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

Initial Prototype Design

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

Questions?