Redesign a new harness system for a backpack vacuum used in commercial cleaning that’s more comfortable for cleaning crews to wear than the existing model.t
An improved harness system product design for a backpack vacuum was the focus of this product design assignment for the design team. For commercial cleaning in offices, the backpack vacuum is a standard tool of the trade. Backpack vacuums came into vogue after egonomic studies showed that office cleaners had less fatigue if they wore a vacuum in a backpack style, rather than pushing a standard floor vacuum hundreds of times per day. The market for backpack vacuum systems was growing but the client noticed their sales of this item were dropping. Research indicated that, while the performance and durability of the backpack vacuum was equal to competing manufacturers, users were complaining about how uncomfortable this backpack vacuum was to wear, so much so that users were opting to carry the backpack vacuum straps in their hands instead of wearing them. In addition, a backpack vacuum weighs between 10-15 pounds empty, and with dirt, can weight up to 40 pounds. Added to the fact that this product was uncomfortable to wear in general and weighed a lot, users also complained that the harness straps routinely twisted, had minimal padding, and cut into their shoulders. As a result, users were either draggin the backpack vacuum on the floor by the straps, or improperly wearing the backpack vacuum by slinging it over one shoulder.
Since the performance of the product was good as far as picking up dirt, it was decided that only the harness system would be replaced to make users more comfortable while wearing the product. The redesign of the Vac Pac started with research into backpacking packs and how they managed weight distribution and improved comfort for the user. We also evaluated other vacuums available in other countries to see what we could learn from them. Then, we conducted ergonomic studies to see how much the harness system would have to be adjustable to fit every one and still be comfortable. After that, a number of concepts were created to show how the harness could be improved. Some were very basic and used the current flat back plate and some were more complex providing a higher level of adjustability. After a review, a few concepts were prototyped and evaluated on a group of users that represented the size range of people that used the product. We also tested a new back plate that had a specially designed curve in it that we found helped transfer weight from the VacPac to the hips taking weight load and strain off the shoulders.
During all the development of the new harness system, we had to ensure that the new harness could easily be retrofitted to backpack vacuum units already in the field. As we worked though the concepts and discovered what worked and what did not we narrowed down the ideas were considering using a cost benefit analysis to weight how much each design element add comfort to the design. Management eventually chose a harness design that provided maximum comfort for a full size range of people with a minimal amount of adjustment needed to make the VacPac fit comfortably on everyone.
Once the design was chosen, we worked with an outside cut-and-sew contractor to develop a production sample and tech pack to send to the company’s overseas sourcing office. We received sample from the factory, evaluated them then communicated changes and improvements back to the factory. We then evaluated a final set of samples and approved them for production.
Improved comfort has occurred which is illustrated by more properly worn vacuums seen in the field, and sales of new units with the new harness have increased, along with orders of the new harness to replace the old ones on existing backpack vacuum units. An added benefit was that the new improved product was able to hold its own when several new competitors entered the market later that year.
Don’t forget to pay attention to the human element in product design. User comfort is sometimes more important than machine performance if users start mis-using products because the product is uncomfortable to use, or if sales start to drop for no good reason.