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MEE-462
B.TECH 8TH SEM MECHANICAL ENGINEERING
MECHANICAL ENGG. DEPTT
Changing Dimensions of
Competition
Manufacturing:!
Cost and
Quality!
Product Development:!
Features and Function!
Product Development
Process
2. Design
3. Manufacturing
Development Team
Product Analysis
Performed before actual design starts
It is based on the information collected about the customers
requirements and the level of competition.
Its objective should be to satisfy as many functions as
possible.
Its objective should be to keep the product cost as low as
possible.
It is a trade off b/w product cost and functionality.
It focuses on multiple product concepts.
Legal Factors
Environment pollution
Import restriction on capital goods
Restriction on finance
Finance related factors
Capital investment-manufacturing
machinery
Cash generation
Govt. support
Shares
Fixed Deposits
resources,
plant
and
Development Time:
Development Cost :
Development Capability:
Concept
System-Level
Detail
Testing and
Production
Developme
Design
Desig
Refinement
Ramp-Up
nt
n
Mission!
Concept!
System Spec!
Critical Design!
Production!
Approval
Review!
Review!
Review!
Approval!
!
Concept
System-Level
Design
Developme
Design
nt
Mission!
Concept!
Cycle Plan!
Approval
Review!
Review!
!
Build
Test
Production
Ramp-Up
Cycle!
Review
!
Test
Design
Concept
System-Level
Planning
Developme
Design
nt
Design
Mission!
Concept!
System!
Approval
Review!
Review!
Design
!
Test
Integrate
and Test
Test
Test
Validation
and RampUp
Production!
Approval!
Concept
Developme
nt
System-Level
Design
Detail
Desig
n
Testing and
Refinement
Production
Ramp-Up
Identify
Customer
Needs
Establish
Target
Specificatio
ns
Generate
Product
Concepts
Select
Product
Concept(s
)
Test
Product
Concept(s
)
Set Final
Specificatio
ns
Developme
Plan
nt
Plan
Downstrea
m
Developme
nt
Concept Generation
Why emphasize early concept generation?
Thorough exploration of alternatives early in the
development process greatly reduces the likelihood that the
team will generate a superior concept late in the development
process or that a competitor will introduce a product with
dramatically better performance than the product under
development.
Concept generation answers the question of how the
product will satisfy the customer needs as mapped into
the functional specifications.
Concept Selection
A process where each concept is evaluated to identify the most
promising concepts.
Requires several iterations and may cause additional concept
generation and refinement.
Design Evaluation
Binary measure
Qualitative measure
Concept Testing
One or more concepts are tested to verify the customer needs have
been met.
to assess the market potential of the product.
Identifying any shortcomings before any further development.
Poor customer feedback could result in terminating a project or
earlier activities may be repeated..
Project Planning:
During this final activity the team creates a detailed development
schedule
Comes up with a strategy to minimize development time
Identifies resources required to complete the project
Home assignment # 1
Old design methods
Strength and weakness of old design methods
Design by Evolution
Evolution of safety razor, camera, centrifugal pump,
Design by innovation
Need statement
Classification of Product :
Consumer products (such as TV, Refrigerator, AC etc
Industrial Product
Technology-Push Products
A firm begins with a new technology, then finds an appropriate market
Example: Rainwear
Planning phase involves matching the technology to the market
Customized Products
Design by drawing:To over come the limitation of design by craft, a new method of design is
developed this method is called Design by Drawing.
Features of Design by drawing :1.The dimensioning of product is specified.
2.The complete manufacturing or design of the product can be subdivided
into separate pieces, which can be made by different people.
3. When the product is to be developed by trial and error, the process is
carried out on a drawing board instead of shop floor.
Think Yourself
DESIGN PROCESS
The Design process
deals with the conversion
of ideas in to reality.
OR
IT is the form of human
activity which aims at
fulfilling human needs
OR
The design process is the
process of produce the
prototype, which is used
as the sample for
reproducing the
particular, goods or
service as many time to
satisfy consumers needs
CAD(EME-701)
RECOGNITION
OF NEED
DEFINITION OF
PROBLEM
SYNTHASIS
ANALYSIS AND
OPTIMIZATION
EVALUATION
PRESENTATION
52
53
1.
Design by craft evolution:The designing of Bullock cart , rowing boat, razor etc
are some product produce by craft evolution process.
Features of craft evolution:The craft man doesnt prepare the dimensioned
drawing of their products.
They can not offer proper justification for the design.
The product design was very time consuming.
The change in product design is very slow or nearly
negligible.
CAD(EME-701)
54
Design by drawing:To over come the limitation of design by craft, a new method
of design is developed this method is called Design by
Drawing.
55
RECOGNITION
OF NEED
DEFINITION OF
PROBLEM
SYNTHASIS
ANALYSIS AND
OPTIMIZATION
EVALUATION
PRESENTATION
CAD ELEMENT\TOOLS
GEO.
MODELLIN
G
ENGG.
ANALYSI
S
DESIGN
REVIEW
AND
EVALUATIO
N
AUTOMAT
EDRAFTIN
G
56
What Not
How
Specificity
Customer Statement
Why dont you put
protective shields around the
battery contacts?
Need Statement-Wrong
The screwdriver battery
contacts are covered by a
plastic sliding door.
Need Statement-Right
The screwdriver battery is
protected from accidental
shorting.
Attribute of
the Product
An automobile cigarette
lighter adapter can charge
the screwdriver battery.
Avoid
Must and
Should
Morphology of Design
Introduction
Morphology means a study of form or structure. Morphology
of design refers to the time based sequencing of design
operations. It is a methodology of design by which ideas about
things are converted into physical objects. The logical order of
different activities or phases in a design project is called the
morphology of design.
Morphology of design is the chronological vertical structure of
the various phases or steps together from the engineering
analysis to the retirement of the product. It consist of SEVEN
PHASES.
Morphology of Design
Phase I:
Feasibility study
Phase II: Preliminary Design/Embodiment Design
Phase III: Detail Design
Phase IV: Planning for Manufacture/ Production
Phase V: Planning for Distribution
Phase VI: Planning for Use /Consumption
Phase VII: Planning for Retirement of the Product
Economic Feasibility
The prime objective of setting up a project is to derive a
fair return on the investment.
Economic Feasibility Study, therefore, concerns itself
with matching of economic resources with the physical
requirements of a project and determining the viability of
investment therein.
Techniques:
Break-even Analysis
Ratio Analysis ( Accounting)
Time, value and money
Conceptual Design
Define
problem
Problem statement
Benchmarking
QFD
PDS
Project planning
Product
architecture
Arrangement of
physical elements
to carry out
function
Gather
information
Concept
generation
Evaluation of
concept
Internet
Patents
Trade literature
Brainstorming
Functional
decomposition
Decision matrices
Configuration
design
Parametric
design
Detail design
Prelim. selection of
material and mfg.
Modeling and
sizing of parts
Embodiment Design
Robust design
Tolerances
Final dimension
DFM
Detailed drawings
and specifications
Design Criteria
1. Strength Based Criteria: the strength of the material must be
larger than the induced stress anywhere in m/c element
especially in critical elements.
Creativity
Develop a creative attitude
Unlock your imagination
Be persistent
Develop an open mind
Suspend your judgment
Set problem boundary
Divergence (Analysis)
To increase the search space to find the solution of the
problem.
In this step the objectives are unstable and tentative , the
problem boundary is unstable and undefined, evaluation is
deferred.
The objective of this stage is to find a valuable method for a
design problem.
Aesthetics
Aesthetics is defined as being sensitive to art showing good
taste, being concerned with study or appreciation of beauty.
Concepts of aesthetics for engineering are summarized as under.
1. Function: description of operating function of the product. It should
cover cost, environment, maintenance user acceptance and familiarity,
as well as aesthetic along with its mechanical operation.
2. Form : a form comprises of element like line, proportion, colour and
texture. A designer should sets a unique form by organizing above
elements properly.
3. Unity (Harmony):signifies the harmonies combinations of
components. The designer is able to affect the unity with the help of
similar proportions and shapes.
4. Styling: Styling means decoration and ornamentation. The purpose of
styling is to attract the consumer towards the product.
Ergonomics
Ergonomics is the science of fitting the job to the worker.
Ergonomics is the science of fitting the job to the worker,
matching the physical requirements of the job with the
physical capacity of the worker.
Ergonomics is used to design an environment (layout, work
methods, equipment, noise, etc) which is compatible with
each individuals physical and behavioral characteristics.
Ergonomics looks at the behavior of the person performing
the job. Good ergonomic design makes the most efficient
use of worker capabilities while ensuring that job demands to
not exceed those capabilities
Application of Ergonomics
Mental Blocks
Habitual Blocks: When designer lacks a positive outlook.
And he continue the old processes. Because of this :
He rejects the alternative solution which are new and,
better compared to tried process
Perceptual Blocks: a designer finds it difficult to use all the
sense of observations. he is unable to distinguish the cause and
effect relationship.
Cultural Blocks: due to this he did not follow the proper
methods and avoid the proper reasoning.
Emotional Blocks: Fear of making mistake or appearing
foolish.
Mental Blocks
Perceptual Blocks a designer finds it difficult to use all the sense of
observations. he is unable to distinguish the cause and effect relationship.
o Stereotyping
o Information overload
o Limiting the problem unnecessary
Cultural Blocks due to this he did not follow the proper methods and
avoid the proper reasoning.
Environmental Blocks
Emotional Blocks
o
o
o
o
Intellectual Blocks
Ideonomics
Ideonomics means the method of collecting ideas.
Ideas by individual:
By study the problem carefully and in depth.
To avoid any hasty decision on the problem at the initial stage.
To prepare a record of his ideas in the form of notes or graphs etc.
Brainstorming
Four fundamental brainstorming principles
1. Criticism is not allowed.
2. Ideas brought forth should be picked up by other
people present.
3. Participants should divulge all ideas entering their
minds without any constraint.
4. A key objective is to provide as many ideas as
possible within a relatively short time.