is too slow for supply to keep up○ 7000+ families in Kerala who can be helped by a device
● There was an attempt earlier to make a weaving device○ Joint venture between Kerala Rural Development Agency
and Ostrich Mobility Instruments○ Failed because strands were constantly breaking
Market Specifications
● Must Have○ Cheap, simple, easy to operate○ Low error rate○ Durable: last a long time (>5 years)○ Operable by hand while sitting○ "Diagonal" weaving
● Like to have○ Increase productivity○ Small in volume/mass○ Modular design for easy maintenance
Product Specifications
Size 3.5ft x 5.5ft x 2ft (max)
Weight 8-10 lbs (3.5-4.5 kg)
Cost Rs. 3000 - 5000 (~$55-90)
Error rate 0.5%-1%
Durability > 5 years and< 2x/year maintenance
Productivity 1 mat/3 hours
Operation By hands on a table
Architecture Modular
Current Prototype Design
Video
Benefits of Design
● Workers can sit to operate the device● Rotating device is easy to operate● Avoids axial stress on strands● Standard strand widths for the mats● Maintains diagonal weaving process ● Easier to adapt to● Cheap and accessible
material in India
Feedback
● KRDA○ Initial review: likes the idea○ Encourages standardizing the mats' strand dimensions
● Artisans○ Positive feedback - weaving from diagonals
● Professor Vinay Mathew John○ Prefers this idea because it avoids placing stress on both
ends of the strands○ Complies with current weaving process
Manufacture and Low Cost
● Parts are easily available in India
● Cheap materials (some material may be reusable between mats)
● Low anticipated maintenance cost
Components Est. Price (Rs.)
Woods ~1000
Rails ~200
Mild Steel Sq. Rod ~250
Mild Steel Flats ~150
GI wire ~100
Carpenter wage ~1500
Other costs ~500
Total 3700 (~$70)
Suitability and SustainabilitySuitable because...● Reduces strain on workers● Entering the screw pine market at a critical time● No current weaving device that satisfies screw pine industry● Can be funded by NGOs
Sustainable because...● Meant to be made and distributed in India● Maintains current method of weaving● Easy to understand and operate● Environmentally friendly
Ethical Plan
● Keep cost low○ But ensure high quality as well
● Preserve health and safety○ No toxic materials○ Design to allow less strenuous weaving○ Test ourselves before showing to potential customers
● Be respectful, sensitive and accountable● Put the customer first
○ Our first priority is the well-being of artisans○ Our product should encourage efficient use of screw pine
leaves
Major Challenges
● Communication across continents
● Distance to Karunagappally (~70 km from Kottayam)
● Receiving feedback from female artisans
● Redesigning for efficient manufacturing and assembly
● Deciding on cheap and durable materials
Future Directions- Design Process● Finalize dimensions and generate CAD models
● Build a full-sized functional prototype○ Manufacture in India and/or at Caltech
● Stress Testing○ How durable is the design?○ Will the strands break?
Future Directions- Partners
● Show a functional prototype to:○ Artisans
■ Adjust design to their preferences
○ KRDA and other NGOs■ Improve prototype based on their suggestions■ Simplify ease of use and understanding
○ Manufacturers■ Discuss with local carpenters■ Seek fabrication suggestions
Acknowledgements
Special thanks to● Prof. Kenneth Pickar● Prof. Jason Cherian Isaac● Prof. Vinay Mathew John● Prof. Thomas Varghese● Katja Luxem● Michelle Jiang● Kerala Rural Development Agency● Artisans of Thazhava