Designed, developed and commercialized a low-cost, ergonomic ventilation system for PPE suits to help front-line COVID healthcare and sanitary warriors
Problem Statement
During COVID 19, covid-warriors worked tirelessly to ensure our wellbeing. In doing so, they had to wear Personal Protective Equipment Suits - which are essentially "plastic bags" with no breathability.
Typical shifts for warriors could last 8-12 hours, leaving them drenched in sweat, severely dehydrated and uncomfortable.
This project sought to develop a highly affordable and ergonomic ventilation system to solve this problem.
My Contribution
Developed a novel ventilation system with an ergonomic design, with universal fit.
Raised INR 15,00,000 of govt and private grants to establish R&D and Manufacturing.
Established overseas supply chain for components and materials.
Established a production and assembly pipeline.
Built sales and distribution network, scaling up to pan-India and international sales.
Impact
Made the job of COVID warriors easier by eliminating the problem of sweating.
Sold units to NGOs and non-profits for minimal cost.
Got invited and funded on Shark Tank, exposing the innovation to millions.
Mentored several University E-Cell programs to help young innovators start up successfully.
The Journey
Product Opportunity Gap
Interviewed over 50 COVID warriors to gather details and outlined product requirements. My mother, being one such doctor, was the key driving force behind this innovation.
A tweet from Dr. Makwana garnered national attention and shows just how grave this problem was.
Market Research | Idea Screening | Product Strategy
Concept
Developed several iterations of designs based on product requirements.
The ventilation system needed to be light-weight and couldn't disrupt their current workflow. It must also retain full freedom of motion, have long-lasting battery and be easy to sanitize.
Product Design | AutoCAD | Concept Sketches
Prototyping
Went over 10 rapid prototype iterations to accelerate time-to-market.
Studied human anatomical factors to refine the design for maximum comfort.
Sponsored by Dassault Systems and partnered with RIIDL for access to MIT Bits & Atoms Fabrication Lab.
Solidworks | 3D Printing| CNC | Laser Cutting | PCB Design | Control Firmware
User Testing
Conducted several rounds of product testing, focusing mainly on healthcare professionals - solving for the most complex use case first and then working my way down.
Co-designed the device with the users and iterated on the designs with new improvements based on user feedback.
User Study | Customer Satisfaction Analysis | Controlled Testing & Experimentation
Final Product
Step 1
Wear the ventilation system like a simple belt. Adjust the strap length to your comfort.
Step 2
Wear the PPE suit on top of this belt as per usual.
Step 3
Attach the provided cap with the N95 filter. Turn on the device and enjoy.
Manufacturing
Set up injection molding and press fitting stations for mass manufacturing.
Setting Assembly Lines
Developed manufacturing processes, assembly SOPs for high volume production. Trained employees to assemble, QA & package product using custom designed fixtures.
Packaging and Labeling
Designed product packaging to reflect brand identity and designed internal compartments to ensure safety during transit.
Distribution
Visited hospitals, clinics and healthcare industry dealers to develop a distribution channel and boost sales.
