Lumens // Inventing Green

2016

L U MENS INVENTING GREEN

RUCHIR GUPTA 1

RUCHIR GUPTA Industrial Arts and Design Practices, Bachelor of Design.

Project Title LED Lightly - Inventing Green

Project Guides Sudipto Dasgupta and Ravi Mani

Institute of Art, Design and Technology Bangalore.

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ACKNOWLEDGEMENT

I express my sincere gratitude to SELCO India and The SELCO Foundation for their guidance through the process and also helping with the required knowledge in reference to the material and possibilities through the project. I would also like to acknowledge and appreciate the help and patience shown by all the communities that I worked with in and around Karnataka.

Most importantly I want to acknowledge Srishti Institute of Art, Design and Technology for offering us this project and also for the consistent support.

This project wouldn’t have taken the desired turns without the mentorship of Mr. Sudipto Dasgupta and Mr. Ravi Mani. Thank you for the constant support through this path that has been established; it certainly feels as if it wouldn’t have been possible without them.

Mr. Vijaykumar, for providing useful insights and references, helping me make this endeavour successful.

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“ How can a product and service ecosystem be created to encourage technical interventions and innovative processes for the marginalized? “

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CONTENTS

Project Background Context Embodied Energy Selco Research and Analysis Re-interpreting the Brief Initial Concepts Design Direction Concept 1 Concept 2 Evaluation Matrix Concept Visualisation Design Draft 1 Design Draft 2 User Testing Design Development Packaging Validation Reflective Statement References

6 7 9 10 15 101 102 108 110 122 140 142 144 154 169 179 186 189 205 206

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PROJECT BACKGROUND The project aims to develop an “Inventing Green� curriculum to prototype solutions for decentralized renewable energy (DRE) lighting products with low embodied energy materials.

Decentralized Renewable Energy (DRE) will help close the energy access gap and enable poverty alleviation by facilitating the access to education, health and livelihood opportunities in the under-served and underserved segments of the society in addition to having a positive bearing on climate change. But the current scenario of using nonrenewable fossil fuel in the forms of plastic and non-replenishable minerals (metals etc.) in products is not sustainable and also traditional crafts communities using locally available natural materials are not making a sustainable livelihood due to dwindling demand for their products.

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CONTEXT The concept of sustainability in materials has often been neglected in the present design world, which is more consumptive in nature and thus is unsustainable in the long run.

Therefore “Inventing Green� is proposed as a new and engaging English language, academic and hands-on curriculum model to reduce the embodied energy of DRE lighting components such as solar lights, battery packs, their packaging by adhering to the principles of cradle-to-cradle philosophy.

It will explore future possibilities for the use of sustainable materials in design to demonstrate new possibilities for green manufacturing in the renewable energy industry in India (current focus Karnataka, but replicable elsewhere).

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EMBODIED ENERGY All the energy that goes into the production process, cumulatively from raw materials to marketable products.

Embodied energy is an accounting method which aims to find the sum total of the energy necessary for an entire product lifecycle. Determining what constitutes this life-cycle includes assessing the relevance and extent of energy into raw material extraction, transport, manufacture, assembly, installation, disassembly, deconstruction and/or decomposition as well as human and secondary resources.

Different methodologies produce different understandings of the scale and scope of application and the type of energy embodied.

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SELCO Selco Foundation is a non-profitable organization that focuses on rural development and environment conservation by promoting the use of renewable energy.

Selco Foundation supports the marginalized to install sustainable energy equipment for their domestic or income generating activities. The foundation has three major programmes under it’s arm - SELCO Labs, Demonstration and Outreach, and entrepreneur incubation.

SELCO Foundation aims to develop robust and field-proven technological and financial models in the field of renewable energy, and generate public awareness about these models. These models can be replicated in other parts of the world, thereby achieving greater leverage on the money spent. https://www.facebook.com/SelcoFoundation http://www.selcofoundation.org/about

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SELCO MANDATE -Bridging gaps in the ecosystem.

-Building solutions that are holistic.

-Addressing heterogeneity of poor segments.

-Scaling processes through replication.

Values -Poor are not a market.

-Customization: Technology + Finance.

-Financing = Cash flows.

-Freebies are not sustainable!

“Poorest three quarters of the global population use only ten percent of global energy.�

Electrification rate- www.worldenergyoutlook. org, Poverty rate- www.worldbank.org

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SELCO FAMILY SELCO INDIA 1995 For profit Social Enterprise.

SELCO FOUNDATION 2010 Non - profit, Research and development wing.

SELCO INCUBATION 2012 Entrepreneur development.

SELCO FUND 2015 Investment for entrepreneurs.

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RESEARCH CONTENTS

Research Questions Research Parameters Project Objectives Eco-Design Strategies Key Question Premise Building Product Analysis Craft Suggestions Service Chart Market Research Community Visit De-Coding Current State Value Stream Map Current State Business Model Opportunities for Intervention Proposition Learning through Making

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RESEARCH QUESTIONS

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Will the learning prepare the user to work in their community?

What will prepare the user community to work for development in their own settings?

Can their large numbers enable them to develop a collective voice?

How can the community be involved in planning for itself?

Are the products services and systems (PSS) that claim to be green really green?

How can sustainable energy and livelihoods innovations happen at the value proposition side?

How do the energy situation impact development opportunities?

How does it improve environment, health and safety standards?

How can a product and service ecosystem be created to encourage technical interventions, innovative processes, and catalyze income-generating mechanisms for the poor?

What are the strengths of the crafts and cottage industry based indigenous communities that work with locally available natural materials?

How does it specifically impact education, health, and livelihood opportunities for the marginalized in a decentralized and environmentally benign way?

RESEARCH PARAMETERS Identifying the lower embodied energy product alternatives.

Identifying crafts and their techniques.

Understanding cradle-to-cradle design principles and applying them to the findings.

Experimenting with the existing natural materials with the scope of use.

Applying the inferences while ideating and conceptualizing.

Understanding the production process of the in use products.

Mapping the supply chain of the products.

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PROJECT OBJECTIVES -Identifying the lower embodied energy product alternatives.

-Reduce the embodied energy of the products.

-Understanding and re-evaluating the production process of the in use products.

-Mapping the supply chain of the products.

-Facilitate the access to better livelihood opportunities for the end user.

-Re-design the existing product solutions without changing the hardware.

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ECO-DESIGN STRATEGIES Using the Eco-Design Strategies as mentioned in the “Okala Practitioner� as objectives to design for innovation, design for reduced material impacts, design for manufacturing innovation and design for reduced distribution Impact. http://www.luptons.com/content/docs/OkalaPractioner%20Chapter%2010%20OPT.pdf Design for Innovation -Design flexibility for technological changes.

-Provide product as service.

-Share among multiple users.

-Create opportunity for local supply chain.

Design for Reduced Material Impacts -Minimize quantity of materials.

-Use re-cycled materials.

-Use waste by-products.

Design for Maufacturing Innovation -Design for production quality control.

-Minimize energy use in production.

-Minimize production steps.

-Minimize number of components.

Design for Reduced Distribution Impact -Reduce product and packaging weight.

-Reduce product and packaging volume.

-Design for durability.

-Design for maintenance and easy repair.

-Create timeless aesthetic appeal.

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KEY QUESTION How can a product and service ecosystem be created to encourage technical interventions and innovative processes for the marginalized?

Technical Interventions LED Lighting, Photovoltaics, Piezoelectricity Innovative Processes Creative / Design Approach How does it improve environment, health and safety standards?

Complication -Most of the Urban-Rural and Rural people haven’t been recognised by the larger community.

-Lack of Business Strategies -Lack of Resources -Subsidised pay for the community Issues -Working Environment -Product Knowledge -Service System -Access to resources -Power requirements

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OPPORTUNITIES

(Top Left) Indoor solar kit.

(Top Right) Portable solar desk lamp.

(Bottom Right) Portable focussed lighting solutions.

(Bottom Left) Solar panel installation.

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GAPS

Dust is the lesser acknowledged factor that significantly influences the performance of the PV installations.

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GOALS

Green alternatives for existing technologies.

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RESOURCES

(Top Left) Printable organic solar cells.

(Top Right) Silicon solar sheets (Bottom Right and Left) Using natural materials to reduce the embodied energy.

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SELCO PRODUCT ANALYSIS

Charge Regulator

BATTERY CHARGER

65 mm

115 mm

Battery Pack

55 mm

65 mm

BATTERY CHARGER The battery charger pulls solar electrical power through the charge regulator and put it through to the battery pack in order to charge the battery.

Power Source: SPV Module Typical Input Power: 20Wp Vin (max.): 22V DC Vin (typ.): 18V DC 26

This Battery Charger is equipped with 4 battery charging units and a wire that connects it to the charge regulator.

The circuit board is what makes the whole process functionable.

The circuit consists of resistors, capacitors, Integrated Circuit (IC), LEDs.

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BALANCE OF SYSTEMS -What are the ways in which they have been manufactured?

The battery casing is made up of plastic which is made through injection moulding.

-Which are the components that can be replaced by components with less embodied energy.

The plastic casing can be replaced either by natural materials like clay or can be replaced by other recyclable products like plastic containers.

-What are the user interfaces already designed?

Existing user interfaces include LEDs and different connection ports.

-What are the service interfaces? Screws nuts bolts solder replacement etc.?

The charger consists of 4 screws at the back and the circuit fits into specific grooves.

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Existing Plastic Casing

Areca leaf

Clay / Terracotta

Paper Mache

-Leaves could start chipping.

-All the pieces after production may vary in size and might not be as precise as required.

-Paper mache might not be as rigid as the other suggested or existing materials.

-Mass-production with clay could only be achieved with the help of industrial machinery which is something that needs to be worked upon.

-Could be covered with a layer of Resin in order to harden the material.

-Problem bending the leaves at the precise angle due to their inherent properties.

-Making grooves for the casing might not be possible due to its softness.

-Prone to fire related hazards.

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100 mm

1000 mm

BPL DESK LAMP Plastic body and Metal Stand for the Lamp.

24 Surface Mounted Device (SMD) LEDs. PCB Diameter - 69 mm.

38 mm

100 mm BPL BATTERY PACK Injection Moulded Plastic (ABS) casing for the battery pack.

Lithium Ion Battery Powered (7.4V - 2200mAH) 30

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CRAFT SUGGESTIONS 5 crafts choices considered for the project concepts.

Wood Carving Terracotta and Pottery Sheet metal work Areca Palm Leaf craft Bamboo craft http://www.cohands.in/handmadepages.

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WOOD CARVING Production Cluster Ulsoor, Bangalore, Karnataka Products Wall panel depictions Carved doors and pillars Bracket figures Sculpted idols Tools Flat chisel Files Sandpaper

Cradle-to-Cradle Framework Being native to the place.

Using waste as an input.

Sun as an Income.

Air, Soil and Water are still healthy.

Enjoyment for all generations.

Easy Accessibility.

The craft could be used for making wooden casing for the existing balance of system where wooden cases could replace the existing plastic and metal components.

The traditional skills of the artisans will help achieving the desired precision.

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SHEET METAL WORK Production Cluster Bijapur District, Karnataka Products Metal pots Chariots Metal claddings Tools Punches Dyes Chisel Hammer

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Cradle-to-Cradle Framework Being native to the place.

Using waste as an input.

Sun as an Income.

Air, Soil and Water are still healthy.

Enjoyment for all generations.

Easy Accessibility.

The craft could be used to come up with solutions that involved both metal and wax as a material just like how the craft involves the use of both the materials.

TERRACOTTA AND POTTERY Production Cluster Udupi District, Karnataka Products Lamps Incense stick holders Water pitchers Candle stands Pots Tools Potters wheel Bamboo knife Wooden mallet Needle

Cradle-to-Cradle Framework Being native to the place.

Using waste as an input.

Sun as an Income.

Air, Soil and Water are still healthy.

Enjoyment for all generations.

Easy Accessibility.

All the pieces after production may vary in size and might not be as precise as required.

Mass-production with clay could only be achieved with the help of industrial machinery which is something thats needs to be worked upon.

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ARECA PALM LEAF Production Cluster Mangalore, Karnataka Products Caps Plates Cups Pots Tools Press to mould

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Cradle-to-Cradle Framework Being native to the place.

Using waste as an input.

Sun as an Income.

Air, Soil and Water are still healthy.

Enjoyment for all generations.

Easy Accessibility.

Areca could be used to make different kinds of casings for different products.

Making moulds is an expensive process.

BAMBOO CRAFT Production Cluster Barpeta District, Assam Products Baskets Stools Sieves Hand fan Tools Bamboo knife Hand saw Sandpaper

Cradle-to-Cradle Framework Being native to the place.

Using waste as an input.

Sun as an Income.

Air, Soil and Water are still healthy.

Enjoyment for all generations.

Easy Accessibility.

Among all the identified natural materials bamboo is the one of the few that is able to meet the market requirements if need be.

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SERVICE CHART Analysing the products and sevices offered to the consumers alongside the company competitors in the current market.

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Litre of Light Kerosene Lamps Battery operated LED Generators Invertors Lamps

SELCO

Rural and Rural-Urban Population

Alternatives

Product/ Service

Customer

Competitors

Features

Teri Inc. Development Alternatives D - Lite Barefoot College Care

Compact East to maintain Accessible

Benefits

Needs

Easy to maintain Easy to fix

Livelihood 39

MARKET RESEARCH

Kenchanahalli Road

Doddaballapur Road

Kenchanahalli Kenchanahalli Road, Yelahanka Bangalore 560064 Karnataka

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Date - 20th January 2016 Time of visit - 08 pm - 09 pm 10 am - 11 am

KENCHANAHALLI

Electricity - Using Grid power.

Livelihood - Most of the activities like cooking, cattle farming happen outside the house.

Education - Primary Government School in the village.

Occupation - Small scale Farmers, Auto-rickshaw drivers, Domestic Helpers, Construction work.

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COMMUNITY ASSESSMENT FORM Please indicate the overall condition of the community after carrying out the assessment: Manageable Potential areas of work: Livelihood BASIC DATA Name of location: KENCHANAHALLI Address: Kenchanahalli Road, (Near Doddaballapur Road) Yelahanka Bangalore 560064 Karnataka Land ownership: OWNED Primary Occupation (MEN): CONSTRUCTION LABOURERS, AUTO-RICKSHAW DRIVERS Primary Occupation (WOMEN): DOMESTIC HELPERS INFRASTRUCTURE Building type: SUB-STANDARD CONSTRUCTION Facilities: KITCHEN, WASHING AREA, TOILET Wall type: CEMENT BLOCKS WATER AND SANITATION Primary source of water: TANKER Water access point: IN/ NEAR HOME POWER Primary source of power: ELECTRICITY Type of equipment used: FANS, LIGHTS, FRIDGE, MOBILE Connection type: GRID OTHER AMENITIES Kitchen fuel type: GAS (LPG), WOOD

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MARKET RESEARCH

Doddaballapur Road

Narayanapura Village Off New Airport Road, Bangalore 560064 Karnataka

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Bangalore-Hyderabad Highway

Date - 28th January 2016 Time of visit - 07 am - 09 am

NARAYANAPURA

Craft - Pottery and Terracotta.

Products - Earthen pots, Garden Pots, Diyas, Plates, Piggy Banks Volume - 1000 - 1500 pieces a day. (Approx.)

Families involved in the craft - 15 - 20.

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CLAY MAKING PROCESS First clay is procured from the village.

The clay is then brought out and cleaned for any fine stones and put on the manually operated wheel.

Clay then mixed in 2:0.5 ratio of water and kept in a cool area or outside with a sac. Pieces of 15 – 20 kg made into big balls and kept for storage.

The clay is then sculpted or shaped to different products.

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After this the products are left for drying for at least 2 days.

Once a week all the dried products are put in the furnace for baking.

Post baking/ firing the products are stacked on one another and later transported to the city market to wholesalers at prices ranging between Rs. 5 – 20.

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NOTES -Clay available in three varieties Red – Piggy Banks, Jewellery.

Brown – Used for making Diyas, Plates, and Small pots.

Black – Used for making Earthen Pots and Garden Pots.

-Villagers are either farmers or potters.

-Working hours 6 am – 2 pm.

-Culture is 50 years old.

-15-20 houses out of 70 who do pottery.

-About 1000 diyas made per day. Whole sale rate Rs 500-600 for 1000 pieces.

-One spin of the manual wheel = 5 or 6 diyas.

-Manual and electric wheels. Electric ones lets them make 1500 diyas per day.

-Kiln lasts for 5 years. Each house has its own kiln.

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COMMUNITY ASSESSMENT FORM Please indicate the overall condition of the community after carrying out the assessment: Manageable Potential areas of work: Livelihood BASIC DATA Name of location: NARAYANAPURA Address: Narayanpur Village Off New Airport Road, (Near Doddaballapur Road) Bangalore 560064 Karnataka Land ownership: OWNED Total number of families: 70 Average size of family: 4 MEMBERS Average income per person: Rs. 1000 (Per Day) Bank Account: YES Highest category of expenses: TRANSPORT, FUEL Primary Occupation (MEN): POTTERS, FARMERS Primary Occupation (WOMEN): POTTERS, FARMERS Craft practice: POTTERY, TERRACOTTA Volume of production per person: 1000-1500 PRODUCTS (Per day) Number of households practicing the craft: 15-20 Working hours: 6-7 HOURS (Per day) INFRASTRUCTURE Building type: SUB-STANDARD CONSTRUCTION Facilities: KITCHEN, WASHING AREA, TOILET, VERANDAH Wall type: CEMENT BLOCKS Flooring: TILES, MUD WATER AND SANITATION Primary source of water: WELL/ BORE-WELL Water access point: IN/ NEAR HOME Water storage facility: OVER-HEAD TANK POWER Primary source of power: ELECTRICITY Type of equipment used: FANS, LIGHTS, FRIDGE, MOBILE, ELECTRIC WHEELS Connection type: GRID OTHER AMENITIES Kitchen fuel type: GAS (LPG), WOOD, NILGIRI LEAVES 49

MARKET RESEARCH

Manipal Road

Selco Rural Community Lab Bhartiya Vikas Trust, Vinayaka Temple Road, Manipal - 576104 Karnataka

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Date - 8th February 2016 Time of visit - 10 am - 12 pm

SELCO RURAL COMMUNITY LAB

Bhartiya Vikas Trust Selco India - Service Providers All Products Made and Manufactured in India.

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Lead Acid Batteries last upto 5 - 6 years.

If maintained well may last upto 7 - 8 years.

150 - 200 units of Solar Water Heaters sold every month compared to the 1000 Home Lighting Systems sold.

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Solar Panels manufactured by Kotak Solar Tech.

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MARKET RESEARCH

Udupi - Agumbe Road

Selco Service Branch Udupi - 576103 Karnataka

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Date - 8th February 2016 Time of visit - 2 pm - 4 pm

SELCO SERVICE BRANCH

Services Provided - AMC - Annual Monthly Charge (Includes 3 services a year), Managing service related complaints, Lighting fixtures and other related components, Mounting

Structures, Solar Grid, Spare Sales and Repair Services. The service branch complements the work of existing branches who is also tasked to address service needs.

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COMMUNITY VISIT

Saralebettu Road

Saralebettu Community IEC Manipal - 576104 Karnataka

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Date - 8th February 2016 Time of visit - 12 pm - 1 pm

SARALEBETTU

Migrant Community No grid connection Total number of houses 100

Number of houses using the IEC - 48 IEC managed by Mr. Manjunath

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The IEC is solar powered and runs on DC current for battery and phone charging.

Batteries charged from 08:30 am - 06:30 pm.

The charge regulator is placed in the IEC where the battery charger charges the battery for Rs. 5 per charge

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Houses are dark and have no ventilation.

The households largely depend on the IEC services.

Desk lamps given by selco are hung up on the scaffolding in most houses.

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NOTES -Houses built on private rented land.

-20 years old community -Soon installation of a refrigerator in the IEC -Refrigerator Specifications 170 Litres Cost - Rs. 90000 Working time - 24 hours.

Battery Type - Central battery unit.

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COMMUNITY ASSESSMENT FORM Please indicate the overall condition of the community after carrying out the assessment: Manageable/ Poor Potential areas of work: Livelihood BASIC DATA Name of location: SARALEBETTU Address: Saralebettu Community IEC Manipal - 576104 Karnataka Land ownership: RENTED Total number of families: 100 Average size of family: 4 MEMBERS Average income from IEC per month: Rs. 11000 Bank Account: YES Highest category of expenses: TRANSPORT, FUEL, FIREWOOD Primary Occupation (MEN): LABOURERS Primary Occupation (WOMEN): WORKERS AT THE KMC Craft practice: POTTERY, TERRACOTTA Number of households using the IEC: 48 Working hours: 6-7 HOURS (Per day) INFRASTRUCTURE Building type: SUB-STANDARD CONSTRUCTION Facilities: KITCHEN, WASHING AREA, SHARED TOILET Wall type: MUD PLASTER Flooring: CEMENT PLASTER WATER AND SANITATION Primary source of water: WELL/ BORE-WELL Water access point: IN/ NEAR HOME Water storage facility: BUCKETS POWER Primary source of power: IEC Type of equipment used: LIGHTS, FRIDGE, MOBILE Connection type: SOLAR OTHER AMENITIES Kitchen fuel type: WOOD 61

MARKET RESEARCH

Higher Primary School

Anand Electronics Ashok Nagar, Near Higher Primary School, Mangaluru - 575006 Karnataka

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Date - 9th February 2016 Time of visit - 10 am - 12 pm

ANAND ELECTRONICS

Supply selco all the electrical components and fixtures.

Products and components produced Charge Regulators (5/ 10/ 15 Amps.)

CFL and LED lights and fixtures Street lights, Repair service

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Production of charge regulators.

LED light with the reflector.

Reflectors aren’t of much use with LEDs since the mounting of the LED is behind the reflector unlike CFLs.

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Di-casted anodized aluminium used for street lights as a mould and heat sinc.

Lighting fixtures and components produced and manufactured by Anand Electronics.

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CHARGE REGULATOR Components Resistor Capacitor Relay Integrated Circuit (IC)

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Resistor

Capacitor

Integrated circuit

Relay

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MARKET RESEARCH

Sangeet Vidyalaya Road

Kalkeri Sangeet Vidyalaya Sangeet Vidyalaya Road, Kalkeri - 580007 Karnataka

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Date - 10th February 2016 Time of visit - 10 am - 12 pm

KALKERI SANGEET VIDYALAYA

A 13 year old residential school for underprivileged children.

Products and services used Solar grid, 5 Solar water heating systems, Solar grid for pumping water, Solar powered street lights Motto - To propagate the classical art form that is being lost.

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14 KW Solar power grid to power the lighting systems and other services in campus.

20 KW inverter for lighting. The inverter used lead acid batteries.

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5.5 KW Solar grid powered DC water pump to pump water.

Solar water heating systems installed in the campus.

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MARKET RESEARCH

Gokul Road

Shri Lakshmi Engineering Works Gokul Road, Industrial Estate, Hubli - 580021 Karnataka

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Date - 11th February 2016 Time of visit - 10 am - 12 pm

SHRI LAXMI ENGINEERING WORKS

Supply selco all the module mounting structures for panels and other related fixtures.

Products and components produced Module Mounting Structures (MMS) Battery boxes Street light fixtures and poles.

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80 tonne Mechanical power press machine used to punch and mould brackets and other components of the mounting structures.

Machines commonly used for production Drill Machine Lathe Machine Grinding Machine Mechanical Power Press Module Mounting Structure (MMS) made out of GI pipes and then powder coated to give it a longer life.

Minimum stock 3000 units (Approx.)

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Street light poles made out of GI pipes with provisions for a battery box, panel mounting and street light mounting.

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COMMUNITY VISIT

Ramamurthy Nagar

Ramamurthy Community IEC Ramamurthy Nagar Bangalore - 560043 Karnataka

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Date - 27th February 2016 Time of visit - 10 am - 12 pm

RAMAMURTHY

Migrant Community No grid connection Total number of houses - 32 Number of houses using the IEC - 32

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NOTES -IEC center for lights.

-Temporary, scared of evictions.

-IEC 75 watt 12V -32 lights and for the projector different panel.

-School for migrant children.

-School has airlight.

-Solar panel with a mobile projector at the school.

-Battery Projector Rs. 32,000, Battery and projector - 10,000 DC 12V -30-40 students per teacher.

-GMR Foundation- help run the school.

-School timings: 9:30-3:30 (Saturday half day).

-Teachers are from hebbal that are appointed by the organization.

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COMMUNITY ASSESSMENT FORM Please indicate the overall condition of the community after carrying out the assessment: Manageable/ Poor Potential areas of work: Livelihood/ Education BASIC DATA Name of location: RAMAMURTHY NAGAR Address: Ramamurthy Community IEC Bangalore - 560043 Karnataka Land ownership: RENTED Total number of families: 32 Average size of family: 4 MEMBERS Average income from IEC per month: Bank Account: YES Highest category of expenses: TRANSPORT, FUEL, FIREWOOD, STRUCTURAL MATERIAL Primary Occupation (MEN): LABOURERS Primary Occupation (WOMEN): DOMESTIC HELPERS Number of households using the IEC: 32 Working hours: 6-7 HOURS (Per day) INFRASTRUCTURE Building type: SUB-STANDARD CONSTRUCTION Facilities: KITCHEN, WASHING AREA, SHARED TOILET Wall type: MUD PLASTER, TARPAULIN SHEETS Flooring: CEMENT PLASTER WATER AND SANITATION Primary source of water: WELL/ BORE-WELL Water access point: IN/ NEAR HOME Water storage facility: BUCKETS POWER Primary source of power: IEC Type of equipment used: LIGHTS, MOBILE, PROJECTOR Connection type: SOLAR OTHER AMENITIES Kitchen fuel type: WOOD 79

DE-CODING Analysing and breaking down the observations and findings into sub-categories based on the primary and secondary research and observations..

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WHAT WE SAW -In some ways the community was disconnected.

-Everything seemed fine but the rooms were dark.

-Cramped and risky fixtures.

-Batteries hung using the connector leading to the key-chain breaking.

-Chances of damage to products due to unusual usage is high.

-The batteries should be kept somewhere, preferably horizontal surfaces like slabs, tables, etc.

-Some houses using Chinese solar panels.

-People using the products for other purposes also.

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UNSEEN

FINDINGS

-Charging points.

-The battery packs are hung instead of being kept.

-Battery packs - Docks, and other similar solutions.

-Preventing damage to battery packs - Bumper covers for protection of battery packs.

-People wanted more from the existing products.

-Re-designing the existing lamps Hanging structure of lamps and the battery pack.

-Battery packs weren’t given for charge regularly which reduces the age and the efficiency of the batteries.

-LEDs or CFLs?

-Solar panels go missing sometimes.

-Fitting a heat sinc within the product and integrating it within the form.

-Tracking solar panels.

-Substituting plastic and other metal parts with natural materials or other re-cycled materials.

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-Battery packs went missing.

GAPS

IMPRESSION

-Battery key-chain breaking easily.

-There was a sense of success

-Desk lamp breaks easily due to the working environment and other related factors.

-There was a sense of gratification.

-Products not used the way they are meant to be.

-The community members have expansion plans.

-Houses are dark.

-Battery packs break.

-Cooking happens indoors.

-LEDs are expensive to service.

CFLs are cheaper.

-LEDs need a heat sinc.

CFLs don’t need a heat sinc.

-Reflectors aren’t useful when used with LEDs.

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CURRENT STATE VALUE STREAM MAP Supplier Annual Production Plan

SELCO (Production Control)

MANUFACTURER (Metal and Plastic Components)

Monthly

Recieving

Daily Schedule

Daily Schedule

INSTALLING HARDWARE

PRIMARY PACKAGING

C/T - 2 C/O - 10 Uptime - 75%

C/T - 1 C/O - 1 Uptime - 20%

1 day

1 day 2 min.

C/T - Cycle Time (min.)

C/O - Changeover Time (min.)

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1 min.

**Inputs provided by Anand Electronics.

Market Forecast END USER (IEC’s and Communities) SELCO Service Center

Daily Schedule

Weekly Schedule

ASSEMBLY and INSPECTION

SELCO GODOWN

Daily

Delivery and Installation

C/T - 1 C/O - 1 Uptime - 70%

2 days

2 day 1 min.

1 day

Total Lead Time= 7 days.

Value Added Time= 4 min.

Material Information 85

CURRENT STATE BUSINESS MODEL - SELCO KEY PARTNERS

KEY ACTIVITIES

VALUE PROPOSITION

Banks and microfinance organisations

Market and customer Identification

Companies and foundations

Product Customization System Integrators Linkage to finance solutions Delivery, Installation and Service

Create solutions for the energy requirements for the marginalized.

Government policies

KEY RESOURCES System components at a low cost but high reliability Bank finance for the marginalized Staff who can work in rural areas

COST STRUCTURE Product components Delivery, Installation and Service cost Marketing costs and taxes

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CUSTOMER RELATIONSHIPS

CUSTOMER SEGMENT

Local executives

Type 1 Low Income Groups Vulnerable communities (Daily wage workers, domestic help, taxi drivers, fruit/ vegetable venders, factory workers)

Business associates

Type 2 Above Low Income Groups CHANNELS Branches and other satellite branches Flexible network of business leveraged

REVENUE STREAMS Daily sales - Selco Products IEC daily charge Post warranty services After sales services

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OPPORTUNITIES FOR INTERVENTION -Charging points.

-Battery packs - Docks, and other similar solutions.

-Preventing damage to battery packs - Bumper covers for protection of battery packs.

-Re-designing the existing lamps Hanging structure of lamps and the battery pack.

-Wires get bitten by rodents.

-Fitting a heat sinc within the product and integrating it within the form.

-Tracking solar panels.

-Substituting plastic and other metal parts with natural materials or other re-cycled materials.

-Business Model

Community - Ramamurthy Nagar Bangalore - 560016

88

PROPOSITION KEY VALUE

KEY STAKEHOLDER

KEY ACTIVITIES

The project aims at catering to the needs of the rural-urban, ruralrural communities using appropriate sustainable/ green solutions decreasing the embodied energy within the existing solutions or with new ones.

ACTIVE Community Members

DESIGN APPROACH Research Analysis Ideation Learning through Making User Testing Concept Generation Concept Development Prototyping PROCESSES INVOLVED SUPPLY CHAIN

COST STRUCTURE

KEY RESOURCES

END USER

DESIGN COST

SELCO Community members Technological components Material Vendors

Family Tribals Communities Student Vendor Selco

PRODUCT COST Material Process Prototype

IMPACT Delivery and Service Impact Lower Embodied Energy Sustainable Product

PASSIVE Artisans IEC Entrepreneur

COMMUNITY ENGAGEMENT Natural material growing process Using the local craft to engage the community in the production process.

Product Interaction

89

LEARNING THROUGH MAKING

Experimenting with the existing natural materials and the given technology for a better understanding the scope of use.

Soaking the Areca leaves in normal water for 24 hours.

90

Pealing the first layer on either side of the leaf to make it soft.

Putting the Areca leaf in a mould to test out the possible shapes.

91

Removing the weight for the leaf to be able to dry.

Taking out the leaf from the mould to see the result.

92

Assembling the Solar lighting system installation to understand the assembly process of the same.

Mounting the solar panel onto the Module Mounting Structure.

93

Connecting the positive and negatives wires through the solar panel to the 10 AMP charge regulator.

Solar Panel connected to the charge regulator which then is connected to the battery charger to charge the battery.

94

Understanding the properties of Concrete when mixed with another material like Saw Dust to reduce the weight and mass of the product.

Mixing concrete with water (3:2) and leaving it for drying after pouring it in a plastic mould.

For the alternate exploration mixing concrete, saw dust and water (2:1:1)

95

Leaving both the explorations for drying for 12 hours in order for them to harden up and become bricks.

Post drying taking out the bricks and measuring the weight.

96

Weight (in grams) Plastic mould 13 grams Concrete 105 grams Concrete and Saw dust 101 grams

Firing the concrete and saw dust brick for 30 minutes in order to reduce the weight of the brick and increase the porosity.

97

Baked concrete brick with increased porosity and less weight.

Weight of concrete and saw dust brick after firing 75 grams

98

PVC Spotlight made to focus the light to one particular area without any mechanical complexity.

Material - PVC pipes, cotton thread, bulb holder and electrical wire.

Materials are mostly found objects which helped give form to the idea.

99

100

RE-INTERPRETING THE BRIEF The project aims at catering to the needs of the rural-urban, rural-rural communities using appropriate sustainable/ green solutions, decreasing the embodied energy within the existing solutions or with new ones.

Direction 1 Using natural materials (Bamboo and Clay) to come up with re-usable and green products in order to reduce the embodied energy.

Direction 2 Designing lighting solutions that provide focus lighting inside the house, or as a replacement for emergency lights, which is accessible and easy to move around without damaging the system or routine habits of the user.

Direction 3 Redesigning the existing lamp that SELCO uses for its light for education programme along with the packaging of the product.

101

INITIAL CONCEPTS Issues -Working Environment -Product Knowledge -Service System -Access to resources -Power requirements Concepts -Outdoor Solar Stove -Electric Cap -Alternative Material Choice For Electrical Components And Fixtures -Power Bank -Custom Tool-kit

102

Solar panels

Stove

LED light Extra work area

OUTDOOR SOLAR STOVE. Meant for outdoor cooking. The stove is solar operated and also contains a small LED spot light which the user can move around and point anywhere within its range.

Materials- Panels, LED Lights, Electric Stove, Bamboo/ pipe sections, Electrical fixtures.

Crafts involved- Bamboo/ Terracotta.

103

Solar panels Charging point LED light

ELECTRIC CAP The cap consists of LEDs and a charging point both run on solar power. If someone can charge their device and use the generated power at any time of the day.

104

Materials- Panels, LED Lights, Cloth, Electrical fixtures.

Bamboo

Light source

ALTERNATIVE MATERIAL CHOICE FOR ELECTRICAL COMPONENTS AND FIXTURES Substituting high grade plastic and metal fixtures/ lampshades for lighting solutions in homes with alternative organic and natural materials or even recycling waste plastics.

Materials- LED Lights, Bamboo and other required natural materials, Electrical fixtures.

Crafts involved- Pottery.

105

http://theviewspaper.net/wp-content/uploadsnew/villages-in-india.jpg

POWER BANK. Outdoor sheds for community meetings which have charging points and other electrical provisions.

106

Materials- Panels, LED Lights, Benches, Bamboo/ pipe sections, Electrical fixtures.

Crafts involved- Bamboo.

Natural Material CUSTOM TOOL-KIT The tool-kit is meant to enable the users to do basic repairs and fix any other basic issues with the system. Tool-kit would be made out of natural materials wherever possible.

Materials- Screwdriver, Hammer, Spanner, Aluminium masonry Nails.

Crafts involved- Bamboo.

107

Mind Mapping the design direction and related ideas.

108

DESIGN DIRECTION Inventing green as a concept in itself inspires the idea of re-thinking the way we design and our approach towards the same. To close the energy and enable poverty alleviation we must also cater to the needs and sometimes wants of communities who mostly don’t get the privilege of living the luxurious urban lifestyles or sometimes even the basic needs like education, livelihood, health leaving Decentralized Renewable Energy a viable option for the members of the community.

The project aims at catering to the needs of the rural-urban, rural-rural communities using appropriate sustainable/ green solutions decreasing the embodied energy within the existing solutions or with new ones.

The existing product range has been of great help to these communities and has promoted and elevated their community status in a lot of ways. Having said that there are still a few traceable gaps that we have been able to trace with the help of different community and manufacturing unit visits as a part of our primary research. There are significant intervention opportunities within this segment, one of them being the existing home lighting system and the battery pack system.

The current home lighting and battery pack system involve an Integrated Energy Centre (IEC), A desk lamp and a battery pack (Both currently designed and manufactured by BPL) which facilitates the engagement between the users and the “entrepreneurs” who manage IEC’s within the community.

The products are not really used the way they are supposed to be used and that is where the biggest gap lies. The lamp and the battery pack are two completely different units. There is a scope of redesigning both the products, or even combining the two within one unit.

The proposed revised concept consists of the same battery pack but with the LED lights in it. It would facilitate portability, mobility, modularity, and a user-friendly ergonomic design.

Additional features like a detachable LED base so that it becomes easier for the user to take the battery pack for charging everyday and also easier to fix.

One of the ways in which we can reduce the current embodied energy is by using less material than currently being used instead of choosing naturally available material options which in turn would make manufacturing processes involved much less and also would open doors for other opportunities. The design would further cater to the other factors like dust, smoke, environmental conditions, weathering, location, etc. responsible for the damages or wear and tear of the products currently being used.

Another area of concern was about the aesthetics of the products that these communities use.

While mostly luxury is what people associate with good aesthetics of a product. Using the same approach here where the design would appreciate and acknowledge the respect shown to these products by the community members. For any product its visual language makes a really big difference along with the other important factors like functionality, etc. and so there is an equal importance of the aesthetics for this project.

109

CONCEPT 1 PRODUCT ALTERNATIVES

Selco products completely or partially converted in terms of material and assembly using natural material or material with low embodied energy.

Design Strategy The strategy aims at reducing the embodied energy using materials with low embodied energy.

110

CHARGE REGULATOR AND BATTERY CHARGER CASING Replacing the existing product casing with alternative materials.

111

CRADLE TO - CRADLE ANALYSIS

112

Being native to the place.

The product is meant for mass production and not just cater to one single place.

Using waste as an input.

The material used for the product is either natural material or an industrial material combined with any other recycled material.

Sun as an Income.

The existing products all run on solar generated current.

Air, Soil and Water are still healthy.

The concept involves materials that are degradable and otherwise don’t use any other production processes which could harm the environment.

Enjoyment for all generations.

Involvement of only the assembly staff required.

Provide enjoyable mobility for all.

Easy Accessibility.

Production of the products could be a slow process due to the choice of materials.

PROTOTYPING Making the moulds for the case with sunboard.

Circuit board dimensions: 135 x 81 mm

Preparing the mixture (Concrete, Sand, Saw Dust and Water).

113

Placing the negative mould on the positive to get the exact shape.

Taking out the mould after drying.

114

Mixture: Concrete Glue Paper Mache Sand Water

Mixture: Concrete Glue Paper Mache Saw Dust

115

Mixture: Paper Mache Water Wire Mesh

The paper mache and wire mesh mixture post drying.

Dried for 2 days in the sun and tested out to take weight.

116

Material: Water Paper Mache Wire Mesh

Mould: Plastic containers

117

Process: Wrap the plastic moulds with wire mesh from inside.

Then plaster the inner walls of the containers with paper pulp.

In a case put paper pulp first and then wrap the same with the wire mesh.

The paper mache and wire mesh mixture post drying.

Dried for 2 days in the sun and tested out to take weight.

Wire mesh used as a mould with only paper mache in order to sandwich it between resin.

118

Cloth tried to see the structural variations possible.

Resin is used to give the material additional strength to increase the age of the product and also to make it resistant to other factors like heat, smoke, fire, water.

Shredded Paper covered with a layer of fibre glass resin.

The Resin Covering needs to be thicker to hold itself together.

119

MATERIALS EXPLORED

120

Mixture:

Mixture:

Concrete Sand Saw Dust Water

Paper Mache Glue Water Wire Mesh

“There is a problem with the material thickness as the cement cracks due to the wall thickness being too thin”.

“Paper Mache could just be used with water to keep its fibre qualities intact”.

“Cement is too brittle and starts cracking as soon as its mixed with any other material”.

“The material composition could be altered to reduce the weight and the material usage”.

Mixture:

Mixture:

Paper Mache Water Wire Mesh

Shredded Paper FiberGlass Resin

“The structure is stable but lacks qualities like water resistance, heat resistance, etc.”.

“The resin covering is too thin to hold itself togther and is becoming very fragile”.

“If only paper mache is used as the material then the minimum required material thickness is more than that of the desired thickness”.

“The Embodied energy of Resin is higher than that of the existing material”.

121

CONCEPT 2 COMBINING PRODUCTS

Redesigning the BPL light and battery pack by combining both the products within one unit.

Design Strategy The strategy aims at achieving the most material-effective way of manufacturing goods to the required level of quality.

The Re-designed products should be compact and portable.

Production Process Injection Moulding.

Local Manufacturers (Karnataka) Plastic Injection MouldingRaj Industries, Bangalore Multitek Auto Parts, Bangalore Metal Hinge/ LockShri Laxmi Engineering Works, Hubli

122

BATTERY PACK AND LIGHT Combining the battery pack and the light source within one unit.

123

CRADLE TO - CRADLE ANALYSIS

124

Being native to the place.

The product is meant for mass production and not just cater to one single place.

Using waste as an input.

The product here does not use waste as an input at any stage of its production or use.

Sun as an Income.

The lamp and battery pack both run on solar generated current.

Air, Soil and Water are still healthy.

The product requires processes like injection moulding which are not environment friendly.

Enjoyment for all generations.

The product aims at being very basic in use which would allow all generations to use and interact with it.

Provide enjoyable mobility for all.

Easy Accessibility.

It aims at basic mechanisms and a compact design which would make is accessible to all.

Combining the battery pack and the light source within one unit.

125

126

Mock-up 1 The battery pack and light combined using a sliding mechanism to switch on the light.

Material - Sunboard and paper pins.

Mock-up 2 The battery pack and light combined using a hinge to switch on the light.

Material - Sunboard, rivets, paper pins and a mortise hinge.

Mock-up 3 The battery pack and light combined using a twisting mechanism to switch on the light.

Material - Sunboard, rivets and paper pins.

127

CONCEPT PROTOTYPING

Connector

LED Module

Battery Pack

104 mm 30 mm 90 mm

Material: HIPS (High Impact Polystyrene) - 2 and 3 mm MEK (Methane Ethane Ketone) - Adhesive GI wire - 1.5 mm LED Module - 12V and Connector 128

44 mm

Battery Pack

LED

Detachable LED Module

Connector

129

OFF

ON

130

Portable Dimensions: 90 x 30 x 44 mm.

Lamp opened and switched ON to use.

Snap fit bottom.

Detachable LED light module for the mobility of the battery pack.

The battery pack after being detached can be taken to the designated IEC for charging.

131

132

133

CONCEPT PROTOTYPING

Battery Pack

LED Module

45 mm

90 mm

Material: HIPS (High Impact Polystyrene) - 2 mm MEK (Methane Ethane Ketone) - Adhesive Electrical Wire LED Module - 12V and Connector 134

Connector

45 mm

40 mm

LED Module

Battery Pack

LED

Connector

135

Position 3 Full Lighting Active LEDs: 3

Position 2 Dim Lighting Active LEDs: 1

Position 1 No Lighting Active LEDs: 0

136

Portable Dimensions: 90 x 45 x 40 mm.

Lamp twisted and switched ON to use.

Snap fit bottom.

3 Position Lamp: Different arrays of LED’s work at different positions. The user can choose the amount of light he/ she requires.

The whole unit can be taken to the designated IEC for charging.

137

POSITION 1

138

POSITION 2

POSITION 3

139

EVALUATION MATRIX

140

Design flexibility for technological changes.

Provide product as service.

Share among multiple users.

Create opportunity for local supply chain.

Minimize quantity of materials.

Use re-cycled materials.

Use waste byproducts.

Identifying the lower embodied energy product alternatives.

Minimize energy use in production.

Minimize production steps.

Design for production quality control.

Minimize number of components.

Reduce product and packaging weight.

Reduce product and packaging volume.

Design for durability.

Design for maintenance and easy repair.

Concept 1 - Product Alternatives Selco products completely or partially converted in terms of material and assembly - using natural material or material with low embodied energy.

Concept 2 - Combining Products Redesigning the BPL light and battery pack by combining both the products within one unit.

Create timeless aesthetic appeal.

Reduce the embodied energy of the products.

Mapping the supply chain of the products.

Facilitate the access to better livelihood opportunities for the end user.

Re-design the existing product solutions without changing the hardware.

Understanding and re-evaluating the production process of the in use products.

141

CONCEPT VISUALIZATION

Softwares 3D digital modelling - Rhinoceros 3D renders - KeyShot 142

DESIGN DRAFT 1

Front View

32.25 mm

67.75 mm

143

Top View

38.25 mm

67.75 mm

144

Side View

32.25 mm

38.25 mm

145

146

147

Component A Component B

Component C

Component D

148

10.25 mm

27.25 mm

5.50 mm

5 mm 15 mm

6 mm 10 mm

10.25 mm

50 mm

67.75 mm

Component A Component: Detachable LED Module Material: Plastic (HIPS) Required number of pieces: 1 Drawings not to scale 149

10.25 mm

27.25 mm

5 mm 1.88 mm 7 mm

20 mm

6 mm

5.75 mm

3 mm 4 mm

54 mm

67.75 mm

Component C Component: Battery Pack Casing Material: Plastic (HIPS) Required number of pieces: 1 Drawings not to scale 150

15.75 mm

6 mm

2 mm 4 mm

4 mm

47 mm

10 mm

67 mm

Component D Component: Casing Base Material: Plastic (HIPS) Required number of pieces: 1 Drawings not to scale 151

Prototype Perspective view of the prototype.

Material: HIPS MEK Screws 5 mm GI wire

LED module and the battery box combined.

152

Detachable LED Module.

Battery box can be taken for charging.

The base can be unscrewed to replace or repair the battery. “The dimensions are making the product very compact and making it difficult to add the electrical components�.

153

DESIGN DRAFT 2

Front View

41 mm

95 mm

154

Top View

55 mm

95 mm

155

156

Side View

41 mm

55 mm

157

158

159

160

Component A

Component B

Component C

161

1 mm

10 mm

40 mm

27.50 mm 9.75 mm

35 mm

5 mm 1 mm

10 mm 18.75 mm

7.5 mm 2.5 mm 7.5 mm 15 mm 85 mm

95 mm

Component A Component: Detachable LED Module Material: Plastic (HIPS) Required number of pieces: 1 Drawings not to scale 162

10 mm

0.85 mm 2.40 mm

5 mm

3.5 mm

9 mm

3.25 mm

4.29 mm

10 mm 1 mm

163

17.5 mm

40 mm 5 mm

15 mm

40 mm

3 mm 5 mm

10 mm 30 mm

7.5 mm

10 mm

85 mm

95 mm

Component B Component: Battery Pack Casing Material: Plastic (HIPS) Required number of pieces: 1 Drawings not to scale 164

4.15 mm

5 mm 45 mm 55 mm

25.5 mm 6 mm 19.5 mm

1 mm 5.75 mm

4 mm 6 mm

67.5 mm

7.75 mm

83 mm

Component C Component: Casing Base Material: Plastic (HIPS) Required number of pieces: 1 Drawings not to scale 165

Prototype Perspective view of the prototype.

Material: HIPS MEK Screws Connector Acrylic Sheet

LED module and the battery box combined.

166

Detachable LED Module.

Battery box can be taken for charging.

The base can be unscrewed to replace or repair the battery.

167

168

USER TESTING

User Response Evidence Observations and Insights Product Comparison User Interaction

169

USER RESPONSE Location - Ramamurthy Nagar Time of Visit - 6:00 - 7:15 pm Date - 13th April 2016 Ramamurthy Community IEC Ramamurthy Nagar Bangalore - 560043 Karnataka Test Participants - 8 Households - 4 **While user testing, the prototype used is a bit different from the final design inclusions and iterations. The test participants were informed of the design changes that would be incorporated in the final product.

-Do users understand what this product or service does?

The users show great concern over the drawbacks in the existing product service and share important insights from their daily routine problems.

-How do users feel about the product or service?

The users are excited to see the product in the market and also appreciate the value of the design whoch allows them more command over the product and more liberty in terms of use.

-What is your LED Lamp for?

The LED Lamp is for the portability, safety and most importantly understanding the needs of the user which the user hints during the user testing period.

The lamp facilitates the daily usage of the product in a more personalised way.

-What scenarios can they picture themselves using it in?

The users acknowledge the fact that their product aspirations have been tried to attempt through the design draft and also suggest changes.

-What changes does the user suggest?

Changes Suggested“The colour of the plastic should be darker.”

“The locking mechanism might not last.”

“The material thickness should be more.”

“Can we also use a 12V battery for the final product?”

170

-Can your target market think of another product that does something similar?

Products in the market that they think are worth their money are - emergency lights, low-cost LED lamps as alternatives.

-Does your target market feel like this product was designed for them?

The user completely associates with product while exploring and using it and shows excitement in interating with the product.

The user also appreciates the basic semantics of the product and compact-ness of it.

-What problem does your idea solve?

The concept idea allows the user to manipulate the usage of the re-designed product to save it from getting damaged through factors like dust, fumes from the stove (angeethi), and also gives them security over the component which they have to store during the day.

-How are users solving this problem currently?

This lamp gives them a better understanding of the circuitory and that really helps them understand the delicacies and importance of the product.

-How have previous solutions failed?

Previous solutions don’t allow the users mobility and portability which they feel needs to be incorporated in a seamless manner.

There is also a need for regular maintainence which they think that can be improved through the design.

171

EXISTING BPL LAMP -The light quality is satisfactory.

-No flat surface enough to use it as a desk lamp so hung on the scaffolding instead.

-The BPL Lamp can either be hung upside down or can be kept on a flat surface.

-The screws fall off and sometimes battery packs fall down..

-The open wires are prone to damage by insects, rodents, etc.

172

RE-DESIGNED LED LAMP -The light quality is good.

-The Lamp can be used either on any flat surface or can be hung on the scaffolding.

-The user finds the product very safe to use and tough enough to last in such conditions.

-The absense of open wires or any such electronics make it last longer.

-The product might be hacked for other purposes.

173

USER INTERACTION 174

175

176

USER INTERACTION 177

178

DESIGN DEVELOPMENT

Final Design Iterations Design Features Design Specifications Dimensions Metal Hang Iterations

179

FINAL DESIGN ITERATIONS The Final Design Iterations are the following based on key research and prototyping insights, user feedback and suggestions and client requirements.

EMBODIED ENERGY

USER

USER SCENARIO

PROBLEMS

PRODUCT PLACEMENT

REPAIR

INFORMATION

DIMENSIONS

SELCO

COST

INTERACTION

MULTIPLE USES

CONVENIENCE

QUALITY

SEMANTICS

180

COMPONENTS

INSTALLING HARDWARE

INJECTION MOULDING

SNAP HINGE

FORM

WEIGHT

HEAT SINC

COLOUR

MECHANISM

TOOLING

HEAT VENT

GRAPHICS

MATERIAL

HARDWARE

BATTERY

PACKAGING

DETACHABLE

DIFFUSER

WASTE

PORTABLE

LOCK

COMPACT

BATTERY INDICATOR

181

DESIGN ITERATION 1 Material - Polypropylene Number of Components - 4 Dimensions - 93 x 53 x 43 mm

Alternate UsesPortable lighting, Signaling, Torch, General light source outdoors and Low light level varieties can be used for decoration.

Dual Function Lock which can be used as a hook, or otherwise to mount the light on a vertical surface.

The light consists of metal hinges which act as a switches for the light source.

1

182

2

3

DESIGN ITERATION 2 Material - Polypropylene Number of Components - 4 Dimensions - 112 x 65 x 60 mm

Alternate UsesPortable lighting, Signaling, Torch, General light source outdoors and Low light level varieties can be used for decoration.

The Lamp can be used in more than one orientation and the metal hang aids in the portibility and the suspension of the product in the usage scenario.

1

2

3

183

METAL HANG ITERATIONS

184

185

EXISTING PACKAGING

300 mm

160 mm Component: BPL Desk Lamp and Battery Pack Material: Cardboard 186

160 mm

PACKAGING

62 mm

115 mm

67 mm

Component: Re-designed Lamp and Battery Pack Material: Cardboard / Paper Mache 187

188

VALIDATION

Embodied Energy Product and Service Analysis Should Cost Analysis Customer and Product Interaction Supply Chain Map Value Streaming Proposed Business Model Sustainable Design Success Criteria

189

EMBODIED ENERGY (MJ / Kg)

Battery Charger

Charge Regulator

Battery Pack

Desk Lamp

0

50

100

150

Polystyrene

117

Paper Iron Resin Cement Water

23.4 25 33 05.6 00.02

Polystyrene Iron

117 25

Paper Iron Resin Cement Water

23.4 25 33 05.6 00.02

ABS Iron

111 25

Polystyrene Polypropylene

117 64

Polystyrene

117

Polystyrene Polypropylene

117 64

Existing Materials Suggested Materials

http://www.victoria.ac.nz/architecture/centres/cbpr/resources/pdfs/ee-coefficients.pdf 190

REVISED EMBODIED ENERGY Embodied Energy Assembly

=

Weight of x EE Value + Weight of x EE Value Material (MJ / Kg) Material (MJ / Kg)

(EE)

Existing Embodied Energy Assembly

Total Weight of all the materials

=

16 x 52 + 80 x 25 + 54 x 117 + 33 x 111 1000 1000 1000 1000

(BPL Lamp + Battery Pack)

183 1000 =

+

0.832

2

+

6.318

+

3.663

183 1000

EE Assembly (MJ)

=

=

12.813

70.02

0.183

Revised Embodied Energy Assembly

=

71 1000

(Re-designed Lamp and Battery Pack)

Revised EE Assembly (MJ)

x

71 1000 =

64

=

4.544

0.071

64

Other factors like volume, transportation and packaging influence the Embodied Energy difference further.

191

PRODUCT AND SERVICE ANALYSIS PRODUCT ACCEPTANCE Anticipated Benefits -The embodied energy is lowered using less material than already being used.

-The semantics of the product make it easier to transport and also cut down on the packaging cost.

-Due to the compact size of the product mobility becomes easy.

-The product is detachable which allows the user to keep it away from fumes, smoke and other harmful factors while not in use which as a result increases the life of the product.

Form Inspiration -Form Inspiration taken from the existing battery pack. They are compact and follow basic geometry.

192

SHOULD COST ANALYSIS

1500

1000 Cost Difference 500

( Rupees )

0 Current Retail Cost for the existing BPL lamp and battery pack.

New Cost for the re-designed BPL lamp and battery pack.

Value Added Tax Profit Margin** Manufacturing Cost (Material, Production and Tooling)

** Assuming that the profit margin is 30%. and the Batch Size is 10000 units.

Injection Moulding Batch Manufacturing Cost Calculations: http://www.custompartnet.com/ estimate/injection-moulding/ 193

CUSTOMER AND PRODUCT INTERACTION

Using the Light in the night (5 - 6 hours)

Taking the Light component for charging to the IEC

User

** IEC

Incase of any repairs the component taken to the IEC

**IEC - Integrated Energy Center 194

Collecting the component in the evening

Paying the IEC for the charging and other services (Rs. 5/day)

Selco Services (Repair and other services)

195

SUPPLY CHAIN

BUY

Material for Injection Moulding Circuit and Other Electronics

MANUFACTURER

Selected Design

Mould for each Part MAKE

Production of each component Secondary Packaging (Instruction Manual)

196

End User (IEC’s and Community members)

Anand Electronics

ASSEMBLY

PACKAGING

SELCO GODOWN

197

VALUE STREAMING Supplier SELCO (Production Control)

Annual Production Plan MANUFACTURER (Injection Moulding)

Monthly

Daily Schedule

Daily Schedule

Daily Schedule

INSTALLING HARDWARE

PRIMARY PACKAGING

SECONDARY PACKAGING (Manual)

C/T - 2 C/O - 1 Uptime - 75%

C/T - 1 C/O - 1 Uptime - 95%

C/T - 1 C/O - 1 Uptime - 80%

Recieving

1 day

0 days 2 mins.

C/T - Cycle Time (min) C/O - Changeover Time (min) 198

1 day 1 min.

1 min.

Market Forecast END USER (IEC’s and Communities) SELCO Service Center

Daily Schedule

Weekly Schedule

ASSEMBLY and INSPECTION

SELCO GODOWN

Daily

Delivery and Installation

C/T - 1 C/O - 1 Uptime - 90%

1 day

1 day 1 min.

Total Lead Time= 4 days.

Value Added Time= 5 mins.

Material Information 199

BUSINESS MODEL - SELCO KEY PARTNERS

KEY ACTIVITIES

VALUE PROPOSITION

BPL

Selco India

SELCO Needs Assessment Facilitating End User Financing Installation After Sales Services

Selco Foundation

Manufacturing

Products and services Buyer - Selco from BPL Co-Facilitator Daily Interaction with product by the End User Selco Services

Anand Electronics

Investment / Financial Facilitators (Banks) IEC Entrepreneurs / IEC Operators

KEY RESOURCES Selco services Infrastructure IEC Selco Products

COST STRUCTURE Initial Investment - Mould Cost (Assuming that the manufacturer already has the required facilities) Recurring Cost - Material Maintenance Machines, Moulds, Service, Staff, Infrastructure, Packaging

200

Pain relievers Design - Easy to Repair Absense of exposed electronics Portable - The user can travel with the product during the night while using the lamp at different locations (Scenarios).

CUSTOMER RELATIONSHIPS

CUSTOMER SEGMENT

Gain creators Cost Benefits Portable and Compact Easy placement of product - Less prone to factors like fumes, water

Adaptable semantics

Type 1 Low Income Groups Vulnerable communities (Daily wage workers, domestic help, taxi drivers, fruit/ vegetable vendors, factory workers)

Aesthetics and Semantics Contemporary (Social Upliftment)

CHANNELS

Social Upliftment Use of user - friendly mechanisms in the products

Type 2 Above Low Income Groups

Awareness Evaluation by customers (Word of mouth) Delivery After sales feedback and services Transportation

REVENUE STREAMS Daily sales - Selco Products IEC daily charge Post warranty services

201

RADAR CHART SOCIO - CULTURAL

ENVIRONMENTAL

Embodied Energy

Cradle - to - Cradle Framework

Livelihood

Okala Practitioner

Health

Cost

Education

Lead Time

Quality

ECONOMIC

Sustainable Design Success Criteria.

(Self Assessment) Measuring Scale 1 - 5.

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Existing System Product Alternatives Combining Products

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REFLECTIVE STATEMENT Inventing Green, as a project has been more of an eye opener to me, and the learning has been overwhelming. The idea of sustainability is always questioned but what I understood of it was that as long as we cater to our environment as a whole with minimum possible impact on our resources, we are beginning to be sustainable.

The Design Process considers the users an important part of the same. The users provided useful insights and concept feedback during the user testing part of the project. As a designer I faced multiple challenges during the course of the project, which helped me strengthen my project further and also the initial failures during material exploration facilitated the validation of the project through different levels of analogies.

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WEB REFERENCES

“World Bank Group.” World Bank Group. Accessed February 01, 2016. http://www.worldbank.org/.

“Energy Demand up One-third by 2035.” Mechanical Engineering-CIME, January 1, 2012.

Centre for Application of Renewable Energy. “Solar Street Lights with LED Luminaries, Made More Relevant.” Solar Street Lights with LED Luminaries, Made More Relevant. December 22, 2011. Accessed February 03, 2016. http://www.slideshare. net/careindia/solar-street-light.

Drazga, Barbara M. “Solar Power Applications.” Technology For Life. 2007. Accessed February 01, 2016. https:// technology4life.wordpress.com/applications-of-solar-power/.

Bhutta, Faiz Mohammad. “Solar energy applications in industrial and commercial sectors in pakistan and barrriers in its grow.” AltEnergyMag. March 29, 2012. Accessed February 03, 2016. http://www.altenergymag.com/content.php?post_ type=1868.

Zipp, Kathie. “7 Cool Solar Energy Applications.” Solar Power World. May 7, 2013. Accessed February 01, 2016. http://www. solarpowerworldonline.com/2013/05/7-cool-solar-energyapplications/.

“Solar Panel Types & Application... Does It Really Matter Which One I Choose?” Solar Panel Types & Application... Does It Really Matter Which One I Choose? Accessed February 01, 2016. http://www.solarstik.com/stikopedia/solar-stiktm-systemoverview/choosing-power-generators/amorphous-vs-cigs.

Wikipedia. “Embodied Energy.” Wikipedia. Accessed March 26, 2016. https://en.wikipedia.org/wiki/Embodied_energy.

Engineerguyvideo. “Plastic Injection Molding.” YouTube.

2015. Accessed March 28, 2016. https://www.youtube.com/ watch?v=RMjtmsr3CqA. Value Stream Map. ConceptDraw. Accessed April 6, 2016. http://www.conceptdraw.com/How-To-Guide/picture/VSMexample.png.

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BOOKS

White, Philip, Louise St. Pierre, and Steve Belletire. Okala Practitioner. USA: Okala Team, 2013. Print. Integrating Ecological Design.

Commission, European. The Business Case for Eco Solution.

UNEP, 2014. Print.

Stouthuysen, Peter, and Dirk Le Roy. Cradle-to-Cradle Network.

European Regional Development Union.

Boyle, Godfrey, Bob Everett, and Gary Alexander. Introducing Renewable Energy.

Wagner, Cynthia G. Design for the Other 90 Percent. New York, 2007. Print. “Embodied Energy.� Accessed March 18, 2016. http://www. victoria.ac.nz/architecture/centres/cbpr/resources/pdfs/eecoefficients.pdf.

McManus, Hugh L. Product Development and Value Stream Mapping Maual. Vol. 01. Lean Aerospace Initiative, 2005.

Accessed April 6, 2016. http://www.metisdesign.com/docs/ PDVSM_v1.pdf.

Johnson, Sharon, Worcester Polytechnic Institute, Jose Macedo, Cal Poly San Luis Obispo, Hugh McManus, Metis Design, Ted Mayeshiba, USC, and Earll Murman, MIT. Value Stream Mapping. Vol. 7.6. Massachusetts Institute of Technology, 2012. Accessed April 6, 2016. http://ocw.mit.edu/ courses/aeronautics-and-astronautics/16-660j-introductionto-lean-six-sigma-methods-january-iap-2012/lecture-videos/ MIT16_660JIAP12_1-6.pdf.

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