The Conception: The 5th Concern for innovation - Case study on Letterbox Design for India Post – Part II DE 402 “Introduction to Design – Case Studies
Generating Concepts
Selected Concept
MATERIAL CONSIDERATIONS Top to be manufactured in engineering plastics with the front posting detail. The door , box and pedestal will be CNC Fabricated in stainless steel.
FORM REFINEMENTS As the basic structure of the box has to be simple, the form of the cap was going to dictate the overall statement of the Post Box. Different variations of the cap were tried out.
FORM REFINEMENTS
FORM REFINEMENTS
FORM REFINEMENTS
COMPUTER AIDED DESIGN
COMPUTER AIDED DESIGN
COMPUTER AIDED DESIGN Aesthetic Refinements
COMPUTER AIDED DESIGN
SMART TOP
LARGE POST BOX
SMALL POST BOX
CLEARANCE TIMING & PIN NUMBER
DESIGN FOR MANUFACTURE
DESIGN FOR MANUFACTURE
Prototype manufacturing
Regular POST BOX
Modular design
PROMINENT FRONT PANEL
EASE OF USE for collecting letters
The valleys of death after prototype MOCK UP WORKING PILOT PRODUCTION FINAL PROTOTYPE PRODUCTION Product Development Manufacturer Design Prototyping Product Mass Planning Manufacturing User Testing User Testing Detail Design, Soft Tooling, 3d Printing, Design Thinking, Prototype Design Small Vendors, Small Manufacturers, Large Scale Tooling, Jigs, Manufacturer Fixtures s
Design improvements after user feedback
Production of 20 numbers
Pilot Production CNC TURRET PUNCH MANUFACTURE
CNC LASER CUT for low quantity production
CNC BENDING for high quality
Work hardening of SS Embossing and Bending
Strong and Durable
EASE OF POSTING
STRONG AND DURABLE
COMMON KEY TO OPEN
TOUGH COMPOSITE TOP
EASY TIME SLIDER
INNOVATIVE SHAPE
Product element Problems countered Benefits Image Stainless steel body corrosion & vandalism Sturdy maintenance damage to box free 5 times Increase in Shoddy repairs life span ``Sloping plastic top Rainwater seepage Intact letters sturdy enveloping body on From Top & side Elegant look all sides Foundation bolt Water seepage from Undamaged box & letters. Soil corrosion Easy to install Rust proof lock and Corrosion. Inconvenience Convenient to use Common key for one Of carrying many keys region And losing them Wide aperture with Folding & spoiling large Convenient to use damage Flap (?) Envelopes, public & children To box prevented dropping rubbish, Bombs etc Time slider Required to carry & Convenient in use change time card every time Overhang/hooks for Discomfort in collecting Convenient in collecting Hanging bags Letters during rains Letters and they remain undamaged Space at beak top base Discomfort in posting in Provision for hand rest While posting letter damaged letterbox opening Space to keep paper Flat top large surface And write Ample space on sides Generate revenue for For advertising post
PACKAGING AND TRANSPORTATION Reduces the volume of the letterbox thus reducing the cost of transportation. This also helps in protecting the plastic top during transit.
Instructions for Assembly
PRODUCT LAUNCH
INAUGURATION OF LIGHTED POST BOX AT AIRPORT
First pilot order of 200 numbers
COLLABORATIVE INNOVATION Stainless Steel from Jindal Stainless Ltd. GELOY Engineering Plastic from GE Plastics Rust Proof Locks from Godrej CNC Manufacturing from Jindal Architecture Ltd. Adhesive from Huntsman Anchor Bolts from HILTI
PROMOTION
The valley of death after Pilot production MOCK UP WORKING PILOT PRODUCTION FINAL PROTOTYPE PRODUCTION Product Development Manufacturer Design Prototyping Product Mass Planning Manufacturing User Testing User Testing Detail Design, Soft Tooling, 3d Printing, Design Thinking, Prototype Design Small Vendors, Small Manufacturers, Large Scale Tooling, Jigs, Manufacturer Fixtures s
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