Assignment No: 1

Product – Wall Fan

A wall fan is a mechanical device that provides localized air circulation by being mounted on a
vertical surface. Unlike ceiling or pedestal fans, it doesn't occupy floor space, making it ideal
for rooms with space constraints. Wall fans are versatile, energy-efficient, and used in
residential, commercial, and industrial settings for better air ventilation.
➢ Why Do We Need a Wall Fan?
1. Effective Space Utilization
• Ideal for compact areas like kitchens, hostels, small shops, and garages.
• Wall-mounted design frees up floor space.
2. Enhanced Air Circulation
• Helps maintain airflow in corners or enclosed areas.
• Ideal for supplementing ceiling fans or AC units.
3. Directional Cooling
• Adjustable oscillation (left to right) and tilting head (up and down).
• Can target airflow to specific zones.
4. Cost-Effective Cooling
• Consumes 40–75 watts only (depending on size/model).
• Cheaper to run than air conditioners.
5. Reduces Indoor Air Stagnation
• Prevents heat build-up in humid conditions.
• Useful in areas with poor ventilation.

➢ How Does a Wall Fan Work?

Wall fans operate by converting electrical energy into mechanical rotation through a motor,
driving fan blades to push air across a space.
Core Components:

Component Function

Electric Motor Powers the rotation of the blades.

Fan Blades Create airflow by spinning at high speed.

Oscillating Unit Provides side-to-side motion.

Tilt Mechanism Allows vertical airflow direction.

Speed Controller Allows users to adjust airflow intensity.

Mounting Bracket Securely fixes the fan to a wall surface.

➢ Types of Wall Fans:

Type Description

Manual Wall Fans Operated via pull cord or rotary knob.

Remote-Controlled Wall Fans Allows operation from a distance.

BLDC Wall Fans Uses Brushless Direct Current motor for energy efficiency.

Smart/IoT Fans Controlled via apps or voice assistants.

1. High-End Features (Premium Wall Fans)

Brushless DC (BLDC) Motor Technology
• Consumes 50–60% less energy than standard induction motors.
• No heat generation = longer life.
Remote Control Operation
• Convenient operation with speed, swing, and timer controls.
Timer & Sleep Modes
• Auto shutoff for energy savings and safety.
Smart Connectivity (IoT)
• App control, Alexa/Google Assistant compatible.
Anti-Rust & Anti-Dust Coating
• Prevents blade corrosion and dust accumulation.
Thermal Overload Protection
• Automatically shuts off in case of overheating.
Stylish Design
• Slim and elegant aesthetics for modern interiors.
Silent Operation
• Noise levels under 60 dB for quiet comfort.
Premium Models:
• Atomberg Efficio+ (400mm) – ₹3,300
• Havells Swing Platina Remote – ₹3,000
• Orient Wall 49 Trendz Remote – ₹2,900

2. Low-End Features (Basic Wall Fans)

Standard Induction Motors
• Higher electricity consumption, basic efficiency.
Manual Pull Cord or Rotary Switch
• No remote, old-school control.
Plastic Blades & Body
• Less durable than ABS or metal.
Limited Oscillation/Tilt
• May have fixed or limited directional settings.
Basic Safety Features
 • No thermal protection, risk of overheating.
Higher Noise Levels
• Can produce noise above 65–70 dB.
Budget Models:
• Bajaj Esteem Wall Fan (400mm) – ₹1,500
• Usha Mist Air Icy – ₹1,700
• Orpat Wall Fan 400mm – ₹1,600

➢ Comparison Between Top Wall Fan Brands

Feature Havells Orient Bajaj Usha

Motor Type Induction Induction Induction Induction
Remote Control Yes (select Yes No No
models)
Smart Features No No No No
Energy Medium Medium Basic Basic
Efficiency
Build Quality Stylish Plastic Glossy Plastic Basic Plastic Basic
Air Delivery 65 CMM 70 CMM 60 CMM 65 CMM
Noise Level Moderate Moderate High High
Price Range ₹2,000–₹3,000 ₹1,800–₹2,800 ₹1,400– ₹1,500–
₹2,000 ₹2,200
Best For Aesthetic spaces Remote control Budget users Small rooms
utility

➢ Customer Reviews for iBELL VIVA High-Speed Wall Fan

1. "Nice look with smooth sound"
Reviewed on August 21, 2024
"I bell wall fan nice look with smooth sound & power saving with remote control nice
product."
2. "Excellent Performance with Low Noise"
Reviewed in April 2023
"Excellent Performance with Low Noise. "
3. "Very good product but fan speed is slow"
Reviewed 4 months ago
"Very good product but fan speed is slow."
4. "Nice product, Attractive colour, Excellent air flow"
Reviewed 1 month ago
"Nice product, Attractive colour, Excellent air flow, so far everything good, Highly
recommended "
5. "Good product, Easy to handle"
Reviewed on September 21, 2024
"I have purchased this high speed tower fan recently and I am completely satisfied
 with it. It is quite easy to handle and portable as well. I definitely love it personally
and highly recommend it."
Need for Wall Fan Development
• Urban Congestion - Need for compact cooling options in high-density homes.
• Energy Awareness - Demand for BLDC and low-power consumption appliances.
• Rise in Smart Homes - IoT integration becoming a standard across appliances.
• Changing Climate - Extended summers and humid zones call for improved airflow
devices.
• Industrial & Kitchen Applications - High-temperature areas require heavy-duty airflow
systems.

Suggestions for Innovation & Improvement

• Solar-Compatible BLDC Wall Fans - Designed for energy-deficient or off-grid areas.
• Eco-Friendly Materials - Use of recyclable or biodegradable plastics.
• Air Quality Monitoring Sensors - Wall fan could include basic sensors to detect
humidity, temp, or CO₂.
• Voice Assistant Compatibility - Integration with smart assistants for hands-free
operation.
• Auto-Clean Function - Dust-resistant grills and blades with vibration cleaning.
• Wireless Charging Panel - For remotes or small mobile devices near the fan mount.
• Multi-Directional Airflow - 360° oscillation with intelligent motion tracking.

Product Development Variant: Improvement of Existing Product

Wall fans already exist in the market, and the version you're describing doesn't create an
entirely new product category—it builds upon existing wall fans with enhancements like:
• BLDC motors for energy efficiency
• Smart/IoT features (remote control, app integration)
• Improved aesthetics and materials
• Advanced features like anti-dust, overload protection, etc.

Improvement Variant Characteristics (Matched to Wall Fan):

Criteria Match in Wall Fan
Existing product category Yes – wall fans are already widely used
Enhancements in performance Better energy consumption (BLDC), quieter
operation
Added features or functionalities IoT control, remote, timers, safety systems
Aesthetic or ergonomic improvements Slimmer design, better materials
Competitive advantage without redefining Yes, the product stands out but is still a
the category “wall fan”
 Assignment No: 2
Product – Ceiling Fan
Models of the Product (Ceiling Fans)
Below are some of the top ceiling fan models across different categories:

Brand Model Name Key Features

Atomberg Renesa+, Efficio Alpha BLDC motor, energy-saving, remote control,

modern look

Havells Festiva Prime, Enticer Decorative trims, high speed, premium finish
Art

Crompton Energion HS, Aura BLDC motor, inverter compatible, silent

Prime operation

Orient Aeroquiet, iFalcon, Aerodynamic blades, silent fans, LED under-lights

Electric Wendy

Usha Bloom Magnolia, Stylish design, high air delivery, rust-free coating
Striker

Positive & Negative Customer Reviews

Positive Reviews
• “Atomberg Renesa+ gives fantastic airflow and saves on electricity bills.”
• “Crompton Energion runs well even during voltage fluctuations and is quiet.”
• “Orient Aeroquiet lives up to its name. No noise even at high speed.”
• “Usha Bloom is both functional and stylish – love the colors.”
• “Havells fans have a premium look and consistent airflow.”
Negative Reviews
• “The remote stopped working after just 3 months.” (Atomberg Renesa+)
• “Becomes noisy after continuous use for a few hours.” (Havells Enticer)
• “Build quality doesn’t justify the price.” (Orient Wendy)
• “Paint and finish look cheap compared to online images.” (Usha Striker)
• “Installation kit missing in the box.” (Crompton Aura)
To develop a ceiling fan that meets customer expectations, use the following methods to
identify needs:
Techniques:
1. Customer Surveys & Online Feedback – Analyse ratings and open-ended reviews on
Amazon, Flipkart, etc.
2. Direct Interviews or In-Home Observation – Understand real-world usage, problems,
and preferences.
3. Complaints & Returns Analysis – Study reasons for product returns or dissatisfaction.
4. Social Media Listening – Monitor what users say about fans on forums, Twitter, Reddit.
5. QFD (Quality Function Deployment) – Convert customer wants into engineering specs.
Example Needs Identified:
• Low noise even at full speed
• Better energy efficiency
• Long-lasting remote control
• Elegant design matching room interiors
• Durable in coastal/humid conditions

Feature Positive Reviews Negative Reviews

Air Delivery “Powerful airflow across the “Fan does not throw enough air
entire room.” even at max speed.”
Noise “Super silent even at top speed, “Very noisy motor. Can’t sleep
great for bedrooms.” when it’s running.”
Energy Saving “My bills dropped 40% after “Energy saving not evident, still
switching to BLDC fan.” drawing high power.”
Remote Function “Remote works from across the “Remote stopped working;
room, very handy.” replacement not available.”
Design/Aesthetics “Looks like a designer piece – “Finish is dull, not like what’s
adds charm to the room.” shown online.”
Durability “Running perfectly after 2 years.” “Stopped working within 6
months.”

Assertive Attribution to the Problem Tackled

Problem: Traditional ceiling fans consume high power and are noisy.
Assertion:
This challenge is addressed using BLDC motor technology, which reduces power consumption
by up to 65% and enhances motor efficiency. Modern designs also incorporate aerodynamic
blades and anti-friction bearing systems, which cut down operational noise drastically. The
result is a quiet, energy-saving fan with longer life.

On What Factors Should I List the Problem – Engineering or Industrial?

Type Description Example in Ceiling Fans

Engineering Technical issues in product design, Noise reduction, airflow

performance, or safety. optimization, motor heating

Industrial Issues related to production, cost, Cost of BLDC motor, supply chain
logistics, or marketing. for remotes

Use Engineering Problem when focusing on product improvement.

Use Industrial Problem when focusing on manufacturing or delivery challenges.

How to Develop Correlation Matrix

A Correlation Matrix connects customer needs (WHATs) with product specifications (HOWs).
It shows how strongly a feature helps in fulfilling a need.
 Customer Needs Energy-Saving Silent Aerodynamic Remote
→ Motor Operation Blades Control

Low power usage ●●●●● ●● ●● ●

Noise reduction ●● ●●●●● ●●● ●

Smart ●● ● ●● ●●●●●
convenience

Good aesthetics ● ●● ●●●● ●●

(● = strength of correlation; more dots = stronger influence)

House of Quality is a tool to transform customer needs into engineering goals. It includes:
• Customer requirements (WHATs)
• Engineering characteristics (HOWs)
• Interrelationships (matrix)
• Correlation among HOWs (roof of house)
• Priorities and technical difficulty

Design PDND Process (Product Design and Development)

The PDND process consists of clear stages to convert an idea into a finished product.
Steps:
1. Need Identification - Identify needs: low noise, energy-saving, smart features.
2. Concept Development - Concepts: BLDC motor, aerodynamic blades, voice control.
3. System-Level Design - Choose power ratings, motor design, app interface, safety specs.
4. Detail Design - CAD models of blades, remote electronics, enclosure design.
5. Prototyping & Testing - RPM test, noise level, voltage fluctuation test, performance
under load.
6. Production Planning - Material sourcing, tooling for blades and housings, assembly line
design.
7. Launch & Feedback - Initial market release → Customer feedback → Refinement cycle.
 Assignment No: 3
1. Introduction
Ceiling fans are a common household appliance used for air circulation and comfort. Although
the core function of a ceiling fan has remained consistent over the decades, evolving user
preferences, energy efficiency concerns, and smart home integration present opportunities to
innovate. In this assignment, we explore how to enhance the design and functionality of a
ceiling fan using the SCAMPER creativity method. The goal is to reimagine the ceiling fan by
applying structured thinking techniques that foster innovation.
2. Objective
To apply the SCAMPER method for creatively re-designing the ceiling fan and propose features
that cater to modern user needs while improving utility, sustainability, and aesthetics.

3. What is SCAMPER?
SCAMPER is a creativity technique based on seven structured idea triggers. It stands for:
• Substitute
• Combine
• Adapt
• Modify (or Magnify/Minify)
• Put to another use
• Eliminate
• Rearrange (or Reverse)

4. Application of SCAMPER to Ceiling Fan Design

S – Substitute
What can be replaced?
• Substitute materials: Use carbon fiber or recyclable plastic instead of traditional metal
for lighter and eco-friendly blades.
• Substitute motor type: Replace standard motors with BLDC motors for better energy
efficiency and lower noise.
C – Combine
What can be combined to enhance function or appeal?
• Combine with lighting: Integrate smart LED lights with dimmable control and color
adjustment.
• Combine with sensors: Add temperature, humidity, and motion sensors to automate
fan speed and lighting.
A – Adapt
What can be adapted from other products or systems?
• Adapt air purification technology from air purifiers to include HEPA filters or ionizers
within the fan.
• Use design elements from aesthetic chandeliers to make it a decorative centerpiece.
M – Modify / Magnify / Minify
What can be exaggerated or toned down?
• Modify blade shape for better aerodynamics, such as using winglet-style blades
inspired by aircraft.
• Minify the size of the motor by using slim DC motors, allowing a sleeker body.
• Magnify user control: Add voice assistant and smartphone integration for remote
control.
P – Put to another use
Can the product be used differently?
• Use the ceiling fan as an air quality monitor (via integrated sensors).
• Use the base of the fan to project patterns or lights on the ceiling for ambiance.
E – Eliminate
What can be removed to simplify the design?
• Eliminate pull cords or manual switches by replacing with gesture controls or mobile
app control.
• Eliminate visible fasteners for a seamless, modern aesthetic.
R – Rearrange / Reverse
What can be rearranged or reversed?
• Rearrange the blade orientation to create both downward and upward airflow for
summer and winter modes.
• Reverse the mounting style for modular ceiling/wall mounting or retractable blade
design.

5. Concept Outcome
Based on the SCAMPER method, the new ceiling fan concept includes the following features:
• BLDC motor with smart speed control
• Integrated LED lighting with ambiance modes
• Temperature and motion sensors
• Air purification system with HEPA filters
• App and voice assistant compatibility
• Aerodynamic, eco-friendly blade design
• Chandelier-inspired aesthetics
• Gesture controls instead of pull cords

6. Conclusion
The SCAMPER method provided a structured yet flexible approach to creatively re-imagine the
traditional ceiling fan. By analysing each aspect of the fan through the lens of SCAMPER, we
developed a multifunctional, energy-efficient, and aesthetically pleasing smart fan that aligns
with modern user demands.

7. References
1. Eberle, Bob. SCAMPER: Creative Games and Activities for Imagination Development.
2. Product reviews and feedback from customers on ceiling fan performance (Amazon,
Flipkart, etc.)
3. Industry innovations in BLDC motors and air purification systems
 Assignment No: 4
1. Introduction
Ceiling fans are essential appliances for air circulation and cooling in homes, offices, and
industrial settings. As energy efficiency, aesthetics, ease of use, and cost reduction become
critical design considerations, applying industrial design principles and DFMA (Design for
Manufacturing and Assembly) is essential. These principles ensure that the product is not only
functional but also easy and cost-effective to manufacture and assemble.
This assignment outlines how industrial design methods and DFMA principles can be applied
to the design of a ceiling fan. It will also include an explanation of developing an exploded view
for better visualization and understanding of the fan's components.

2. Industrial Design Principles for Ceiling Fan Design

Industrial design focuses on optimizing the usability, functionality, aesthetics, and
manufacturability of a product. When designing a ceiling fan, several industrial design
principles need to be applied:
a. User-Centered Design (UCD)
This principle focuses on designing with the end-user in mind, ensuring that the ceiling fan is
comfortable, easy to use, and meets consumer needs. Features such as easy-to-reach controls,
remote control compatibility, and quiet operation should be prioritized to improve user
experience.
• Example: A ceiling fan with smart functionality that can be controlled through a mobile
app or voice commands (e.g., using Google Assistant or Alexa).
b. Ergonomics
Ergonomics deals with designing products that provide comfort and reduce strain during use.
For a ceiling fan, this means ensuring that the remote control or app interface is intuitive, with
easy-to-understand buttons, and that the fan speed control is smooth and non-straining.
• Example: Using dimmer switches or touch-sensitive controls for adjusting fan speed
without excessive effort.
c. Aesthetics and Form
The form of the ceiling fan must align with current interior design trends and consumer
preferences. The blades and motor housing should be designed in a sleek, minimalistic style,
with attention to texture, color, and proportion. The fan should look elegant in both traditional
and modern spaces.
• Example: A fan with integrated LED lighting, offering not just cooling, but also mood
lighting with adjustable color temperatures.
d. Sustainability
Sustainability is becoming increasingly important in product design. Designers must consider
the materials used, the energy efficiency of the fan, and its end-of-life recyclability.
• Example: Designing a fan with recyclable components, energy-efficient motors (such as
BLDC motors), and using eco-friendly materials for the blades and housing.
3. Application of DFMA (Design for Manufacturing and Assembly) Principles
DFMA is a set of principles aimed at simplifying the design process to reduce manufacturing
costs, improve assembly efficiency, and minimize potential assembly errors.
a. Simplify Part Count
Reducing the number of parts in a product makes it easier and cheaper to manufacture. For a
ceiling fan, this means designing fewer components and using multi-functional parts that serve
multiple purposes.
• Example: Instead of separate components for the motor housing and blade mounts,
these can be combined into a single unit, reducing the number of parts required.
b. Standardize Parts
By using standardized components (like screws, motors, and bearings) across multiple
products or product lines, manufacturers can reduce production complexity and cost.
• Example: Use standard motor and LED light modules that are interchangeable across
various fan models, making production and maintenance more cost-effective.
c. Design for Ease of Assembly
Designing for easy assembly means ensuring that parts fit together easily and intuitively,
without the need for complex tools or excessive manual labor.
• Example: Snap-fit connectors for the fan blades and motor housing can eliminate the
need for screws, simplifying the assembly process.
d. Minimize Handling and Assembly Steps
Limiting the number of operations during assembly improves efficiency and reduces errors.
Parts should be designed so they can be assembled in a single step or with minimal
manipulation.
• Example: Use quick-release mechanisms to attach blades to the motor housing,
reducing the assembly time and simplifying the process.
e. Design for Easy Testing and Quality Control
Incorporating testing features directly into the design ensures that the product can be easily
checked for quality without needing complex or time-consuming procedures.
• Example: Integrating test points or LED indicators that show when the motor is
functioning correctly, ensuring fast and efficient quality control.

4. Developing the Exploded View of the Ceiling Fan

An exploded view provides a detailed visualization of how the components of a product fit
together. It helps in understanding the relationships between parts, assembly steps, and ease
of manufacturing.
Steps to Develop an Exploded View:
1. List All Components
Begin by listing all components of the ceiling fan, such as:
 1. Motor
2. Blades
3. Blade mounts
4. Housing
5. LED light module (if integrated)
6. Remote control receiver
7. Wiring and connectors
8. Mounting bracket
2. Define Assembly Sequence
Determine the sequence of assembly from the motor, blade mounting, wiring
connections, to final mounting to the ceiling.
3. Create a 3D CAD Model
Using software such as SolidWorks, AutoCAD, or Fusion 360, model the ceiling fan's
components in 3D. Then, arrange them in the exploded view.
4. Generate Exploded View
In your CAD software, position each part in an exploded view, ensuring that the parts
are slightly separated to show the relationship between them.
5. Label All Components
Label each part clearly in the exploded view, and annotate any special assembly
instructions, such as torque specifications or orientations for parts.
Example:
• The motor is at the center, with blade mounts attaching to the motor housing.
• Fan blades extend outward from the mounts.
• Wiring runs from the motor through the housing to connect with the power source.
• The LED module (if applicable) is positioned at the center or bottom, with connections
leading to the motor or control system.

Designing a ceiling fan involves understanding user needs, applying industrial design
principles, and using DFMA to ensure cost-effective manufacturing and assembly. The goal is
to create a fan that is energy-efficient, quiet, and integrates seamlessly with modern homes.
1. Problem Identification
Key Design Challenges:
• Effective air circulation
• Quiet operation
• Energy efficiency
• Smart home compatibility
• Aesthetic appeal
Market Research: Consumers prioritize energy-efficient motors (e.g., BLDC motors) and smart
features (app/voice control).
2. Concept Development
Brainstorming: Ideas include using BLDC motors, integrated LED lighting, motion sensors, and
smart home compatibility.
Concept Selection: The selected concept combines:
• BLDC motor for energy efficiency.
• Aerodynamic blades for improved circulation.
• Smart controls via app and voice assistants.
3. Design and Engineering
Preliminary Design:
• Blade materials: Lightweight, durable composite blades.
• Motor housing: Compact, modular design.
• Smart controls for speed and lighting adjustments.
Engineering Analysis:
• Aerodynamics: Optimize blade shape for airflow.
• Thermal & Noise Analysis: Ensure motor efficiency and quiet operation.
4. DFMA Principles
Simplify Part Count: Reduce complexity by using fewer parts, e.g., a combined motor housing
and blade mount.
Standardize Components: Use common parts across models, such as motors and LED
modules.
Design for Easy Assembly: Implement snap-fit components and quick-connect wiring.
5. Prototyping and Testing
Prototype: Build a working model to evaluate motor performance, noise levels, and smart
functionality.
Testing: Ensure optimal airflow, noise reduction, and functionality (speed control, smart
features).
6. Final Design and Production
Adjustments: Refine design based on test results (e.g., blade shape optimization).
Manufacturing: Setup production lines for blade molding, motor assembly, and quality control.
Use DFMA principles to minimize manufacturing costs.

Applying industrial design principles ensures that the ceiling fan is user-friendly, aesthetically
appealing, and aligned with current trends. The use of DFMA principles streamlines the
manufacturing process, reducing costs and improving efficiency. By developing an exploded
view, we visualize the assembly process and gain insights into potential improvements.
The integration of these principles not only enhances the design but also improves product
quality, reduces production costs, and facilitates easier assembly and maintenance.

6. References
1. Gausemeier, J., et al. (2009). Design for Manufacturability and Assembly. Springer.
2. Helms, M. M., & Nixon, J. (2020). The Principles of Industrial Design. Prentice Hall.
3. SolidWorks Documentation – Exploded Views & Assembly Techniques.