Design and Development of Premium gas stove for Indian upper middle class

Final Project Presentation Design and Development of Premium Gas Stove for Upper Middle class Indians Basil Jose BTB0909029 M. Sc. (Engg.) in Product Design

Academic Guides : Mr. Lohith H.S (Asst.Prof. DOD) Dr.Era Poddar(Prof. DOD) MSRSAS, Banglore Basil Jose

Industrial Guide : Mr.Chandrasheakar (Design Head) Geneva Innovations Bangalore

M. S. Ramaiah School of Advanced Studies

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Aim and Objectives of the Project Aim :

To design and develop a premium stand alone gas stove for Indian upper middle class and above, considering the aspects of aesthetics, usability & ergonomics

Objectives : • • • • • • •

To carry out literature review on Gas stove, to understand the latest design trends, present design practices To study the existing products, the market study, the user study and understand the consumer needs To generate QFD and to arrive at target PDS To generate concepts as per PDS and create CAD models of generated concepts To select the final concept by concept selection method To make prototype and collect feedback from user

Basil Jose

M. S. Ramaiah School of Advanced Studies

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Methodology Gas Stove

Data collection

Patents, Books , Internet

User study / Customer survey

Data analysis

Concept generation

Customer Brain Storming, Voice

Finalization of concepts

Prototype

Feedback

Concept evaluation

Planning

User/Technical Rating

QFD

Concept sketching

Weighted rank selection

Material selection

PDS

Digital modeling

Final concept

Model making

Rendering

Concept detailing

Model detailing

Benchmarking

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M. S. Ramaiah School of Advanced Studies

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Methodology •

•

• • • • •

Literature review on premium gas stove has been carried out to understand the latest design trends, present design practices and collect relevant data by referring published materials such as books, journals, manuals and patents Data collection has been done by product study, user study and market study through ethnography research, questionnaires, personal interviews, finding visual inconsistencies , investigating user behavior and ergonomic study QFD is generated based on the needs identified, and PDS has been arrived based on the needs having highest priority in QFD Concepts has been generated using various idea generation techniques like brain storming, mind mapping, theme boards Five concepts has been selected and the digital model was created by using Alias studio, CATIA, Adobe Photoshop, AutoCAD Final concept has been selected by using weighted ranking method and detailed engineering drawing was created prototype of the final concept is made and feed backs were collected

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Introduction A stove is a heat-producing device used for heating or for cooking food.

Typically the word is used to refer to a kitchen appliance used for either generating warmth or for cooking. Gas stoves are basically used in home kitchens, hotels, restaurants and for outdoor cooking. In current scenario like all the other modern kitchen appliances stove also plays a role in maintaining the over all uniqueness of the kitchen.

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Mile stones of Gas Stove • Chinese, Korean, and Japanese civilizations had discovered the principle of the closed stove in (221 BC–206/207 BC).

• The mode of power source was charcoal and wood.

• In the Middle Ages, waist-high brick-and-mortar hearths and

Mortar hearths (221 BC–206/207 BC)

the first chimneys came in to picture.

• Around 1728, cast iron ovens began to be made in quantity.

These first ovens of German design were called Five-plate or First stepped cast iron stove

Jamb stoves.

• In 1735 the first enclosed gas stove was designed by French architect François de Cuvilliés • Small refinements has happened in the end of 18th century.

Cast iron stoves 1728

• The Franklin stove, invented in 1743 and used for heating.

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Mile stones of Gas Stove continued ...

• Around 1800, Count Rumford invented a working iron kitchen stove called the Rumford stove • In1834 Stewart's Oberlin patented the first compact iron stove Franklin stove-1743

Rumford stove-1800

• Frans Wilhelm Lindqvist designed the first soot less kerosene oven.

• British inventor, James Sharp patented a first gas oven in

Soot less kerosene oven

1826, the first semi-successful gas oven to appear on the market. Jordan Mott invented the first practical coal oven in 1833.

• In 1910s, gas stoves appeared with enamel coatings that

Electric stove

made the stoves easier to clean.

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Literature Review Ed Sobey [1] Says The kitchen has become an important part of each home and a place for people to showcase the technology. Kitchen is not only meant for cooking but also to eat, talk, or just hang out. Current scenario shows lot of cutting edge technologies are used in kitchen appliances like the latest ways to slice, dice, mix, bake, and cook. A detailed description of the modern kitchen appliances and different technologies used are explained starting from automatic knife cutter to induction stove.

Hal Philipp [2] says about the capacitive touch controls which is widely used in the modern appliances starting from kitchen appliances to personal products like Mobile, laptops etc. Quantum’s QT401 Q Slide™ sensor chips developed

by Gorenje’s is widely used in the cook tops touch interface. According to the article the buttons and sliders on these cook tops permit a much faster and more satisfying control of heat settings. The QT401 slider chip and QT1100A buttons are used in MP3 players to microwave ovens.

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Literature Review continued . . .

An Article published by schout solutions [3] says Colors convey emotions and values. They can give a product an exclusive look and influence a consumer’s buying behavior. A study conducted by the schout says customers are usually interested in metallic, elegant or luxurious color shades when it comes to kitchen appliances. Two color families such as gray shades ranging from gunpowder to graphite and Twilight Blue with just a touch of metallic brilliance or a shimmer of silver can be popular in recent future.

Anne Fuhlbrigge, Scott Weiss [5] says about the major contributor of indoor air pollution is combustion products from gas appliances. Her studies shows people living in homes with gas stoves and other unvented gas appliances experience more respiratory diseases than those who use other fuels for cooking and heating.

Especially the women are seriously affected by respiratory health issues.

Jonathan Ceda [4] say about the importance of low emission cooking stoves .Article says about the technology which is used for developing a biolite stove. The stove works with use of wood but compared to the normal wood stoves the consumption of wood is 50% less and it also achieves a 95% smoke reduction without reliance on external power sources.

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Literature Review continued . . .

Pankag Sreenivasan [6] says about the recent trends in Indian kitchens. Influence of modular kitchen has changed the over all appearance of the Indian kitchen Use of cook tops and modern kitchen appliances are making the Indian house wife's life easier. Neat and clean look of the appliances and the proper lay out of the kitchen provides great ambience for cooking.

Seema Seath [7] says about the change in Indians shopping attitudes. The article says about the different habits of shopping product in gender wise. Most of the women customers are attracted to the aesthetics and the offer based products but male customers are more practical minded and the selection of the product depends on the overall value of the product. Women customers are more interested to spend time for shopping when compared with men.

Mr. Don Norman [8] says usability is one of the key factors to be considered in the design. When there are more parts for a product the look and feel always depends on the proportion and balance of the different parts. The relations between each parts and components determines the life of the product. User friendliness and positive interface also affects the commercial success of the product.

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Summary of Literature Review •

The study shows the gas stoves are not only meant for its core function but its aesthetics and surprising factors also attracts the customers.

•

Literature surveys shows the choices and taste of women are predominant while purchasing kitchen appliances.

•

Advanced interface technologies gives the kitchen appliances a new definition when it comes to premium class.

•

Study says electricity can become the major power source in kitchen for the coming future.

•

Gas appliances are one of the major indoor air polluting agent.

•

Colors, surface finish and form of the product is an important factor in the stove design.

•

The layout of the kitchen and the environment has significant effects on the stove design.

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Product configuration study

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Basic Structure

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Basic Structure continued . . .

01. Aluminum Washer 02. Cast Iron Fly Nut

04. Dial Plate 06. Bakelite Knob

16. Rubber Leg

18. Gas Valve Assy.

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Basic Structure continued . . .

Pan Support

Drip Tray, Burner and Pipe Assembly

Rubber Tube Green ,LPG Fasteners

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Basic Structure continued . . .

•Safety system used in combination of gas and electric stoves •Parts Of Euro Burner Basil Jose

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Functional Attribute Analysis

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Product environment study Types of Kitchen:

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Prestige Glass Top Gas Tables GT 02

Glass Top Gas Tables GT 03L

Glass Top Gas Tables GT 04

Gas Tables GS-04 N

Gilma

Prestige

Market Study

Butterfly

Gilma –Innova 2B

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Butterfly Ideal 2B

Gilma –Nero 3B

Butterfly Fond 3 Rectangular

Gilma –Innova 3B

Butterfly Fond 3

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Gilma G PLUS

Butterfly Fair deal

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Pigeon

Market Study Continued‌

PG 321 T

PG 421 T

PG 4110 DT

Glen

PIGEON 2110 DT

GL 1035SSTR

GL 1047PLTRAI

Jyothi

GLEN 1022GT

Jyothi GT11

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Jyothi Freedom

Jyothi 3wl APPY

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GL 1045SSHF

Jyothi 3EU APPY

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Market Study Continued‌ Study on Premium Range Products: Products:

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Market Study Continued…

• Advanced Technologies are used in Interface especially touch sensitive surfaces • Manual actions are reduced with automatic mechanisms.

• Elegant displays are provided for most of the premium products in shop.

• Use of simple graphics designs on the surface of the product is one of the noticeable feature.

• Use of chrome plating and metallic shades like red ,black, blue etc are widely used.

• Stainless steel and ceramic glass is emerging as a new countertop favorite in kitchen.

• Sleek and geometric forms are nicely blended to create the forms.

• Number of colors used are limited to one or two.

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Product Bench Mark Study:

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Product Bench Mark Study continued‌

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Product Bench Mark Study continued‌

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Product Bench Mark Study continued‌ Bench Marked product:

Prestige Glass Top Gas Tables GT 03L AI Premium Look ISI certification mark Brand Value Spill proof design Elegant black toughened glass top High-efficiency brass burners Individual pan supports Ergonomic knob design Multi spark ignition Size:740 x395x115 Price Rs:9945

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Classification of Gas stove Ranges

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SI No:

Features

1

Manual Ignition

2

Stainless steel body

3

Aluminum mixing tube/C.I mixing tubes

4

Bakelite knobs

5

Brass Burner /Al alloy

6

S.S spill tray

7

M.S coated Pan support

8

Rubber /S.S Legs

9

Single directional nozzle

10

S.S pan support

11

Multi directional nozzle

12

Euro coated brass burner

13

Yellow flame control/Auto ignition

14

Multi spark Auto Ignition

15

ABS knobs

16

Glass toughened body

17

Aesthetically Rich

18

Use of Graphics

19

Edge beading support

Basic Model

Medium Range

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Premium Range

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Trend Study Aesthetically good Higher Efficiency

•Clean and Neat look

•Glossy, Matt finishes are used • Colors are limited to black ,gray and silver •Sleek and elegant look

•Effective use of energy • Advanced burners like euro burners are used • Fast Cooking

Product Trend

•Lesser cooking time •Auto ignition system •Yellow flame control

•Use of small Graphics on the body

•Multi spark injection

Different Materials •Stainless steel with different finish •Stainless steel with euro coated

Ergonomically designed

•Multi Directional Nozzle •Ergonomically positioned knobs

•Toughened glass tops in different thickness

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•Effective pan support

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Other cooking stoves Electric Stoves:

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Other cooking stoves Induction Stoves:

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Comparison chart for stoves No

Gas

Electric

Induction

1

Food cooker faster and better.

Time consumption is more.

40% Faster than Gas stove

2

cooking with gas is more accurate.

Distribution of heat is uniform in electric and control over heat is less.

Distribution of heat is uniform in induction but the control over heat is less.

3

Gas stoves usually have sealed burners.

Helps for easy cleaning.

Electric stoves come with coil burners or Solid-top contain the radiant heat element below a glass or ceramic top.

Induction stoves use electromagnetic technology to transfer heat directly to the pan rather than heating the surface like a traditional electric cook top with radiant burners.

4

Power Source is LPG ,Natural gas, butane, propane etc.

Power source is 240 v electricity.

Power source is 240 v electricity.

5

Installation steps are difficult ,expensive and time consuming,

Installation procedure is easy and less time consuming.

Installation procedure is easy and less time consuming.

6

A gas stove creates more amount of over all heat and leads to warm environment inside the kitchen

Electric stove also produces more amount of over all heat and leads to warm environment inside the kitchen

Induction stove produces less overall heat and keeps the environment cool

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Comparison chart for stoves Continued‌ 7

Gas stove is suitable for all kind of cooking vessels.

Suitable for all kind of vessels

All kind of vessels are not suitable for induction stove

8

A cook is able to control the amount of heat to be delivered to the cooking pot by visually.

Controlling the heat is not as effective like gas stove

Where as the vessel itself has become the source of heat. Controlling the heat is not possible by visual assistance.

9

Use of pressure canners which make the use of gas stoves more efficient. In short gas is usually more energy-efficient.

Pressure canners are less efficient

Pressure canners are less efficient in induction stoves

10

Less Expensive, Aesthetically poor when compared with induction stoves

Expensive, and Maintenance cost is more

Costly, Aesthetically rich when compared

11

User Friendly interface

Less user friendly when compared with gas stoves

Less user friendly when compared with gas stoves

12

Interruption of power source is less

Chance of interruption of power source is More

Interruption of power source is More

Safety is less

Safety is more when compared with gas stove

Safety is more

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User Study Stake Holders Users Age Group 16 to 70

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User Study continued‌ Questionnaire Survey: Which One You Prefer?

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What is your prime factor when you buy a stove? Preference on Number of Burners ?

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User Study continued‌ Which one You Prefer?

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Which One You Prefer?

Frequently replaced spare part ?

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User Study continued‌ Space constraints on the kitchen slab. The whole area is congested with other table top appliances like blender, Microwave Oven and cooking vessels.

Position of the gas tube obstructs the user while cooking.

People buy hob type stoves but most of the cases they don’t want to cut the granite for making the counter. Separate frames are used for converting the hob type into stand alone stove.

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User Study continued‌ Difficult to access the back side burners.

Handles of the vessels can touch the kitchen wall.

Orientation of the knobs are in different patterns like, sides, front and top face.

Which leads to difficulties in identifying the proper burners in some models.

Sharp edges are not preferred by the customers.

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User Study continued‌ Clearance between the stove bottom and the kitchen slab is very less in case of stand alone stove and this area is very difficult to clean.

Each Burners are meant for particular cooking vessels. As the stoves come with jumbo burner, medium burner and small burner.

While cleaning the stove body, the knobs tend to switch on and the possibilities of gas leaking is more.

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User Study continued‌

Over a period of time the grates easily gets rusted. Grates are cleaned by keeping it in soap water for a long period to remove the stains.

Use of scrubber and other cleaning accessories leads to make scratches on the stove.

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User Study continued‌ The Free space between the burners are used for keeping small vessels, spoons or tong.

Collective grates are arranged in such a way that the height variation on each burner helps to avoid the congestion of the vessels when it is placed over the stove .

Knob area is difficult to clean. Lot of oil and food particles are accumulated on this portion.

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User Study continued‌ Majority of the people like glass top and black color. But at the same time they are aware of the draw backs of glass. Glass is not that much rough and tough when compared with the S.S. Indian Burner

Italian Burners are widely used in modern stoves. Italian burners are efficient in terms of fast cooking, easy to clean. But the gas consumption is more when compared with the Indian burners.

Triple Ring Burner

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Rapid Burner

Semi Rapid Burner

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User Study continued‌ Majority of the gas stove users keep one cylinder extra because the cylinder gets empty with out any intimation.

Knobs are the major part which always replaced due to complaints.

Ladies always find it difficult to fix the Regulator.

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User Study continued‌ Ethnography Video:

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User Study continued‌ Vessels Used for Indian Style of Cooking: Vessels

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Spec

Material

Cooker

250 to 290,Flat

Aluminum Alloy

Saucepan

150 to 200,Flat & Round

Copper, S.S

Kadai

180 to 300,Flat & Round

Copper, S.S, Aluminum

Frying pans

180 to260,Flat & Round

Copper, S.S, Aluminum

Milk Cooker

100 to160 ,Flat

Copper, S.S, Aluminum alloy

Pot

Max size 300,Round

Copper, S.S, Aluminum alloy

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Ergonomic Study

• 48 Mid Position Length: 5%ile-749mm [9] • 49 Mid Position Height: 5%ile-1229mm • 51 Lower Position Height 95%ile-939mm • Maximum Working zone:596.9mm • Normal working zone: 393.7mm • Standard width of the kitchen slab:660.4mm

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Ergonomic Study

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Inference From Studies •Easy Cleaning •Aesthetically rich •Easy Installation •Effective burner lay out •User Friendly Interface •Scratch Proof Design •Corrosion resistant grates •Free space between the burners •Individual Grates •Effective safety system •Effective use of all the burners at a time •Fast Cooking •Gas Level Indication

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QFD

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PDS Description

Specification

Product Name Age Group Area of Usage Colors Life Span Power Source

Premium Gas Stove 16 to 70 Kitchen Black and Silver, 5 to 10 Yrs LPG 2.942 KN/M2 (30gf/cm2) 830 x400x115 8 to 10Kg ISI Min 3 and Max 4

Size Weight Certification mark Number Of Burners Burner Size Small

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Material

Semi Rapid , Auxiliary, dia 60mm

Medium

Rapid, dia 70mm

Large

Triple Ring ,dia 84 to 100 mm

Stove Body

Stainless Steel, Toughened Glass

Knob

ABS, ABS plated, Bakelite

Burner

Aluminum, Brass,

Burner cap

Black Powder Painting Brass ,

Hose

Dia 6.4mm rubber hose

Grates Surface Finish Cost Features

CRCA, Vitreous enamel coated Glossy, Smooth 9000 to 10000



Automatic Ignition

Gas Level Indicators.



Improved Safety

Use Of Graphics



Cooking Timer



Touch interface

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Flame Failure Safety device

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Ideation Mind Mapping

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Life Style Board

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Theme Board

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Doodle s

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Doodle s

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Concept - 1

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Concept – 1 Detailing

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Concept - 2

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Concept – 2 Detailing

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Concept – 3

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Concept – 3 Detailing

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Concept-4

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Concept – 4 Detailing

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Concept -5

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Concept – 5 Detailing

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Concept Selection

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Concept Selection continued‌ Concepts

1

2

3

4

5

Aesthetics

22

15

17

15

19

Features

15

13

10

12

17

Usability

19

11

12

12

21

Efficiency

16

18

16

14

19

Interface

17

14

13

12

19

Total

89

71

68

65

95

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Final Concept

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Final Concept Detailing Over all Dimension :830x400x115

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Exploded View

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Mock Up Model Making

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Model Making continued ...

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Finished Model

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Finished Model

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Validation

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Future Work • Development of Working prototype for proper validation • Engineering refinement and testing is required for industrial production of the stove.

• Branding of the product for premium segment.

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Gantt Chart Task

September '10 1

2

3

4

October '10

November '10 December '10

5

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

6

7

8

Problem Definition, Data collection

Finalize design Intent

Product, Market, competitor study, User study

QFD,Target Product Design Specification

Concept Generation, selection

3D Models, Renderings, Animations

Januaray '11

Design Intent

Design Research

PDS

Ideation

Representation & Detail design

Prototyping

Documentation

Final Presentation

Final Presentation

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Planning

Material selection, model making

Documentation

February '11

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Conclusion • This project has given the opportunity to learn the new product design and development process in an organization. • The user and the company requirements were met through this project.

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References [1] Ed Sobey, The way Kitchens Work, The science behind the Microwave,Teflon pan Garbage Disposal and more, Library of Congress Cataloging,2010 [2] Hal philip,http://www.appliancedesign.com,Controls and sensors,2007,15-102010 [3] Schout solutions,http://www.arkitectrue.com, Colorful Menu ,18-11-2010 [4] Jonathan Ceda http://www.sustainablelifemedia.com,Biolite,Retrived On 10-112010 [5] Anne Fuhlbrigge, Scott Weiss, http://www.ncbi.nlm.nih.gov,Domestic Appliances and lungs disease,21-10-2010 [6] Pankag Sreenivasan,http://www.hindu.com A facelift for the Indian kitchen,2006,20-11-2010 [7] Seema Seath,http://retail.franchiseindia.com,Shoping-habits-gender-wise330,Retrived on 29-10-2010 [8] Don Norman., The Design of Everyday Things, Reach and control, volume 1, 1992 [9] Debkumar Chakrabarti, Indian Anthropometric Dimensions For Ergonomic Design Practice, IIT Ahmadabad, volume 1, 1992 Basil Jose

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Thank You

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