[email protected] engr-11_lec-07_chp13_detail_design.ppt 1 bruce mayer, pe engineering-11:...

[email protected] • ENGR-11_Lec-07_Chp13_Detail_Design.ppt1

Bruce Mayer, PE Engineering-11: Engineering Design

Bruce Mayer, PELicensed Electrical & Mechanical Engineer

[email protected]

Engineering 11

DetailDesign



OutLine Detail Design

Flow of design information Responsibility for “details” Graphic communication Written communication Oral presentations



Product Development Pick a product, any product

• Most require more than one Engineering discipline to develop.• Some need many disciplines, including (but not limited to):

– Manufacturing Engineering Industrial Engineering Tooling Engineering Process/Manufacturing Engineering Test Engineering

– Design Engineering Mechanical Engineering Electrical Engineering Software Engineering Packaging Engineering Industrial Design Research &

Development

– Quality Engineering Product Assurance Engineering Software Quality Engineering Supplier Quality Engineering Reliability Engineering



Product Development But wait, there’s more!

• Also need NON-ENGINEERING groups to make a product– Financial Analysts– Product Managers– Marketing Managers– Marketing Communications– Sales, Order Entry, Account Managers– Customer Service / Field Service– Production Control– Purchasing & Commodity Management– And many more, depending on the industry . . .



Information FlowSpecial Purpose Parts: Features Arrangements Relative dimensions Variable list Standard Parts: Type Variable list

ParametricDesign

ParametricDesign

Design variable valuese.g. Sizes, dimensions Materials Mfg. processesPerformance predictionsOverall satisfactionPrototype test results

DetailDesignDetailDesign

Product specificationsProduction drawingsPerformance Tests Bills of materials Mfg. specifications



Design Info Flow & Decision-Making

Finance

Product Manage-ment

Project Manager

Marketing

OperationsEngineering

TeamLeader

Quality

• New Product Introduction Manager – Subproject Leader• Manufacturing Engineering• NPD Procurement• Tooling• Test Engineering• Packaging Engineering

• Product Assurance – Subproject Leader• Production Quality• Supplier Quality Engineering• Software Quality Assurance• Technical Assistance

• Systems Engineering – Subproject Leader• Electrical Engineering• Mechanical Engineering• Software Engineering• Acoustic Engineering• Engineering Services

• Product Marketing – Subproject Leader

• Channel Marketing• Sales• PR• Advertising

• Finance – Subproject Leader• Information Technology

• Product Management – Subproject Leader• Industrial Design



Sales & Marketing Duties

Product Warranty Shipping & Installation Plans Warehousing for Spare Parts Advertising campaign Product literature Owner’s manual (layout, printing)

• Often Done by a Technical Writing Group

Product launch



Industrial Design Duties

Overall Product Appearance/Impression• Color(s) & Paneling• Product trim details• Finish details

Ergonomic Refinements

Product Packaging

“Curb Appeal”



Design Engineering Duties Detail design performance analyses Preproduction prototype performance tests Manufacturing process specifications Owner manual(s) (technical: operation &

maintenance) Layout drawings

Detail drawings Assembly drawings Bills of materials Engineering change notices/orders Intellectual Property

• Patents • Trademarks • Copyrights



Industrial Engineering Duties

Materials & Product flow Facility layout/remodeling Material handling equipment Inventory warehousing Assembly planning (machines &

workers) Materials Lead-Time Planning



Manufacturing Engineering Duties Fixture design & fabrication Tool design & fabrication Process equipment

refurbishment/adaptation Process equipment acquisition &

installation Process planning & development Supplier Selection & Qualification Worker Training



Purchasing Dept. Duties

Supplier Contract Negotiations Second Source Identification Issuing Requests for Quotation (RFQs) Materials planning Purchased-Part

Cost Control Purchased-Part

Delivery Schedule Control



Production

Tooling changeover (assist ManufE) Receiving Inspection (Physical) Received-Part

Acceptance Testing Worker Training Material Movement Workforce

Scheduling



Communicate Design Information Written and Oral Communications

• eMail• Memoranda & Letters• Phone calls & Voice mails• Reports • Meetings

Communicate to ALL the stakeholders: • often • thoroughly & clearly



Graphic Comm Drawings

Detail drawings (a.k.a.”BluePrints”) • Fabricated “Piece-Parts”

Assembly and SubAssembly Drawings Bills of Materials

• sometimes on Assembly• Sometime in a form of a SpreadSheet

Layouts• Scaled & Accurate, but not “finished”



Detail Drawings Show all necessary dimensioned

views needed to make the part. Indicate material and tolerances. Indicate any finish treatments (plating, etc.)

and requirements for surface-finish roughness. Detail drawings are not necessary for

purchased parts, only for parts that will be manufactured to the Engineer’s design.

It is often preferred to show just one part per sheet so the same part drawing can be included in multiple assemblies without confusion.



Fabrication Drawing (ENGR22)

TWO Parts on this Sheet

Poor form



Fabrication Drawing



Assembly Drawings Can be exploded-isometric, sections, single

views, exterior views, or assembled isometric drawings.

Not usually dimensioned unless there are dimensions that are critical to maintain during assembly.

Hidden lines not usually needed.



Assembly Drawing



Parts Lists (Bill of Materials) Parts list (a.k.a. “BoM”) on assembly

drawings or combined assembly and detail drawings indicates part name, item number, material, and quantity required.• Parts List May be on a Separate Document

– Reference in NOTES Section of the Dwg

Often a company stock number is also included

Part ID on Dwg• Balltags on drawing indicate which part is being

called out (next slide)• Part No. may be Placed Directly on Drawing



Ball-Tag BoM Assy Dwg

BallTag

Ref. toParts List



Direct P/N Callout; No BallTags



Anatomy of a Working DwgRev. Block

Note Block

Zone No.

Zone Ltr.

On-Dwg BoM

Title BlockFOIA Disclaimer

Note Indicator

BoM BallTag



Anatomy of a Working Dwg

Section/View Line

Zone Block

Detail Bubble

Separate-SheetParts List



Anatomy of a “BluePrint” Title Block

Drawing Title SubBlock Release SubBlock

Tolerance SubBlock

Matl-Spec SubBlock

BoM Table SubHeadings Company ID SubBlock

Drawing Number Revision Level Dwg Sheet Size Dwg Scale

Dwg Sheet: No. & Cnt Co. Division ID



Graphic Comm – Illustrations CHARTS - portray relationship(s) among numerical

data, for example sales versus time. DIAGRAMS - explain how something works or the

relationship between the parts; e.g., free body diagrams to analyze how forces and moments interact with rigid bodies

SCHEMATICS - uses abstract symbols; e.g., fluid Plumbing schematic, or electrical-wiring schematic.

FIGURES - illustrates textual material SKETCHES - hand-drawn preliminary, or rough

“drawings”, drawn without the use of drawing instruments.



Analytical XY Graph (ENGR25)Temperature Field Self-Iteration Convergence Plot

0.0

0.3

0.5

0.8

1.0

1.3

1.5

1.8

2.0

0 3 6 9 12 15 18 21 24 27 30

Iteration Number, i

I = (

Ti-T

o)/

(Tf-T

o)

file = Chuck Heat_Xfer_Oct99.xls

PARAMETERS• Inj/Ceiling Temp, T1 = 65C• Chuck Temp, T2 = 550C• k[T(z)) for N2 by Reid, Prausnitz, Poling• To = 483.5 °C• Tf = 519.47 °C



Technical Column ChartWafer Processing Time Budget for 8k-USG and 5k-BPSG • Apr00

0

2

4

6

8

10

12

14

16

18

20

USG: mill sys3 USG: 2@3X/1 USG:2@3X/2 BPSG: mill sys3 BPSG: 2@3X/1 BPSG:2@3X/2

Pro

ce

ss

ing

Tim

e (

min

/wa

fer)

t0 = Dep-On TimeTclnThc

file =

Th

ruP

ut_

Ca

lc.xls



FreeBody Diagram (ENGR36)

Shows How Forces & Moments InterAct with Physical Objects

Example

FBD for DrawBridge Plank



Plumbing Schematic



Technical Illustrations

WJ -15 0 0 M uffl e

Cros s B elt N2 Dis t ribut iont ube (8 P l)

Cros s B elt N2 Dis t ribut iont ube Header/P lenum

Figure 1. Top/Plan view showing how the cross-belt N2 distribution tubes integrate into the M2 WJ-1500 muffle



Desig

n S

ketch



Gantt Chart (MileStone Sched)ID Task Name Duration Start Finish

28 Confirm Design Engineer Availability 0.2 wks Mon 10/8/01 Mon 10/8/01

29 Electrical/Controls Engineer 1 day Mon 10/8/01 Mon 10/8/01

30 Mechanical/Plumbing Engineer 1 day Mon 10/8/01 Mon 10/8/01

31 Mechanical/Automation Engineer 1 day Mon 10/8/01 Mon 10/8/01

32 System Engineer 1 day Mon 10/8/01 Mon 10/8/01

33 Travel To Japan 0.6 wks Sat 12/8/01 Mon 12/10/01

34 Air Travel to Narita/Tokyo 2 days Sat 12/8/01 Sun 12/9/01

35 Ground Travel Tokyo=>Tatsuno 1 day Mon 12/10/01 Mon 12/10/01

36 Full S2/S8/CE Testing at FIS in Tatsuno 1.9 wks Tue 12/11/01 Fri 12/21/01

37 S2/S8 Review & Testing 0.7 wks Tue 12/11/01 Fri 12/14/01

38 Intro, Task/Plan Review 0.5 days Tue 12/11/01 Tue 12/11/01

39 Testing, Document-Review 2.5 days Tue 12/11/01 Thu 12/13/01

40 Summary & Action Items 0.5 days Fri 12/14/01 Fri 12/14/01

41 CE (EMC/EMI) Testing 1.2 wks Fri 12/14/01 Fri 12/21/01

42 Plan Test Activities 0.5 days Fri 12/14/01 Fri 12/14/01

43 Contingency Day 1 day Sat 12/15/01 Sat 12/15/01

44 Testing<=>Remediation Cycles 3 days Mon 12/17/01 Wed 12/19/01

45 Summary & Action Items 1 day Thu 12/20/01 Thu 12/20/01

46 Contingency Day 0.5 days Fri 12/21/01 Fri 12/21/01

47 Return Travel 1.5 days Fri 12/21/01 Sat 12/22/01

48 Write Reports 29 days Sun 12/23/01 Wed 1/30/02

49 Analyze Report 9 days Thu 1/31/02 Tue 2/12/02

50 Review Report Analysis 9 days Wed 2/13/02 Mon 2/25/02

51 Remediation Effort (if Needed) 6.2 wks Tue 2/26/02 Tue 4/9/02

52 Plan Remediation if Needed 6 days Tue 2/26/02 Mon 3/4/02

53 Implement Remediation Items 38 days Tue 2/26/02 Mon 4/8/02

54 Remediation Review 1 day Tue 4/9/02 Tue 4/9/02

55 Write Compliance Report 1 day Wed 4/10/02 Wed 4/10/02

YKitahara

BMayer,GS3,HHoshino

YKitahara,BMayer,GS3

BMayer,GS3

GS3

BMayer

YKitahara

BMayer,YKitahara

YKitahara,BMayer

BMayer,YKitahara

BMayer

Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug SepQtr 4, 2001 Qtr 1, 2002 Qtr 2, 2002 Qtr 3, 2002



Written Design Communication

Letters & eMail• Brief communications, often <1 page in

length• Sent to a few selected individuals • On a specific, usually familiar, topic• HardCopy Letters are FORMAL

– Use Company LetterHead Paper

• eMail “letters” are INformal in format and typically very brief



Written Design Communication Memoranda

• Longer than letter, from 3 to 9 pages,

• Sent to a broader, usually Internal audience

• Can cover more topics in greater depth than a letter.

• Memoranda often emailed as attachments




Test Reports• Technical reports detailing engineering

and/or scientific tests (on materials, prototypes and or products).

• Can vary in length from few pages to hundreds of pages.

• Contents include sections on: test objectives, test procedures,

• data/results, summary and recommendations




Research reports• Similar to test reports• But longer in length and

broader in coverage • Include additional sections

such as: an abstract, background, literature review, laboratory/test program description and bibliography.



Owner’s Manuals Often Written by the Design Engineer Include sections on:

• SetUp/Installation of the product • Operating the product • Maintaining (i.e. clean, lubricate and adjust) • Repair, if necessary.

Can vary in length from 1 page to hundreds of pages

Illustrations usually very important

LED Indicatorsfor Level Sensorsin Bubbler Tanks

1, 4, 7 (for Injector 1)



Spare

B Source

P Source

Si Source

OpticalSensorBoard

High Resolution

83 Card 81 Card

80 Card

35 Card 34 Card 33 Card

Temperature InterfaceBoards (80 Card, 81 Card)

Thermocouple Interface Boards(33 Card, 34 Card, 35 Card)

P37 P38 P39

Thermocouple Terminal Block 1 (TCBlk #1)





Engineering Change Orders Brief descriptions of

changes made to a product (i.e.; what, why, how)

Detailed on a company-approved form

Authorized (signed) and distributed to all the critical depts.



Project Progress/Status Reports

Sent to Management, Customers, Clients and other stakeholders,

Covers project status re: workscope, schedule and budget.

Can vary in length from one to hundreds of pages

Prepared weekly, monthly, quarterly, and annually



Design PostMortem Report Major Sections of an “AfterAction” Report

1. Introduction

2. Design Problem Formulation

3. Project Engineering

4. Concept Design

5. Configuration Design

6. Parametric Design

7. Prototype Tests

8. Final Design

9. Conclusions and Recommendations



PowerPoint Presentations

Preparation Strategy1. Plan (time, topics, temperament, audience)

2. Outline

3. Compose

4. Rehearse

5. Refine

An excellent presentation requires excellent preparation

• See also ENGR10



Presentation BOTTOM LINE Tell them what you WILL tell them

• Start with an OUTLINE

Tell them • The BODY of the Presentation

– Make it Inter– esting & Relevant

Tell them what you just TOLD them• End with a SUMMARY that emphasizes

the important points/conclusions



PowerPoint Presentation Plan

Decide on:• who the audience will be

– Know the Audience and their Interest

• what we wish to communicate– Know the Subject – be Ready for Questions

• why we are giving the presentation– Know the Point, and Don’t Obscure

• how long it should be– Time is Valuable – Emphasize Main Point(s)



PowerPoint OutLine Prepare a draft outline of the topics. If a group presentation, the Group needs to

agree upon responsibilities. Estimate the time devoted to each topic. Break up longer topics into smaller chunks. Combine or eliminate incidental topics. Discuss the draft outline with your co-workers. Confirm the draft outline with your immediate

supervisor.



Compose Presentation Use the outline to compose Speaker’s Notes

on 3x5 note cards (can be imbedded in ppt)• Write clear and concise statements for major ideas

and facts. • Number each card in succession.

Compose clear & concise PowerPoint slides, Prepare Diagrams using CAD, or Photos with

Digital Camera, Movies with videorecorder Bring a MockUp or Working Model if at all

Possible for Physical Demonstration



Rehearse Presentation

Important Presentations Should be Rehearsed in front a forgiving audience

Practice saying the note card phrases. Give your draft presentation to some

friendly coworkers. Rehearse using the intended room and

audio/visual aids – always precheck fcn Video tape and critically evaluate

presentation delivery & visual-aids.



Refine Presentation

Revise or re-write the note cards Eliminate confusing visual aids. Refine the visual aids. Revise presentation room layout or

equipment • Bring Your OWN Equipment if Unsure

about the suitability of the actual Venue– Typically LapTop & LiteWeigt PPT Projector



Execute (Give) Presentation Make your listeners physically comfortable.

• Seating, lighting, room temperature, noise level and ventilation.

Expect & accept to be somewhat nervous. • Convert nervousness to enthusiasm.

Take a deep breath and relax before beginning. Start on time, stick to presentation schedule, and

finish on time. • Do not go overtime!

Pronounce clearly, sufficient volume, relaxed pace.



Execute (Give) Presentation Vary the pitch or tone of our voice

occasionally Add enthusiasm to our delivery. Use visual aids to judiciously make points Use appropriate gestures and avoid annoying

mannerisms – no one wants to be annoyed Make frequent eye contact with our audience. Use a Laser pointer when appropriate. Relax and “enjoy the ride.”



Summary Detail Design

Product “Launched” Only When Detail Design Complete

Detail Design Elements• Flow of design information • Responsibility for “details”• Graphic communication• Written communication• Oral presentations



All Done for Today

MorePPTTips

Tip 1: Put the PPT files on a USB Drive

Tip 2: Use Arial or Times New Roman Font

Tip 3: Always Carry the Microsoft PowerPoint Viewer

Tip 4: Print a PDF of your PowerPoint Presentation

Tip 5: Take Care of Margins Tip 6: Some Presentation

Rooms Can Be Very Big Tip 7: TurnOFF Screensavers,

etc. Tip 8: Power Management



Bruce Mayer, PERegistered Electrical & Mechanical Engineer

[email protected]

Engineering 11

Appendix



Tip 1: Put the PPT files on a USB DriveYes, there’s box.net, slideshare.net and tons of other PowerPoint hosting services where you can upload your PPT files but I still recommend carrying files on a USB drive because there are chances that Internet may be very slow (or unavailable) in the presentation room. With files on the USB stick, you are always in control.Tip 2: Use Arial or Times New Roman FontThe default fonts in Office 2007 programs are Calibri, Corbel, Cambria, etc but unfortunately these fonts are not available on computers running older version of Microsoft Office. If you want the presentations to look the same in the conference room as on your laptop, use fonts like Arial or Times New Roman which are universally available.Tip 3: Always Carry the Microsoft PowerPoint ViewerYou have designed a great presentation using the latest PowerPoint 2007 but it possible that the computer, where you will run the presentation, is running an ancient copy of PowerPoint 2000. In that case, your presentation will fail to run. not run at all. Download the free Powerpoint 2007 Viewer, transfer it your USB drive and be rest assured that your slide show will be play just perfect on any Windows computer. Tip 4: Print a PDF of your PowerPoint PresentationYou can use Acrobat or the Save as PDF plugin of Microsoft Office 2007 to convert your PPT into a read only PDF file. Some members in the audience will always ask you for a copy of the Presentation slides and if you are not too happy in giving away the source file, PDF is a great alternative - it also maintains the layout, transitions and even the fonts.Tip 5: Take Care of MarginsIf the display properties of your computer do not match that of the projector, chances are that the presentation slides will be cut off at the edges - to avoid this, designate a margin safe area when designing presentations and limit your text or graphics to that area.Tip 6: Some Presentation Rooms Can Be Very BigDo not use small fonts as that will make your slides unreadable especially for back-benchers when the room size is large. The minimum recommended font size in PPT slides is around 24-points (more for headings).Tip 7: Screensavers, IMs, New Email NotificationsTurn Off all these distractions before running the slideshow - they can sometimes be very embarrassing.Tip 8: Power ManagementSome computers (especially laptops) turn off the screen after 5-10 minutes of inactivity. Always turn off this feature using the Power management console.

[email protected] engr-11_lec-07_chp13_detail_design.ppt 1 bruce mayer, pe engineering-11:...

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