THE JOURNEY SO FAR…

• The group, named Project Hope by popular vote, did its first visit to

Anandwan in August. The idea behind the visit was to get a feel of the

task at hand, to witness the site and to interact with the workers on a

first hand basis. The group also met with senior management staff at

Anandwan and the project is known to Mr. Vikas Amte (s/o Baba

Amte). He has appreciated our efforts and the staff has pledged its

support for the project.

• The Project Hope recruited Project Assistants from Sophomore Year,

Mechanical Engineering VNIT. They are full of ideas and energy and

their support has been, and will be indispensable.

• The second visit to Anandwan happened in September with the

intention of acquiring useful data on Process Times as well as

inspection of design. The group has also procured a tricycle and is

making active changes to it.

PROGRESS MADE IN DESIGN

• The brakes which were used in the tricycle were

extremely rudimentary made of linkages with

drilled holes and were very difficult to apply.

• They have been replaced by wire brakes giving

it the ease of application.

• The location where it was placed is also

changed to give minimum strain to the muscle

of the hand applying it (ergonomically better).

• The cost of the brakes was inspected and it was

found out that it cost nearly the same, and will

be cheaper if bought in bulk. Thus this idea was

found to be suitable for mass production.

CHANGE IN BRAKING SYSTEM

THE 3D MODEL

• We have also created a 3D model of the frame

of the tricycle. This model was made on the

software CREO. All the dimensions of the

tricycle were measured with accuracy and a

wire frame model was created. The sweep

command was then used to create a solid

model.

• The purpose of this activity is to analyse the

design for stresses. The low stress members

can then be reduced in dimension. This will give

us benefits in weight and cost reduction.

• This is currently presenting problems in

meshing and representation of welding joints.

The team is seeking the aid of experts and will

come up with solution and viable results.

THE 3D MODEL MADE IN CREO

INDUSTRIAL SOLUTION

The process times were noted and arranged in sequence. A process time

chart was created and the with the name of the process, the time

required for the processes and the number of workers required in each

of the processes.

PROCESS TIME CHART CONTINUED

INDUSTRIAL SOLUTION FINDINGS

• This process time chart was then used to

divide the processes amongst workers in such

way that all the machines and workers are

utilised to the maximum extent. The following

were the findings of the solution.

• Currently , one tricycle is produced in a day.

Using the prescribed solution, the production

per day can be increased to three.

• The pace of the workers, i.e. the time required

for a worker to complete a task is assumed to

be that observed while taking readings. The

workers need not increase/ decrease their

working speed after the application of the

solution.

INDUSTRIAL SOLUTION FINDINGS

• Currently, five workers are employed full time at the

factory. After implementation of the solution, we

need to have a workforce of six workers employed

full time in the plant.

• These six workers are to be divided in three teams

of two workers each. They will each work of one

tricycle. One worker in each team should be trained

in welding, should know how to use the cutting

machine , should be physically strong enough to

use the bending machine and should know the

procedures for installation of equipment like

handles, brakes, wheels etc.

• Both the workers should be able to follow the

procedure prescribed by the solution. A supervisor

may be needed in the initial days to help in the

transition from the old system of operation to the

prescribed system of operation.

ACTIVITIES ENVISIONED

• It was observed by personal testing that the rotationof the pedal requires a substantial amount of force. Itis particularly felt when during the motion of thepedal in the upper half of rotation.

• The team has planned to provide ease of pedalrotation by changing the diameter of the backfreewheel. For the same diameter of the frontsprocket, if the diameter of the back freewheel ischanged, it will have fewer rotations than the pedal,which means that a large number of pedal rotationswill have fewer back wheel rotations. This will easethe force to be applied on the pedal.

• We have bought a large diameter freewheel and wewill get it installed. The chain length also has to beadjusted accordingly . The complete installation andcost analysis report will be given in the nextpresentation.

ACTIVITIES ENVISIONED

• The tricycle has to be transported to customers in far off

locations. To cater the needs of a bigger market, it would

be profitable if we could transport a greater number of

these cycles in one batch.

• Thus we planned the idea to install a Do-it-yourself kind

of detachment system which will involve outer screw

threads on some linkages and inner screw threads on a

cuff. Once removed, the cycle will be able to be separated

in two parts, one having the handle, handle accessories,

footrest and the front arch, while the other part will have

the seat, back wheels and the chain.

• To make this happen, we will have to visit Anandwan and

suggest changes while the manufacturing is on.

EASE OF TRANSPORT

ACTIVITIES ENVISIONED

• It is observed that the design is very old and rudimentary.

It uses a large number of welded joints which are cost

ineffective and take a major portion of the process time.

We have planned to create a design which uses lesser

number of welded joints and more number of bends as it

is cheaper and takes less time.

• This will require a better bending equipment as the

current one requires high physical strength to operate.

• Attachments like luggage carrying system are also to be

incorporated in the tricycle.

• It was also observed that the clearance of the cycle is

very large. It is not required and creates problems for the

elderly to climb up to the seat. We will refer to a design in

which small clearances are required and use of sheet

metal for footrest will also be reduced.

A NEW DESIGN