Untangle the tangledReport prepared by:Tatiana CardonaSri Sandilya VenuthurumilliAbhinay Reddy Gudimetla

PROJECT REPORTDFSS

GROUP 6 DATE OF THE REPORT 05/09/2016

UNTANGLE THE TANGLE

Table of ContentsI. IDENTIFY..............................................................................2

OverviewBackgroundProject descriptionProject goalProject boundaries

II. PLAN OF ACTION.................................................................3DeliverablesGantt chart

III. INVENT / INNOVATE............................................................3VOICE OF THE CUSTOMER (VOC)Survey responses summary.Affinity diagramKano AnalysisBENCHMARKINGQUALITY FUNCTION DEPLOYMENTHouse of Quality (HOQ)

IV. DEVELOP PHASE..................................................................9Design for x methodsPUGH’S CONCEPT SELECTIONDFMEAAppendix 1:....... UNTANGLING THE TANGLE SURVEYAppendix 2: ............................. SURVEY STATISTICS

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IDENTIFYOverviewIn everyday world we can find opportunities to develop new products and services that can make life more comfortable. Great innovations or simple improvements of products already in the market can change the people’s perspective about life and allow them to enjoy doing more things without sacrificing time, or in enterprise terms: productivity.

Not just products evolve but the techniques used to make that evolution happen. Because there is not prosperity in a product/service that is not aligned to a need to be satisfied, nowadays can be found Management Techniques as Design for Six Sigma (DFSS), which allow companies to be more successful in the identification of needs and their connection trough the product/service system in order to reduce losses in the production of useless products/services.

In order to develop a new design for a device that prevent the wire of the earphones from getting tangle, this document will present a general application of several DFSS tools as an academic exercise.

BackgroundThe history of the headphones confirms some of the key matters they have evolved for: isolation of what a person is listening to to the environment, portability (ability to be easily carried), and quality of the sound. After this another features have been included for example noise cancelling and pretty design.

In terms of portability one of the most popular products in the market has been the earphones, a very small headphone that can be worn inside of the ear; they can be easily fit in a pocket to be carried, and offer an acceptable quality of the sound. However, if portability is also seen in terms of how ready is the product to be used once is taking out from the container, then the time this activity consumes should also be taking in account at the moment to improve the design of the earphones.

Lately, the trouble people are having with the earphones’ wire after they kept them somewhere to be carried has become a very popular complaint; the wire get so tangle that it is annoying to try untangle it, which is for most a matter of time, also a factor of damage.

Although some of the devices created to prevent tangling work just fine for this purpose, some of them are really basic meeting the customer requirements, having low levels of popularity.

Working judiciously in the identification of the customer needs, an improved product to prevent tangling can be developed without interfere with the principal features of the earphones.

Project descriptionApply DFSS tools to design a device to prevent the wire of the earphones from tangling, reducing the time users take to untangle them and control damage.

This product is developed primarily for earphones and not for other kind of headphones or other benefit different from prevent tangling.

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Project goalTo reduce to a 70% the average time a person consumes getting the earphones ready to use. This is to be accomplished by the design of a device to prevent tangling of the wire with the application of DFSS tools provided in class. This project must be complete by May 1, 2016.

Project boundaries As an academic exercise the DFSS tools are going to be applied just to the system level and no

further because of time limitations. The project will neither contain information about manufacturing process nor associated costs. The documented prototypes are just to demonstrate the shape of the concepts and not meant

to be developed in the real purposed materials.

PLAN OF ACTIONDeliverables

1. Project Charter2. Plan of action3. Analysis of Voice of the customer4. Quality Function Deployment (House of Quality system level)5. Documentation of concepts generated.6. Superior Concept.7. DFMEA

Gantt chart

Table 1: Gantt chart

INVENT / INNOVATEVOICE OF THE CUSTOMER (VOC) A 12 questions survey was designed to gather the voice of the customer. (See Appendix 1: Survey) The survey was posted trough google forms (go to survey link:Untangling the tangle)

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Almost 3 weeks after the survey was released it was possible to collect 159 responses. (See attached file 1: Survey responses - spreadsheets)

Survey responses summary. Below there is an analysis of the responses per each question from the survey. For a better

understanding of the information see Appendix 2: Survey responses statistics. Paretto analysis was used for questions 3 and 4 where the results were not clearly conclusive. Histograms were for questions 7 and 12 to have a more visual tool to make conclusions.

Results:1. Most of the people targeted for this survey was between the ages of 20 to 29.2. From which the majority were male (63.3%). Although not enough to let aside females for further

conclusions.3. The information was collected mostly from people located in United States and India (91% of the

responses).4. 34% of the people use their earphones once or twice per day, 24% three to five and 15% six to ten

times while 6.9 % never use earphones.People prefer to use the earphones all the time than use them more than 10 times.

5. 50.6% of the time the people find the wire of the earphones tangled before use them, and 44.9% sometimes find the wire tangled.

6. 69.6% of the people estimate they take less than a minute to untangle the wire. While 29.1% said it takes less than 5 min.

7. 79% of the interviewed would like to have an accessory to prevent the earphones wire from getting tangled.

Reasons why:

Table 2: Answers question No. 7 Untangling the tangle survey

8. 39% of the people think that probably need the product, 20.8% think they definitely need the product, while 20.1% remain neutral and 11.9% think they probably do not need the product.

9. Most of the people do not have yet an accessory to prevent tangle (94.9%). 10. The question was not clear so the answers. 11. 75% of the people is not willing to pay more than $4, 19% is willing to pay between $5 and $9. Just

5.5% of the people would pay more than $10.12. Reasons people think would make more likely to buy the accessory:

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Table 2: Answers question No. 12 Untangling the tangle survey

Affinity diagramThe affinity diagram tool is applied to the original data pool (survey responses) to stablish what the customer values more in the development of a product as the device to prevent tangling of the earphones’ wire.The data pool has 159 responses (4 blanks), and each one may contain more than one category:

Table 3: Affinity diagram filter # 1

After a second round categorizing the answers we obtained the next principal needs expressed by the customer in order of importance:

Reason Responses

Prevents tangling 69

Saves time 57Easy to use 56

Easy to carry/keep 38To prevent damage 26

Low price 31

Color and design 7Universal (can be used in all kinds of earphones) 6

Filter #2 and final

Table 4: Affinity diagram filter #2 and final.

Kano AnalysisCategorization of the VOC according to the Kano model:

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Expected needs: - Using the device to prevent tangling should not interfere with the quality of the sound given

by the earphones.- It must not alter the earphones ability of being portable.

Expressed needs:This kind of needs have been collected through the survey and analyzed trough the affinity diagram:

- The use of the device should prevent tangling of the earphones’ wire.- Also should save time - And be easy to carry- It should prevent damage - Have a low price - Color and design must be thought in the development of the device. - And it should be universal for the all kind of earbud’s currently in the market.

Exciting needs:- Different ways of usage.- Customization

BENCHMARKINGIn order to deploy the quality function tool House of Quality, a research of what is in the market was conducted with the following findings.

Earphones features of interest:- The length of the earphones changes between brands and even between the different versions of

the same brand, see examples of the bestselling brands in the table below:This table shows the total length of the earphones including the buds cable (separated portion of the wire).

Brand Length (inches)

Bose 52

Apple 54.92

Skullcandy 51.18

Jvc 47.28

Beats 54

MEElectronics 51

Klipsch 51.18

Jlab 50.76

Sennheiser 55.11

Table 5: Earphones brands (Resources: google shopping, Amazon.com)

From the specifications given by the brands, there is very limited information available about the width of the wire, which unfortunately is not significant or conclusive. However, from the specs of the different devices to prevent tangling (sleeve type) it can be inferred the wire is usually less wide than 0.3 inches.

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Devices to prevent tangling

Table 6 : Benchmarking, accessories to prevent earphones’ wire from getting tangle.

Note 1: this qualification is made based on the principal features found in the market, however the devices can have other functions, or also fit in more than 1 category. Note 2: The table below contain some of the products in the market (best reviewed and better sells ranking), it is important to clarify there are many others, with different features.

QUALITY FUNCTION DEPLOYMENTSelection of competitors:

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Table 7 : Selection of competitors.

House of Quality (HOQ)House of quality can be also found as: Attachment 2: House of Quality spreadsheet.

Relationships:RELATIONSHIP MATRIX (Results):

Figure 2: HOQ Relationship matrix results

- The most relevant requirements are for the design according to the weight of importance (form most important to less:

1. Time to operate de device2. Material3. Width of the wire the

device can hold.

4. Size5. Weight.6. Length of the wire the device can hold.7. Color

- The most difficult requirements to achieve are (from most difficult to less)

1. Size and Length of the wire the device can hold.

2. Time to operate de device and color.

3. Width of the wire the device can hold and weight.

4. Material.

- Conclusions: The most important requirements are not the most difficult to achieve, although time to operate the device is in a medium level of difficulty.

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ROOF:

Figure 1: HOQ Roof

- The longer the wire the device can hold, bigger in size.

- The thicker the wire the device can hold, bigger in size.

- Most of the time, the bigger the device, the heavier.

- Most of the time, the longer the wire, takes more time to operate the device.

- Sometimes, the wider the wire the device can hold, the heavier.

- Depending on the materials there are more or less options of colors.

COMPETITIVE MATRIX (Results):

Figure 3: HOQ Competitive matrix.

Total Rank:

1. The nest Earbud case 28 points.2. CordCruncher 27 points.3. Curvyman 26 points.4. Retrak 18 points.

DATUM- The best ranked accessory from the

competence is The Nest earbud case, which is taken as the Datum for the Pugh’s concept selection.

- It also can be observed in the figure the cordCruncher is more consistent accomplishing the VOC, but the features that doesn’t meet the customer needs have a really low rate. Improving

- this concept would generate a really good ranking accomplishing the VOC.

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DEVELOP PHASEDesign for x methodsConcept 1: Bracelet earphonesThis concept uses the retractable ear phones mechanism incorporated into a wrist band which is green in color as shown in the picture below. The idea is to cover the ear phones with a material of our choice to provide the aesthetics. It is designed in a compact size that is easy to wear as possible and all the materials that are used in making this are flexible in nature. This band has magnets to hold the band onto the wrist.

We have another bracelet kind of structure which has magnets on it too and the material used to make it is customizable. This can be wrapped to your phone or can be attached to the pink colored band and wrapped to your hand. This is more convenient and can be used according to the user’s need. The problem associated with this concept is the universality but after the second step of PUGH matrix we integrated the universality of recoil concept into bracelet earphone.

Concept 2: The loopThe “loop” concept has wired earphones which are arranged in coil structure and is rigid. When the jack is plugged into the audio port the wire untangles. The wire gets untangled due when the sound waves pass through the wire of the ear phones when the user plays some music. When the jack is unplugged the wire comes back to its initial state. Another interesting feature of this concept is the change in color of the wire depending on the type of music being played and the volume. This is a very expensive concept but is more user friendly.

Concept 3: Chained earphonesIn this concept we have integrated earphones into a chain structure. The audio jack and both the ear

phones are closed together to form a loop as shown in the picture below using the magnets. When the

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user wants to use the ear phones, the jack and the earphones are to be separated which are attached by a magnet on the chain. Women can use this as a trendy chain or bracelet and men can use it as a wrist band or a bracelet depending on the type of material used to design the chain. Different types of materials can be used for the chain ranging from metal to fabrics based on the customer need. This concept is not universal as the earphones are integrated into it and are not detachable.

Concept 4: Button magnetThis is the simplest and easiest concept to untanglethe earphones considerably in less time. The mini jack is placed in a single hole present on one side of the button magnet, where it can stay even when plugged into the phone or iPod. The two earphones are placed in two other holes which allows everyone to quickly remove them whenever the user needs them and place them back when done with using the ear phones. Adding magnets, clip and radium to the product are the additional features so that it can be more attractive and user friendly.

Concept 5: StrapThe “strap” concepts makes use of the hand strap with earphones attached to it. The strap contains holders at the back as shown in the picture. The wire is inserted into the holders when not in use which can be strapped to the hand. This concept is handy and more flexible. The problem with this concept is we have to place the earphones every time we have completed using them. This takes lot of time which is not an optimal solution.

Concept 6: WinderA product that allows users avoid tangled mess every time they pull earphones out of pocket or backpack. This product can stay attached to headphones whether in usage or in storage. It is not integrated and it is universal, so there is no need to buy new set of earphones. It is a circular plastic accessory that winds the earphones in two ways allowing it to extend and retract according to the needs.

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Concept 7: Stretching sleeveThis concept is explained with more detail after the Pugh’s concept selection.

PUGH’S CONCEPT SELECTIONROUND 1

Table 8: Pugh’s concept selection round 1

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ROUND 2

Table 9: Pugh’s concept selection round 2

SUPERIOR CONCEPT: The Stretching sleeveDescription:Earbuds elastic sleeve.

Instructions

Contains: 1 Sleeve, 1 plastic stick with loops, 2 end lockers.

1. Insert end locker. 2. Insert the jack on the loops of the

stick.

3.Insert the stick in the sleeve.

4. Insert the second end locker ans secure them in the sleeve.

How does the stretching sleeve work?

Figure 4: Superior concept instructions.

Once the earphones are inside and locked, the stretching sleeve works by retracting the cord into folded form during storage while permitting full length extension during use, letting you customize cord length while granting the convenience of accessibility.To use the stretching sleeve simply pull one end of the cord out from its sleeve. When ready to store pull the sleeve back over the excess cord length.

Features Prevents tangling : The elastic sleeve adjusts from 24 inches to 50

inch eliminating excess cordage and providing tangle-free movement during keeping.

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Easy to use and Reduces time : The operation of the device takes approximately 3 sec every time it stretches out and come back.

It is lightweight and Easy to carry: can be kept in any bag purse or drawer-without ever worrying about tangled retrieval-or keep them wrapped around the wrist or neck to highlight fashion and function in between uses.

Colors and material : more than 13 colors available in a material that is impermeable lightweight and flexible.

Specifications: Material : Stretch vinyl fabric.

Plastic look from outside. Color: More than 13 colors. Length : Normal position 24 inch.

Stretched 50 inch. Width: 1 inch Weight: 2 ounces.

DFMEA

Table 10: DFMEA

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CONCLUSIONS Using DFSS tools for an academic project Untangle the tangle have finally come up with the

design of product as a superior concept i.e. stretch sleeve. This satisfies all our customer requirements like universality, low cost, trendy designs, less time to use, easy to operate, convenient to store and protecting the earphones from damage. The concept selected went through the FMEA analysis and the most impacting risks were assessed.

The major accomplishment that needs a mention is we have made a concept that costs less than 10$ and reduces the time to usage by 80 percent.

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REFERENCES Thompson D. 2012, How Headphones Changed the World. From

http://www.theatlantic.com/technology/archive/2012/05/how-headphones-changed-the-world/257830/

Habil, 2015.The Complete History of Headphones. From http://pulseaudio.com/the-complete-history-of-headphones/

Griffiths, S., 2014. Mystery unraveled: Headphones can form 120 'complex knots' in your pocket because loose ends weave through coiled strands. From http://www.dailymail.co.uk/sciencetech/article-2662681/Mystery-unravelled-Headphones-form-complex-knots-pocket-loose-ends-weave-coiled-strands.html.

Benjamin, T., How to Use Benchmarking Techniques Effectively. From http://smallbusiness.chron.com/use-benchmarking-techniques-effectively-13083.html

Heckler, B., 2016. 5 Fundamental Areas that Are Key to Success for Innovative Manufacturers. From http://www.industryweek.com/innovation/5-fundamental-areas-are-key-success-innovative-manufacturers.

Gygi, C., Williams, B., and DeCarlo, N., Six Sigma Failure Mode Effects Analysis.Six Sigma For Dummies, 2nd Edition. From http://www.dummies.com/how-to/content/six-sigma-failure-mode-effects-analysis.html

About the devices and benchmarking:

- http://www.amazon.com/Stashcord-Prevents-Tangled-Earbuds-Original/dp/B004SY9J0G?ie=UTF8&refRID=FTHQXXNXTH36Q750B964&ref_=pd_ybh_a_61

- http://www.amazon.com/CordCruncher-Tangle-Free-Adjustable-Headphones-Metal/dp/B019YY5782?ie=UTF8&refRID=AB352TXPBTV4RXKRKPTE&ref_=pd_ybh_a_19

- http://www.amazon.com/Nite-Ize-Curvyman-Cord-Supervisor/dp/B002LED4II? ie=UTF8&refRID=VR95FS9CHJ5Z5PFD1AR2&ref_=pd_ybh_a_20

- http://www.amazon.com/Digital-Innovations-Nest-Earbud-Case/dp/B00CBKBD44?ie=UTF8&refRID=XRGR2WCZP667575590XE&ref_=pd_ybh_a_21

- http://www.amazon.com/ReTrak-Retractable-Stereo-Earbuds-ETAUDIOBLK/dp/B00CTEL83S? ie=UTF8&refRID=B76MMYGW8EVC38NNKNN2&ref_=pd_ybh_a_28

- http://www.amazon.com/Recoil-AUTOMATIC-Headphones-Retactable-Organizer/dp/ B00CXZTFGU?ie=UTF8&refRID=GHK1JMEW8EQ25CGEAB54&ref_=pd_ybh_a_30

- http://www.amazon.com/Kikkerland-HH40-W-Small-Bobino-White/dp/B0042RVA4W? ie=UTF8&refRID=BB7840GHKP56XH99XAXC&ref_=pd_ybh_a_36

- https://www.cordcruncher.com/

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APPENDICESAppendix 1: UNTANGLING THE TANGLE SURVEYIntroduction: As a team of graduate students at MS&T University, we are researching the market preferences for the development of a new product as a class project: Earphones accessory to prevent tangling of the wire. We would appreciate your help in answering a few questions for us. Answering the survey will take about 3 minutes.

1. Age:Under 20

20-3031-45

46-60Over 60

2. Sex: MaleFemalePrefer not to answer

3. Country:4. How often do you use earphones per day?

Once or twiceThree to five timesSix to ten timesMore than ten times

All the timeI never use earphones __________________________End of

the survey.

5. How often do you have to untangle the wire of your earphones?Every time before I use themSometimes before I use themThe wire never gets tangleMy earphones are wireless______________________ End of the survey. If you are using wired earphones continue with

the questions.6. How long does it take to untangle the wire?

Less than a minuteLess than five minutesFive to ten minutes

More than ten minutesYou give up untangling

7. Would you like to have an accessory to prevent the tangling of the wire?YesNo Why __________________________________________________________________________

8. When you think about the product, do you think of it as something you need or you don’t need?Definitely needProbably needNeutralProbably don’t needDefinitely don’t need

9. Do you already use an accessory to prevent tangling?YesNo

If yes, describe it ______________________________________________________________________10. Does the accessory keep the wire untangled?

All the timeMost of the timeSometimes NeverI don’t use any accessory

11. How much are you willing to pay for a product which prevents tangling of wired earphones?

$1 - $4 $5 - $917

UNTANGLE THE TANGLE$10 - $19

$20 - $49More than $50

12. What would make you more likely to use a product to prevent wire tangling?___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Thank you for taking the time to help us.

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Appendix 2: SURVEY STATISTICS

United States

India South America

Other locations

United Kingdom

027.5

5582.5110

0%25%50%75%100%Location

Series1 Series2

Once or twice

Three to five times

Six to ten

times

All the time

More than ten

times

I never use ear-

phones

015304560

0.0%25.0%50.0%75.0%100.0%Frequency of using earphones

per day

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