Price: These crafts are much cheaper as made from plastics in mass numbers
Ease of Use: If the user falls out of the craft it is very simple to jump back on, unlike with conversional kayaks were this is an impossible feet. This is why sit-on-tops are popular with fishing and SUCUBA diving users. This is because these users require to leave and enter the craft constantly, change seating position, and access storage hatches.
Functionality: Sit-on-tops may be used for a variety of applications. In rapids, the bay, rivers, cave exploring, lakes, surf, almost any application thinkable. They are also very easy to use, but are still fun for the professional user.
Storage: Sit-on-tops are typically shorter and a little wider than their conventional kayaks. This reduction in size allows for easy storage in almost any garage or shed.
Transport Transportation is easy on roof racks, or even within some larges cars. As a typical sit-on-top only ways around 15-20Kg a single person can load and unload from the roof of a car.
Life: As these products are made from plastic they are very durable, and can be knocked around a lot more than fiberglass kayaks. Also these products are quite easily to repair if they are damages.
Materials:
Plastic type:
For a superior construction the vessels must be neither nor flexible or too stiff. A flexible material does not work as well however is much harder to crack. On the other hand a stiffer material creates a more efficient hull, but will crack easily. Abrasion is also an issue with users often hitting objects in the water, and dragging the vessel to and from the water. The best plastic product that meets all of these characteristics is a linear, medium-Density, Polyethylene compound. This has the correct stiffness when used with a good hull design, and will give enough on normal impacts not to crack. Also it holds very good abrasion-resistant characteristics, and is UV resistant which is important for the long-life of our product.
Safety Rope:
Nylon rope will be used as a safety rail as it will not hold water, and stay true to its structural properties even when wet.
Glass window:
Acrylic glass is the number one pick to be used for both our actual window, and our window protector. This is as it is relatively feasible with price, but more importantly it can withstand much greater impact than glass without breaking. This was a very big safety concern when first designing our kayak. As Acrylic glass does not shatter, it is much safer than glass. One downfall is that it is more prone to scratches, however there is a scratch resistant coating which may be applied.
Fittings Clip:
These will all be made of injected plastic products as they are relatively cheap, have a long life, and work well in water based applications.
Screws & Rivets
All screws and rivets will be stainless steel to prevent corrosion and failure of their duty.
Market research
Same size and class sit-on-top’s already in the market minus a viewing window Retail for around $500 to $800. Our product will be of a superior make plus have a major benefit, a window into the world bellow. For this reason our crafts will be priced at $750 Retail including paddle, and $650 including paddle wholesale and for bulk orders.
Our product will be sold to the general public in retail stores such as Rays outdoors, Capacity Sports, and Rebel Sports. However a large number of sales will be direct to sporting clubs, tour group companies, tourism companies, and other recreational water user groups.
From market research of a local manufacturer ‘Wave dance Kayaks’ a yearly average of stock turnover is around 10 Units a week. This number varies significantly to season.
Within Victoria there are around 980,050 residents living along the coast. If we were to sell to just 1% of this population over the next 10 years it would result in the requirement of 18 kayaks per week. Assumptions that only 1% of costal residence would want a kayak and that of these many would wait until they are due for a new product.
Ocean View kayaks will also look into expanding to selling overseas, firstly to New Zealand, and then marketing in the USA, Europe, and Asia depending on market requirements.
It can be seen that there is a need for this product, with vast amount of market growth available. Also it was found that there are only 3 Sit-on-top kayak manufacturers currently in Victoria.
From This information Ocean View K&A have set a target manufacturing rate of 19 units per week.
N.B. Population figures obtained from www.vcc.vic.gov.au/stratergy.fut-demo.html
Cost Estimates
The following is an estimation on cost of materials per Unit, and Labor Costs
Fig 1.1
Labor based on 19 Units per week (38hour working week)
Operating costs based on 20% of labor & materials cost. This is an industrial rule of thumb. Operating costs include things such as gas, electricity, phone, consumables etc.
Set up Cost (equipment) is based on $250,000 over 10 years, per unit. A large amount of this set-up cost if from plant machinery. For more information regarding machine costs please see Fig 3.1 on page
From this we find we have a profit of around $310. This will include funds to cover any other unexpected costs.
Bill of Materials
Fig 1.2
Product Drawing
Initial Plant Layout
Assembly Sequence
Assembly Chart
Kayak Hull (1)
Plexiglas Window (1) SA1 Fixed Window Assembly
Silicone
Plexiglas Protector(1) Window
Silicone A1 Assembly
Large Storage Lid (1)
Rubber Seal ‘A’ (0.6M) SA2 Lid Assembly
Silicone
Bungee Rope (0.1M)
Rubber seal ‘B’(0.6M)
Silicone A2 Rear Hatch
Hatch Clips (2) Assembly
Storage Fitting (1)
Storage Cap (1)
Self tapping screw (4) A3 Front Hatch
Silicone Assembly
Handle
Handle (2) SA4 Assembly
Nylon Rope (6.5M)
Rail rope clips (18) A4 Safety Rail &
Self tapping screws (36) Handle
Assembly
Paddle shaft (1)
Shaft Cap (2) SA5 Shaft Assembly
Silicone
Paddle (2) Finished Kayak
Pop Rivet (2) A5 F & Paddle
Silicone
Paddle
Assembly
Fig 2.1
Indented Bill of Materials for Window Kayak
Fig 2.2
Operations Chart
Fig 2.3
Machinery
Table of Machines
Fig 3.1
The following two routing sheets (Fig 3.2 & 3.3) are for the two items which are made in-house, and used in the production of the paddle.
Routing Sheet
Part #: 0014 Part Name: Shaft
Raw Material: Aluminum
Order Qty: 1
Fig 3.2
Part #: 0013 Part Name: Paddle
Raw Material: Plastic
Order Qty: 2
Fig 3.3
Draft Layout
Relationship Diagram
Fig 4.1
Activity Relationship Worksheet
Fig 4.2
Dimensionless Block Diagram
First Design
1 2 7
5 11 6 10 8
3 4 9 15 13
c
14 12
Fig 4.3
Second Design
12 13 15 8 7
2 14 9 10 5
1 3 4 6 11
Fig 4.4
Final Design
12 13 15 10 6
Toilet Lunch Cleaning kayak Dispatch
Lockers Maint. Make-up
3 7 8 4 11
Injection Rotation Plexiglas Paddle Load Bay
2 1 9 14 5
Drill/ Cut of Power Office Reciev-
Grinder saw Tools ing
Fig 4.5
Actual blocks, in final formation
Fig 4.6
Ocean view has chosen this layout as it was more practical when looking at the whole of the process, and not just how individual blocks related to each other.
Flow of Material through Dimensionless block diagram
Fig 4.7
Although the flow of materials may not seem streamlined, it is actually in a way which is the most feasible. Ocean view is not producing thousands of products a day. We just produce two quality kayaks in a day (Average)(One day a week will just be producing injected molded products, another day may just be assembling final product etc). This means that our factory should be set up more as a job shop so that we can use the smallest amount of space required, and therefore turn a greater profit.
Flow Chart
Fig 5.1
Layout
Fig 6.1
Additional Layout Requirements
Work Station Ergonomics
When designing a workstation 6 key principles should be taken into consideration.
There are 8 key steps to making the most of hand motions these are;
- Use as little hand motions as possible.
- Try and combine tasks to help eliminate unnecessary motions.
- Motions should be kept as short as possible, i.e. no excessive reaching.
- Make motions as easy as possible, little required force.
- Make use of both hands at all time.
- Hand motions should mirror each other.
- Do not use the “one armed bandit” as a hand is probably the most expensive fixture in the world.
- Location of tools and parts should be made as close as possible to the task at hand.
The three basic motion types are important to keep in mind as this will produce a more efficient, and ergonomic workstation. The types are as follows;
- Ballistic motions. These are motions in which an item or object is thrown, or a fast throwing like motion to execute a task. These motions are efficient as they are fast, and are easy to execute.
- Controlled or restricted motions. These are motions which take more concentration and control. These motions should be reduced as much as possible.
- Continuous motions (Curved motions). This type of motion is much more natural than ridged liner motions, and therefore should be encouraged.
- Lactation (Parts & Tools)
Placement of object around the workstation is a crucial part of designing a workstation. Parts and tools should have a permanent location. This helps workers to fall into a good habit, and learn faster. It also will reduce time otherwise wasted looking or retrieving objects. This is also important if more than one person will be working on the workstation, as all workers will know exactly where everything belongs. This said it also important to have objects placed as close as possible to their intended usage point. Items used more often should have priority on closeness.
- Lessening work load on hands
The workers hand will most likely be the most expensive tool being used on the work station. For this reason it is important to free it from tasks in which other cheaper tools may be used. For instance to hold an object a special jig could be used. Assorted fixtures are available to free the hands from tasks so that they can be used for more productive purposes.
When possible use gravity to its full potential. For example hoppers may be used to load, or store a product and dispense without any mechanical operations needing to be carried out.
Occupational health and safety is one of the most important factors to take into consideration. The Australian government has guidelines in which a workplace must meet, however it is in the interest for the designer to exceed these guidelines. A safe workplace means fewer injuries, and hence times off and work cover payment. Some important things that must be incorporated into a workstation are adequate lighting, space, and making sure that the workstation is ergonomically (correct height, worker is not required to strain particular muscular groups).
Design 1: Kayak Make-up Bench
The following table (Fig 8.1) is a key to the drawing of this workstation on the following page.
Fig 8.1
This design has taken into account all the concepts discussed above, but also has ensured that the work station was economically viable.
Make-Up Bench
Storage bins (some sectioned) are used around the table to store smaller consumable items which are used on a regular basis, i.e. handles, screws, clips.
Wound items such as the rope and rubber seal will be housed on one end of the table where they will be fitted on a spindle which allows for compact storage, and ease of use. This also means for the rope it can be fed through the craft while still on the spindle, and cut to size without having to rewind any excess rope back onto the spindle.
The space under the table is utilized with draws which may slide out on either side. These have the other larger consumable items which are required for the Kayak assembly. This is also were the cordless drill will be charged.
The bench top has a cradle for both a cordless drill and silicone gun. It was looked at to have a directional overhead drill fitted, however the costs had overweighed the benefits at this stage.
There is also some free space left which will be used for either scraps, or any unforeseen future needs.
Roller Trolley
This is the mode of transport so that the kayak’s may be moved easily by one person. The trolley has a top consisting of angled rollers which allow for ease of loading and unloading.
Fixed castors on one end so that steering of the table is made easy. Wheel breaks are also fitted so that the trolley does not move around when loading and unloading.
Optimization of Design Layout
For the following techniques applied to our process flow, some assumptions should be pointed out. Upon the completion of any individual part, it is stored in dispatch ready to be used. In our actual factory this is not the case, as parts will be stored as WIP were they will be needed next.
Area Key
Fig 8.2
Operation Sequence
Fig 8.3
String Diagram
R A B C D E F G H
Fig10.1
From this we see that there is no back tracking, so from a multi-column process chart we would find that this process is 100% efficient. For this reason it was chosen not to do a multi-column process chart.
From-To Chart
Fig 10.2
Initial From to chart
Fig 10.3
Fig 10.4
Fig 10.5
From Fig 10.4 and Fig 10.5 it is easy to find the efficiency of the alphabetical layout.
Efficiency = (411/3220) x 100
= 12.7%
From Fig 10.5 it is shown that G needs to be closer to D, and D is required closer to R to dramatically improve the efficiency.
Fig 10.6
With the rearrangement of area distances there are both improvement in the larger weighted items, and some backtracking for the less weighted items. It is now possible to find the efficiency of the second From-To Chart (Fig 10.6)
Efficiency = (411/1255) x 100
= 32.7%
This is a huge saving in efficiency.
N.B. Ocean view does not work on a production line type basis, so these optimization techniques do not have full relevance when used with processes such as ours. However from the from/to diagram we find the relative importance of having some of the major departments closer to each other.
This was also shown on the Block Diagram analysis. Our design allows for this with superior materials handling equipment which almost makes all items have the same relative importance when relating to the table Fig 10.2. As this is the case we have chosen not to change our process or layout as it originally contained no backtracking.
References
Manufacturing Facilities Design and Materials Handling (Third Edition), Fred E. Meyers, Matthew P. Stephens,2005.