1

IPD

Objectives of LectureObjectives of Lecture

Have the students become familiar with the following:

1) The definitions of design, manufacturing and IPD

2) The various philosophies of design

3) The role of engineering, industrial design and business in new product development

4) The importance of innovation and new technology in materials and processes

5) Product development in the context of business

2

IPD

The Design Process: IntroductionThe Design Process: Introduction Design: to fashion something new after a plan Design is the essence of engineering To pull together -- synthesis Satisfy a recognized need of society Learn design by experience Science discovers -- engineers create Analysis is an important tool for design Domain of design is global

3

IPD

Design is a ProcessDesign is a Process System, subsystem and component design Sequential process Iterative process Starts and Ends with the customer Comparison and contrast to scientific method

Need Concepts Feasibility Produce Sell Time and cost as key factors

4

IPD

Major Models In the CourseMajor Models In the Course

Ulrich and Eppinger Roozenberg and Eckels Pugh – Total Design Human Factors in Product Design Many others

Human-centered Design Systems Design Methodology

5

IPD

Steps in the Design ProcessSteps in the Design Process Recognition of a customer’s need Definition of the problem Gathering of information Conceptualization Evaluation Communication Production Distribution, sales and customer support

6

IPD

Recognition of a Customer’s NeedsRecognition of a Customer’s Needs

Market research identifies customers and needs R&D creates ideas that are relevant to an

organization’s capabilities Needs arise from dissatisfaction Technology push(examples computers, audio)

7

IPD

Definition of a ProblemDefinition of a Problem Design Process and possible solutions depend on

how the problem is defined Define problem in broad terms Breadth limited by time, money and other

resources Separate exiting solutions from the problem itself Write down a formal problem statement Include objectives and goals, constraints Gather information and reevaluate statement

8

IPD

Definition of a ProblemDefinition of a Problem Create four categories of objectives/goals

Musts

Must Not's

Wants

Don’t Want In class exercise: Identify a common dissatisfaction

with a common product. Each team create a problem definition. Compare definitions.

9

IPD

Gathering InformationGathering Information Previous exercise is just the start -- based on personal

experience (i.e. only one or two customers--you!!) Information needed is often not in text books, but in

Technical Reports, trade journals, patents, handbooks etc. Experts -- in-house or subcontractors

Problems: Where can you find the right information?

How do you get it? Is it credible? Is it applicable to your needs? Is there ever enough information? …..

Web

10

IPD

ConceptualizationConceptualization Identify components, systems, chunks in various

combinations to satisfy customer’s needs Employ inventiveness and creativity Employ models Synthesize Think across disciplines and products

Trend analysis, Hierarchical Analysis

Be curious -- How things work?

11

IPD

Evaluate Early and OftenEvaluate Early and Often Weighing and judging at various steps Mathematical checks Engineering Sense-Check Dimensional consistency Limits and bounds Common sense checks Know when to freeze the concept -- just one more

design iteration -- just one more feature

12

IPD

Communication Communication Does the client really know what they want? Written and Oral communication = 60% of

engineers time Dialog needed not periodic reports Use what ever works:

Scale models Sketches Drawings

Looks-like mock ups CAD Model

13

IPD

Morphology of DesignMorphology of Design Phase I. Feasibility Study Phase II. Preliminary Design Stage Phase III. Detailed Design Phase IV. Plan for Manufacturing Phase V. Plan for Distribution Phase VI. Plan for Use Phase VII. Plan for Product Replacement

14

IPD

Other Design ConsiderationsOther Design Considerations Functional Requirements – we will read Suh

Performance specifications Deterministic Vs Statistical Prediction Methods Reliability Reparability

Total Life Cycle-- materials, producibility, durability, recycle

Standards and regulations

15

IPD

Other Design ConsiderationsOther Design Considerations Aesthetics Design for intentional misuse -- lawn mower Human Factors - Ergonomics Cost Product characteristics:

One of a kind Consumer Large expensive system Design to code

16

IPD

Design DrawingsDesign Drawings Standard way (legal) to Communicate Design Multiview layout Assembly layout Pictorial views Detailed drawings: Dimensions and Tolerances Surface finish Material and Process Notes

17

IPD

TolerancesTolerances Interchangeability of part Standards for mating parts Classes of fit Allowable variation of size, location and form GD&T standards

18

IPD

DimensionsDimensions Identify mating features Determine types and classes of fits (size

variations) Locate features from Datums Use GD&T approach to apply location variation Size other features Design for Assembly

19

IPD

SizesSizes Rationalize size -- pump example Use geometric rather than arithmetic--WHY? Advantages to limit the number of sizes of a

product: Tooling Inventory Support Spare parts

20

IPD

Surface RoughnessSurface Roughness Roughness effects fatigue, wear, fit Roughness specifications Waviness Materials and manufacturing operations

21

IPD

CAD/CAM/CAECAD/CAM/CAE Geometric modeling and down stream

applications: Drafting Photo realism Marketing FEM/FEA Kinematic/dynamic simulation Component analysis Process Simulation in the design stage

22

IPD

Design to StandardsDesign to Standards Product Data Management Systems Engineering Change Management Interface to Business Information Management Data Exchange between vendors Design Automation - parametric models, group

technology Design rules and codes (parametric design)

23

IPD

Concurrent EngineeringConcurrent Engineering Replace by Integrated Product Development Teams to include:

Product design people Production systems people Market analysis people Sales, distribution and service Manufacturing Purchasing Legal

24

IPD

Design ReviewDesign Review Design requirements Functional requirements Environmental requirements Manufacturing requirements Operational requirements Reliability requirements

25

IPD

Objectives of Design ReviewObjectives of Design Review Review and redesign focuses on achieving the

performance, producibility, reliability and cost (As compared to what) objectives.

Competitive benchmarking Reverse Engineering of competitor’s products Still must sell it to a customer Early bird gets the profit