Mechanical Design

Process

PART A:
1

Chapter 1:

Introduction to Mechanical Design Process

1.
2.
3.
4.

The Phase of Design

Problem Identification and Definition
Product Design Specification
Concept Development, Evaluation and
Selection

Reference:
Dieter, G. Engineering Design A Materials and Processing Approach, 4th Edition, McGraw Hill, 2009
2
Ulrich, K. and Eppinger, S. Product Design and Development, McGraw-Hill,
2000

The Phase of Design

What is Design?

Design is an innovative and highly iterative process.

It is also a decision-making process

The process of identifying and deeply understanding a problem or need, thinking creatively,
using sound decision-making processes to identify the best solution, and using project
management and teamwork skills to drive the entire process, implement the solution, test it,
and modify it.

Engineering Design integrates mathematics, basic sciences, engineering sciences,

economics and other subjects for the creation of components, systems, product and
processes to satisfy specific needs and constraints (i.e., economics, safety, health,
environmental and social factors, the requirements of standards and legislation, and other
consideration such as maintainability, serviceability, and manufacturability)

The Phase of Design

Engineering Design Problems

Problem Area - Poorly defined

Statement of Problem - Vague

Information Available - insufficient

Final Solution - Compromise of many
solutions

A design problem summaries what is undesirable in a particular situation, and the problem is
considered solved when an improvement in the situation is achieved and acceptable to all parties

The Phase of Design

7 Phases of Design Process

Define
Problem

Gather
Information

Concept
Generation

Evaluation
of Concepts

Product
Architecture

Configuratio
n Design

Phase II.
Embodiment
Design

Phase I.
Conceptual
Design

Phase III.
Detail Design

Phase VII.
Planning for
Retirement

Phase V.
Planning for
Distribution

Phase VI.
Planning for Use
5

Phase IV.
Planning for
Manufacture

Parametric
Design

The Phase of Design

7 Phases of Design Process

Define
Problem

Gather
Information

Concept
Generation

Evaluation
of Concepts

Phase I.
Conceptual
Design

The process in which concepts are

generated with a view to fulfill the
objective (Feasibility Study).
Requires greatest creativity, involves the
most uncertainty and requires
coordination among many functions in
the business organization.
Discrete activities to be considered:
Identification of customer needs
(recognition of problem)
Problem definition (definition of
problem)
Gathering information
Conceptualization (developing design
concept)
Concept selection (evaluation)
Design review

The Phase of Design

7 Phases of Design Process

Need to find: Problem Statement &

Design Specification
Most important steps in the engineering
design process is identifying customer
needs (Problem Identification).
The customer needs can be gained
from:
Interviewing customers Customer
survey
Focus group
Customer
complaints
Tools to achieve this:
Benchmarking
Product Design Specs. (PDS)
Quality Function Deployment
(QFD)
Total Quality management (TQM)
emphasize customer satisfaction
through TQM tools (e.g.,: QFD) and
finally generates a PDS.

Define
Problem

Gather
Information

Concept
Generation

Evaluation
of Concepts

Phase I.
Conceptual
Design

Identification of Customer Needs

Problem Statements/Design Specifications
In order to carry out a design project successfully, two things need to be established as early as possible:
A clear statement of problem to be solved, for which solutions will be sought; and
A set of design specifications, requirements and constraints against which to evaluate the proposed
solutions
Effective problem statements put the problem in context (background), state that problem succinctly (what
the client is trying to solve), and a short discussion on critical goals that the solution must address.

Question to Ponder

Who are my customer?

What does the customer want?
How can the product satisfy the customer while generating profit?
Key questions include:
Which needs are critical? Which are secondary? How well are these needs being currently met?
How do customers use existing products to meet these needs? What other products are out in the
market?
How do customers perceive current products relative to meeting their needs?
Why do customers use the existing products? Practical and/or emotional reasons?
8

Preliminary Research on Customer Needs

Initial works may be done by a marketing department specialist or a team made up of marketing and design
professionals.
Marketing specialist focus on the buyer of the product & similar products.
Design professionals focus on the needs that are unmet in the marketplace and technological approaches in
meeting the needs.
Ways to understand the needs of a targeted customer:
Own experience of the product development team themselves.
No better group to start identifying unmet needs than the members of a product development team who also
happen to be end users of what they are designing.
Brainstorming common practice.

Gathering information from customers

Customers desire that usually drives the development of a product, not the engineers vision of
what the customer should want.
Except for technology driven innovative products where customers have never seen before.
How to gather information from customers?
Interviews with customer key questions to ask? (recorded)
Focus groups discussions (recorded)
Customer complaints telephone, letter or email
Warranty data statistics on warranty claims
Customer surveys by mail, email, telephone or in-person
9

Customer Requirements

Not all information gathered from the customers through various methods are all the needs that the customer require.
Some requirements are not expressed because it has become a standard or common need (e.g. a remote control on a TV)
still a need but no longer excites the end user and they may forget to mention it.
Human needs in general:
- Physiological needs thirst, hunger
- Safety & security needs protection against danger
- Social needs being loved, feel belonging to othersPsychological needs self-esteem, self-respect, recognition
- Self-fulfillment needs a persons potential

Views of Customer Requirements

Different customer has different requirements.

Design team point of view mainly related to:

- Product performance
- Time to market
- Cost
- Quality

10

8 basic dimensions of quality for a manufactured

product:
1. Performance
2. Features
3. Reliability
4. Durability
5. Serviceability (maintenance wise)
6. Conformance (meets customer
expectations and established standards)
7. Aesthetics
8. Perceived quality (reputation)

Classifying Customer Requirements

The design team must identify the

requirements that are most important to
the success of the product.
A bit conflicting with engineering
viewpoint to deliver the best possible
performance in all product aspects.
Use Kano Diagram partition
customer requirements into 4 levels:
1. Expecters
2. Spokens
3. Unspokens
4. Exciters

11

Need Analysis Techniques

Defining the Problem

Evaluate the customer needs: separate into musts and wants and prioritise wants
Begin to identify the customer requirements.
Clearly establish the relationships between the customer requirements and the engineering
characteristics of the design
With all of the above information, write a PDS.
The PDS becomes the controlling documentation for the design

13

Benchmarking
Method for measuring company operation against the best company inside and outside of the industries.
Select the product, process, or functional area that is to be benchmark.
Identify the performance metrics that will be measured and used for comparison.
Compare the best in class product or process with the in house equivalent using the performance metrics.
Specified program and actions to meet an exceed the competition

QFD Quality Function Deployment color

A planning and problem solving tool that is finding growing acceptance for translating customer
requirements into engineering characteristics of a product.
A largely graphical method that systematically looks at all the elements that go into the product definition.
Helps organisations seek out both spoken and unspoken needs.
QFD links the needs of the customer (end user) with design, development, engineering, manufacturing,
and service functions.
A process devised to identify the voice of customer and channel it through the entire product development
process (PDP).
Also known as House of Quality

PDS Product Design Specification

A statement of what a product to be designed is intended to do.
Its aim is to ensure the development of a product meets the need of the users.
The PDS is a specification of what is required but not the specification of the product itself.

14

QFD- Quality Function Deployment

15

Identify customer wants

Identify how the good/service will
satisfy customer wants
Relate customer wants to product
hows
Identify relationships between the
firms hows
Develop importance ratings
Evaluate competing products
Compare performance to desirable
technical attributes

House of quality
Interrelationships

Customer
importance
ratings

Relationship
matrix

What the customer

wants

Target values

Competitive
assessment

How to satisfy
customer wants

Weighted
rating

Technical
evaluation
16

E.g.: Designing a new camera

Interrelationships

What the
Customer
Wants

Relationship
Matrix

Technical
Attributes and
Evaluation

What the customer

wants

Customer
importance
rating
(5 = highest)

17

Analysis of
Competitors

How to Satisfy
Customer Wants

Interrelationships

What the
Customer
Wants

Relationship
Matrix

18

Ergonomic design

Paint pallet

Auto exposure

Auto focus

Aluminum components

Low electricity requirements

Technical
Attributes and
Evaluation

How to Satisfy
Customer Wants

Analysis of
Competitors

How to Satisfy
Customer Wants

Interrelationships

What the
Customer
Wants

High relationship
Medium
relationship
Low relationship

Relationship
Matrix

Technical
Attributes and
Evaluation

Relationship matrix
19

Analysis of
Competitors

How to Satisfy
Customer Wants

Interrelationships

What the
Customer
Wants

Relationship
Matrix

Technical
Attributes and
Evaluation

20

Ergonomic design

Paint pallet

Auto exposure

Auto focus

Aluminum components

Low electricity requirements

Relationships
between the things
we can do

Analysis of
Competitors

How to Satisfy
Customer Wants

Interrelationships

What the
Customer
Wants

Relationship
Matrix

Technical
Attributes and
Evaluation

Weighted rating

21

Analysis of
Competitors

How to Satisfy
Customer Wants

Interrelationships

Relationship
Matrix

How well do competing

products meet customer
wants

Company B

Technical
Attributes and
Evaluation

Company A

What the
Customer
Wants

Analysis of
Competitors

How to Satisfy
Customer Wants

Easy to use

Reliable

Easy to hold steady 2

Lightweight

Color corrections

Our importance ratings

22

22

Interrelationships

What the
Customer
Wants

Relationship
Matrix

Analysis of
Competitors

How to Satisfy
Customer Wants

Technical
Attributes and
Evaluation

23

Completed House of Quality

24

Tutorial: http://www.webducate.net/qfd/qfd.html
Eg: Design cloth to
facilitate climbing

Tutorial:Development of a climbing harness

QFD: Quality Function Deployment (QFD).pdf

Product Design Specification (PDS)

Product Planning Information

Customer requirements (What should it do?) - describes the customer needs in language that they
understand
Engineering requirements/characteristics (How should it do it?) Refers to the technical aspects of the
design
- Each ER should be measurable and have an associated target value of range
Correlation between customer requirements and engineering characteristics

Inputs into Design Specification

Customer
Information from customer
Market research
Customer feedback
Technical
Expert information
Technical research
Technical community
feedback
Environmental
Constraints & standards
28

PDS is a basic control and reference document for the design and manufacture of a product or
process
PDS finalizes the process of establishing customer requirements, prioritizing them, and casting
them into a technical framework so design concepts can be established
A PDS specifies a problem not a solution. Rather it denies the task by listing all the conditions the
product will have to meet. This can involve a good deal of research, into market conditions,
competing products and the relevant literature including patents
A document that contains all of the facts related to the outcome of the product development
(document listing the problem in detail).
It should avoid forcing the design direction toward a particular concept and predicting the outcome.
Should be understood that the PDS is evolutionary and will change as the design process
proceeds.
It is important to work with the customer and analyze the marketplace to produce a list of
requirements necessary to produce a successful product.
The designer should constantly refer back to this document to ensure designs are appropriate.

29

Identifying Design Specifications

What do you want the product or process to be

(goals)?
What do you want the product or process to do
(functions)?
What attributes might this new product/process
have to meet functional requirements (features)?
What limitations must the design adhere to
(constraints/standards)?
Generate an specification list with requirements,
functions, and features

Design specifications to consider include:

Functional
Safety
Quality
Manufacturing
Economic
Ergonomic
Ecological
Aesthetic
Life-cycle

30

Steps for Design Specifications

Identify/prioritize customer requirements

Demands &
Wishes

Identify engineering requirements

PDS Checklist

Select target values for engineering

requirements

Mapping
Table

Map engineering and customer requirements

Identify Problem
and Needs

Do
Requirements
Satisfy
Needs?

Determine
Requirements

No

31

Yes

Prioritizing Customer Requirements

On approach to prioritize essential and preferred requirements is to compile information on demands
and wishes
Demands (D) must be met at all times or the proposed solution is not acceptable
Wishes (W) should be taken into account, but only within acceptable costs.

Design Specification Checklist

Requirements

Contributing Factors

Points to Consider

Functional

Overall geometry

Size, heights, width, length,

diameter, space, etc.

Safety

Human

Warnings, training, instructions,

protection, etc.

Quality

Quality control

Inspections, testing, measurements,

etc.

Ergonomic

Design

Human interface, operation,

comfort, layout, etc.

32

Constraints vs. Standards

Constraint a design decision imposed by the environment of a stake holder that impacts or limits
the design
Example: The system must use a PIC18F52 microcontroller to implement processing
functions as per customer request
Standard an established way of doing things that ensure interoperability
Example: USB Ports, D Cell Batteries (Source: Design for Electrical and Computer
Engineers)

Recognizing Constraints/Limitations

Standard

Physical constraints like size or weight

System constraints like power, controls, balance
(gravity), etc
Resources like time and money
Environmental conditions
Ethical/legal
Health/safety
Manufacturability
Sustainability

Safety
Testing
Reliability
Data formats
Documentation
Design methods

33

PDS Document

Product Identification
Market Identification
Key Project Deadlines
Physical Description
Financial Requirements
Life Cycle Targets
Social, Political, & Legal Requirements
Manufacturing Specifications
PLUS - Design Requirements (a) Mapping Table-Customer Requirements/Engineering
Characteristics for comprehensive design specifications along with (b) Design
Specification Checklist)

34

30

Example: PDS
1. What is the product going to be?
2. What are the dimensions of the product?
3. What materials does the product require?
4. What is the estimate cost of the materials?
5. What tools/technology will be used to work on the project?
6. Are the tools/technology accessible, or will special arrangements need to be made?
7. What is the time estimate for completing the project?
8. Where will the product be worked on primarily?
9. Will an outside company be used to complete the project?
10.Will materials need to be ordered? If so, how much time should be allotted for shipping,
ordering, etc?
11.Will an expert in the field need to assist with the creation of the product? If so, when will
this person be contacted to set up a mutually convenient time to meet?
12.Who will benefit from the benefit from the creation of the product?
13.Why is it necessary to create this product?
14.How will the product demonstrate technical knowledge?

35

E.g.:
Product

PRODUCT DESIGN SPECIFICATION

: Lightweight wheel for Formula Student car.

Weight
:Maximum 3 kg
Size
:13 diameter; 15-25mm centre thickness
Timescale
:18 weeks from initial phase to manufacture.
Cost
:Maximum RM300 per wheel
Quantity :4 on initial design run
Safety
:-Design for fatigue life of 250000 cycles at approximately
1.4g loading
-Interface between centre and rims must be airtight
-Smooth surface finish
-Secure fittings
Competition
:There are few competitors in niche market, but various racing wheel
manufacturers.
Maintenance:Seals and bolts must be checked occasionally.
Customer :Lightweight motorsport / weekend racer.
Manufacturing Facilities:Dependent upon material
CNC and Casting in-house.
Other manufacturing must be out-sourced.
Installation :4 inch PCD 4 stud formation.
Materials :Range of materials to be modelled:
Aluminium 2024 T6
Steel
Plastics

36

The Phase of Design

7 Phases of Design Process

Define
Problem

Gather
Information

Concept
Generation

Phase I.
Conceptual
Design

Evaluation
of Concepts

Information from Internet

Engineering URLs

Patent Literature
Intellectual Property
Patents

Handbook

Trade Literature

The Phase of Design

7 Phases of Design Process

Define
Problem

Gather
Information

Concept
Generation

Phase I.
Conceptual
Design

Evaluation
of Concepts

Brainstorming

Functional decomposition

Morphological chart

Generating Design Concepts

Brainstorming
Most common method used by design teams for generating
ideas for design concepts in conceptual design.
Think of all the possible limitations or shortcomings of the
product.

Functional decomposition (breakdown)

A logical approach for describing the transformation between the
initial and final states of a system or device.
Physical decomposition separating the product or
subassembly directly into its subsidiary subassemblies and
components (output = physical decomposition block diagram).
Functional decomposition a general description of a device is
refined into more specific arrangements of functions and
subfunctions.

39

E.g.:
Physical decomposition

Suspension
system

Steering
system

Urban Car

Chassis

Braking
system

Power train

Functional decomposition
Power train

Variable valve
timing

The controller are use to

varies the operational of
the open-closed valve

Direct injection

The gasoline is highly

pressurized, and injected
via a common rail fuel line
directly into the combustion
chamber
40

3.5 cc

The engine consist of 6

pistons

Morphological chart Representing and exploring all the relationships in multidimensional

problems regarding shape and form

41

The Phase of Design

7 Phases of Design Process

Define
Problem

Gather
Information

Concept
Generation

Evaluation
of Concepts

Phase I.
Conceptual
Design

Comparison Based on Absolute

Criteria
Pughs Concept Selection Method
Measurement scales
Weighted Decision Matrix
Analytic Hierarchy Process (AHP)

Comparison Based on Absolute Criteria

Strongly dependent on the expertise of the design team.

Comparing the concepts to a series of absolute filters
Evaluation based on judgement of feasibility of the design
Overall evaluation (definitely will not work/conditionally will work/yes it will work)
Evaluation based on assessment technology readiness
The technology used must be matured enough to be used in the product without
additional research needed.
Evaluation based on go/no-go screening of customer requirement
Question back customer requirement either being addressed by concept or not
Answer should range from (yes-go, maybe-go, no-no go).

43

Pugh Concept Selection Method

This method compares each concept relative to a reference or datum concept.

Each criterion determines whether the concept is better than, poorer than or about the same as the
reference concept.
Steps in this Pugh concept selection method:
1. Choose the criteria by which the concepts will be evaluated
- Can refer to QFD (House of Quality).
2. Formulate the decision matrix
- Concepts on the row headings and criteria on the column headings.
3. Clarify the design concepts
-Make sure every team member understand every concept developed.
4. Choose the datum concept
- Reference concept with which all other concepts are compared.
5. Run the matrix
-Use a three-level scale, better (+), worse (-) or same (S).
6. Evaluate the ratings
-Sum up the +, - and S ratings.
7. Establish a new datum and rerun the matrix
- To gain added insight regarding the highest rated concept.
8. Examine the selected concept for improvement opportunities
- Is there any improvement that can be done considering the worse ratings gained for the
selected concept.

44

45

Weighted Decision Matrix

Evaluating competing concepts by ranking the design criteria with weighting factors and scoring
the degree to which each design concept meets the criterion.
Weighting factors:
- A 5-point scale (0-4) knowledge of the criteria is not very detailed.
- An 11-point scale (0-10) the information is more detail.
The evaluation steps are quite similar to Pugh concept selection method but without any datum.

46

E.g.: Crane hook

Proposed concepts :
Concept 1 : Steel plates welded together
Concept 2 : Steel plates riveted together
Concept 3 : Cast-steel hook (monolithic)

Step 1 Identify the design criteria :

Material cost

Manufacturing cost

Time to produce

Durability

Reliability

Reparability

Step 2 Determine the weighting factor for each design criteria

Construct hierarchical objective tree

47

Crane hook

Cost

Mat.
Cost

Manuf. Cost

Quality in service

Reparability

Durability

Reliability

Time to
produce

O1= 1.0

O11= 0.6

O111= 0.3

O112= 0.5

O12= 0.4

O113= 0.2

O121= 0.6

48

O122= 0.3

O123= 0.1

Step 3 - Form the decision matrix

Concept 1
Design Criterion

Weight
factor

Concept 2

Concept 3

Units
Magnitude

Mat cost

0.18

RM/kg

Manuf. Cost

0.3

Reparability

Score

Rating

Magnitude

Score

Rating

Magnitude

Score

Rating

60

1.44

60

1.44

50

1.62

RM

2500

2.1

2200

2.7

3000

1.2

0.12

Experience

Good

0.84

Excellent

1.08

Fair

0.6

Durability

0.24

Experience

High

1.92

High

1.92

Good

1.44

Reliability

0.12

Experience

Good

0.84

Excellent

1.08

Fair

0.6

Time to prod.

0.04

Hours

40

0.28

25

0.36

60

0.2

7.42

8.58

5.66

The Phase of Design

7 Phases of Design Process

Preliminary Design.
Decisions are made in this design phase: strength, material
selection, size, shape, and spatial compatibility.
Any major changes beyond this design phase become very
expensive.

Product
Architecture

Configuratio
n Design

Parametric
Design

3 major activities:
Phase II.
1. Product architecture
Embodiment
Arrangement of the physical functions
Design
Dividing the overall system into subsystem module
How the physical components of the design are to be arranged and combined?
2. Configuration design
Preliminary selection of materials, modelings and sizing of parts
What features (e.g., holes, ribs, splines and curves) will be present and those features are to be
arranged in space relative to each other?
3. Parametric design
Involves the information on the part configuration and aims to establish its exact dimensions
and tolerances
Important aspect of parametric design is to examine the part, assembly and system for design
robustness

50

Phase II

Embodiment Design: the process in which a structured development of the preferred

concept is carried out

Common Questions to Ask:

Will it Work?
Is it safe?
What function does it serve?
Will it be made from scratch, bought in, or made from a
semi-finished material?
How does it fit in with the rest of the design?
What development will be required?
How long will it last?
How might it fail in practice?

51

43

The Phase of Design

7 Phases of Design Process

Arrangement of the physical elements to carry out its

required function.
Relationship among the components in the product
and the function the product performs.
i.e. defining the building blocks of the product in
terms of what they do and their interfaces
Design for Human Factor
Creating user-friendly Design
2 types:
Integral architecture
Modular architecture

52

Product
Architecture

Configuratio
n Design

Phase II.
Embodiment
Design

Parametric
Design

Integral Architecture
The implementation of function uses only one or
few chunks (large pieces).
Component perform multiple function: so called
function sharing
E.g., wrench, screw driver
1 physical element save large number of function
Changes made to any component tend to
propagate to other (or many physical elements)
Often adopted when there is a constraint of weight,
space or cost

Modular Architecture
The chunk implement only one or a few function.
Accomplish overall function through combination of
building block/modules
Interaction between chunks are well defined
E.g., computer
Advantages:
Components can be manufacture in higher
quantity (reduce cost)
Shortening product development cycles (mod.
develops independently)
Easier to evolve over time
To adapt to needs of different customers
To replaced components as they wear out or
used up

53

Design for human factor

Designing something and considered the
interaction between human and product
Deals with the characteristics, abilities and need of
human and the interfaces between human and
product technical
Related with ergonomics and anthropometric data
4 ways human interact with a product:
as an occupant of workspace
as a power source (muscle power)
as a sensor (looking for warning light)
as a controller (control pedal)

Creating user-friendly design

Fit the product to the users physical attributes and
knowledge (from ergonomics and anthropometric
data)
Simplify tasks-straightforward
make the controls and their functions obvious
(place the control for function adjacent to the
device)
Provide feedback (sound or flashing dashboard
light)
Good displays (digital/analog)
Make controls easy to handle
Standardize (arrangement of brake and clutch)
Anticipate human errors (provide warning or
emergency button)

54

The Phase of Design

7 Phases of Design Process

Establishing the shape and general dimensions of

the components.
Preliminary selection of materials, parts, sizing, etc
Components include special purpose parts, standard
parts, standard assemblies or modules.
Develop from function.
Configuration depending on:
1. Available materials and production methods
2. Spatial constraints
3. Product architecture

55

Product
Architecture

Configuratio
n Design

Phase II.
Embodiment
Design

Parametric
Design

Modeling
Represent physical appearance of the design ideas
Engineers use model for thinking, communicating,
predicting, controlling, and training
various types (e.g., scale models, prototype, equtions,
CAD/CAE modeling)

Simulation
Model subject to various input or environmental
condition
To observe how they behave

Explore the result has might be obtained form the

real-world system
Manipulation of the model
Usually involves computer performance
E.g., prototype model, simulator

Analysis
Involves calculation form understanding of
mathematical and engineering fundamental
Ensuring the design concept are able and reliable to
performed and manufactured
Finite-element analysis solves wide range of
engineering problems area such as stress, thermal,
flow, etc
Several type of software (Nastran, Abacus, Lusas,
Ansys)
*However, understanding the fundamentals are
important

Materials Selection
An important aspect of design for mechanical,
electrical, thermal, chemical or other application is
selection of the best materials
Systematic selection of the best material for a given
application begins with properties and costs of
candidate materials.

56

The Phase of Design

7 Phases of Design Process

Final Dimensions, Design for Manufacturing, Structural

analyses
Set the dimensions and tolerances in order to maximize
quality and performance and minimize cost.
Objective : to set values for the design variables that will
produce the best possible design considering both
performance and manufacturability.
A few established method in designing to maximize
performance and quality :
FMEA (Ratings for severity, occurrence and
detection of failure)
Design for reliability
Robust design
Design for Assembly (DFA)
Design for Manufacture (DFM)

57

Product
Architecture

Configuratio
n Design

Phase II.
Embodiment
Design

Parametric
Design

Failure Mode and Effect Analysis (FMEA)

FMEA is designed to assist the engineer improve the quality and reliability of design
Properly used FMEA provides the engineer several benefits such as:
Improve product/process reliability and quality
Increase customer satisfaction
Early identification and elimination of potential product/failure modes
Prioritize product/process deficiencies
Capture engineering/organization knowledge
Emphasizes problem prevention
Documents risk and actions taken to reduce risk
Provide focus for improved testing and development
Minimizes late changes and associated cost
Catalyst for teamwork and idea exchange between functions.

58

Design for Assembly (DFA)/Design for Manufacture (DFM)

Principle of DFA/DFM
Minimize part count
Use standardize part
Correct assembly tolerances

Design for Assembly Guidelines

Simplicity-minimize part number, part variety, simplify assembly sequences and component handling and inse

Standardize-On material usage

Use the widest possible tolerance

Choose material that suit function and production process

Minimize non value added operations

Team work

Reduce number of parts

Ensure that the remaining parts are easy to assemble

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Design for Assembly Outcomes

Shorten product design time
Reduce assembly time
Simplify assembly process
Reduce total material cost
Improves quality and reduce defects
Reduce labour content

Guidelines for Manual Assembly

- Handling

Divided into 2 areas:

- Insertion and fastening
Design Guidelines for Insertion and Fastening

Provide chamfers

Provide clearance

Standardize

Design a part which can be locate before it is released

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Design Guidelines for Part Handling

Avoid tangling part
Part should have end to end symmetry
Avoid part that stick together, small slippery and dangerous to the handler

Factors that will affect handling

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Design feature that will help assembly process

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Design to avoid adjustment during assembly

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Design concept that will provide easier access during assembly

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Design for Manufacture (DFM)

Design for ease of manufacture of the collection of parts or product

More as a philosophy
It is a way of thinking that can be applied to component or product
DFM 3 key element
Process selection
Reducing the number of process stages
Designing of the process

Process Selection

Analysis of material and processing methods for individual component based on:
Tolerance requirement
Production volume
Component complexity requirement
Critical performance criteria

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Reducing Process Stages

Eliminate unnecessary process stages through:
Component minimization
Elimination of finishing process
Combining processes

Basic Principles of Designing for Economic Production

Standard material and component

Standardized design of product itself

Liberal tolerance

Design part so that many operation can be carried out without reposition it

Simplicity

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Relationship between relative cost and surface roughness

Surface symbol designation

Surface roughness (um)

Approximate relative cost %

Rough machine

250

100

Standard machining

125

200

Fine machining, rough ground

63

440

Very fine machining, grinding

32

720

Fine grinding shaving and honing

16

1400

Very fine grinding, shaving honing

2400

Lapping, burnishing polishing

4500

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Relationship between relative cost and dimensional tolerance

Process

Dimensional Tolerance
(in)

Approximate relative cost %

Rough machining

0.03

100

Standard machining

0.005

200

Fine machining/ Rough grinding

0.001

300

Very fine machining/ ordinary grinding

0.0005

600

Fine grinding, shaving honing

0.0002

1000

Lapping, burnishing, super honing

0.00005

3000

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Design of the Process

To ensure design of component will satisfy the specific production process
Exploit the benefits and limitation of the process
Design for machining
Design for casting
Design for injection moulding
Design for Powder Metallurgy

Design for Machining

Choose raw materials that will result in minimum component cost
Try to design component that can be machined by one machine tool only
Utilized standard pre shaped workpiece
Avoid bent holes and dogleg Avoid internal feature for long components
Provide base for work holding and references
Employ standard machine features wherever possible
Specify the widest tolerance and the roughest surface that will give the required
performance

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The Phase of Design Process

7 Phases of Design Process

Creation of final drawings and specifications

Any missing or incomplete information are added
arrangement, form, dimensions, tolerances, surface
properties, materials and manufacturing of each part
Activities to be completed in the detail design phase
(documentation):
Detail engineering drawing.
Verification testing of prototype.
Assembly drawings and instruction, BOM.
A detailed product specification.
Decisions either to fabricate each part or to
buy it
A detailed cost estimation.
A design review as a conclusion of the detail
design phase before being passed to
manufacturing.

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Final Phase- Detail design

Waiting for final decision to be manufacture
The design is brought to the stage of a complete
engineering description of a tested and
producible product.

Phase III.
Detail Design

Phase III

Detail Design : the process in which the precise shape, dimension, and tolerances are specified, the material
selection is confirmed, and the method of manufacture is considered for every individual component of the
product
Detail Engineering Drawing - First task to be complete in detail design
Gives details of product specification in size and layout/views
Should also be understandable to production or customer
Drawing of each:
Component
Subassembly
Assembly
Information on details drawing include:
Standard views of orthogonal projection (top, front, side views)
Auxiliary views such as section, enlarge views or isometric views that aid in visualizing the
component and clarifying the details
Dimensions (Presented according to the standard)
Tolerances
Materials specification, and any special processing instructions
Manufacturing details; such as parting line location, draft angle, surface finish
Title block-with drawing title, scale, type of projection, name, logo, file location, etc.

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Bill of Materials (BOM)

is a list of each individual component on the product
It lists the part description, quantity needed for a complete assembly, part number, sources of the
part and purchased order number
also lists the name of responsible person

NOTE: While many consider that the engineering design process ends with detail design, there
are many issues that must be resolved before a product can be shipped to the customer. These
additional phases of design are often folded into what is called the product development process.

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The Phase of Design

Phase IV: Planning for manufacture
Design of tooling and fixtures, designing the process sheet and the production line, planning the
work schedules, the quality assurance system, and the system of information flow.

Phase V: Planning for distribution

Planning for packaging, shipping, warehousing, and distribution of the product to the customer.

Phase VI: Planning for use

The decisions made in phases I through III will determine such important factors as ease of use,
ease of maintenance, reliability, product safety, aesthetic appeal, economy of operation, and product
durability.

Phase VII: Planning for product retirement

Again, decisions made in phases I through III must provide for safe disposal of the product when it
reaches its useful life, or recycling of its materials or reuse or remanufacture.

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Example Questions related to Part A : Mechanical Design Process

A

Answer

Answer