Shattering Design Paradigms

From a dental system that combines two previously separate systems, to a sleek rotomolded commercial floor scrubber to a horizontal-axis washer with the North-American consumer in mind, to the “world’s first fully integrated print and mail finishing system,” this year’s Excellence in Design winners showcase some impressive efforts by appliance OEMs and their design firms to rethink the traditional, to break the mold, to boldly go where no design has gone before . . .

O.K. You get the point. And so did our judges, a three-person panel of industrial-design experts, who evaluated the 121 entries according to these criteria: 1) aesthetics 2) ergonomics/human factors 3) innovative features. Overall, this year’s panel was impressed with the uniqueness (features, technology, etc.), as well as overall styling of the winning entries. 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 Runners-Up this year. Judges also had the option of not choosing a Winner and/or Runner-Up in a specific category. This happened in HVAC and Portable Power Tools, which have strong Winners, but no Runners-Up.

Best Overall
Medical

Cavitron SPS Scaler, DualSelect Dispenser by Dentsply International, York, Pa. and its industrial firm, ECCO Design, New York, N.Y., and its mechanical design firm, Goggin Research, Wilmington, N.C.
The objective of this project was two-fold:

• Redefine the image of the company’s scalers, making them less intimidating and more attractive.
  
• Develop ground-breaking product in the form of the DualSelect Dispenser, which delivers medicated solutions to an ultrasonic scaler.

Previously, scalers could only deliver line-water during dental procedures, making it necessary for dentists to jerry-rig tubes and containers.

Together, the scaler and dispenser, with their soft colors and rounded forms, succeed in eliminating the harsh, clinical feel inherent in the appearance of many medical systems. Yet, the design is both professional in appearance and simple to use. Large knob controls are easy to grip and turn, and there’s nothing complicated about the low, medium, high settings. To help conserve counter space, the dispenser is designed to sit on top of the scaler. And to ensure that the dispenser is fool-proof, a safety interlock allows pressure to build-up only when the shield is closed. Any accidental spill or pressurized release is contained behind the shield.

“Its ‘look’ is appropriate for its environment,” says Judge Chris Gilbert. “It has character, yet it does not command attention. Its simple controls and organization makes for a nonintimidating design.”

Key project players from ECCO Design: Eric Chan, principal; Jeff Miller, senior designer.

From Dentsply International: Jim Mosch, vice president of product development; Allen Hoube, director of research and development; Tom Leonardi, director of marketing.

Commercial

Phoenix Automatic Floor Scrubber by Breuer Tornado, Chicago, and its design firm, Herbst LaZar Bell, Chicago.
This project represents a major rethinking of automatic floor scrubbers in terms of subsystems and the unit’s overall look. Two separate rotomolded housings provided a logical means for addressing the solution and recovery tanks. The hollow housings made it possible to incorporate the tanks in the housings. Electronics were integrated into a single digital controller. A sloped front end and domed side section allow the operator greater visibility, while vertical ribs on the bumpers minimize damage to the body in key collision areas such as the front. All in all, the unit is reminiscent of today’s sports utility vehicles—a dramatic departure for what was previously a visually mundane product.

All this plus other design details, such as a molded-in cup holder for operator convenience did not go unnoticed by the judges.

“The entire form has very functional underpinnings, while ergonomic features such as the drink holder are important to good design,” says Judge Carl Garant.

Key project players from Herbst LaZar Bell:
David Pacchini, project manager; Josh Goldfarb, staff industrial designer; Mark Dziersk, design team member. From Breuer Tornado: Linda Breuer, president and CEO.

Key suppliers:
Cherry Electrical Products (switches)

Pawnee Rotational Molding (rotomold)

Viking Pattern (tooling)

Warner Electric (actuator)

Computers/Electronics

DocuMatch Integrated Mail System, Pitney Bowes, Shelton, Conn.
Positioned as the “world’s first fully integrated print and mail finishing system,” this product takes an original from a PC and, without user intervention, prints a personalized letter, collates additional preprinted cut sheets, folds them, adds a reply piece, inserts those materials into an envelope, ink-jet prints the address and seals the envelope. Yet, as complex as the system is, its “copier-like” appearance is deliberately simple, so as not to intimidate.

Forms were driven by what was required by the mechanical architecture. Take for example the heart of the printing mechanism, the laser printer. Since its life is limited (about two years), the decision was made to conceal the printer to ensure a visually integrated design, regardless of how many times the printer would need to be replaced during the life of the system. The control panel is designed in a way that suggests to the user how to approach the machine. That is, the apex of the curve centers the user in front of the machine.

Other design choices solved usability and reliability issues. Mechanisms for clearing jams are easily accessible using pull-out drawers. Cues on the lighted interface inform users where the jam has occurred. The system regenerates damaged pieces, virtually assuring a match between enclosures and envelopes. It also leaves one piece per batch unsealed for checking purposes.

“The simple design, logical workflow and attention to detail inside and out make this an eye-pleasing design, while the pull-out internal drawers and component placement help simplify the use of the product,” says Judge Chris Gilbert.

Key project players from Pitney Bowes:
Paul Porter, director, industrial design; David Beckstrom, manager, industrial design; Doug Long, senior industrial designer; Charlie Klein, senior industrial designer; Fran Blackman, manager, human factors and design; Julie DiVerniero, graphic designer.

Key suppliers:
Bennett Mfg. (sheet metal components)

Mach Mold and Die (injection molds)

Mack Molding (injection molding, gas-assist injection molding; structural foam)

Modern Plastics (blow-molded ABS)

Winner HVAC

Cyclone XHE Extra High Efficiency Water Heater by A.O. Smith, McBee, S.C., and its design firm, BOLT, Charlotte, N.C.
This water heater includes an advanced method of heating water using a helical heating element which allows for the placement of burners and controls at the top of the tank, which are surrounded by a bright yellow ribbed cover with curved top, designed to communicate the product’s advanced technology. Aesthetics aside, the pressure-formed plastic cover was designed to fit around complex components, and for easy removal and replacement

“The design breaks away from the traditional image of water heaters. The use of color focuses the user’s eye on the interface area,” says Judge Carl Garant. “The control panel height and service accessibility are well thought out.”

Key project players from Bolt:
Edgar B. Montague, design principal; Christopher F. Yonge, industrial designer; Robin C. Smith, mechanical engineer. From A.O. Smith: Peter J. Phillip, (formerly) manager, product design; Ralph Perez, (formerly) general product manager; Darryl Ruark, senior project engineer.

Key suppliers Control Design Supply (power switch distributor)

Deltec Plastics (plastic covers)

Revcor (blowers)

Southwest Tape and Label (control graphics and logo graphics)

Tridelta (PCBs)

Lawn & Garden/Outdoor

GrillMaster Series Gas Grills by Sunbeam Outdoor Products, Neosho, Mo., and its industrial design firm, Design Continuum, W. Newton, Mass.
Featuring a shapely hood reminiscent of the homemade “oil drum” barbecues of yesteryear, these grills incorporate a significant number of cooking innovations in a stylish package. Among the innovations: multiple temperature controls so the user can cook steaks rare and well-done at the same time and stainless steel burners with “porcelainized tents” that create even heat distribution.

Offered in stainless steel, as well as black, hunter green, garnet red and cobalt blue, the grills successfully incorporate advanced features in a contemporary, yet retro kind of way.

“The product is a nice combination of high-tech features and user-friendly design,” said Judge Bill Cesaroni. “The uniform work surface height, tool storage, cup holder and oversized lid handle are pluses. The functional and aesthetic use of materials, such as the bowed stainless steel access doors (for fuel-tank storage) blend together well.”

Key project players from Design Continuum:
Mark Bates, principal industrial designer; Paul Gregory, senior mechanical engineer; Greg Hunter, principal mechanical engineer; Pat McDermott, senior mechanical engineer; Luis Pedraza, principal industrial designer; Kevin Young, senior industrial designer. From Sunbeam Outdoor Products: Danene Jaffe, vice president, marketing, outdoor cooking; Augie Picozza, manager, corporate product development; Henry Schubert, design engineer; Cynthia Vahlkamp, general manager; Ben Williams, project engineer.

Key suppliers:
Bulk Molding Compounds (thermoset components)

Morton International Powder Coatings (high-heat paint)

Pace Industries (castings)

R.W.C. (automated welding machinery)

Semco Plastics (injection molded plastics)

Majors

Neptune Washer/Dryer System by Maytag Appliances, Newton, Iowa.
The most significant design challenge surrounding this product was overcoming the disadvantages of European-designed front-load washers: small openings, awkward access, limited visual access and small capacity.

Several design solutions addressed these challenges. An extra-wide, 17-in. door opening was elevated to the highest possible point on the front of the washer, 18-in. from the floor at the bottom, and 33-in. from the floor at the top of the opening. The top-front edge of the washer was flattened into an angled section that opens with the door, reducing the possible bumping of shoulders or arms on the upper part of the opening. And the inner, stainless steel tub was tilted up 15 degrees for easy loading.

The judges were impressed with the angled front access, large door opening and increased capacity, but were quick to add that they felt the control panel was rather ordinary for the advanced nature of the product.

Key project players from Maytag: Curran Cotton, vice-president, research and development; Bill Swartz, director, industrial design; Steve Joerger, director, new product development; Don Erickson, manager, h-axis washer design; Frank Nekic, director, laundry product planning; Chris Millet, manager, continuous improvement design; Scott Merkle, manager, stacked and international design; Gary Jackovin, project industrial designer; Steve Bookout, general supervisor, h-axis assembly; Larry Steffen, manager, h-axis assembly; Mike Johnson, supervisor model shop.

Key suppliers: AMP (piezoelectric accelerometer)

Ark-les (switches)

Cherry Switch (tub-mounted accelerometer)

Clorox (bleach testing)

DAC (machine controller)

Dayco (polyvl belt)

Electric Power Research Institute (financial contribution and utility expertise)

Emerson (switched-reluctance motor)

Ferro (outer tub)

Hoechst Celanese (drive pulley)

Inland Steel (steel forming)

Mallory (timer)

Medibeg (door-boot seal)

Northern Engraving (fascia and medallion)

Pella Plastics (console)

Plastic Products (inner door and dispenser)

Procter & Gamble (detergent development)

Personal Care/Portable Appliances

Flexible Shower Massage by Teledyne Water Pik, Ft. Collins, Colo., and its design firm, Machineart Industrial Design, Hoboken, N.J.
The primary challenges of this project were to design a shower head that children can reach and adjust easily, but is still convenient for adults to use, and to design a flexible arm that holds its position while withstanding high-water pressure. It had to be stiff enough to hold a bend while being loose enough to be easily manipulated.

The effort resulted in a flex arm designed like a spine—a series of molded acetal copolymer ball and socket joints that are coupled end to end. A 0.5-in. diameter hose runs through the center of the spine.

The product also received high marks from the judges for its large and simple-to-identify, shower-setting icons.

Key project players from Machineart Industrial Design:
Mirzat Ko¿senior designer; Andrew Serbinski, principal. From Teledyne Water Pik: Milton Hollinshead, engineer; Robert Male, product engineer.

Key suppliers:
Dow Plastics (Isoplast nut)

GE Plastics (Xenoy control ring and spray cup)

Hi-Tech Hose (flexible hose cover)

Hoechst Celanese (acetal copolymer spinal beads)

Kottman GmbH (internal hose)

Lockwood Products (molders of spinal lock beads)

Portable Power Tools

Woodhawk 6-1/2-in. Circular Saw by Black & Decker, Towson, Md.
The No. 1 challenge for this project was to arrive at a design that reduces the intimidation factor felt by unskilled do-it-yourselfers when it comes to using a circular saw.

To help make the new offering more approachable, designers challenged the 7Þ-in. standard, opting for a 6Þ-in. blade capable of bevel-cutting common “2x” lumber to 45 degrees. The smaller blade provides a quieter (half the noise level of 7Þ-in. saws), lighter (by about 2 lbs.), low-profile design. For confidence and safety, the handle orientation provides novices with sure-grip handles for both hands. The Sightline™ window provides clear blade visibility with virtually no static build-up of dust, allowing better body posture in use.

“This is a safe look for what can be a dangerous product,” says Judge Bill Cesaroni.

Key project players from Black & Decker:
Chuck Frohlich, program manager; Lynn Lentino, engineering manager; Scott Price, manager, industrial design; Rand Ruland, marketing director.

Key suppliers:
Eaton (switch)

Gemtron (Sightline window)

Innovations & Development (preliminary design concepts)

Technimark (gas-assist handle)

Trebor (alignment guide)

Test, Measurement, Inspection

LEM~flex Flexible AC Current Probe by LEM DynAmp, Grove City, Ohio, and its design firm, Herbst LaZar Bell, Chicago.
This design allows users, primarily electricians and maintenance personnel, to comfortably measure AC currents in areas previously inaccessible to conventional current transformer products. Applications range from electrical panels in conditioned spaces to dirty industrial areas and outdoor equipment. Once in place, the ends of the measuring head simply snap together enabling most test and measurement instruments to make current measurements. A flexible measuring head allows the product to be easily threaded around most conductors without having to interrupt the circuit.

The measuring technology eliminates the physical limitations of “hard-cored” current transformers as well as much of the weight. The device connects to standard test equipment and instrumentation and oscilloscopes. The integrator includes a large loop at each end that assists the user when storing the product. The coil can be snapped through the loops—into the integrator for easy storage and transportation. The product’s form is intended to rest comfortably in the user’s hand.

Molded-in connectors reduced parts count and the shell-design housing helped improve automated assembly, resulting in an overall manufacturing-cost reduction of 50 percent.

Key project players from Herbst LaZar Bell:
Jon Lindholm, senior industrial designer/project manager; Christine Gilbert, industrial designer; Aaron Eiger, design engineer. From LEM DynAmp: David Shepard, tactical marketing manager.

Key suppliers:
MK Enterprises (tooling)

Compression Engineering (moldings)

Runners-Up

Commercial
Product: M-Smart Transit Vehicle Terminal
OEM: Motorola
Design firm: Herbst LaZar Bell (HLB)
Key project players from HLB: Bill Lee, account manager; Greg Holderfield, senior industrial designer/ project manager; Matt Potter, mechanical engineer.
From Motorola: Arnold Crater, product manager, Bradford Butts, lead mechanical engineer.

Lawn & Garden/Outdoor Appliances
Product: 5xi Series Garden Tractor
OEM: Toro
Design firm: Inhouse
Key project players from Toro: Darrell Hinklin, industrial designer; Danae Rem, graphic designer; Don White, project engineer; Nathan Friberg, designer.

Key suppliers: Ataco Steel Products (sheet-metal body parts)
Engineered Polymers (grill and dash panel)
Kelch Wheels (steering wheel)
Michigan Seat (seats)

Computers/Electronics
Product: Digital Home Theater
OEM: Projectavision
Design firm: Montalbano Development.
Key project players from Montalbano Development: Greg Montalbano and Chris Montalbano, principals; Aaron Klein, senior designer.
From Projectavision: Monica Dettling, director of engineering; Eric Fleisher, manager of engineering

Key suppliers: AMP (docking connector)
C-Mac (printed circuit boards)
GE Plastics (plastics)
LDM (injection molded components)
Texas Instruments (DLP light engine)

Computers/Electronics
Product: PC Systems and Peripherals
OEM: IBM
Design firm: Inhouse.
Key project players from IBM: David Hill, personal systems group design manager; Richard Sapper, corporate design consultant; Aaron Cox, industrial designer; Toshiyuki Imai, industrial designer; Joseph Jasinski, industrial designer; Pauline Lamont-Fisher, IBM Greenock Design Center Manager; Nariaki Mieke, industrial designer; Susan Moffatt, brand design manager, commercial desktop; Markus Oates, industrial designer; Hisashi Shima, industrial designer; Ron Smith, IBM strategic design; Robert Steinbugler, manager, IBM strategic design; John Swansey, brand design manager, Aptiva; Tomoyuki Takahashi, industrial designer; Robert Tennant, industrial designer; Julie Tierney, industrial designer; Kazuhiko Yamazaki, designer/manager, IBM Yamato Design Center.

Test, Measurement, Inspection
Product: 70 Series III Digital Multimeters
OEM: Fluke
Design firm: Stratos Product Development.
Key project player from Fluke: Joseph Ferrante, industrial designer.
From Stratos Product Development: Mike Nelson, design director.

Key suppliers:
Autoroll Machine (pad transfer equipment)
Conductive Rubber Technology (keypads)
Dow(Plastics)
GE Plastics(Plastics)
Philips Plastics (multishot tools and molding)
RTP(Plastics compounder)
VL Electronics (LCDs)

Medical
Product: Epic System Console
OEM: Coherent Medical
Design firm: Bridge Design.
Key project players from Bridge Design: Bill Evans, president; Carl Bettag, principal, product development; Ricardo Salinas, principal, industrial design; Chris Gadway, industrial designer; Terence Arjo, industrial designer.
From Coherent Medical: Tom Brunner, vice president, opthalmology; Dave Dewey, staff optical systems engineer; Jerzy Orkiszewski, principal, product development; Kevin Miller, mechanical designer.

Key suppliers: Armstrong
Technologies
Cercor
Plynetics

Personal Care/Portable Appliances
Product: Expresso Mio, Microwave Espresso Maker
OEM: Black & Decker Household Products Group
Design firm: Inhouse
Key project players from Black & Decker: Patrick Nolan, senior industrial designer; Stuart Naft, manager of industrial design.

Key suppliers: Advanced Elastomer Systems (Santoprene thermoplastic elastomer)
Concept Molds (tooling)
Filter Tech (filter)
GE Plastics(Noryl plastic)
Prospect Machine (metal basket)

Majors
Product: Rangemaster by Broan Mirage Range Hood
OEM: Manufactured by Best s.p.a. Fabriano, Italy, for Broan Mfg., Hartford, Wisc.
Key project player from Broan Mfg.: Dave Voelz, project engineer.
From Best: Aldo Frati, marketing manager; Sandro Prischich, technical director.

Key supplier:
Curvet (glass)
Elektromec (blowers, motors and controls)
Metaltecnica (plates manufacturing)
Scatolificio Sonia (packaging)
Tad Metals (plates)

CATEGORY: Commercial
PRODUCT: Automatic Floor Scrubber
OEM: Phoenix
DESIGN FIRM: Herbst LaZar Bell

CATEGORY: Computers / Electronics
PRODUCT: DocuMatch Integrated Mail System
OEM: Pitney Bowes
DESIGN FIRM: In-house.

CATEGORY: HVAC (Heating, Ventilating, Air-Conditioning)
PRODUCT: Cyclone XHE - Extra High Efficiency Water Heater
OEM: A.O. Smith
DESIGN FIRM: Bolt (Charlotte, N.C.)

CATEGORY: Lawn & Garden / Outdoor
PRODUCT: GrillMaster Series Gas Grills
OEM: Sunbeam
DESIGN FIRM: Design Continuum

CATEGORY: Majors
PRODUCT: Neptune Washer/Dryer System
OEM: Maytag
DESIGN FIRM: In-house.

CATEGORY: Medical & BEST OVERALL
PRODUCT: SPS Scaler and DualSelect Dispenser
OEM: Dentsply Cavitron
DESIGN FIRM: ECCO Design

CATEGORY: Portable Appliances / Personal Care
PRODUCT: Flexible Shower Massage
OEM: Teledyne Water Pik
DESIGN FIRM: Machineart Industrial Design

CATEGORY: Portable Power Tools
PRODUCT: WoodHawk 6¿’ Circular Saw
OEM: Black & Decker
DESIGN FIRM: Innovations & Development

CATEGORY: Test, Measurement & Inspection
PRODUCT: flex II Flexible AC Current Probe
OEM: LEM
DESIGN FIRM: Herbst LaZar Bell

Eleventh Annual Excellence in Design Runners-Up

CATEGORY: Commercial
PRODUCT: M-Smart Transit Vehicle
OEM: Motorola
DESIGN FIRM: Herbst LaZar Bell

CATEGORY: Computers/Electronics
PRODUCT: Digital Home Theater
OEM: Projectavision
DESIGN FIRM: Montalbano (Great Neck, N.Y.)

CATEGORY: Computers/Electronics
PRODUCT: Personal Computer System and Peripherals
OEM: IBM
DESIGN FIRM: In-house.

CATEGORY: HVAC
PRODUCT: No Runner-Up.

CATEGORY: Lawn & Garden/Outdoor
PRODUCT: 5xi Series Garden Tractor
OEM: The Toro Company
DESIGN FIRM: In-house.

CATEGORY: Majors
PRODUCT: Mirage Range Hood
OEM: Manufactured by Best s.p.a., Fabriano Italy for Broan Mfg., Hartford, Wis.
DESIGN FIRM: In-house

CATEGORY: Medical
PRODUCT: Epic (opthalmic) System Console
OEM: Coherent
DESIGN FIRM: Bridge Design, San Francisco

CATEGORY: Portable Appliances / Personal Care
PRODUCT: Espresso Mio
OEM: Black & Decker (U.S.) Household Products Group
DESIGN FIRM: In-house.

CATEGORY: Portable Power Tools
PRODUCT: No Runner-Up

CATEGORY: Test, Measurement, Inspection Equipment
PRODUCT: 70 Series III Digital Multimeters
OEM: Fluke
DESIGN FIRM: In-house.