CONCEPT OF ENGINEERING DESIGN

Design
To create something new or arrange existing things in a new way to satisfy recognized need of society.

DESIGN PROCESS
General information Specific information Design operations Outcome --------------- Evaluation [yes] Go to next stage

IMPORTANTS OF DESIGN (FOUR CS OF DESIGN)

Creativity Complexity Choice Compromise

CONSIDERATION OF GOOD DESIGN

1.Design requirements 2.Life-cycle issues 3.Regulartor and social issue

1. Design requirements
The acceptable performance of the design is the major role in the design requirements. Performance requirements can be divided in to two groups. Functional requirements
In this phase capacity to measure the force, strength, energy, materials flow and power, efficiency of design, accuracy and sensitivity.

Performance requirements
In this phase considering as useful life of design, service environment, Reliability, economy and safety of maintenance, noise level of design

2. Life cycle issue

In this phase material selection and Evaluation of the material is the major role in life cycle process Cost of material Strength of material such as creep, toughness, fatigue, ductility, corrosion resistance etc.

3. Regularity and social issues

Specifications and standards are important (ASTM and ASME)

MORPHOLOGY OF DESIGN
Conceptual design Embodiment design Details design Plan for manufacturing Plan for distribution and use Plan for retirement of product

1. Conceptual design
In this phase design is initiated, carried to a point of creating to point of possible solution and narrow down to single best concept. Identification of customers needs Problem definition Gathering information i ) Interview with customers ii) Focus groups iii) Customers survey iv) Customers complaints Conceptualization Concept selection Refinement of PDS (after concept selection) Design review

2. Embodiment design
in this phase ,structure development take place for the selected design concept and this phase is called as preliminary design. This design concentrated three major tasks Product architecture (dividing the system in to number of subsystem) Configuration design of parts and components Parametric design of parts and components

3. Detail Design
Detailed Engineering drawing is prepared which is suitable for manufacturing process. Assembly of the components and testing of several preproduction version of the product. Final review was conducted before entering in to manufacturing division.

4. Plan for manufacturing

Method for manufacturing components to be prepared. Process sheet is established which include i) Sequence list of manufacturing operations ii) Condition of materials iii) Tooling iv)Production machines

5. Plan for distribution and use

Effective distribution (shipping package of product to customers) Usage of the production Maintenance Product safety Convenient to use Duration of service Reliability

6. Plan for retirement of product

Useful life may be determined by actual deterioration and wear to point at which the product can no longer function. The design of product should include a plan for i)Either disposal in Safeway ii)Recycling of its material iii()Remanufacturing of its component.

ORGANIZATION FOR DESIGN

Research Development Design Production and Construction

Operations and Maintenance

Marketing

Sales
Management

CONCURRENT ENGINEERING
Systematic approach to the integrated design of products and their related process such that Manufacturing and support Product life cycle Product service in the field Disposal CAE i)Functional teams ii)Parallel design iii)Vendors partner

PRODUCT AND PROCESS CYCLE

The product and process cycle consist of following stages Introduction of the product in to market Growth Maturity Decline

MARKET IDENTIFICATION
Market research should provide the following information Define market segment Identification of early adapters Identifying competitive products Establish the market size Determine product price- volume relationship Establish customers need and wants

CUSTOMER ORIENTED DESIGN AND SOCIETAL CONSIDERATION

CUSTOMER REQUEIREMENTS
Performance: Primary operating characteristic of product. Features: basic function of the product Reliability: Capability of a part or the system to operate without failure during service environment. Durability: Measure of product life.

Serviceability: Ease and time require for repairing the product after breakdown . Aesthetics: Product looks,feels,testes,sounds etc
Perceived quality: Customer will tend to expect that all producers of the product will have same quality.

QUALITY FUNCTION DEPLOYMENT (QFD)

Translating customer needs in to Engineering characteristics of product. It is often called as HOUSE OF QUALITY. a) Customer requirements :( CR) b) Competitive assessment: Considering top two or three competitive products rank w.r.t customers requirements and give rating including of our designed product.

c) Engg. Characteristics: (EC) Enable to satisfy customers needs through advanced engineering principles.
d) Correlation matrix: It shows that the degree of interdependence among the engineering characteristics.

f) Relationship matrix: This determines correlation between EC and CR.

g) Determine the absolute importance: Multiply the numerical values of each cells of the relationship matrix by importance rating.

h) Relative importance: Values from the absolute importance in which EC having highest rating, we should give special attention. (Such as 1 is low probability of success and 5 is high probability of success
i) Technical competitive assessment: Compare your company performance against two or three top competitors for each of the engineering concept.

j) Technical difficulty: This indicates that ease with which each of engineering characteristics can be achieved. k) Target values: Select the high rated values of EC and set target of the concept to satisfy customers need.

PRODUCT DESIGN SPECIFICATIONS(PDS)

This is the basic control and reference documents for the design and manufacturing of the product. The listed below are the key elements to be found in PDS. a)Function requirements: Flow of energy, Efficiency, Accuracy, Tolerance, Material ,operation steps etc

 b) Physical requirement: Shape, Size, Weight, Surface finish etc c) Life cycle issues: Reliability Maintability Repairability Retirement from service Cost of operation etc.

d) Service environment: (Under what conditions the product is to work) Temperature Pressure range Salt spray Rain Humidity Shock loading Vibration Noise Corrosive environment etc.

d) Life cycle issues: Reliability Maintability Repairability Retirement from service Cost of operation etc. e) Human factors: Aesthetic Man-machine interface (Ergonomics) User training

HUMAN FACTORS IN DESIGN

1.Fit the product to, the users physical attribute and knowledge. 2.Simplify task Control operations should have minimum number of operations and straight forward. The product should look simple to operate with minimum number of controls. 3. Make the controls and functions obvious: Place the controls for a function adjacent to the device that is controlled

4.Use mapping: The goal should be to make the operation clear enough that it is not necessary to refer from nameplate, stickers or the operation manual.(e.g. car sheet adjustment) 5.Utilize constraints to prevent incorrect action: Do not depend on the user always doing correct thing. An example is the automatic transmission that will not go into reverse when car moving forward. 6.Provide feedback: The product must provide the user with a clear, immediate response to any action taken. This feedback can be provided by sounds, light or display information.

7.Provide good display: Most human machine interface require that the human sense the status of the system and the control it based on the information received. 8.Make controls easy to handle 9.Anticipate human error: Human error is unavoidable, so that the designer designs the product as possible to reverse or undo the error easily.

DESIGN FOR ENVIRONMENT (DFE)

Dividing DFE in to two categories 1. Material recycles 2. Remanufacturing a) Design for material recovery and reuse.

b)Design for disassembly: Provide for easy access and removal of component. Minimize the use of adhesive and weld. Try to avoid the screws, snap fits.

c) Design for product waste minimization: Minimize the amount material used by avoiding overdesign. Realize which material are incompatible in recycling and will have to separated and segregated. Avoiding the certain adhesives, paints, labels can cause contamination in recycling. d)Design for packaging recovery e)Avoid the use of hazardous material

f)Design for waste recovery and reuse in processing: The recycling steps are Collection and transport Separation Identification and sorting Reprocessing g)Considering environmental hazards of production: Exhaust gases from machines, smoke exposure with very high or low temperature. h)Design for noise reduction:

CONTRACT

Contracts are a promise by one person to another and mutually understand the agreement.

Types
Bilateral contract Contract in which two parties have both made promise to each other. (Documents are prepared and signed by both parties) Unilateral contract Contract in which one person made a promise

Express contract Contract in which all the terms are agreed upon and expressed in words either return or oral.
Implied contract Contract in which agreement between the parties is inferred by the legal system wholly or in part by their action.

PRODUCT LIABILITY
Design aspects of product liability:

1. Take every precautions that there is strict adherents to industry and government standard. 2. All products should be thoroughly tested before being released for sale. 3. Make a careful study of the system relationship of your product and upstream and downstream component. You are required to know how malfunction are in the product.

4. Documentation of the design, testing and quality activities can be very important. 5. The design of warning label and user instructions manual should be an integral part of the design process. 6. There should be formal design review before the product is released for production.

PROTECTING INTELLECTUAL PROPERTY

Protecting Intellectual Property: It is protected by 1.Patents 2.Copy rights 3.Trade marks

Utility patents:

The functional features of a design can be protected with utility patent. This also protect embodiment of the idea shown in the patent application. A well written patent is the best protection of the valuable idea.

Design patent: This covers the ornamental aspects of a product such as shape, configuration or surface decorations. Design patent is easier to obtain than utility patent and easier to enforce in the court. Copy right: This form of intellectual property is primarily intended to protect writing It has the dominant method of protecting software.

Trade mark: These are used to protect the names or symbols (Logo) of product.