Design Validation Series ....

How to Ensure that Your Designs Work?

EGS India

Agenda

Current Scenario

Design Process

Validating Design Why & When

Ensuring Working Design How?

Benefits

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Where do we stand today?

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Design Process

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Validating Design Why & When

Increases Design Confidence
Improves Reliability
Eliminates Errors
Reduces Input Cost
Assures Superior Performance
Enhances Product Quality
Protects Product Safety
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When to Validate a Design?

If...

Product Cost is Important

Increased Profitability is a Must

Enhanced Warranty is a Threat

Improved Reliability is mandatory

Green Design is in Focus to protect Environment

Customer Satisfaction is required

Product Development Cycle Time should be reduced

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Design Validation Objectives

Sizing

Weight

Cost

Safety

Performance (Deflection, Stresses, Vibration, Efficiency)

Life (Warranty)

Quality

Sustainability

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Machine Design Validation

Will any Shaft break?

What is the life expectancy of the
system?
Can I meet the weight target?
Will Power consumption be more?
Will anything break under
Warranty?
If I were to reduce 10% of product
cost, where would I start?
Will I get vibration & noise?
Why should the customer buy my
product?

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Power Train Design Validation

Will my Gearing Wear out?

Will there be vibration and noise
during operation?
Does the casting wall thickness
need to be 22mm?
Can heat generation be kept
under control?
Can I select lower sized bearings
without compromising on
performance?
What is the abusive load the
system can handle?
Can my product be robust at the
same time look sleek?

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Anti-Vibration Mounts Design Validation

Can the Mount meet the
required dynamic
Charateristics ?
Will the mounts meet the NVH
Targets?
How does the product compare
to competitive products already
in market place?
Will the mount meet the tri-axial
durability targets?
How to achieve the cost targets?
Will the design meet the life
expectancy?
Can alternate material be used?
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Equipment Design Validation

Will my equipment pass hydro-test?
What will happen during earthquake?
Can I get pressure and velocity profiles
for higher efficiency?
How can I eliminate shaft breakages?
Will my design meet ASME Code FEA
requirements?
Can I achieve weight targets without
compromising on safety?
Can I use alternate material?
Can I find out the load distribution?

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System Design Validation

Will my system withstant burst
pressure test?
Can I reduce my BOM?
Are my pipe sizing and support
adequate?
What are the possible failure modes
I can expect?
Is it possible to use a smaller pump
for lower power consumption?
Where are the performance
bottlenecks?
Is my Design Safe?

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Machine Tool Design Validation

Can Tool Vibration be

eliminated?
Can I increase tool life?
Is it possible to reduce tool
change over time?
Frequent failures of tool
can be prevented?
Can deflections be
maintained within specified
limits?
Call all forces be
estimated?

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Material Handling Equipment Design Validation

Will deflections be under control?
How much material can I save?
Can I get load distribution?
Do I have acceptable Weld strength
in critical locations?
What is the maximum load the
structure can withstand?
Will there be vibrations during
operation?
How to meet price reduction
targets?
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Medical Equipment Design Validation

Will my medical device work without
any stoppage?
How reliable is my product?
Will the surgeons be able to handle it
without any problem?
How to keep our development costs
low?
Can I avoid product recall?
Is my device safe for usage?
What is the technological edge I have
over my competition?

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Pump Design Validation

How efficient is my pump?
Can power consumption be
reduced for the same flow
characteristics?
How can we reduce product
cost?
What is the MTBF for my pump?
How can I eliminate vibration
problems?
How can I ensure that the
bearings and seals do not fail?
How can I extend warranty
without cost penalty?
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Mechanism Design Validation

Will my Design Work?
How efficient is the design?
Can I Optimize my design for least
power ?
Is it possible to obtain required
response time?
Where would it fail?
What is the Mean Time Between
Failures?
Can my design be cost-effective?

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Corporate Social Responsibility

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Sustainability Touching Lives

Will anyone:

Buy a pump that consumes more energy?

Buy an Air-conditioner that draws more current?
Live next to door to a garbage disposal centre?
Buy a washing machine that consumes more water?
Drive a noisy car?
Buy a mobile with less talk time between power
recharge?

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Sustainability Regulatory Angle

Eco-friendly labelling of products is mandatory

Initially applicable to Refrigerators, Air-Conditioners,
Distribution Transformers, Fluorescent Lamps
Now on Electric Motors, Color TVs, LPG Stoves have to carry
mandatory labelling

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ISO 14001:2004 Environmental

Management Systems Guidelines
An EMS meeting the requirements of ISO 14001:2004 is a
management tool enabling an organization of any size or
type to:

Identify and control the environmental impact of its activities,

products or services, and to
Improve its environmental performance continually, and to
Implement a systematic approach to setting environmental
objectives and targets, to achieving these and to demonstrating
that they have been achieved.

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Sustainability Considerations in Design

Environmental Impact

Carbon Footprint

Energy Consumed

Air Acidification

Water Eutrophication

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Implementation Considerations

Minimal Material Use

Improved Material Choices
Design for Ease of Disassembly
Product Reuse or Recycling at End of Life
Minimal Energy Consumption
Manufacture without producing Hazardous Waste
Use of Clean Technologies as a Fundamental Mindset

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Sustainability & Bottom line Profitability

Goal

Benefits

Least amount of material

Reduced Cost

Least amount of Energy

Reduced Cost

Least amount of Resources

Reduced Cost

Eco-Friendly

Increased Value / USP

Smallest Carbon Footprint

Incalculable Value

Recipe for Success !

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Design Validation Enables us to ...

Innovate

Improvise

Indigenize

Improve Profitability

Give the Best to our Customers

Be the Best Corporate Citizens

Leave a Greener Earth for Future Generations

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