PORTLAND STATE UNIVERSITY
Product Design
Specification
Yakima T.O.C. Load Assist
Group Members:
Haidar Al Gharash
Michael Dixon
Ben Gheliuc
Daniel Gheliuc
Fue Her
Zach McCurter
P.S.U. Advisor:
Evan A. Thomas, Ph.D., P.E.
1/30/2012
Table of Contents
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 ............................................................................................................................. 4
................................................................................... 5
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
Yakima is a company that designs and sells rack systems. One product they have not
brought to production is a system that will assist a person to load kayaks on top of a vehicle.
Yakima had previously designed a system but the estimated market price for the system was too
much, so they wanted to design a new system that would be efficient yet affordable. This is
where they made the load assist system into a capstone project for the Portland State University
students.
Yakima’s previous attempt at a load assist system had an estimated retail price of $2000,
which was too expensive for the market. The system can hold up to 100 pounds of load capacity
of boats, bikes, or cargo boxes. All the loading are done by the side of the car as seen in the
picture below.
There are many design aspects that are need to be considered for designing the system
which include: weight limit, ergonomics, safety, and the market price after completion.
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The purpose of this document is to clearly define the customer requirements, lay out a
project plan, set milestones, discuss risk management and create a design specification list.

The purpose of this project is to design a system that will provide load assistance for one
person to load a kayak on the roof of a vehicle. The targeted price for the system is around
$500. The final prototyping is to be finished in early June.

Task
Assign Date
Finish Date
Tasks due
Discussion of ideas and scope of project
Dec-13-11
Jan-11-12
Internal and External Research
Jan-9-12
Feb-3-12
Draft Design
Jan-23-12
Feb-29-12
PDS Report
Jan-16-12
Jan-30-12
Jan-30-12
PDS Report Presentation
Jan-30-12
Feb-13-12
Feb-13-12
Evaluation Of Drafted Design
Feb-13-12
March-5-12
Design/make Product
Feb-20-12
March-15-12
End of the Term Progress Report
Feb-27-12
March-12-12
Progress Report Presentation
Feb-27-12
Feb-27-12
Presentation design to Sponsor
March-12-12
March-14-12
Testing and Prototyping
March-14-12
April-4-12
Redesigning Concept And Prototype
March-21-12
April-18-12
Repeat Testing
April-11-12
April-25-12
Manufacture Final Product
April-25-12
May-23-12
Feb-27-12
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
The internal customers are defined as any PSU affiliate that has any input to the capstone
process. The following are people that are internally part of the capstone process.
 The Yakima PSU team
 Should demonstrate technical proficiency in the final product at the time of testing. Team
members must demonstrate equal amount of effort.
 Dr. Thomas and Dr. Etasami
 The team must show progress of project on a weekly basis to Dr. Thomas along with the
required presentations.
 PSU Machine Shop
 Machine shop shall be used on an as needed basis. Team members will machine parts
under supervision.

External customers are those who are not affiliated with PSU. The following list identifies
external customers and their input on the project.
 Yakima
 Chris Sautter (Mechanical Engineer); Mark Elliott (Design Engineer - Team Lead)

Load assist must pass all Yakima Performance and Test Standards.

Holds at least one kayak.

Minimum number of steps to use.

No rattling when loaded or unloaded

Reliable

Minimize Weight of load assist.

Visual and/or audible confirmation that load assist is secured.
 Yakima Legal Department

Must clear existing IP (patents).

Safe to use.
 Yakima Financial Department
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
Low cost (equal to competitor in features and benefits for cost)
 End-User
 Target Persona

An average 45 year old 5’2” woman who paddles a sea kayak, rides a bike and drives
a Subaru Outback

Ergonomic design allows user to easily load boat on top of vehicle.

Mark Elliot and Chris Sautter of Yakima explained to the capstone group what the scope
and reason for this project is. Yakima had approached this project a few years prior but decided
to not release the product to the market as the price was not competitive. Mark and Chris
explained the current project along with the "must-haves" and "wants". The emphasis of this
project was on keeping the system relatively simple, to maintain a low cost, and that the intended
end user could load her kayak on her own without causing damage to her vehicle or the kayak
equipment. Feedback from Yakima thus far has helped the capstone group fine tune the
requirements, scope, and expected end results of the project.

The testing of the prototype as well as the final product will be tested in Beaverton at the
Yakima headquarters. Testing can only commence when the initial prototype is assembled.
Yakima will provide any testing material such as kayaks, cross bars and boat mounts. The load
assist must pass Yakima’s internal standards, specifically the forward pull at 4 times the rated
carrier load and the upward pull at 2500 N.
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With the complexity of this project, there are multiple risks that can cause the load assist
to fail. One of the most critical components is the preloaded mechanism. Without a configured
and working preloaded mechanism, the entire scope of the project may come to a halt or possibly
fail. The purpose of a top of car load assist is such that the user will not feel the full load of the
kayak. Failing to have a working mechanism will result in the user lifting all of the weight of the
load assist as well as the kayak that he/she is loading.
Another risk of failure in the project is clearance between the side of the car and the load
assist. Without calculating the proper clearances damage could occur to the sporting equipment
that is held, the car side and the windows. Things that must be taken into account are: the amount
of space between lowered rack assist and side of car, deflection of the load assist due to the
maximum load and clearance between the rack and the roof of the car.
One thing that must be considered heavily during the design of the final product is safety.
Recognizing potential hazards such as pinch points, user misuse and sharp edges is critical so
that no one will be harmed during operation.
The cost of the final product is an important design consideration, because if the profit
margin is too small or the market price too high, Yakima will not bring the load assist to market.
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Applicable Codes and Standards
Customer
Yakima
Requirement
Adhere to fatigue
standards: YS2015,
ISO 11154, and DIN
75-302
Adhere to
Durability/Road Loop
standard YS2014
Adhere to Pull Tests
standard: YS2015
Metric
Cycle Test
Target
100% Design
load, 30k
cycles
Basis
Standard
Definition
Verification
Testing
Durability
/Road
loop test
Pull tests
100% Design
Load
Standard
Definition
Testing
Standard
Definition
Testing
Yakima
Work Place safety
codes
Safety and legal
standards
Review of the
safety and legal
standards
Yakima
Adhere to Pull Tests
standard: ISO 11154
Number
of codes
to be
violated
Pull tests
Pass Yakima
standard pull
test (refer to
appendix)
Zero
ISO 11154
Testing
Yakima
Adhere to Pull Tests
standard: ISO 11154
Pull tests
ISO 11154
Testing
Yakima
Adhere to Pull Tests
standard: ISO 11154
Pull tests
ISO 11154
Testing
Yakima
Adhere to Pull Tests
standard: ISO 11154
Pull tests
ISO 11154
Testing
Yakima
Mount shall meet
performance
standards
NA
Pass 4x Max
load FWD and
AFT load @
CG
Pass 4x Max
load 20 degree
horizontal
force @ CG
Pass 2x max
load LAT load
@ CG
Pass 4x max
load (up) load
@ GC
Meet all
standard
criteria
ISO 11154,
YS2015, and
DIN 75-302
Standard
Definitions
Yakima
Yakima
See appendix 1 for Yakima standard tests
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Ergonomics
Customer
Yakima
Yakima
Requirement
Metric
Low loading
Lbs. of lift assist
effort
Comfortable
Handles and levers
handles or levers
Target
60 lbs.
All
Basis
Customer
Requirement
Physical testing
Verification
Measurement
Basis
Course requirements
Verification
Good Grade
Course requirements
Good Grade
Course requirements
Good Grade
Customer
verification
Documentation
Customer
PSU
Requirement
Metric
PDS Report
Completed Report
PSU
Progress
Report
Final Design
Report
PSU
Completed Report
Completed Report
Target
January 30,
2012
March 12,
2012
June, 2012
Life in Service
Customer
Yakima
Requirement
Product should have no
mechanical or structural failures
for 5 years of moderate use
Metric
Product life
cycle
Target
Theoretical
life cycle of
5 years.
Basis
Yakima
warranty
standards
Verification
Testing
Disposal
Customer
Yakima
Requirement
Metric
Use only
Plastic
recyclable
recyclability
plastics
Target
100%
recyclable
Basis
Yakima
recyclability
standard
Verification
Customer definition
and or standards
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Maintenance
Customer
Yakima
Requirement
Non-water
soluble lubricant
on moving metal
parts
Metric
Lubricant
type
Target
Use only non-water
soluble lubricant
Yakima
Plastic parts to
be cleaned with
soft cloth and
mild detergent
Plastic type
Use only plastics that
can be cleaned with
cloth and mild detergent
Basis
Chemical
composition
and lubricant
manufacturer
specs
Customer
definition
Verification
Test
Lubricant
for nonwater
solubility
Test plastic
for cleaning
Verification
Testing
Testing
Performance
Customer
Yakima
Requirement
Metric
Ease of use
Loading time
Target
Load and lock
bike or boat in less
than 5 minutes
Yakima
Low reach
distance
Distance from ground
to loading rack
36 inches from
ground to rack in
loading position
Yakima
Should be
easily fitted
to standard
rack systems
No rattling
when loaded
or unloaded
Modular design
No removal of
base rack system
Basis
Customer
definition
and physical
test
Height of
2011 Subaru
Outback(64
inches)
Customer
definition
Noise or chatter
during loading and
unloading process
No audible sound
to loader
Customer
defined
Yakima
Testing
Testing
Safety
Customer
Yakima
Yakima
Requirement
No sharp
edges/corners
No pinch points
Metric
Number of sharp
corners or edges
Number of pinch
points
Target
Zero
Zero
Basis
Customer
Requirement
Customer
Requirement
Verification
Inspection
Inspection
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Timeline
Customer
PSU
Requirement
PDS Report
Metric
Completed Report
PSU
Progress
Report
Final Design
Report
Final Product
Completed Report
PSU
Yakima
Completed Report
Target
January 30,
2012
March 12,
2012
June, 2012
Timely Completion
June 1, 2012
Basis
Course
requirements
Course
requirements
Course
requirements
Customer
Verification
Good Grade
Good Grade
Good Grade
Customer is
Satisfied
Company Constraints and Procedures
Customer
Yakima
Requirement
Keep product
inherently safe
Metric
N/A
Target
Consider pinch
points and potential
user “misuse”.
Basis
Yakima
Requirement
Verification
Inspection
Cost of production per part
Customer
Yakima
Requirement
Low retail
price
Metric
Dollars
Target
$1000
maximum
Basis
Customer
feedback
Verification
Study of price in
market
Environment
Customer
Yakima
Requirement
Operates in a harsh
wet environment
Metric
Years of Resistance to
rust and corrosion
Target
5 years
Basis
Group
decision
Verification
Study of
standards
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Manufacturing facilities
Customer
Requirement
Project team
and Yakima
Yakima provides
facilities needed
Metric
Use of
Yakima’s
Facilities
Target
No need to
use other
facilities
Basis
Verification
Customer
input
Similar
system
comparison
Basis
Verification
Shipping
Customer
Yakima
Requirement
Fit in not too large
shipping container
Metric
Target
Cubic inches
10” X 24” X
36”
Expert
opinion
Study of
standards
Materials
Customer
Requirement
Metric
Target
Basis
Verification
Yakima
Product
components
Aesthetics
Yes/no
Typical Yakima
materials
Looks sturdy &
professional
Yakima
requirement
Customer input
Inspection
Yakima
Yes/no
Inspection
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House of Quality
Requirement
Retail Price
Fatigue/corrosion
resistance
ergonomics
lift assist
Installation
Customer Importance
Engineering Criteria
end user
***
lift
capacity
*
end user
end user
end user
end user
***
**
*****
**
***
****
*****
*
Competition
cost Materials
**** ***
Size Life Cycle
**** **
Thule
***
Malone
****
**
**
***
*
*
***
*
****
****
****
***
****
**
**
**
*
****
*
**
*
****
**
***
**
Competition
Thule
75
Malone
70
35"
590 Aluminum w
35"
270 Aluminum w
120
35"
500 Aluminum w
Target
Legend: low importance *  ***** high importance
Limited lifetime
1 year
Limited Lifetime

Yakima has put the most emphasis on this project to keep it simple as can be to serve its purpose. The purpose is clearly defined
within this document including the main points of performance, safety, and cost. One of the main challenges the capstone team will
face will be in the area of providing the load assist in a simple cost effective way. Yakima has made stated that cost is important in
this project but it is not a “make or break” for them as they have lower cost sourcing options they can implement if needed.
Appendix 1
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