Concepts of Engineering

Design

Engineering is defined as an activity of

overcoming difficulties for practical
applications of concepts that are proved
to be true theoretically. This activity is
composed
of
mental
activities,
paperwork, human power and machine
power.

Design
The creation of end results that
satisfies a human need by taking
definite action

Concepts of Engg Design

Definitions- an overview
CONCEPTS : Principles
ENGINEERING
: Practical application of
science
DESIGN
: Systematic plan to
physically realise or
upgrade a
component /
a product / an assembly
or system to satisfy a
need or purpose.

ENGINEERING MARVELS

BURJ TOWER, DUBAI

BURJ TOWER, DUBAI

MACINTOSH LAPTOP

Classifications of Design

Empirical Design
This type of design depends on empirical
formulae based on practice and past
experience.
Many times scientific proof may not be
there but is practiced as it did not pose
problems or worked well.
Seldom people will have mind to change
or find alternatives for the thumb rule
formulae or empirical relations adopted.

Rational Design
This type of design depends
on
mathematical
formulae,
scientific
principles and principles of mechanics.
The design is made with scientific rational
theories and hence allows scope for
modification / improvements.

Adaptive Design
This mainly deals with adaptation of
existing design.
This type of design needs no special
knowledge or skill and can be attempted
with ordinary technical training.
The
designer
makes
only
minor
changes/alterations/modifications in the
existing design of the product.

Adequate Design
The design is made adequate enough to
meet one or two basic or few requirements
The design does the intended functions
but cannot be claimed as the best suited
one.

Industrial Design
This depends upon the production aspects
to
manufacturing
any
machine
components in the industry.
Generally it concentrates on aesthetic
aspects and ergonomic aspects.

Development Design
This type of design needs considerable scientific
knowledge/ training/ ability to modify the existing
design into a new idea, by adopting new
material or different methods of manufacture.
We may start from the existing design but end
up in a product that is markedly different from
the original product.
Example: Design of Mixie from grinding
operation.

New Design
This type of design needs lot of research /
technical ability, creative thinking /
innovative skills that changes the concepts
of methodologies of working procedure
thoroughly and differently .
Example:
Concepts of a pager to the concepts of a
mobile

Optimum Design
It is the best design for the given objective
function under the specified constraints. It
may be achieved by minimising the
undesirable effects.

Computer Aided Design

Digital computers have enhanced the design
procedure by making use of software which
adopt the design procedures very effectively and
quickly and allow variety of designs to be made.
It very often gives the best or optimum design
conditions. The load and their effects can be
effectively studied and analysed before the
product is made. Virtual simulation of the
product performance allows critical parameters
to be established and the system performance
studied in a more effective manner.

Benefits
Many alternatives can be tried and
optimum design can be obtained
Lead time reduces
Highly cost effective
Prototype can be made after the best
design is selected.

Benefits(Cont.)
Since Rapid Prototyping facilities have
come into existence if facilitates
development of plastic or metallic physical
models with the digital designs. After
inspecting the models, the suggested
changes can be incorporated in the digital
design and a thorough physical model can
be and then the final prototype is made.

The Four Cs of Design

Creativity

Requires creation of something that has not existed before or

not existed in the designers 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 smallest detail of shape

Compromise

Requires balancing multiple and sometimes conflicting

requirements

SCIENTIFIC METHOD

DESIGN METHOD

OVERALL DESIGN
PROCESS/MORPHOLOGY OF DESIGN
Design need

CAD Process

Marketing

CAM Process

Shipping

CAD Process
Design need

Design
definitions
Specifications
and
requirements

Collecting
relevant
design
information
and feasibility
study
SYNTHESIS

Design
Modelling and
simulation

Design
Communication
and
documentation

Design
evaluation

Design
conceptualisation

Design
optimization

Design
analysis
ANALYSIS

CAM Process
Production
planning

Production

Procurement of
new tools

Quality control

Process
planning
Order materials

NC, CNC,
DNC programming

Packaging

Shipping

Marketing

MAJOR POINTS THAT AFFECT

PRODUCT DESIGN
1. Cost
The overall product cost consists of design process cost,
material cost, capital cost of machinery / process
equipments and labor cost for manufacturing the product.
Among these though the design process cost is very little,
yet it influences the other costs to a large extent. If design
proves to be faulty just before the product goes to the
market, it costs a great deal of money to correct the
problem. Further the market is lost and the industries will
face consumer courts and have to pay heavy penalty.
Note: Therefore the decisions made in the design process
though costs very little in terms of the overall product cost,
will have a major effect on the cost of the product

MAJOR POINTS THAT AFFECT

PRODUCT DESIGN
2. Quality
Product quality can be checked during
inspection after the products is manufactured.
This gives very less chance to improve the
quality of the product because the product is
already manufactured.
If the required quality is thought of in the design
stage itself, rejection of the products will reduce
and hence due consideration for quality should
be given in the design stage itself.
Note: Quality cannot be built into a product
unless it is designed into it.

MAJOR POINTS THAT AFFECT

PRODUCT DESIGN
3. Cycle time
Cycle time is the development time required to bring a
new product or revise an existing product to market.
Computer aided design methods and rapid prototyping
methods help to reduce the product cycle time
considerably
The reduced cycle time increases the marketability of
the product and also reduces the product
development cost.
Note: The designer should aim methods that reduces
the cycle time considerably at different stages of
design.

MAJOR POINTS THAT AFFECT

PRODUCT DESIGN
Summary
The design process should be
conducted so as to develop qualitycost competitive products in the
shortest possible time

Static Products
Static products are those where changes in their design concepts,
takes place over a long period of time.
Incremental changes may occur at component or subsystem level
but overall product stays for a long time in the market.
Static products exist in the market for a long time where customer is
not eager to change .
Fashion or styling plays a very little role for the change.
The technology of design and manufacturer is by and large stable.
Ex. Machine tools like lathe, drilling machine,
Automobiles or machineries
Consumer appliances like Refrigerator, Washing machine or
Dishwasher.

Dynamic Products
Dynamic products are those where basic design concepts
change frequently and rapidly.
Customers are often willing for a change or many times
drive the change
The products stay for a shorter time in the market
Fashion, styling also play important role in some products
The technology of design and manufacture often change
Ex. Telecommunication systems/devices like cell phones
Consumer goods and Television sets
Garments, Foot wear and Fashion jewelleries
Software, showcase items

MORPHOLOGY OF DESIGN
(PHASES OF DESIGN PROCESS)

Discrete steps in engineering design process from problem definition to detail design.
The chief tools or techniques applicable in each step are given

Define problem
Problem statement
Benchmarking
QFD
PDS
Project planning

Gather information
Internet Patents
Trade
Literature

Concept
Generation
Brainstorming
Functional
decomposition
Morphological
chart

Evaluation
of concepts
Pugh concepts
Selection
Decision
matrices

Conceptual design

Product
Architecture
Arrangement of
physical elements
To carry out
function

Configuration
Design
Prelim, selection
matls. & mfg.
Modeling/sizing
of parts
Embodiment design

Parametric design
Robust design
Tolerances
Final dimen. DFM

Detail design
Detail drawings
and
specifications

PHASE I. CONCEPTUAL DESIGN

Identification of customer
needs
Problem identification, task
specification- Product Design
Specifications

PHASE I. CONCEPTUAL DESIGN

Gathering information
1. Gathering information from customers
Voice of the customers
Evaluation of customer need/response

2.Gathering information for engg designSources of information

Public, Government, private, individuals
Library sources, codes & standards

PHASE I. CONCEPTUAL DESIGN

Conceptualization
Concept generation, evaluation
& selection
Refinement of the product
design specifications (PDS)
Design review

PHASE II. EMBODIMENT DESIGN

Product architecture- arrangement of
physical functions
Preliminary selection of materials, modeling
and sizing of parts
Configuration design of parts and
components-basic dimensional requirements
Parametric design of parts and componentsfinal dimensions & tolerances

PHASE III. DETAIL DESIGN

Creation of final design drawings
and specifications

PHASE IV. PLANNING FOR

MANUFACTURE
Designing of tooling & fixtures
Design of process sheet of
production line
Work schedules
Quality assurance

PHASE V. PLANNING FOR

DISTRIBUTION

Packaging
Shipping
Warehousing
Distribution of product to customer

PHASE VI. PLANNING FOR USE

Ease of maintenance
Safety
Reliability

PHASE VII. PLANNING FOR

RETIREMENT OF THE PRODUCT
Safe disposal of products recycling, remanufacture, reuse
industrial ecology, environmentally
safe design (green design)

Jai Hind
Be Proud of Being an Indian

PHASES OF DESIGN PROCESS

Phase I. Conceptual Design
Identification of customer needs
Problem identification
Gathering information
Conceptualization
Concept selection
Refinement of the product design
specifications (PDS)
Design review

PHASE II. EMBODIMENT DESIGN

Product architecture- arrangement of
physical functions
Preliminary selection of materials, modeling
and sizing of parts
Configuration design of parts and
components-basic dimensional
requirements
Parametric design of parts and
components- final dimensions & tolerances

PHASE III. DETAIL DESIGN

Creation of final design drawings and
specifications

PHASE IV. PLANNING FOR MANUFACTURE

Designing of tooling & fixtures
Design of process sheet of
production line
Work schedules
Quality assurance

PHASE V. PLANNING FOR DISTRIBUTION

Packaging
Shipping
Warehousing
Distribution of product to customer

PHASE VI. PLANNING FOR USE

Ease of maintenance,
Safety,
Reliability

PHASE VII. PLANNING FOR RETIREMENT

OF THE PRODUCT
Disposal

OVERALL DESIGN
PROCESS/MORPHOLOGY OF DESIGN
Design need

CAD Process

Marketing

CAM Process

Shipping

CAD Process
Design need

Design
definitions
Specifications
and
requirements

Design
Modellinf and
simulation

Design
Communication
and
documentation

Design
evaluation

Collecting
relevant
design
information
and feasibility
study

SYNTHESIS

Design
conceptualisation

Design
optimization

Design
analysis
ANALYSIS

CAM Process
Production
planning

Production

Procurement of
new tools

Quality control

Process
planning
Order materials

NC, CNC,
DNC programming

Packaging

Shipping

Marketing