Welcome to Engineering Design, At UMD-MIE

we say:

 “Student teams use design and analysis methods

learned in previous courses to develop, design or
improve an industrial system problem. These ‘design
problems’ are, generally, drawn from ‘real-world’
system problems existing in industrial organization in
the region.”
 We consider that design is a customer-centric
process that will lead to mutually beneficial outcomes
 It is truly a process so we start with a clear problem
analysis and then propose and pursue a final design
in hardware, software, and/or system improvement
Welcome to Engineering Design

• Function to form
• Phases of design
• Product realization process
• Roles for engineers
• Concurrent engineering
• Teamwork
• Summary
Engineering Design

machines sketch / draw customer desires

mechanisms predict behavior company constraints
motion test / experiment synthesize alternatives
energy conversion materials analyze
manufacturing evaluate
 What is Design, really?

Which of the following is design and which is analysis?

A. Given that the customer wishes to fasten together two steel

plates, select appropriate sizes for the bolt, nut and washer.

B. Given the cross-section geometry of a new airplane wing

we determine the lift it produces by conducting wind tunnel
experiments.

Design Analysis

Form is the solution to a design problem.

F
o
r
m
E
v
e
How are Function and Form related
r
F
o control
l hold
l
o move
w Function
s protect
F store
u
n
c Design decision making processes
t
i
o shape
n configuration
. Form
size
materials
manufacturing
processes

Form Ever Follows Function

Luis Sullivan
 Design – definition

Set of decision making processes and activities

to determine the form of an object,
given the customer’s desired function.
Making Decisions? Use the design process

Establish functional requirements

Formulating Determine constraints
Problem Set performance targets
Design specifications

Create alternative forms

Generating (shape, configuration, size, materials,
Alternatives manufacturing processes)
Redesign
iteration

all alternatives

Analyzing
Alternatives
feasible alternatives

Evaluating
Alternatives

best alternative design candidate

Manufacturing specifications
Are there “phases” of design?

How do design decisions change over time?

Is there a logical grouping of decisions?
 Example design problem - Stop a spinning shaft
(8 inch diameter, 1000 lbs, steel, 3000 rpm)

Early in the design process, we decide upon the specifics

of the function to be performed:
• Decide upon a satisfactory rate of deceleration
• Determine the length of the shaft
• Determine where it is supported
• Determine what actuating energy is available
• Decide to reverse engineer an existing product
• Choose to research brakes in the library

“Formulation” Phase
 Decisions relating to concept?

Decide physical principles that will perform the function

• 1. surface friction (e.g. drum brake, disk/caliper)

• 2. opposing magnetic fields (e.g. inverse motor)
• 3. air friction (e.g. fan blades)
Assume we decide on surface friction

“Concept Design Phase”

Decisions on configuring products
and new components?

Decide upon product components & how they are arranged

Decide upon part features & how they are arranged
Product configuration:
disk/caliper, or drum, or band brake
location on shaft (right. left, middle)
(Assume we decide on a disk/caliper brake)
Part configuration:
relative size of hub to disk
relative size of rotor thickness to diameter

“Configuration Design” Phase

Values for Parameters?

Decide upon specific values for design variables

1. rotor diameter (outer)

2. rotor thickness
3. brake pad width
4. pad material
5. hydraulic pressure on piston

“Parametric Design” Phase

Completing the details

Decide upon the remaining manufacturing specifications

• machined rotor tolerances

• pad bonding resin
• assembly/testing procedure

“Detail Design” Phase

 Final “Form” is the solution to a design problem

Function ---- stop a spinning shaft

Form
•rotor: 10 inch diameter, CG Cast Iron, 3/8-inch thick, cooling
passages
•forged steel caliper/housing
•brake pads, 2 opposing, 4 sq. in., metal particles/epoxy matrix
•steel piston,1-inch diameter, with elastomeric seals
•100 psi hydraulic piston pressure
Design Phases
Formulation

Concept

Preliminary Configuration
Design
Embodiment
Design
Parametric

Detail
 Design versus the Product Realization Process?

Realized
Product

Production Design Service

Disposal
Engineering Design Distribution
Industrial Design Manufacturing
Sales / Marketing (Production)

Customer
Need
Phases in the life of a product

establish function
Design
determine form

fabricate
Manufacture assemble
distribute
set up
Use operate
maintain
repair
take down
Retire
disassemble
recycle
dispose
To satisfy the consumer…
We must consider all the phases in the life of a product
Product realization begins the Product Life Cycle

Introduction Growth Maturity Saturation Decline

Income

Sales
Investment

Time
Product
Development
How do we, as engineers, fit into the PRP?
 Where do engineers work?

Employer Thousands %

Manufacturing 732 50

Engineering Services 401 27

Government (Federal, State & Local) 179 12

Self-employed 43 3

Other 110 8

Total 1465 100

(U.S. Department of Labor, 2000).

Engineering Roles in Design & Manufacturing
Job Title Description
Sales & Sales Engineer Meets customers, determines
Marketing needs, presents product offerings
Applications Engineer Assists sales & marketing solving
technical issues with respect to the
use of product
Field Service Engineer Installs, maintains and repairs
equipment at customers’ sites

Research & Industrial Designer Establishes essential product

Development appearance, human factors
Design Engineer Decides part or product form
including: shape, size,
configuration, materials, and
manufacturing processes
Materials Engineer Investigates and develops improved
materials
Test Engineer Designs and conducts performance
and safety tests
Engineering Roles in Design & Mfg

Manufacturing Industrial Engineer Designs fabrication,

assembly and warehousing
systems
Manufacturing Develops manufacturing
Engineer tools and fixtures
Quality Control Establishes and maintains
Engineer raw materials and finished
goods quality controls

Processing / Plant Engineer Designs and maintains

Operations processing plant facilities
Project Engineer Coordinates project work
tasks, budgets and
schedules
 “Functional” organization chart
Stockholders

Board of Directors

President

Purchasing Manufacturing Research & Development Sales & Marketing Finance

Purchasing Production Operations Design Engineering Sales Accounting

Estimating Quality Control Industrial Design Customer Service Budgeting
Expediting Industrial Engineering Prototyping Marketing Planning
Manufacturing Engineering Testing Advertising
Production Planning Materials Research
Tooling

typical manufacturing company

 Concurrent engineering design team

Product
Manager
No more
“over the wall”

Sales Industrial Design Industrial Mfg.

Marketing Design Engineering Engineering Engineering Purchasing Production
 Teamwork is a professional team sport!

Professional Team Industry

Competitors Companies
Team owners Investors
Coaches Managers
Referees, umpires Lawyers, judges
Communication Coordination
Fumbles, injuries Mistakes, losses
Individual skills Specialized jobs
Team skills “People” skills
 Summary

• Design is “decision” making

• Product realization process includes engineering design
• Design process requires formulating, generating,
analyzing, evaluating, refining
• Form follows function
• Product realization is a professional team sport