Appliance Design: User-Focused Designs

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COVER STORY:
User-Focused Designs

By Charmaine Jones

Posted on: 04/30/2001

Assessing user needs, from storage to maneuverability to aesthetics, is a key ingredient to good design and a theme common to this year’s Excellence in Design Winners and Runners-up. The design teams behind the award-winning entries preceded their final products with intensive market research, user testing, and manufacturability analysis. The result: an impressive line of products aimed at easing consumer lives.
A three-person panel of industrial design experts selected the winners from a total of 102 entries which were evaluated according to 1) aesthetics, 2) ergonomics/human factors, and 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, which occurred in Lawn/Garden & Outdoor Appliances with two Runners-Up. Judges also had the option of not choosing a Winner and/or Runner-Up in a specific category, which occurred in Floor Care and HVAC, which have no Runners-Up.
Coverage of this year’s Winners begins on this page. For a look at this year’s Runners-Up, see page 48. And for a profile of this year’s judges, see “Meet the Judges,” page 38.

Best Overall: Lawn/Garden & Outdoor Appliances

Spin-Steer Technology™ Lawn Tractor by John Deere, Horicon, Wis., and its industrial design firm, Henry Dreyfuss Associates, Wood Ridge, N.J.
More high school kids may be flipping burgers this summer rather than mowing lawns now that John Deere has managed to create a lawn tractor that combines convenience with unprecedented user-friendliness. The key ingredient? Spin-Steer Technology.
“Homeowners needed a more maneuverable lawn tractor—a vehicle that was as solid and user-friendly as a tractor while at the same time providing the maneuverability of a zero-turn machine,” explains Barry Goebert, advanced designer, John Deere. “The Spin-Steer Technology (SST™) lawn tractors are the first in the industry to offer zero-turning-radius maneuverability and a steering wheel to provide the traditional look and feel of a lawn tractor.”
Although traditional zero-turning-radius (ZTR) vehicles are propelled using two separate hydraulic wheel motor systems, one for each side of the vehicle, they operate independently and can be difficult to manage.
“The solution was a differential steering transmission that incorporates a propel transmission and a steering transmission in the same case,” Goebert adds. “The two transmissions work in unison to allow the rear wheels to rotate at different speeds and to counter-rotate, allowing this vehicle to perform a nonturf-damaging maneuver—a spin turn. The benefit is that the efficiency of this new transmission is the same on each side of the machine, thus making straight-line tracking much better. It also provides full-time differential lock- and power-steering, which are both unusual features for a tractor of this size.”
However, controlling a differential steer transmission with a steering wheel presented its own set of problems: When backing up and turning the wheel to the left, the front of the machine, not the rear, moved to the left. The solution is John Deere’s reverse-logic system. The moment the operator’s foot touches the reverse pedal, a vacuum-actuated system senses the direction and switches the motion of the steering rods to control the machine in the manner the operator expects. Thus, backing up and turning the wheel left results in the rear of the machine moving left. The system switches to forward operation the instant the operator touches the forward pedal.
“The design is fantastic for this price level of lawn tractor,” notes judge Jim Kaufman, professor, industrial design, The Ohio State University. “It offers many design features to help users operate and maintain the product for years. The tractor represents very thoughtful design and innovative engineering.”
Although John Deere’s designers thought long and hard about usability, they did not neglect the tractor’s appearance. Tests revealed operators were distracted by the front wheels lack of movement. Thus, John Deere hid these wheels with fenders for greater ease-of-use.
According to judge Carl Price, manager, industrial design, Bose, the tractor’s forms suggest a race car more than a tractor.
“The message in the styling of this tractor is consistent with the rest of the design—it conveys the impression that this is a fun, agile, and comfortable lawn tractor,” Goebert adds.
Enhanced ergonomics are evident in the mower deck’s lifting mechanism. Rather than requiring the operator to pull a heavy handle or lever, the mower deck is lifted via a foot pedal.
Key project players from John Deere: Timothy Post, project engineer; Wayne Hutchison, senior engineer; Barry Goebert, advanced designer; Dave Marchese, engineer; John Blalock, designer; Gene Hayes, senior engineer; Jim Swartzendruber, advanced designer; Donald Ackley, senior product manager; Chad Jennings, procurement engineer; Richard Teal, project manager; Denny Docherty, manager, marketing, lawn & garden products; Jim Hardzinski, sr. engineer, transmissions. From Henry Dreyfuss Associates: Bengt Nestell, senior project manager; Jeff Christian, project manager.

Commercial/Vending

Lipton Brewed Iced Tea Dispenser by IMI Cornelius, Inc., Anoka, Minn., and Lipton’s industrial design firm, Worrell Design Inc., Eden Prairie, Minn.
This sleek beverage dispenser is the result of a goal to combine traditional cues, provocative aesthetics, and time-saving operation in restaurant and self-serve iced tea dispensing. Using Lipton’s extraction technology, the appliance offers fresh tea on an as-needed basis with minimal clean-up.
The product’s stainless appearance helps convey a sense of cleanliness, while a sight glass reveals the beverage’s appearance. To enhance the product’s impression of ease-of-use, all technology is hidden inside.
“We made sure that lights, control panels, and buttons would not confuse the customers, and confuse their impression of the product,” Jeff Waffensmith, senior industrial designer, Worrell Design, explains. “The detailing helps create the image of a low-tech experience.”
Twice daily, the operator slides the upper door open to run start-up and shut-down routines. The door is designed to discourage access from consumers, and the control panel allows the operator/service technician to run diagnostics, check the number of hits, and run a cleaning cycle that propels a blast of hot water through the system. However, the dispenser also features a cap to promote the impression that the product is a container, as well as handles to suggest the urn is lifted and cleaned or refilled.
“The dispenser balances visual appeal with subtle, sophisticated vertical forms,” notes judge Greg Montalbano, principal, Montalbano Development. “The product has leading-edge aesthetics while still possessing traditional appeal through the judicious use of metalized detail.”
Disassembly is achieved with a minimum number of steps, and assembly was streamlined. A structural foam bottom housing is designed to act as a pallet accepting a fully assembled internal brewing system. This allows the system to be secured and tested before the cosmetic outer cladding is added.
“To reduce the reject rate and tooling cost, a vacuum-formed coextruded laminate of ABS and Kynar was used to simulate a high-polished stainless appearance,” Waffensmith notes.
Key project players from IMI Cornelius Inc.: Brian Jones, program manager; Russell Duchene, mechanical designer; Daniel Ludovissie, project manager. From Pepsi/Lipton: Lars Woebcke, marketing manager; Sanjay Kumar, equipment development manager; Vincent Masotta, design manager, Lipton Creative Resources. From Worrell Design: Jeff Waffensmith, senior industrial designer; Matt Leyden, engineering manager; Thom Tedham, design manager.

Computers/Electronics Communications

Motorola NFL Headset by Motorola, Schaumburg, Ill., and its industrial design firm, Herbst LaZar Bell, Chicago.
After becoming the official sponsor of the National Football League (NFL), Motorola found itself with a tough assignment: creating headsets that NFL coaches found comfortable and effective while heightening consumer awareness of the Motorola brand.
Developed in just four months in order to make the nonflexible release date of the NFL season kick-off, the new headset managed to draw attention to a formerly innocuous element of games while meeting the needs of multiple users.
“The headset is an excellent example of advanced product design and branding,” says judge Greg Montalbano.
To enhance the product’s appearance, the design team used bold color contrast, high-impact logo placement, a new profile, and a design that complements other Motorola-branded products.
“Introducing such a new, dramatic look with such a high-tech appeal into a tradition-bound atmosphere as football was risky, but it paid off as this new design represents the latest in wireless communication devices without ignoring the mud and guts of professional football,” says John Hartman, lead industrial designer/project manager, Herbst LaZar Bell.
To blend form with function, NFL coaches, players, and fans evaluated the new design. Adjustability and “float” were built into the headset wherever possible (ear cups, headband, boom) in order to make the product as comfortable as possible. The headset is bidirectional and may be worn on either side of the head. Coaches may adjust the microphone piece, which is coated with elastomer, making
it bend easily while standing up to rigorous use.
“This elegant design is placed in a rough environment and makes a unique statement as far as corporate communications for Motorola,” notes judge Jim Kaufman. “It’s a perfect blend of branding and great product form.”
Robust parts are easily replaced and reconditioned while all plastic components are recyclable.
Key project players from Motorola: Terry Taylor, manager, industrial design;
Dan Williams, director, industrial design; Luigi Fiora, lead engineer; Connie Kus,
engineering manager;
David Weisz, director, global sports & event marketing; and Geoff Frost, vice president, global marketing/ media relations. From Herbst LaZar Bell: John Hartman, lead industrial designer/ project manager; Steve Remy, lead mechanical engineer; Jason Billig, industrial designer; and Elliott Hsu, industrial designer.

Floor Care

Multi-Surface Vacuum by Daewoo Electronics Co., Ltd., Korea, and its distributor, Tacony Corp., Fenton, Mo.
Creating a vacuum that combined the best of uprights, canisters, stick vacs, and shop vacs was the impetus behind the Multi-Surface Vacuum (MSV), which is available as the Quick Silver (Simplicity) or the Riccar (Omni-Clean).
“The MSV incorporates an efficient straight-suction nozzle for bare floor and carpet cleaning,” explains David Hamm, director, R&D, Tacony Corp. “It has a turbo-nozzle option for effective plush carpet cleaning. It also includes a folding handle, shoulder strap, and rotating on-board tool assembly with a removable telescopic wand for a wide variety of above-floor cleaning configurations.”
“Being able to switch it from upright to an easily carried canister vac is really great,” adds judge Carl Price. “It also has nice features, like the cord retraction. Plus, it collapses down for easy storage and offers multiple carry positions.”
The handle grip was ergonomically weighted and formed so that it rests comfortably in the hand with a low center of gravity to reduce handle weight of the overall vacuum. The MSV also incorporates a highly maneuverable pivoting nozzle that reduces the forces and effort required to steer around obstacles. The low weight of the system makes it easy to carry. It can be lifted either with the handle extended, the handle folded down, or the shoulder strap.
To effectively trap dust particles, the MSV utilizes a four-stage filtration system with electrostatic filtration media. By placing the electrostatic filter after the motor, the filter media capture any remaining fine particles, including carbon dust, from the motor.
To reduce part and tooling costs, the designers incorporated small metal reinforcement plates under ABS plastic components in high wear and stress areas rather than using filled resins or larger metal parts. The motor for the MSV is manufactured on an automated line, reducing the cost of the most expensive component by 25 percent.
Key project players from Daewoo Electronics: Chang Woo Son, general manager; Nam Ho Lee, manager; Sung Chul Park, assistant manager; Jae Duk Lee, assistant manager. From Tacony Corp.: John Kaido, president, Simplicity Vacuums; David Hamm, director, R&D.

HVAC

Bionaire Convection Heater by The Holmes Group/Bionaire, Milford, Mass., and its industrial design firm, Herbst LaZar Bell, Chicago.
Carving a new niche in the HVAC market, the Bionaire Convection Heater is a mobile, small room heater designed to match the performance of oil-based radiator heaters without the associated expense and danger.
“By using patented heating ‘fins’ in place of traditional oil tanks, the design team was able to create a silent source of heat for rooms up to 150-sq. ft.,” explains Anthony Pannozzo director, industrial design, Herbst LaZar Bell. “The technology can reach 175?F in just seven minutes. As it operates, it stays cool to the touch. Its triple safety protection features an auto safety shut-off, an over-heat back-up fuse, and a wide track wheel base to ensure maximum stability. Also, since the unit does not contain oil, there is no danger of spills or leakage onto the floor.”
Judge Jim Kaufman adds, “It is a product that needs to be as safe as it can be, which seems to be the case with this product.”
In addition to safety, the heater was designed with form in mind. A handle was integrated into the simple, racetrack cross-section for easy maneuverability. The top was designed with a crown to prevent the placement of objects that might impair performance. Addition-ally, the controls were all designed and spaced to be easy to use and intuitive for users of all shapes and sizes.
Key project players from Bionaire: Heather Jones-Lawlor, category director, household products; Paul Powers, vice-president, houseware products. From Herbst LaZar Bell: Anthony Pannozzo, director, industrial design.

Majors

Viking Designer Series Electric Single Oven by Viking Range Corp., Greenwood, Miss.
The Electric Single Oven is a member of Viking’s new Designer Series, which features a contemporary look as well as the quality and performance characteristics of Viking’s “Professional” line of appliances.
“Although the unit is built on the Viking ‘Professional’ oven chassis, the ‘Designer’ oven takes on a whole new personality,” explains Brent Bailey, industrial design manager, Viking Range Corp. “All ventilation was removed from the front fascia and moved to the perimeter to give a sleeker, non-cluttered look.”
Additionally, the handle is constructed from investment-cast stainless steel with a brushed front surface to match the door surface. All other knobs and buttons are cast stainless steel, offering the product a monochromatic look and substantial feel.
“This product design achieves a high level of aesthetic appeal, which it deserves at this high-end market,” notes judge Jim Kaufman. “The design is very consistent throughout the entire product line. Each product in the line was carefully planned to complement the others.
An exclusive feature is the clock/timing device, which incorporates fully synchronized analog and digital features. While the oven is at rest, only the analog clock display is shown. Digital functions appear out of the black analog fascia when activated and are used for timing functions. By setting the time digitally, the analog calibrates itself.
Market research indicated that consumers preferred manual/analog controls rather than analog in regard to oven function and temperature setting. The handle was designed using anthropometrical data, while the high-temperature silicon rubber grip area provides a nonslip surface and comfort.
“We feel this feature’s design helps convey the jewelry-like, high-end appearance necessary for the Designer Series,” notes Bailey.
Key project players from Viking Range Corp.: Robert Mcbryde, senior product manager; Brent Bailey, industrial design manager; Mike Sparks, mechanical engineer; and Mark Finke, industrial engineer.

Portable Power Tools

DuraSpin Screw Fastening System by Senco, Cincinnati, Ohio, and its industrial design firm, Joss Design Group, Chicago.
A gotta-have-it power tool for home improvement enthusiasts, the DuraSpin Screw Fastening System aims to ease heavy, screw-related tasks in a dynamic, robust package.
The adjustable nose piece features legible length markings that adjust to screw lengths from 1 to 2 in. With its pop-in and pop-out quick-bit release system, no chuck is necessary. The 2,300-rpm high-torque motor is designed to drive screws without bogging down, while the 14.4 V battery provides optimum power and run-time across the full range of screws.
“Ergonomics were a key driver in the development of the design,” explains John Van Akkeren, vice president, product development, Joss Design Group. “The tool is carefully balanced to optimize user comfort and reduce repetitive strain. The comfort grip and cushioned trigger were designed for better productivity. The clutch design extends motor and bit life by disengaging when the drive is completed, and the second hand grip is designed to combat worker fatigue.”
Safety was also a design goal, as the screw guard design protects hands and clothing.
Key project players from Senco: Gary Bohar, product manager; Tom Day, marketing manager. From Joss Design Group: Steve Cozzolino, designer; Paul King, designer; John Van Akkeren, vice president, product development/designer.

Medical Appliances/Laboratory Equipment

Midmark Dental Chair and Light by Midmark Corp., Versailles, Ohio, and its industrial design firm, Big Design, Atlanta.
With its emphasis on patient comfort, the Midmark Dental Chair and Light may be just the solution to anxiety-ridden dental visits.
In addition to improving the physical and psychological comfort of patients, the design team at Big Design aimed to improve the manufacturability and serviceability of all components while improving light quality, user interface, and overall system operability.
To improve patient comfort, multiple durometer (hardness) foams were used in the seat cushion, and the armrests were placed on the back of the seat rather than the base, thereby easing shoulder strain and eliminating interference problems during chair entry or exit.
To reduce patient anxiety, the designers employed an elegant, contemporary product shape and appearance. Additionally, they eliminated clinical materials and shapes such as exposed fasteners, connectors, and parabolic light fixtures. Lastly, they used a hydraulic, rather than screw-type, actuation system, eliminating noise and enabling smooth, precise chair movement.
“The seat looks sensual and inviting,” notes judge Carl Price. “Without having ever sat in it, it appears to be comfortable and supportive. I think they did a great job at creating a seat that decreases patient anxiety.”
To reduce part count, large castings, rather than metal fabrication, were employed, in addition to injection molding, rather than pressure- and vacuum-forming.
“It will be fun to go to the dentist with this equipment,” judge Jim Kaufman adds.
Key project players from Midmark Corp: Bill Zulauf, product manager, dental division; marketing, design, engineering, and manufacturing teams. From Big Design: Steven Meister, vice president, marketing; industrial design, mechanical engineering, and 3D modeling teams.

Portable Appliances/Personal Care

Electric Knife - Model CEK-40 by Cuisinart, Stamford, Conn., and its industrial design firm, Ecco Design, New York, N.Y.
The staid electric knife has seen little innovation since its inception, making it just the kind of product Cuisinart hoped to improve. After conducting market research and benchmarking the existing assortment of electric knives, the design team created the CEK-40 for the high-end consumer market.
“There is no new technology in the makeup of the components, but the innovation is in the concept and the knife holder,” says Kerry Cooper, senior marketing manager, Cuisinart. “The knife itself was made to be rugged and durable, and the materials produced a matte finish to replicate the finish of expensive kitchen knives.”
The product features two blades: one for carving, one for slicing bread. They are secured safely in the stand by a spring-loaded catch, while the knife is secured by an inlet groove for the tip and a press-fit on the strain relief at the base of the stand. Cord storage is offered around the flexible foot at the base of the stand. The foot allows the stand, which is made of hard wood, to lie flat in a drawer or rest on a counter.
“It looks like the grip is comfortable and safe,” adds judge Jim Kaufman. “It is easy to clean and store.”
Judge Greg Montalbano adds, “It’s an excellent combination of quality design, color, texture, and finishing details.”
Key product players from Cuisinart: Barry Haber, senior vice president; Paul Ackels, group vice president, marketing; Jill Orent, director, marketing; Kerry Cooper, senior marketing manager; Barbara Schnabel, marketing manager; Art Sansone, vice president, engineering; Asik Braginsky, lab technician. From Ecco Design: Jeff Miller, vice president, design.

Test, Measurement, Inspection Equipment

Fluke Networks OptiView™ Integrated Network Analyzer by Fluke Networks, Inc., Everett, Wash.
With its multiple diagnostic tools, the OptiView Network Analyzer required power, flexibility, and durability in order to execute its many functions. Additionally, it had to adapt to various environments, from the office desktop to the wiring closet and from open, well-lit areas, to dark, compact spaces.
“The design combines a Pentium processor, running Microsoft Windows, using a touchscreen for the interface, with state-of-the-art network test and monitoring hardware,” explains Wayne Hoofnagle, senior industrial designer, Fluke Networks, Inc. “It provides the power of a rack-mounted system with the portability of a laptop, all in a rugged package. Add this to the ability to swap-out the test hardware board and you have the flexibility to upgrade and enhance the product in minutes.”
Based on customer feedback, the design team used a rectilinear, flat form for portability. The desk tilt-stand angle was optimized for the standard office desk surface. The use of color—the gray body with the yellow over-mold—complements traditional Fluke test products.
“Fluke has done it again,” judge Carl Price says. “They have the amazing ability to introduce new products which continue to support the Fluke image while moving it forward. Everything they make looks easy to use and friendly while at the same time saying ‘precision, high-tech equipment.’”
Judge Greg Montalbano adds that the intuitive touchscreen interface eases information navigation, while the clean design implies ruggedness and quality.
Serviceability was enhanced through the design of an interchangeable hardware test board, making repair or replacement simple. Other components are readily accessible once the case is opened. The display is modular and easily removed, while the tilt-stand is designed to pop off if overextended, preventing breakage.
As the complexity of the instrument renders assembly challenging, the design team included built-in test points in the hardware test boards and PC board to allow full diagnostics during assembly. The main case components assemble in the Z axis with the test hardware board module inserted last. Additionally, the overmold is easily manufacturable with little cost or size penalty to the product. The LED lenses are in-molded in the module, eliminating an assembly step and increasing part reliability.
Key project players from Fluke Networks, Inc.: Wayne Hoofnagle, senior industrial designer; Roger Howell, senior mechanical engineer; Tom Resman, project manager; Frank Actis, product planner; Paul Swanson, electrical engineer; Stan Bowlin, electrical engineer.

Electrical Fitness Equipment

SportBrain Personal Fitness Assistant by Sport Brain Inc., Sunnyvale, Calif., and its industrial design firms, Stratos Product Development LLC, Seattle, and Lucente Design, San Francisco, Calif.
If tracking stock performance has lost its appeal, the personal fitness assistant offers an alternative. The tiny device records the user’s physical movement and downloads the data to a personal Web page where the user can track, share, and compare progress with others.
“The SportBrain tracker is a truly groundbreaking concept—users just wear it—there are no buttons to press and nothing to configure,” says Deane Gardner, co-founder & chief technology officer, SportBrain. “Users simply place it onto their belt or waistband and the tracker monitors all their activity over the course of a day.”
Users connect the accompanying SportPort to a regular phone line. At the end of the day, users place the SportBrain tracker into the SportPort where a dial-up number is automatically dialed and the information is sent to the SportBrain Web servers in 60 seconds. Users see all their information on their personalized Web pages, which offer detailed information and graphics on all their activity.
“The product possesses a soft, unobtrusive, minimalist aesthetic that is very appealing,” notes judge Greg Montalbano. “I like the fact that the user interface is web-based, allowing the product to remain clutter-free.”
The small size of the product, high use of injection-molded plastics, along with the use of sheet metal/stampings render the manufacturing and assembly processes simple. The lack of display and buttons minimizes manufacturing costs and keeps reject rates low.
“It makes working out and tracking improvements simple to do,” adds judge Carl Price. “I can see how this would
be appealing to people intimidated by technology.”
Key project players from SportBrain: Deane Gardner, co-founder, chief technology officer; Michelle Hickford, co-founder, chief marketing officer. From Stratos Product Development LLC: John Harvard, analog engineer; Brent LaPorte, digital engineer; Mike Nelson, industrial designer; Macen Shinsato, project manager. From Lucente Design: Sam Lucente, principal.

Peripherals/Accessories

Belkin Regulator Pro Gold UPS by Belkin, Compton, Calif., and its industrial design firm, Hauser, Inc., Westlake Village, Calif.
Preventing the loss of valuable PC data, the uninterruptible power supply (UPS) ensures consistent power to computers, while its battery allows for up to 30 minutes of backup time in case of a power outage. The USB interface and software automatically saves data and shuts down the computer in the event of a power outage.
The primary design objective for the Belkin Regulator Pro Gold UPS was to provide the largest possible surface area to accommodate eight plugs—even bulky transformer “bricks”—while keeping the entire package and footprint as small as possible. Other challenges included managing up to eight power cords, designing the status indicator lights and on/off button to be accessible, making it easy to manufacture, and creating a physically appealing product.
The sloped surface allows for a large outlet area, and the angle makes it easy to insert plugs. The integrated, flexible cable corral keeps the power cords directed toward the rear of the unit. The indicator lights are centrally located and wrap around the top edge, making them easy to see from all angles. The on/off /test button is also centrally located and on the top edge for easy access, while being flush mounted in the recessed scoop to avoid accidental actuation. The battery is easily accessed from a lower rear door.
“The silver parabolic shield-like form on the face of the unit was designed to evoke a sense of protection, security, and power,” adds Rob Curedale, project manager, Hauser, Inc. “When viewed from other angles, the profile and cuts into the form are dynamic, symbolizing the constant activity of the power conditioning.”
According to judge Carl Price, the Belkin Regulator Pro Gold UPS is one of the few UPS products he would be willing to leave in plain sight.
“Wire management is incorporated, which most similar products ignore,” judge Carl Price adds. “The UPS is small and compact with outlets easily accessible.”
Key project players from Belkin: Ernesto Quinteros, director, industrial design. From Hauser, Inc.: Rob Curedale, project manager; Kenneth Mori, lead industrial designer; Oliver Duncan Seil, industrial designer; Mark Westcott, mechanical engineer.

AUTHOR INFORMATION

Charmaine is assistant editor of Appliance Design Magazine. She can be reached at 440/349-3060 x208.

E-mail Charmaine at: am2edit@nowonline.net