Design Process

Introduction

Engineering and the Company

Product Development

New Product Genesis

The Role of Engineering Design

Product Personnel

Types of Design
Variant
Changes to an existing product

Adaptive
Applying an existing product to a new use

Original
New product for existing or new use

Product Cost

Design and Manufacturing Cost

Change of Effort with Time

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Design Process and Tools

Specifications

QFD

Conceptual
Design

Axiomatic
Design

Embodiment &
Detailed Design

DFX

Concurrent
Engineering

Robust Design
Reliability
FMEA

Prototyping
Testing
Manufacture

DFM/DFA

Repair and
Maintenance

Installation

DFX

Retirement

Commissioning

Customer

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Identify Specifications
Feasibility study
Perform groundwork
Identify customer, listen to customer, identify
product characteristics, perform questionnaire

Quality Function Deployment (QFD)

House of quality
Full QFD

Develop specification
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Project Planning
Business plan
Timeline
Gantt charts, critical path method (CPM),
PERT diagrams

Resource identification and deployment

Risk analysis

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Specifications
Example of specifications
Mass and geometry
Static requirements
Load, deflection, durability
Dynamic requirements
Power, torque, and speed required
Thermal
Operating temperature, heat transfer rate, heat storage
Fluid flow
Flow rate, flow velocity, pressure
Special requirements
Ergonomic considerations, ease of repair
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Conceptual Design
Develop systems by which to address a
design requirement
How can it by solve NOT what can solve it

Try and identify three or four ways by

which to accomplish the design task
Compare the alternates by using a tradeoff
matrix

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Trade-Off Matrix
Characteristic
Weight

Design
Options

Ranking Matrix

Weighted
Sum

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Embodiment
Turn concept into a physical system
Identify elements needed in the design
Identify the location of components within
the design
Determine basic component geometries

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Design Analysis
Static analysis
Yield stress, maximum stress, cycles to failure,
buckling, impact tolerance

Dynamic analysis
Kinematics, kinetics, dynamic forces, interference,
vibration modes

Thermal analysis
Temperature distribution

Fluid flow analysis

Fluid mechanic forces, pressure distributions, velocity
field
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Other Design Considerations

Robust Design
Determine design characteristic that will make
the design insensitive to change

Design for Manufacture

Examine the design with respect to ease and
cost of manufacture

Design for assembly

Examine the design with respect to ease and
cost of assembly (human or automated)
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Detailed Design
Identify all components
In-house manufactured parts
Off-the-shelf components (standard sizes)

Perform an assembly analysis

Tolerance and fit requirements

Generate drawings
Multi-view, exploded view, assembly

Develop parts list

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Prototype Construction
Prototypes allow design solutions to be
evaluated and redesigns to be considered
Optimal design characteristics can be
identified
Manufacturing issues can also be
identified at this stage
Cost is a secondary concern, since one-off
items have to be used
Rapid prototyping methods can be used
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Testing
General operation (benchmarking)
Stresses and deflection
Operating envelope
Torque v speed

Vibration mode determination

Natural frequencies and modes, and noise

Reliability
Accelerated testing
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Reliability Analysis
Component reliability
System reliability
Fault trees and event trees

Failure-Mode Effect Analysis (FMEA)

Failure monitoring
FRACAS (Failure reporting, analysis, and
corrective action system)

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Manufacturing
Identify most appropriate method
Casting, bulk deformation, cutting, joining

Tool path analysis

Path optimization, fixture and jig location, tool
selection, code generation

Manufacturing process lists

Equipment layout
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Summary
The design process has a big impact on
the economic success of a product
The design process has multiple steps and
all should be followed if a successful
design is to be achieved
Concurrent design practices have to be
use and this is facilitated by the
appropriate use of design software
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