Chapter 1
- 1. DEPARTMENT OF MANUFACTURING AND MATERIALS ENGINEERING MME 4116 PRODUCT DESIGN AND DEVELOPMENT BY: DR MOHD RADZI BIN HAJI CHE DAUD
- 3. 1.1 Introduction What is design? Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies 3
- 4. What is design? 4 • “To fashion after a plan!” • To design is: To synthesize new or to arrange existing things in a new way to satisfy a recognized need of society. “Design establishes and defines solutions to and pertinent structures for problems not solved before, or new solutions to problems which have previously been solved in a different way.” Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies
- 5. The Four C’s of Design 5 • Creativity Requires creation of something that has not existed before or has not existed in the designer’s mind before. • Complexity Requires decisions on many variables and parameters. • Choice Requires making choices between many possible solutions at all levels, from basic concepts to the smallest detail of shape. • Compromise Requires balancing multiple and sometimes conflicting requirements. Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies
- 6. 1.2 Engineering Design Process Why is engineering design process needed? Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies 6
- 7. Importance of the Engineering Design Process 7 • Decisions made in the design process cost very little in terms of the overall product cost but have a major effect on the cost of the product. • You cannot compensate in manufacturing for defects introduced in the design phase. • The design process should be conducted so as to develop quality, cost-competitive products in the shortest time possible. Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies
- 8. Product Cost Commitment during Phases of the Design Process 8 Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies Adapted from D. Ullman, The Mechanical Design Process, 4th ed., McGraw-Hill, New York,2010.
- 9. Types of Designs 9 • Original Design: Innovative design • Adaptive Design • Redesign: Variant design • Selection design Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies
- 10. 1.3 Ways To Think About The Engineering Design Process What do we mean by “designing a system”? Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies 10
- 11. Simplified Iteration Model 11 Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies Adapted from M. Asimow, Introduction to Design, Prentice-Hall, Englewood Cliffs, NJ, 1962.
- 12. Design Method Versus Scientific Method 12 Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies Adapted from P. H. Hill, The Science of Engineering Design, Holt, Rinehart and Winston, New York 1970.
- 13. A Problem-Solving Methodology 13 • Definition of the problem • Gathering of information • Generation of alternative solutions • Evaluation of alternatives and decision making • Communication of the results Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies
- 14. How The Design Depends On How The Problem Is Defined 14 Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies
- 15. Design Paradox Between Design Knowledge and Design Freedom 15 Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies
- 16. 1.4 Description of Design Process What are the steps of Design Process? Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies 16
- 17. Design Process Phases 17 • Phase I: Conceptual Design • Phase III: Detail Design • Phase II: Embodiment Design Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies
- 18. Phase I. Conceptual Design 18 Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies
- 19. Phase II. Embodiment Design 19 Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies
- 20. Phase III. Detail Design 20 Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies
- 21. Engineering Design Process 21 Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies
- 22. 1.5 Consideration Of A Good Design What are the various considerations of a good design? Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies 22
- 23. Considerations of Good Design 23 1) Achievement of Performance Requirements 2) Life-Cycle Issues 3) Social and Regulatory Issues Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies
- 24. Achievement of Performance Requirements 24 • A major characteristic of a design is its function. • Performance Requirements: Primary Performance Requirements Complementary Performance Requirements Part (Component): A single piece requiring no assembly Assembly: When two or more parts are joined. Subassemblies: Smaller assemblies which compose larger assemblies. Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies
- 25. Total Materials Life Cycle 25 Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies Reproduced from “Materials and Man’s Needs,” National Academy of Sciences, Washington, D.C., 1974.
- 26. Regulatory and Social Issues 26 The code of ethics of all professional engineering societies require the engineer to protect public health and safety. Example of Standards and Codes: ASME: American Society of Mechanical Engineers ASTM: American Society for Testing and Materials OSHA: Occupational Safety and Health Administration CPSC: Consumer Product Safety Commission EPA: Environmental Protection Agency DHS: Department of Homeland Security Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies
- 27. 1.6 Computer-Aided Engineering What are the changes that plentiful computing has produced? Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies 27
- 28. Computer-Aided Engineering (CAE) 28 The advent of plentiful computing has produced a major change in the way engineering design is practiced. Advantages of Computer-Aided Engineering: Automated engineering drawing in two dimensions Three dimensional modeling Finite Element Modeling (FEM) Rapid prototyping Design optimization Computer-Aided Design (CAD) Computer-Aided Manufacturing (CAM) Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies
- 29. 1.7 Designing To Codes And Standards What are the codes and standards? Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies 29
- 30. Designing To Codes And Standards 30 • A code is a collection of laws and rules that assists a government agency in meeting its obligation to protect the general welfare by preventing damage to property or injury or loss of life to persons. • A standard is a generally agreed-upon set of procedures, criteria, dimensions, materials, or parts. • Efficiency • Safety • Interchangeability • Compatibility Chief Aspects of Designing To Codes and Standards: I n c r e a s e Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies
- 31. Two Broad Forms of Codes 31 • Performance Codes are stated in terms of the specific requirement that is expected to be achieved. • Prescriptive(specification) Codes state the requirements in terms of specific details and leave no discretion to the designer. Performance Codes Prescriptive Codes Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies
- 32. 1.8 Design Review What is design review? Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies 32
- 33. Design Review 33 • A design review is a retrospective study of the design up to that point in time. • The essence of the technical review of the design is to compare the findings against the detailed Product Design Specification (PDS). • The PDS is a detailed document that describes what the design must be in terms of: – Performance requirements – Environment in which it must operate – Product life – Quality – Reliability – Cost – Host of other design requirements Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies
- 34. Redesign 34 • Two categories of redesigns: – Fixes – Updates • A fix is a design modification that is required due to less than acceptable performance once the product has been introduced into the marketplace. • Updates are usually planned as part of the product’s life cycle before the product is introduced to the market. Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies
- 35. An Examples of Design Update 35 Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies
- 36. 1.8 Societal Considerations in Engineering Design What are the effects of engineering design on society? Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies 36
- 37. Societal Considerations in Engineering Design 37 • ABET Code of Ethics: “Engineers shall hold paramount the safety, health, and welfare of the public in the performance of their profession.” • Some influences on the practice of engineering design due to increased societal awareness of technology: – Greater influence of lawyers on engineering decisions – More time spent in planning and predicting – Emphasis on “defensive research and development” – More effort expended in research, development, and engineering in environmental control and safety.Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies
- 38. Characteristics of an Environmentally Responsible Design 38 • Easy to disassemble • Able to be recycled • Contains recycled materials • Uses identifiable and recyclable plastics • Reduces use of energy and natural materials in its manufacture • Manufactured without producing hazardous waste • Avoids use of hazardous materials • Reduces product chemical emissions Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies
- 39. Keys Roles of Government in Interacting with Technology 39 • As a stimulus to free enterprise through changes in the tax system • By influencing interest rates and the supply of venture capital through changes in fiscal policy to control the growth of the economy • As a major customer for high technology, chiefly in military, space, andS energy systems • As a funding source (patron) for research and development • As a regulator of technologyDieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies
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