Академический Документы
Профессиональный Документы
Культура Документы
Dr Deivanathan R
Assoc Prof., SMBS, VIT Chennai
Introduction
• The economic future of India depends on our
ability to design, make and sell competitive
products. Excellent design and effective
manufacture are the pre-requisites.
• It is usually said that design is the essence of
engineering.
• The ability to design is both a science and an art.
The science can be learned through procedures
developed by eminent scholars. But the art can
be learned only by doing design.
Product
• A product is the tangible end result of a manufacturing
process and is meant for satisfying human needs. The
product can be classified as follows: -
Convenience goods
• E.g. Cigarette, Candy, Magazines etc.
Shopping goods
• E.g. Jewellary garments etc.
Specialty goods
• E.g. Rare objects like stamps.
Industrial goods.
• Eg. Raw materials.
Requirements in a good product: -
Customer Satisfaction & Profit
• How to achieve customer • How can it be profitable?
satisfaction? • It must be easy to
• The product should function manufacture
properly. • The raw material must be
• It must have desired accuracy cheap and easily available
• It must have desired reliability • The manufacturing process
• It must be easy to operate has to the decided on the
• It must be serviceable basis of quantity to be
produced
• It must make minimum space • It must use standard parts
utilization
• It must withstand rough • It must be easy to pack and
handling distribute.
• Pleasant appearances.
• Reasonable price.
Design
• Definition of Design:
• “Design is that which defines solutions to problem
which have previously been solved in a different
way”
• “ Design is the conscious human process of
planning physical things that display a new form
in response to some pre-determined need”.
• “Design is an act of collecting all pertinent
information for the production of goods and
services to meet some human need”.
Design
• The design of any component includes two things,
• Product design
• Process design
• The product design involves the development of
specification for a product that will be functionally
sound, good in appearance, and will give satisfactory
performance for an adequate life.
• The process design involves developing methods of
manufacture of the products so that the component
can be produced at a reasonably low cost.
History of Design Process
• Design by Single Person
• Over-the-wall design
• Simultaneous Engineering
• Concurrent Engineering
• Integrated design and Manufacture.
Over the wall Design:
In this method each functional departments were separated from others, as shown by wall.
There was only one-way communications between Customer, Marketing, Engg. Design and
production department. This single direction over-the-wall approach is inefficient and costly
and may result in poor quality products.
By the early 1980's the concept of simultaneous engineering emerged. Here, the goal was the
simultaneous development of the product and the manufacturing process. This was
accomplished by assigning manufacturing representatives to be members of design team, so
that they could interact with the design engineers throughout the designs process.
Concurrent Engineering:
In the 1980's the simultaneous design philosophy was broadened and called concurrent
engineering.
A short definition of concurrent engineering is the simultaneous progression of all aspects,
at all stages of product development, product specification, design, process and equipment
etc.
In concurrent engineering the primary focus is on the integration of teams of people having
a stake in the product, design tools, and techniques and information about the product and
the processes used to develop and manufacture it. Tools and techniques connect the teams
with the information.
Features of design process
The following features can be observed in a design process.
• Iteration
• Decision-making
• Conversion of resources
• Satisfaction of need
• Creativity
• Majority of designs belong to variant design, where the designer simply modifies
an existing system. But the success of engineering design depends on the modes
of thinking and acting distinctively different from others. A creative designer is
distinguished by his ability to synthesize new combinations of ideas and concepts
into meaningful and useful forms.
• Design is commonly thought of as a creative process involving the use of
imagination and lateral thinking to create new and different products.
Qualities of a creative designer
The creative designer is generally a person of average intelligence, a visualiser, a hard
worker and a constructive non-conformist with average knowledge about the problem
at hand.
Generally, a creative designer has the following qualities.
• Visualization ability.
Creative designers have good ability to visualize, to generate and manipulate visual
images in their heads.
• Knowledge
All designers start their job with what they know. During designing, they make minor
modifications of what they already know –or, creative designers create new ideas out
of bits of old designs they had seen in the past. Hence, they must have knowledge of
past designs.
• Ability to manipulate knowledge
The ability to use the same knowledge in a different way is also an important quality
of a designer.
• Risk taking
A person who does not take the risk of making mistakes cannot become a good
designer. For example, Edison tried hundreds of different light bulb designs before he
found the carbon filament.
Qualities of a creative designer
Non-conformist
There are two types of non-conformists:-constructive and obstructive. Constructive
non-conformists are those who take a firm stand, because they think they are right.
Obstructive non-conformists are those who take a stand just to have an opposing view.
The constructive non-conformists might generate a good idea. But the obstructive
non-conformists will only slow down the design process. Creative designers are
constructive non-conformists, and they want to do things in their own way.
• Technique
Creative designers have more than one approach to problem solving. They are
prepared to try alternative techniques, till they reach a satisfactory solution.
• Motivation
They always motivate others in the design team. In such a favourable environment
creativity is further enhanced.
• Willingness to practice
Creativity comes with practice. Creative designers are ready to practice for a long
enough period.
Roadblocks to Creativity
• Fear of making a mistake
• Unwillingness to think and act in a way other than the accepted norm.
• Desire to conform to standard solutions.
• Unwillingness to try new approaches
• Fear of criticism
• Lack of knowledge
• Overconfidence due to past experience
• Unwillingness to reject old solutions
• Fear of authority
• Difficulty in visualization
• Inability to distinguish between cause and effect
• Inability to collect complete information
• Unwillingness to be different
Methods to enhance Creativity
• Use of analogy
• Asking question from different view points
• Memories of past designs
• Competitive products
• Deliberate day-dreaming
• Reading science fictions, etc.
Intuition
• Intuition means sudden ideas or flashes of inspiration and
involves complex associations of ideas, elaborated in
subconscious mind. Intuitive ideas lead to a large number
of good and even excellent solutions.
Creative Design Route
• During preparation period, the designer
analyses the need and collect all the
necessary information required at
various stages.
• Concentration is the period when the
designer digests all the aspects of the
problem situation and tries various
possible combinations.
• The next step is the incubation period.
The designer relaxes away from the
problem for some time.
• Illumination is the sudden insight and
throwing up with a solution.
• The final step is the verification. Now,
testing and inspection of the design is
done and the details are completed.
• For a designer using creative methods
for design, habitual or familiar methods
must be avoided.
ENGINEERING DESIGN
• This is a logical and intellectual attempt to solve design problems. It largely depends on discoveries
and laws of science.
• Any design work starts with Recognition of the need . The need for a design is initiated by either a
market requirement, the development of a new technology or the desire to improve an existing
product.
• Once the need has identified, the next step is to define the design problem . The definition of the
problem expresses as specifically as possible, what the design is intended to accomplish. It should
include objectives and goals, definitions of any special technical terms, the constraints on the
design and the criteria that will be used to evaluate the designs.
• The success of a design project depends on the clarity in the definition of the problem. Need
Analysis is the technique used to define the problem.
• The next step is collecting information . In many phases of deign process a large quantity of
information may be required. The required information can be obtained from textbooks, journals,
or other agencies.
• The conceptualization step involves, finding several design ideas to meet the given need.
Inventiveness and creativity is very important in this step.
• The different ideas conceived are weighted and judged in the evaluation step. The advantages and
disadvantages of each idea against its performance, cost aesthetics etc is valued.
• After evaluation, the best design is emerged. This final design with every detail is furnished in last
step-ie communicating the design.
•
Problem-solving Methodology
Whatever may be the situation, a company has to identify or locate a need before the production of any
device. This crucial step is called Recognition/ Identification of need.
Examples:
1. With the free-entry of Chinese products to Indian market, manufacturers in India recognize a need to sell
their products at a lower price.
2. When a company observes that their products do not perform well, the company recognizes a need to re-
design it.
Need Statement
• Once the need has recognized, the next step is to prepare the need statement.
• It is a general statement specifying the problem for which a solution is required. In other
words-It is the objective of design, expressed in the form of a statement.
Need Statement – Examples
Give one need statement for each of the following
Bicycle
Voltage stabilizers
Personnel Computer
i). Bicycle: -
“A device for a common person to travel reasonable distance comfortably with least effort” –
“The initial cost should be low- and be as light as possible, have adequate life, be easy to
maintain etc “
(ii). Voltage stabilizer
“A solid state noiseless electrical device of adequate power rating to provide continuously an
output at constant voltage, accepting the input power at varying voltage between the
limits__and__volts “. The indications for input and output voltage levels may be provided.
iii). Personnel Computer
“A computing device to accept input data, manipulate it according to a set of instructions
and provide the desired output on CRT and printer”
Identification/Recognition of Needs
• The beginning of any design process is the recognition of need or
problem.
• When a turner hears an awkward noise from some part of the lathe
he identifies/ recognises a need. i.e. the lathe requires repair.
• When the sales personnel observes that their customers are always
complaining of poor performance of the products, a need to
develop a better product is identified.
• Similarly, when the customers are unsatisfied with the present
‘model', a new need is recognised.
• Needs can be identified from,
• Careful market analysis
• Statements made by politicians from their observations
• Interpretations of a community's requirements
• Trends in other parts of the world
Need identification and Problem
definition
• Understanding any problem thoroughly is crucial to reaching an outstanding solution.
• Gathering Information from Customers
• - Interviews with Customers: continuously meet w/current and potential customers
- Focus Groups: A FG is a moderated discussion w/ 6-12 customers of a product.
- Customer Complaints: A sure way to learn about needs for product improvement
- Warranty Data: Statistics on warranty claims can pinpoint design defects.
- Customer Surveys: A written questionnaire
• The PDS is the basic control and reference document for the
design and manufacture of the product.