PORTLAND STATE UNIVERSITY

Product Design Specification

Yakima T.O.C. Load Assist

Group Members:Haidar Al Gharash

Michael DixonBen Gheliuc

Daniel GheliucFue Her

Zach McCurter

P.S.U. Advisor:Evan A. Thomas, Ph.D., P.E.

1/30/2012

Table of Contents

...................................................................................................................................2

...................................................................................................................3

........................................................................................................................3

...................................................................................................................................3

.....................................................................................................................4

.....................................................................................................................4

....................................................................5

...............................................................................................................................................5

Technical Risk Management..................................................................................................6

..............................................................................................7

........................................................................................................................12

1.......................................................................................................................................13

1 | P a g e

Yakima is a company that designs and sells rack systems. One product they have not

brought to production is a system that will assist a person to load kayaks on top of a vehicle.

Yakima had previously designed a system but the estimated market price for the system was too

much, so they wanted to design a new system that would be efficient yet affordable. This is

where they made the load assist system into a capstone project for the Portland State University

students.

Yakima’s previous attempt at a load assist system had an estimated retail price of $2000,

which was too expensive for the market. The system can hold up to 100 pounds of load capacity

of boats, bikes, or cargo boxes. All the loading are done by the side of the car as seen in the

picture below.

        There are many design aspects that are need to be considered for designing the system

which include: weight limit, ergonomics, safety, and the market price after completion.

2 | P a g e

The purpose of this document is to clearly define the customer requirements, lay out a

project plan, set milestones, discuss risk management and create a design specification list.

The purpose of this project is to design a system that will provide load assistance for one

person to load a kayak on the roof of a vehicle. The targeted price for the system is around $500.

The final prototyping is to be finished in early June.

Task Assign Date Finish Date Tasks due

Discussion of ideas and scope of project Dec-13-11 Jan-11-12

Internal and External Research Jan-9-12 Feb-3-12

Draft Design Jan-23-12 Feb-29-12

PDS Report Jan-16-12 Jan-30-12 Jan-30-12

PDS Report Presentation Jan-30-12 Feb-13-12 Feb-13-12

Evaluation Of Drafted Design Feb-13-12 March-5-12

Design/make Product Feb-20-12 March-15-12

End of the Term Progress Report Feb-27-12 March-12-12

Progress Report Presentation Feb-27-12 Feb-27-12 Feb-27-12

Presentation design to Sponsor March-12-12 March-14-12

Testing and Prototyping March-14-12 April-4-12

Redesigning Concept And Prototype March-21-12 April-18-12

Repeat Testing April-11-12 April-25-12

Manufacture Final Product April-25-12 May-23-12

3 | P a g e

The internal customers are defined as any PSU affiliate that has any input to the capstone

process. The following are people that are internally part of the capstone process.

The Yakima PSU team

Should demonstrate technical proficiency in the final product at the time of testing. Team

members must demonstrate equal amount of effort.

Dr. Thomas and Dr. Etasami

The team must show progress of project on a weekly basis to Dr. Thomas along with the

required presentations.

PSU Machine Shop

Machine shop shall be used on an as needed basis. Team members will machine parts

under supervision.

External customers are those who are not affiliated with PSU. The following list identifies

external customers and their input on the project.

Yakima

Chris Sautter (Mechanical Engineer); Mark Elliott (Design Engineer - Team Lead)

Load assist must pass all Yakima Performance and Test Standards.

Holds at least one kayak.

Minimum number of steps to use.

No rattling when loaded or unloaded

Reliable

Minimize Weight of load assist.

Visual and/or audible confirmation that load assist is secured.

Yakima Legal Department

Must clear existing IP (patents).

Safe to use.

Yakima Financial Department

4 | P a g e

Low cost (equal to competitor in features and benefits for cost)

End-User

Target Persona

An average 45 year old 5’2” woman who paddles a sea kayak, rides a bike and drives

a Subaru Outback

Ergonomic design allows user to easily load boat on top of vehicle.

Mark Elliot and Chris Sautter of Yakima explained to the capstone group what the scope

and reason for this project is. Yakima had approached this project a few years prior but decided

to not release the product to the market as the price was not competitive. Mark and Chris

explained the current project along with the "must-haves" and "wants". The emphasis of this

project was on keeping the system relatively simple, to maintain a low cost, and that the intended

end user could load her kayak on her own without causing damage to her vehicle or the kayak

equipment. Feedback from Yakima thus far has helped the capstone group fine tune the

requirements, scope, and expected end results of the project.

The testing of the prototype as well as the final product will be tested in Beaverton at the

Yakima headquarters. Testing can only commence when the initial prototype is assembled.

Yakima will provide any testing material such as kayaks, cross bars and boat mounts. The load

assist must pass Yakima’s internal standards, specifically the forward pull at 4 times the rated

carrier load and the upward pull at 2500 N.

5 | P a g e

With the complexity of this project, there are multiple risks that can cause the load assist

to fail. One of the most critical components is the preloaded mechanism. Without a configured

and working preloaded mechanism, the entire scope of the project may come to a halt or possibly

fail. The purpose of a top of car load assist is such that the user will not feel the full load of the

kayak. Failing to have a working mechanism will result in the user lifting all of the weight of the

load assist as well as the kayak that he/she is loading.

Another risk of failure in the project is clearance between the side of the car and the load

assist. Without calculating the proper clearances damage could occur to the sporting equipment

that is held, the car side and the windows. Things that must be taken into account are: the amount

of space between lowered rack assist and side of car, deflection of the load assist due to the

maximum load and clearance between the rack and the roof of the car.

One thing that must be considered heavily during the design of the final product is safety.

Recognizing potential hazards such as pinch points, user misuse and sharp edges is critical so

that no one will be harmed during operation.

The cost of the final product is an important design consideration, because if the profit

margin is too small or the market price too high, Yakima will not bring the load assist to market.

6 | P a g e

Applicable Codes and Standards

See appendix 1 for Yakima standard tests

7 | P a g e

Customer Requirement Metric Target Basis VerificationYakima Adhere to fatigue

standards: YS2015, ISO 11154, and DIN 75-302

Cycle Test 100% Design load, 30k cycles

Standard Definition

Testing

Yakima Adhere to Durability/Road Loop standard YS2014

Durability/Road loop test

100% Design Load

Standard Definition

Testing

Yakima Adhere to Pull Tests standard: YS2015

Pull tests Pass Yakima standard pull test (refer to appendix)

Standard Definition

Testing

Yakima Work Place safety codes

Number of codes to be violated

Zero Safety and legal standards

Review of the safety and legal standards

Yakima Adhere to Pull Tests standard: ISO 11154

Pull tests Pass 4x Max load FWD and AFT load @ CG

ISO 11154 Testing

Yakima Adhere to Pull Tests standard: ISO 11154

Pull tests Pass 4x Max load 20 degree horizontal force @ CG

ISO 11154 Testing

Yakima Adhere to Pull Tests standard: ISO 11154

Pull tests Pass 2x max load LAT load @ CG

ISO 11154 Testing

Yakima Adhere to Pull Tests standard: ISO 11154

Pull tests Pass 4x max load (up) load @ GC

ISO 11154 Testing

Yakima Mount shall meet performance standards

NA Meet all standard criteria

ISO 11154, YS2015, and DIN 75-302

Standard Definitions

Ergonomics

Documentation

Life in Service

Disposal

8 | P a g e

Customer Requirement Metric Target Basis VerificationYakima Low loading

effortLbs. of lift assist 60 lbs. Customer

RequirementMeasurement

Yakima Comfortable handles or levers

Handles and levers All Physical testing Customer verification

Customer Requirement Metric Target Basis VerificationPSU PDS Report Completed Report January 30,

2012Course requirements Good Grade

PSU Progress Report

Completed Report March 12, 2012

Course requirements Good Grade

PSU Final Design Report

Completed Report June, 2012 Course requirements Good Grade

Customer Requirement Metric Target Basis VerificationYakima Product should have no

mechanical or structural failures for 5 years of moderate use

Product life cycle

Theoretical life cycle of 5 years.

Yakima warranty standards

Testing

Customer Requirement Metric Target Basis VerificationYakima Use only

recyclable plastics

Plastic recyclability

100% recyclable

Yakima recyclability standard

Customer definition and or standards

Maintenance

Performance

Safety

9 | P a g e

Customer Requirement Metric Target Basis VerificationYakima Non-water

soluble lubricant on moving metal parts

Lubricant type

Use only non-water soluble lubricant

Chemical composition and lubricant manufacturer specs

Test Lubricant for non-water solubility

Yakima Plastic parts to be cleaned with soft cloth and mild detergent

Plastic type Use only plastics that can be cleaned with cloth and mild detergent

Customer definition

Test plastic for cleaning

Customer Requirement Metric Target Basis VerificationYakima Ease of use Loading time Load and lock

bike or boat in less than 5 minutes

Customer definition and physical test

Testing

Yakima Low reach distance

Distance from ground to loading rack

36 inches from ground to rack in loading position

Height of 2011 Subaru Outback(64 inches)

Testing

Yakima Should be easily fitted to standard rack systems

Modular design No removal of base rack system

Customer definition

Testing

Yakima No rattling when loaded or unloaded

Noise or chatter during loading and unloading process

No audible sound to loader

Customer defined

Testing

Customer Requirement Metric Target Basis VerificationYakima No sharp

edges/cornersNumber of sharp corners or edges

Zero Customer Requirement

Inspection

Yakima No pinch points Number of pinch points

Zero Customer Requirement

Inspection

Timeline

Company Constraints and Procedures

Customer Requirement Metric Target Basis VerificationYakima Keep product

inherently safeN/A Consider pinch

points and potential user “misuse”.

Yakima Requirement

Inspection

Cost of production per part

Customer Requirement Metric Target Basis VerificationYakima Low retail

priceDollars $1000

maximumCustomer feedback

Study of price in market

Environment

Customer Requirement Metric Target Basis VerificationYakima Operates in a harsh

wet environmentYears of Resistance to rust and corrosion

5 years Group decision

Study of standards

10 | P a g e

Customer Requirement Metric Target Basis VerificationPSU PDS Report Completed Report January 30,

2012Course requirements

Good Grade

PSU Progress Report

Completed Report March 12, 2012

Course requirements

Good Grade

PSU Final Design Report

Completed Report June, 2012 Course requirements

Good Grade

Yakima Final Product Timely Completion June 1, 2012 Customer Customer is Satisfied

Manufacturing facilities

Customer Requirement Metric Target Basis Verification

Project team and Yakima

Yakima provides facilities needed

Use of Yakima’s Facilities

No need to use other facilities

Customer input

Similar system comparison

Shipping

Customer Requirement Metric Target Basis VerificationYakima Fit in not too large

shipping containerCubic inches 10” X 24” X

36”Expert opinion

Study of standards

Materials

Customer Requirement Metric Target Basis VerificationYakima Product

componentsYes/no Typical Yakima

materialsYakima

requirementInspection

Yakima Aesthetics Yes/no Looks sturdy &professional

Customer input Inspection

11 | P a g e

Requirement CustomerImportance Engineering Criteria Competition

lift capacity cost Materials Size Life Cycle Thule Malone

Retail Price end user *** ***** *** **** ** *** ****

Fatigue/corrosion resistance end user *** *** ** **** * **** **** **ergonomics end user ** **** ** * *** ** **** **lift assist end user ***** ***** *** ** * *** *** **Installation end user ** * * * **** ** **** *

Competition

Thule 75 590 Aluminum35" w Limited lifetime

Malone 70 270 Aluminum35" w 1 year

Target 120 500 Aluminum35" w Limited Lifetime

House of Quality

Legend: low importance * ***** high importance

Yakima has put the most emphasis on this project to keep it simple as can be to serve its purpose. The purpose is clearly defined

within this document including the main points of performance, safety, and cost. One of the main challenges the capstone team will

face will be in the area of providing the load assist in a simple cost effective way. Yakima has made stated that cost is important in

this project but it is not a “make or break” for them as they have lower cost sourcing options they can implement if needed.

Appendix 1

1 | P a g e

2 | P a g e

3 | P a g e

4 | P a g e

5 | P a g e