The Process. The parachute packing process has many steps and 8 inspections total. While it is very intricate, it can be broken down into 5 main tasks:.

Laying The Parachute Out

Parachutes are long and slippery—this can take a while

Flaking

Folding each section of the parachute, called panels, symmetrically.

Packing the Parachute into the Bag

A deployment sleeve is added over the parachute, and it is S-folded into the deployment bag

Stowing

Parachute lines need to be threaded through loops on the outside of the pack

Securing the Bag

Various flaps and openings need to be secured, lines need to be stored, and pins need to be checked

Parachute packing is slow and painstaking work—one error could lead to someone losing their life. We have been tasked with improving this process, while maintaining a low rate of errors, so that ADFSD can produce parachutes more efficiently..

Secondary Research.

When we started our research, we knew very little about parachute packing. We had to do a deep dive into ADFSD, the US Army, parachutes, parachute packing itself, and the many subdomains within these categories. Once we had more general knowledge on our problem space, we decided that analogous domain research would be helpful.This process involves looking at similar fields to your problem and seeing how that problem is solved. Parachute packing involves folding large swaths of fabric, so we researched origami, textile manufacturing, and sail making. The packing process also involves compacting something large—the parachute—into something small—the deployment bag. For this, we looked at how airbags are packed and installed in cars, or how spacecraft deployable objects are made. We were also curious if there were processes that were already automated for folding or packing large, complex pieces of material, so we researched automated manufacturing for tent and sleeping bags. While we gained valuable insights from the analogous domain research, it made us realize that there is no automated process that closely matches parachute packing. We would have to see the process for ourselves to gain a better understanding of it.

Finding the Problem Behind the Problem.

Now that our team has received the problem brief from our client and gone on base to see the process, it's time to synthesize and figure out the problem behind the problem.

Affinity Diagramming
We took all of our findings and sorted them into groups based on similarities. From there, we could find common patterns and extract insights.

Some key findings were that there was a high incentive for efficiency—riggers can go home once they successfully complete 15 parachute packs. As a result, balancing efficiency with quality, especially during times of high stress like "push weeks", was very hard. The physically taxing, repetitive work often results in strain and injury. Finally, the work is hard, so boosting morale is important. They play loud music, compete with each other, and have a strong sense of camaraderie to get through the day.

Rigger reliance on inspectors (1:4 inspectors:rigger ratio) is a bottleneck for packing efficiency

Not relying completely on inspectors to move to the next step can increase rigger efficiency while maintaining safety standards.

The one-size-fits-all approach to the packing process disregards individual ergonomics, resulting in strain and injury

A shift towards a more adaptable process can foster a healthier work environment and boost productivity

Limited variability and collaboration makes work monotonous, impacting rigger morale and job satisfaction

We can increase rigger engagement and satisfaction by addressing the monotonous nature of parachute packing

Small, inefficient tasks, add up throughout the day, wasting riggers’ time and reducing manpower

By optimizing parts of the parachute packing process, we can free up manpower and improve efficiency

Guiding Principles.

We reworked our insights into actionable questions that helped guide us through the rest of our journey.

How might we make the process less physically demanding and reduce repetitive motions?

How might we collect and analyze performance data to optimize packing techniques?

How might we develop modular packing techniques that allow for faster and/or scalable rigging?

How might we facilitate team collaboration without losing accountability?

Exploring Possible Solutions.

Since we had principles to guide us, we could begin to think of potential solutions. We started with a modified version of “Crazy 8s”. Normally, you would have 8 minutes to draw 8 potential solutions to a problem statement. However, we did crazy “15” since we gave everyone 15 minutes per principle. We generated 200 ideas, give or take a few.

Since we had principles to guide us, we could begin to think of potential solutions. We started with a modified version of “Crazy 8s”. Normally, you would have 8 minutes to draw 8 potential solutions to a problem statement. However, we did crazy “15” since we gave everyone 15 minutes per principle. We generated 200 ideas, give or take a few.

Refining

We couldn’t show the client 200 ideas, so we took out duplicates, combined similar solutions, and sorted them into broader categories. Four main categories developed: ergonomics & physical assistance, workflow automation & tooling, in-process monitoring & data collection, and organizational changes. Now, we could sort the ideas based on how much they satisfied insights and see which categories offered the biggest gains.

In-Process Monitoring & Data Collection Matrix

Combined, our four categories addressed each of the four problem areas.

So what does ADFSD mean anyway?

The Problem.

The Aerial Delivery and Field Services Department of the U.S. Army is looking to automate their parachute packing process to increase efficiency to meet the needs of the U.S. Military.

Riggers. MOS 92R Parachute Rigger (NS).

Inspectors. Previously MOS 92R Parachute Riggers, now considered "Subject Matter Experts" on parachutes.

The Process. The parachute packing process has many steps and 8 inspections total. While it is very intricate, it can be broken down into 5 main tasks:.

Laying The Parachute Out

Flaking

Packing the Parachute into the Bag

Stowing

Securing the Bag

Parachute packing is slow and painstaking work—one error could lead to someone losing their life. We have been tasked with improving this process, while maintaining a low rate of errors, so that ADFSD can produce parachutes more efficiently..

Finding the Problem Behind the Problem.

Now that our team has received the problem brief from our client and gone on base to see the process, it's time to synthesize and figure out the problem behind the problem.

Affinity Diagramming
We took all of our findings and sorted them into groups based on similarities. From there, we could find common patterns and extract insights.

Rigger reliance on inspectors (1:4 inspectors:rigger ratio) is a bottleneck for packing efficiency

The one-size-fits-all approach to the packing process disregards individual ergonomics, resulting in strain and injury

Limited variability and collaboration makes work monotonous, impacting rigger morale and job satisfaction

Small, inefficient tasks, add up throughout the day, wasting riggers’ time and reducing manpower

Guiding Principles.

We reworked our insights into actionable questions that helped guide us through the rest of our journey.

How might we make the process less physically demanding and reduce repetitive motions?

How might we collect and analyze performance data to optimize packing techniques?

How might we develop modular packing techniques that allow for faster and/or scalable rigging?

How might we facilitate team collaboration without losing accountability?

Refining

Time to Design.

With all of this groundwork being laid by our secondary research, contextual inquiry, and design thinking activities it was time to turn these insights into protoypes!

So what does ADFSD mean anyway?

The Problem. The Aerial Delivery and Field Services Department of the U.S. Army is looking to automate their parachute packing process to increase efficiency to meet the needs of the U.S. Military.

Riggers. MOS 92R Parachute Rigger (NS).

Inspectors. Previously MOS 92R Parachute Riggers, now considered "Subject Matter Experts" on parachutes.

The Process. The parachute packing process has many steps and 8 inspections total. While it is very intricate, it can be broken down into 5 main tasks:.

Laying The Parachute Out

Flaking

Packing the Parachute into the Bag

Stowing

Securing the Bag

Parachute packing is slow and painstaking work—one error could lead to someone losing their life. We have been tasked with improving this process, while maintaining a low rate of errors, so that ADFSD can produce parachutes more efficiently..

Finding the Problem Behind the Problem. Now that our team has received the problem brief from our client and gone on base to see the process, it's time to synthesize and figure out the problem behind the problem.

Affinity DiagrammingWe took all of our findings and sorted them into groups based on similarities. From there, we could find common patterns and extract insights.

Rigger reliance on inspectors (1:4 inspectors:rigger ratio) is a bottleneck for packing efficiency

The one-size-fits-all approach to the packing process disregards individual ergonomics, resulting in strain and injury

Limited variability and collaboration makes work monotonous, impacting rigger morale and job satisfaction

Small, inefficient tasks, add up throughout the day, wasting riggers’ time and reducing manpower

Guiding Principles. We reworked our insights into actionable questions that helped guide us through the rest of our journey.

How might we make the process less physically demanding and reduce repetitive motions?

How might we collect and analyze performance data to optimize packing techniques?

How might we develop modular packing techniques that allow for faster and/or scalable rigging?

How might we facilitate team collaboration without losing accountability?

Refining

Time to Design. With all of this groundwork being laid by our secondary research, contextual inquiry, and design thinking activities it was time to turn these insights into protoypes!

The Problem.

The Aerial Delivery and Field Services Department of the U.S. Army is looking to automate their parachute packing process to increase efficiency to meet the needs of the U.S. Military.

Finding the Problem Behind the Problem.

Now that our team has received the problem brief from our client and gone on base to see the process, it's time to synthesize and figure out the problem behind the problem.

Affinity Diagramming
We took all of our findings and sorted them into groups based on similarities. From there, we could find common patterns and extract insights.

Guiding Principles.

We reworked our insights into actionable questions that helped guide us through the rest of our journey.

Time to Design.

With all of this groundwork being laid by our secondary research, contextual inquiry, and design thinking activities it was time to turn these insights into protoypes!