Designing in Safety

Ergonomics and product innovations played even greater roles in AM's Tenth Annual Excellence in Design competition, as this year's entries incorporated sophisticated features in stylish ways. This year's winners are a diverse lot indeed. Among them: an all-in-one video conferencing unit, a mosquito-killing device, and a medical appliance for treating impotency.

A three-person panel of industrial-design experts evaluated entries according to these criteria: 1) aesthetics 2) ergonomics/human factors 3) innovative features. Each judge granted each entry 1-5 points per criterion so that an entry's maximum score was 15 points per judge; 45 points overall. Top point scores within a category were declared Winners, with Runners-Up being those that scored second highest in a category. For categories that were especially strong in terms of the number of high-quality entries, judges had the option of declaring additional Winners and/or Runners-Up. This happened in the Computers/ Electronics category, which has two Winners this year. Judges also had the option of not choosing a Winner and/or Runner-up in a specific category. This happened in HVAC, which has a strong Winner, but no Runner-Up.

Best Overall
Small Electrics

Sheltra Monitors by Coleman, Wichita, Kan., and its design firm, ZIBA Design, Portland, Ore.
Proving that stellar designs aren't exclusive to today's pricey techno-gadgets, this line of CO and smoke detectors (suggested pricepoint: $15-$40) is attractive, "visually quiet," and a cinch to figure out. "The design is unobtrusive, yet comforting," says ZIBA's Sohrab Vossoughi. "The design was developed as a silent guardian--out of sight until needed. The forms are gentle without being soft and the subtle edges give the product a safe and dependable feel."

But what really makes the product safe and dependable is the design attention that went into the user interface.

"We developed a large indented button that can be easily engaged with the tip of a broomstick, making it easier to use," continues Vossoughi. "The LEDs are large and wrap around the bezel to be visible from almost any angle. And to assure users that the product is loud enough to protect them, the large speaker holes are a signature element throughout the product line."

None of this was lost on this year's judges. "The clean, simple forms and contemporary styling, combined with the bold treatment of wording on the product and the button designed for broomstick engagement," says judge Steve Wilcox, "are important parts of what is an inventive user-friendly approach to home safety."

Key project players from Coleman:
David Stearns, executive vice president; Pat McEvoy, divison president, safety and security. ZIBA Design: Sohrab Vossoughi, Penny Yao, Steve McCallion, Greg Hinnzmann, Kim Porter, Dave Knaub.

Key suppliers:
Allegro Microsystems (IC)
D.J. Plastics (injection molder--smoke detectors)
Trend Plastics (injection molder--CO detectors).

Computers/Electronics:
All-in-One Videoconferencing

SwiftSite Videoconferencing Unit by PictureTel, Andover, Mass., and its design firm, GVO, Palo Alto, Calif.
Finishing in a virtual tie with the Compaq Presario (below) for top honors in computers/ electronics is this self-contained, compact videoconferencing system that integrates a pan/tilt/zoom camera, three microphones and electronics in a TV set-top enclosure. Its rounded shapes give the appearance that the system is rising out of the TV set.

One client (PictureTel) demand--to have the design firm (GVO) conduct all design presentations via videoconferencing--helped drive the design of the system, according to Jay Wilson, director, GVO.

"The design involved careful coordination with the client," says Wilson. "Measurements were made of the top surfaces of all existing televisions to define the maximum footprint. By making the camera an external articulated element, we were able to reduce the height so that the frontal area is minimized. The external camera also allows very wide angle and low combinations. This extends the usability by allowing the system to be placed in higher positions while still capturing all room positions."

"The system's sculptural form treatment is visually interesting, but in a subdued way, which is important for a product that is most effective when it's felt to be unobtrusive," says judge Marilyn Johnson.

Key project players from PictureTel:
Nunzio Napoleone, group manager; Steven Coleman, mechanical engineer; Kendra DeSimone, mechanical engineer. From GVO: Shawn Hanna, designer; Jay Wilson, director; Jeff Chen, mechanical engineer.

Key suppliers:
Bermo (EMI shield)
Maysteel (metal chassis)
Panasonic (camera block)
SMK Electronics (hand-held IR remote)
Solectron (assembly and testing)
Trend Plastics (plastic enclosure parts)

Computers/Electronics:
'Boom-Box' PC

Presario 3020 by Compaq, Houston, and its design firm, Fitch, Columbus, Ohio.
For the money, consumers perceive PCs to be a better value than laptops, though laptops are more convenient when it comes to portability and space requirements. This product is designed to be a hybrid, utilizing the manufacturing economies of a desktop PC (standard card cage, standard drives, standard motherboard, etc.) in combination with the space-saving efficiencies afforded by a flat-screen LCD, which is mounted in front of the speakers. Occupying 40 percent less space than traditional PCs, while offering powerful features, this offering "has been described as a ïboom-box PC' that fits into a home in much the same way a portable stereo does," says Jim Couch, vice president of design, Fitch. The appliance's dimensions are 15.1-in. x 19-in. x 9.1-in., and it weighs a scant 26 lbs.

Space savings were "achieved by adopting a transverse-mounted engine meta-phor," says Couch. "By mounting the LCD screen, in essence, to the side of a mini-tower, a large surface is created for the speakers. The speakers back the flat-panel display, resulting in a look that is reminiscent of a framed picture."

"When it comes to computers, it's hard to design something new," says judge Carl Garant. "But this product succeeds in doing that with many innovations."

Key project players from Compaq:
Steve Goodrich, director, Consumer Product Division; Bill Dorr (formerly of Compaq); Kevin Mundt, manager, industrial design; Linda Middendorf, mechanical R&D designer; Don Ross, tool engineer; Kevin Frost, manager, product marketing, Mobile Products, Compaq Consumer Group; Greg Nemo, product marketing director, Mobile Products, Compaq Consumer Group. From Fitch: Markie Davidson, research associate; Elizabeth Nutter, senior research associate (formerly of Fitch); Jim Couch, senior industrial designer and project manager, vice president; Keith Kresge, industrial designer, vice president; John Guerra, industrial designer, senior associate; Bob Hayes, senior engineer, vice president; Chris Cicenas, engineer, director; Eric Navin, engineer, associate; Josh Broehl, engineer, associate; Matt Paprocki, engineer.

HVAC:
Comfort Control

Personal Environments by Johnson Controls, Milwaukee, and its design firm, Fitch, Boston.
Today's workplaces consist of more modular offices and cubicles inhabited by employees wishing to control their environmental conditions. Often, this is simply a wish, as most building systems aren't designed to meet the needs of every individual.

This was the design challenge that drove development of the Personal Environments System (PES), which allows individuals to adjust air flow, radiant heat, background noise and lighting.

The system consists of five components: the electronics/fan unit mounted underneath the desk to save space, an optional radiant heat panel, task lighting, vents and a control unit.

Only two vents and the control unit are actually visible on the surface of the desk. (The control unit also can be wall-mounted.) The diffuser vents can be horizontally and vertically adjusted to create the desired airflow. If air conditioning/heat is available from a floor, wall or plenum, a mixing capability can be used to provide individual control. Energy usage is minimized by means of an occupancy sensor which shuts down the system when the the cubicle is unoccupied.

The system is designed for "tool-free" snap-together installation. Parts consolidation was also important in that fewer fasteners and components help achieve air containment and vibration reduction. All this had to be achieved, says Fitch's Doug Cooke, group leader, while meeting "the ultimate challenge of creating a PES that would, from an installation perspective, be compatible with nearly any office-furniture system."

Key project players from Johnson Controls:
Dennis Miller, program manager of Personal Environments, Keith Lengling and Herb Mueller, engineers. From Fitch: Richard Watson, senior industrial designer and project manager, vice president; Doug Cooke, industrial designer, director; Sven Adolph, industrial designer, senior associate; John Devanney, industrial designer, associate; Terry Jones, senior engineer, vice president; Ricardo Fernandez, engineer, director; Anthony Giordano, engineer, director; Ken Shown, engineer, senior associate.

Key suppliers:
Columbus Industries (sheet-metal enclosures)
EBM (fan impeller)
PMC (injection-molded plastic parts)
Scandia Plastics (blow-molded plastic parts)
Tuscarora (EPP foam enclosures)

Lawn & Garden/Outdoor:
Mosquito eater

Dragonfly by Biosensory Insect Control, Groton, Conn., and its design firm, Group Four Design, Avon, Conn.
This "mosquito-eating" device simulates natural factors that attract mosquitos to their victims--body heat, carbon dioxide and small amounts of octenol on the breath.

The device combines a thermal lure for regulating heat, with precisely released amounts of carbon dioxide and octenol (simulating animal respiration), all of which are contained in a molded housing. The housing incorporates a silent electronic killing grid and a catch basin to collect dead insects (the device also kills biting flies--sand flies, biting midges, etc.). "Aesthetics were driven by two factors," says Robert Bruno, director of product design, Group Four. "First, since a mosquito doesn't fly directly towards its target, but circles around it, we found a grid of four walls perpendicular to the lure preferable, and arranged it in a clover-leaf pattern to be most effective. Second, the aesthetics reflect the product's advanced technology while blending with its natural outdoor environment."

Judges were especially impressed by the uniqueness of the product. "The introduction of an effective technology to target and eliminate potentially disease-carrying insects has significant benefits, including reduction of chemical pesticide usage," says judge Marilyn Johnson.

"It's clear that the scientific analysis of the biting behavior of insects led to a design that addresses the needs of the user while functioning effectively."

Key project players from Biosensory Insect Control:
James Nolen, president. From Group Four Design:
Robert H. Bruno, director of product design; Paul Metaxatos, senior designer; David Mathieu, senior engineer.

Key suppliers:
Bedoukian Research (octenol lure)
BioLogic (EPA registration)
Electro-Flex Heat (thermal lure)
Inflation Systems (valve)
KIP (solenoid valve)
Koster Keunen (waxes)
Mersey Mold and Model (plastic components)
PSI Plus (CO2 cylinder)
Scenturion (biological attractant packaging)
Waterbury Companies (plastic components, assembly)

Medical:
Treating impotence

ErecAidÐ System Esteem(TM) by Osbon Medical Systems, Augusta, Ga., and its design firm, Inno, Atlanta.
One in three men over the age of 60 suffer from impotence, yet only 6 percent are treated. Vacuum constriction devices (VCDs) are the most successful method for dealing with the issue, with a reported 98 percent success rate. To use a VCD, a tension ring is loaded onto the cylinder using the ringloader. The unit is assembled by pushing the cylinder onto the pump. The user places his penis inside the cylinder and applies the vacuum by pressing a button (battery-operated models) or by pumping (manual models). Blood is drawn into the penis, making it erect. The tension ring is slid off onto the base of the penis, maintaining the erection.

While successful, VCDs can be difficult to use, painful, loud, difficult to clean, and "geriatric" in appearance. These factors were successfully addressed during the design and development of the Esteem.

"The client (Osbon) wanted a unit that would fit seamlessly into a couple's life," says Steven Gamper, program leader, Inno. "The appearance was as critical as the ergonomics. The appearance needed to eliminate the stigma of being a product for the elderly, and it needed to be nonin-timidating. The greatest design challenge was to design a pump system that exceeded the performance of current VCDs, while reducing cost and size of the unit."

By mounting the pump and motor directly off the cylinder, tubing and seals found on most units could be eliminated, allowing for easier set-up and use. User comfort was also addressed by flipping the axis of the pumping action away from the base of the penis. Sleek, integrated housings simplify the product's appearance as well as operation. And the silver and black color scheme gives the product a masculine feel.

Key project players from Osbon: John Mitchell, manager of product engineering and development; Paul Peterson, president; Jack Pahl, vice president of new business development; Jeffrey Clark, product manager; J. Neil Osbon, manufacturing coordinator. From Inno: Steven Gamper, program leader; Steven Flynn, mechanical designer; Scott Rowley, industrial designer; Devin Moore, industrial designer; Maureen Carroll, industrial designer; John McMillian, mechanical designer; Amy Ryan, mechancial designer.

Key suppliers:
ASF (vacuum pump)
Cadmold Group (tooling)
Clairson Industries (molding and tooling)
Mack Molding (assembly)

Majors:
Ventless washer/dryer combo

Equator Clothes Processor Model EZ 3600 marketed and distributed by Equator, Houston, and manufactured by Philco Italia, Bergamo, Italy.
The purpose of this project was to develop a front-loading combination washer-dryer that eliminates the need to vent hot dryer exhaust air, making it suitable for apartments without dryer vents, or for built-in applications.

The horizontal-axis offering features a choice of 500 or 1,000 rpm spin during the normal wash cycle. During the final wash spin, the automatic preheat function begins, followed by the automatic drying cycle, which eliminates the need for a dryer-vent hose. Instead, the drying cycle uses a condenser dryer. With this feature, the hot air used to dry the laundry is cycled into a drum, where it passes through a mist of cold water. The cold water causes the hot air to cool and condense. This water, along with the condensed moisture from the hot air, is then pumped from the machine via the water outlet. Lint particles in the dryer exhaust collect in the cooling water and are filtered through the drain screen as the water is pumped from the machine.

Design elements such as a contoured control panel, easily accessible soap dispenser, simple graphics, and a large opening for easy loading/unloading, contribute to the functionality and aesthetics of the unit.

"The product's control panel is very simple and well thought-out," says judge Carl Garant. "And the product itself fills a real need in today's marketplace."

Key project players from Equator: Atul Vir, president. From Philco Italia: Sante Casamenti, project manager; Ernesto Rebolini, chief engineer.

Key suppliers:
Eaton Controls (timers)
GRE (pump)
Kema Keur (thermostat)
Remco (control board)
Sole (main motor)

Power Tools:
Gripping design

D-Series Pistol Grip Assembly Tools by Ingersoll-Rand Co., Flemington, N.J., and its industrial design firm, Group Four Design, Avon, Conn.
This entry showcases distinctive elliptical shapes that reflect extensive ergonomic research conducted with assembly-tool users.

The curves and soft textures enhance the user's ability to hold the tool in a variety of hand positions required of a tool used in tight spaces. The curved handle is designed to fit 95th percentile male to 25th percentile female. The multifinger, soft-touch TPE (thermoplastic elastomer) is designed to reduce operator stress. The one-finger forward/ reverse switch allows single-finger, right- or left-handed operation. And the shape and position of the light ring allow for visual feedback regardless of the tool's position.

Key project players from Ingersoll-Rand: John McCallopps, project engineer and group leader; Don Warner, senior designer; John Linehan; Joe McDermott. From Group Four Design: Robert Bruno, director of product design; Paul Metaxatos, senior designer; David Mathieu, senior engineer; Bill Sterline, director of graphic design.

Key suppliers:Alliance Precision Plastics
Amphenol
ETC
Ledtronics
Mold-Pro Technologies
Olflex Cable
Rochester Gear
Sensortronics
W.L. Gore Associates

Test, Measurement, Inspection:
Precision handling

Computrac 3000 by Arizona Instrument, Phoenix, and its design firm, Designology, Scottsdale, Ariz.
The purpose of this project was to develop an advanced moisture analyzer simple enough for anyone to use while maintaining consistent lab-grade results.

The system incorporates a noninvasive sensing technology, eliminating the need for wet chemistry, glassware, hazardous materials and trained technicians. Analysis consists of simply loading a reusable test vial onto transport rails. Upon insertion, a test probe pierces a membrane within the vial cap, linking material to internal-sensing modules. The entire process is directed via step-by-step on-screen menu prompts.

The user-friendly design features a minimal number of large easy-to-understand controls, soft corners, and housing split-lines and details, designed for easy cleaning.

Key project players from Arizona: Carolyn Gardner, program manager; Steve Fahrner, manager, mechanical engineering; Walfred Raisanen, president. From Designology: Roy Fischer, president; Randall Toltzman, vice president.

Key suppliers:
Blackhawk Metal Products (sheet-metal housing)
CMS (printed circuit boards)
Singletree Machine (machined internal components)

Runners-Up

Lawn & Garden/Outdoor
Product: Troy-Bilt Tiller/Edger
OEM: Garden Way
Design firm: Fitch
Key project players from Garden Way: Jim Bold, senior product engineer; Mark Hebert, product manager (formerly with Garden Way); Will Martinez, product engineer (formaerly with Garden Way); Kevin Connelly, director, product management/market research. From Fitch: David Gresham, senior industrial designer and program manager, vice president; Marty Gage, human factors specialist, vice president; Bob Mervar, industrial designer (formerly with Fitch); Chris Cicenas, project engineer, director.

Key suppliers:
GE Plastics (Xenoy resin for plastic parts)
Tecumseh (engine)

Small Electrics
Product: Snakelight Outdoor Lantern Model CL1 & CL2
OEM: Black & Decker Household Products Group
Design firm: Altitude Product Design and Development
Key project players from Black & Decker: Brooks Rorke, senior industrial designer; Steve Mowers, project engineer; Peter Kemp, product manager. From Altitude Product Development: Alan D. Ball, principal; Thomas Swyst, project designer.

Key suppliers:
Advanced Elastomer Systems (Santoprene thermoplastic elastomer)
Bayer, Polymers Division (ABS resin)
Lockwood Products (flexible core sections)
Torx Products (tamper-resistant fasteners)

Power Tools
Product: SnakeLight Electric Work Light
OEM: Black & Decker Household Products Group
Design firm: Anderson Design Associates
Key project players from Black & Decker: Rich Carbone, senior industrial designer; Rick Farrington, senior designer. From Anderson Design Associates: David Kaiser, principal; Pat Nolan and Glen Nielsen, industrial designers.

Key suppliers:
Chicago Miniature Lamp (bulb)
Hatch Transformers (electric transormer)
Lockwood Products (flexible core sections)
OEM Miller (core sleeve)
Victor (cordset)

Majors
Product: SMT 36 Cooktop
OEM: Caldera
Key project players from Caldera: Suzanne Shute, president; Allen Olsen, chief design technician; Alan Shute, CEO; Ralph Biddle, chief design engineer.

Key suppliers:
Applied Wiring (wiring harness)
Ceramaspeed (heating elements)
EuroKera North America (ceramic glass)
The Graphics Guy (design consultant for control panel)
Pressenk Instruments (touch-control technology)
U.S. Toyo Fan (control fan)

Medical
Product: Dinamp Select Patient Monitor
OEM: Johnson & Johnson Medical
Design firm: Hauser
Key project players from Johnson & Johnson: Richard Bloom, director, product development; Gerald Maass, director of marketing; Jacqueline Benz, product director; Michael Duich, project leader; Jim Lattimore, lead engineer; Rush Hood, lead engineer; Brent Benoist, Len Ducharme, Darryl Parmet, Judy Clifford, Mike Steedle and Alex Winkler, engineers; Brian Pate, lead software engineer; Kathy Smith and Bob Wallce, software engineers; Glenn Bartolotti, product graphics. From Hauser: Ernesto Quinteros, industrial designer; Ed Cruz, program manager; David Hoard, user interface design; Andrew Hooper, product graphics; John Hoppe, prototyping; Matias Ocana,prototyping.

Key suppliers:
Chicago White Metals (aluminum castings/enclosures)
Clairson Industries (injection-molded components)
Jabil Circuit (circuit-board and finished-product assembly)
Planar America (electroluminescent display)
Printed Circuit (printed circuit boards)

Test, Measurement, Inspection
Product: Hamilton SoftGrip Pipettes
OEM: Hamilton
Design firm: Lunar Design
Key project players from Hamilton: Bob Scalese, director of research and development; Victor Strandberg, engineering project leader; Steve Ijams, mechanical engineer; Phil Prenholme, mechanical engineer; Randy Hall, mechanical engineer. From Lunar Design: Jeff Smith, president and project manaager; Dave Laituri, senior industrial designer; Kyle Swen, industrial designer; Jeff Hoefer, CAD sculptor; John Edson, senior product designer

Key supplier:
Alchemy (3D CAD contractor)

Computers/Electronics
Product: Shark 40S Home/Office Shredder
OEM: GBC - General Binding Corp.
Design firm: Herbst LaZar Bell
Key project players from GBC: Todd Henreckson, director, Shredder Division; Tim Bohn, marketing manager. Key project playes from Herbst LaZar Bell: Mark Dziersk, designer; Gary Prokop and Jos® Perez, design team members.