BITS Pilani

Pilani | Dubai | Goa | Hyderabad

Revision
The Four C ’s of D esi gn

Choice
Engineering Design Process
• Importance of the Engineering Design Process

Cost Commitment

Labour
15%
Overhead
50%
30% Design

Production and
5%
Material
Engineering Design Process

• Types of Designs

– Original design (Innovative design)

– Adaptive design

– Redesign (Variant design)

– Selection design

– Industrial design
Description O f Design Process

Design process (Morris Asimow : Morphology of design)

Conceptual Design

Embodiment Design

Detail Design

Planning for Manufacture

Planning for Distribution

Planning for Use

Planning for Retirement of the Product

Description O f Design Process

• Phase I: Conceptual Design

• Phase II: Embodiment Design
• Phase III: Detail Design
• Phase IV: Planning for Manufacture
• Phase V: Planning for Distribution
• Phase VI: Planning for Use
• Phase VII: Planning for Retirement
of the Product
Product Develo pment Process

Types of product development process:

1. Stage gate development process
2. Spiral product development process
3. Hybrid product development process

Success of a product:
• The quality, performance, and price of the product.
• The cost to manufacture the product over its life cycle.
• The cost of product development.
• The time needed to bring the product to the market.
Product and Process C ycl e
C oncurrent Engi neering Teams

• Conventional way:

– Distinct Functions

– Separate department (No interlinking)

• Main elements:

– Cross-functional teams

– Parallel design

– Vendor partnering
R everse Engi neering and R edesi gn
Product Qual i ty and C ustomer R equi rements
H ouse of Qual i ty: Exampl e C D case
Team
Probl em -sol ving Tool s
• Brainstorming
Problem Definition • Affinity diagram
• Pareto chart

• Gathering data
Cause Finding • Analyzing data
• Search for root causes

Solution Finding and • Brainstorming

Implementation • How-how diagram
• Concept selection
Sources of Informati on
C reati ve Thi nki ng Methods
Functi on Structure
Functi on Structure
Morphol ogical Method: Exampl e
TR IZ

• TIPS (TRIZ) is based on two basic principles

1. Somebody, sometime, somewhere has already solved your problem or one similar to it.
Creativity means finding that solution and adapting it to the current problem.

2. Don’t accept contradictions. Resolve them.

Pugh concept sel ecti on: Exampl e
• Improvement of on/off switch in a right-angle drill:

• Concept A is a modest change to the

existing switch, and will be the DATUM.
• Concept B adds three buttons for on/off/
and reverse.
• Concept C is a track and slider design.
• Concept D is an add-on accessory to make
it easier to operate the existing switch.
Pugh concept sel ecti on: Exampl e

• The highest-ranking design, an add-on

attachment that makes it easier to operate the
switch, has two negatives, poorer aesthetic
appeal and poor ergonomics (comfort to the
hand).
• Design D provides force amplification, but it is
not easy on the ligaments in the fingers.
• The next ranking design, the track and slider
design, has only a single minus for “availability
of materials.”
Introducti on
Content : Embodiment Design
• Introduction
• Product architecture
• Configuration design
• Best practices for configuration design
• Parametric design
• Dimensions and tolerances
• Industrial design
• Human factors design
• Design for environment
• Prototyping and testing
• Design for ‘X’
Product Archi tecture
 Product Archi tecture

• Product architecture is the arrangement of the physical elements of a product to carry out
its required functions.

– Mapping from product function to the product form

– Layout and architecture of the product their interfaces (Best possible architecture
selection).

– Rough sketches of concepts

– Proof-of-concept model

– Key decisions on how the product will physically operate

– Key milestone for any class of products

Archi tecture Types

Architecture
Types

Integral Modular

Slot Bus Sectional Mix

Integral Archi tecture

 Only one or few modules

 No individual isolated components
 Components perform multiple
functions
 Complex interactions
 Changes made to any component in a
integral architecture tend to propagate
to many
 High-volume products
 Product architecture has strong
implications for manufacturing costs.
Modul ar Archi tecture

• Overall function through the combination of distinct building blocks

or modules.
• A modular architecture makes it easier to evolve a design over
time.
• Difficulties may be faced in initial stages because compatibility of
the modules in first product needs to be established with those in
the subsequent products.
• The product can be adapted to the needs of different customers by
adding or deleting modules.
Modul ar Archi tecture

• It helps to develop a product family.

• Modular products make economic sense

• They offer easier assembly and disassembly, modification and reassembly

• Standardization of components

• Re-configurability of devices
Modul ar vs. Integrated archi tecture

Pros Cons
• Improve device reconfigurability • May make devices look
• Increases the device variety and similar
speed of introduction for new • Reduces device
Modular devices performance
• Improves maintainability and • More expensive
Serviceability
• Decuples development and
manufacturing tasks
• Harder for competitor to copy the • Hinders changes of design
design in production
Integral • Tighter coupling of teams with less • Reduce the varity of
interface problems devices that can be
• Possible reduction in system cost produced.
C onsi derati ons at product archi tecturi ng

• How will it affect the ability to offer product variety?

• How will it affect the product cost?

• How will it affect the design lead time?

• How will it affect the development process management?

Modul ar Archi tecture

Modular
Architecture

Manufacturing Function based

based modularity modularity

Original
Assembly Equipment
Conceptual
modules Manufacturing Sizable Bus
(OEM) modules modules Slot Sectional Mix
modules
Functi on based modul ari ty
Functi on based modul ari ty
 Functi on based modul ari ty: E xampl e

Modular trailer architecture exhibiting a one-to-one mapping

Function structure of a trailer from functional element to physical component

Karl Ulrich, The role of product architecture in the manufacturing firm, Research Policy 24 (1995) 419-441)
 Functi on based modul ari ty: E xampl e

Integral trailer architecture exhibiting a one-to-one mapping from functional element to physical component

Karl Ulrich, The role of product architecture in the manufacturing firm, Research Policy 24 (1995) 419-441)
 Functi on based modul ari ty: E xampl e

Karl Ulrich, The role of product architecture in the manufacturing firm, Research Policy 24 (1995) 419-441)
 Functi on based modul ari ty: E xampl e

Karl Ulrich, The role of product architecture in the manufacturing firm, Research Policy 24 (1995) 419-441)
 Functi on based modul ari ty: E xampl e

Karl Ulrich, The role of product architecture in the manufacturing firm, Research Policy 24 (1995) 419-441)
Factors affecti ng archi tecture modul ari ty

• Product changes
Upgrade
• Product variety

• Component standardization

• Product performance Add-ons Re-use

• Manufacturability

• Product development management

Flexibility
Adaptation
in use
Archi tecture D esi gn Process

Create a schematic of the product

Cluster the elements of the schematic

Create a rough geometric layout

Identify the fundamental and incidental interactions

Archi tecture D esi gn Process
• Creating a product schematic: DeskJet Printer Schematic
Archi tecture D esi gn Process
• Cluster the elements of the schematic: DeskJet Printer Schematic
Archi tecture D esi gn Process
• Create a rough geometric layout: DeskJet Printer Schematic
Archi tecture D esi gn Process
• Identify the fundamental and incidental interactions: DeskJet Printer Schematic
 Archi tecture D esi gn Process
Laser-fusing rapid prototyping machine
Archi tecture D esi gn Process
Archi tecture D esi gn Process
Archi tecture D esi gn Process
• Define Interactions and Determine Performance Characteristics:

– Functional requirements

– Drawings or sketches of the module and its component parts

– Preliminary component selection for the module

– Detailed description of placement within the product

– Detailed descriptions of interfaces with neighboring modules

– Accurate models for expected interactions with neighboring modules

Fundamental D eci si ons

• Integral vs. modular architecture?

• What type of modularity?

• How to assign functions to chunks?

• How to assign chunks to teams?

• Which chunks to outsource?

C onfi gurati on D esign

Four possible configurations of features for a right-angle bracket. (a) Bent from a flat plate.(b) Machined from a solid
block. (c) Bracket welded from three pieces. (d) Cast bracket.
C onfi gurati on D esign

• Review the product design specification and any specifications developed for the particular
subassembly to which the component belongs.

• Establish the spatial constraints that pertain to the product or the subassembly being designed.
C onfi gurati on D esign

• Create and refine the interfaces or connections between components. Much design effort occurs
at the connections between components, because this is the location where failure often occurs.
Identify and give special attention to the interfaces that transfer the most critical functions.

• Before spending much time on the design, answer the following questions:
– Can the part be eliminated or combined with another part?

– Can a standard part or subassembly be used?

• Generally, the best way to get started with configuration design is to just start sketching
alternative configurations of a part (Substituting, Combining, Decomposing, Magnifying,
Minifying, Rearranging).
Anal yzi ng the C onfi gurati on D esign
Eval uati ng the confi gurati on desi gn

• Performance

• Cost

• DFMA

• DFE

• Ergonomics and aesthetics

Best practi ces for confi gurati on desi gn

• Clarity of function pertains to an unambiguous relationship.

• Simplicity refers to a design that is not complex and is easily understood and readily produced.

• Safety should be guaranteed.

• Minimal impact on the environment

• Design guidelines:
– Force transmission

– Division of tasks

– Self-help

– Stability
Addi ti onal Design guidelines

• Tailor the shape to the stress or load distribution

• Avoid geometry that is prone to buckling

• Use triangular shapes and structures

• Don’t ignore strain considerations in design

Interfaces and C onnecti ons

Adjustable connection

Fixed, nonadjustable
Connections

connection

Separable connection

Hinged or pivoting
connection

Locator connection
C heckl i st for C onfi gurati on D esign

• Identify the likely ways the part might fail in service:

• Excessive plastic deformation.

• Fatigue failure

• Stress concentrations

• Buckling

• Shock or impact loads

• Identify likely ways that part functionality might be compromised:

• Tolerances.

• Creep.

• Thermal deformation
C heckl i st for C onfi gurati on D esign

• Materials and manufacturing issues:

• Is the material selected for the part the best one to prevent the likely failure modes in service?

• Is there a history of use for the material in this or similar applications?

• Can the form and features of the part be readily made on available production machines?

• Will material made to standard quality specifications be adequate for this part?

• Will the chosen material and manufacturing process meet the cost target for the part?
C heckl i st for C onfi gurati on D esign
• Design knowledge base:
• Are there aspects of the part design where the designer or design team is working without adequate

knowledge?

• Have you considered every possible unfortunate, unlikely, or unlucky event that could jeopardize the

performance of the design? Have you used a formal method like FMEA to check for this?
Parametri c desi gn

Formulate the parametric design problem

Generate alternative designs

Analyze the alternative designs

Evaluate the results of the analyses

Refine/Optimize
Fai l ure Modes and Effects Anal ysi s (FMEA)
• FMEA is an analytical technique used to identify, define, and eliminate, to the extent possible, known
as potential failure modes of product system.
• FMEA Goals:
– Evaluation of design requirements and design alternatives.
– Initial design for manufacturing and assembly requirements.
– Increasing the probability that potential failure modes and their effects on system operation have been
considered in the design/development process.
– Providing additional information to aid in the planning of thorough and efficient design improvements and
development testing.
– Providing an open issue format for recommending and tracking risk reducing action.
– Providing future references to aid in analyzing field concerns, evaluating design changes, and developing
advanced designs.
FMEA basi c questi ons

• What could fail or go wrong with each component of a product?

• To what extent might it fail, and what are the potential hazards produced by the failures?

• What steps should be implemented to prevent the failures?

• These questions gives rise to three basic elements of FMEA: failure modes
(identification), failure effects (ramifications) and failure criticality (relative importance of
given failure states).
Steps i n FMEA

List each sub-assembly and component number,

along with the basic functions or function chains of
the component
11 –– No
Almost
effect
certain
Identify and list the potential failures for each product
component 22 –– Very
2/3 High
– Lowminor
(relatively
(only noticed
few failures)
by
discriminating
4/5/6
3 – Moderate customers)
– Moderate (occasional
List the possible potential causes or mechanism of the
failure modes 3 – Minor
failures)
4/5/6 (affects very
– Moderate – mostlittle on
the
7/8 system; notice
– High (repeated
customers are byfailures)
annoyed average
List the potential effects of the failure, including impact
customers)
on the environment, property and hazards to human •9/10
7/8 ––Low
1000 Very high (failure
= Harmful is almost
or hazardous
users 4/5/6 – Moderate (most
•9/10
inevitable)
1 = –Failure is highly unlikely
customers are annoyed)absolute
Very remote to
Rate the likelihood of occurrence (O) of the failure and unimportant
uncertainty
• 100
7/8 – High (causes
= Need a loss of
to consider
Estimate the potential severity (S) of the failure and its
•primary functions; customers are
30 = Safe
effects
dissatisfied)
Logi cal rel ati onshi p of FMEA
FMEA Templ ate
FMEA Exampl e: Bal l poi nt pen
 Tol erances stackup

𝑋𝑚𝑎𝑥 = +
−0.01 𝑚𝑚

The tolerance on the overall length is TL = 86.04 – 85.96 = 0.08 and L = 86 (+-) 0.04 mm.
Geometri c D i mensi oning and Tol eranci ng

• Tolerance issues are described and specified by a system of Geometric Dimensioning and
Tolerancing (GD&T) based on ASME standard Y14.5M-1994.

• GD&T is a universal design language to precisely convey design intent

1) It clearly defines the datum surfaces from which dimensions are measured

2) It specifies a tolerance zone that must contain all points of a geometric feature

Datums:
Materi al C ondi ti on Modi fi ers

• Maximum material condition (MMC)

• Least material condition (LMC)

• Regardless of feature size (RFS)

Gui del i nes for Tol erance D esi gn

• Focus on the critical-to-quality dimensions that most affect fit and function.

• For the noncritical dimensions, use a commercial tolerance recommended for the production
process of the components.

• A possible alternative for handling a difficult tolerance problem might be to redesign a component
to move it to the noncritical classification.

• A difficult problem with tolerance stackup often indicates that the design is over constrained to
cause undesirable interactions between the assembled components.

• If tolerance stackup cannot be avoided, it often is possible to minimize its impact by careful design
of assembly fixtures.
Gui del i nes for Tol erance D esi gn

• Another approach is to use selective assembly where critical components are sorted into narrow

dimensional ranges before assembling mating components.

• Before using statistical tolerancing make sure that you have the agreement from manufacturing

that the product is receiving components from a well-controlled process with the appropriate level

of process capability.

• Consider carefully the establishment of the datum surfaces, since the same datums will be used in

manufacture and inspection of the part.