Designing Products & Engineering

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Designing Products Engineering
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People,Problem-Solving, and Practicality

• Industrial Engineering
• the People and Systems Engineers

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What is Industrial Engineering?

• Industrial engineers design, install, and improve
  the complex systems which provide both goods and
  services vital to our society and economy. These
  systems integrate people, materials, and
  equipment, and thereby place unique demands for
  breadth of preparation upon industrial engineers.
  The traditional arenas for the practice of
  industrial engineering are the manufacturing
  facilities of industry. However, today fully
  one-third of practicing industrial engineers are
  employed in non-manufacturing enterprises such as
  hospitals, banks, and government.

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Industrial Engineering

• Industrial engineers perform the following tasks
  in manufacturing and service industries.
• Forecast the demand the product
• Prepare a plan to produce the product
• Analyze the cost and benefits of the product
• Design the layout of the plant to produce the
  product
• Select the manufacturing processes to make the
  product
• Identify the people and their skills for
  production and supervision
• Integrate people, materials, machines, and
  processes to work together
• Schedule the machines and processes for
  production
• Supervise the day-to-day operation of the
  facility
• Design the workplace and procedures for workers
  to follow
• Handle occupational and safety concerns
• Model and analyze the performance of the system
  and find ways to improve it

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Areas of Study Within Industrial Engineering 1.
Human Factors (Ergonomics)
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Areas of Study Within Industrial Engineering 2.
Optimization/Operation Research
Factories
Distributor/Retailer Warehouse
Customers
Product Flow
Information Flow
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• Deterministic Operations Research Optimization
• Goal to Choose the best (optimal) solution
  satisfying the limitations (constraints) of the
  system
• Stochastic Operations Research
• Goal to evaluate the behavior of a stochastic
  (random) system

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• Areas of Application
• Manufacturing and Production
• Schedule jobs on the shop floor
• Plan facilities layout
• Formulate inventory policy
• Improve reliability of products
• Business
• Determine advertising strategy
• Determine mix of product to sell
• Select an investment portfolio
• Public Sector
• Locate and equip emergency facilities
• Design traffic systems

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Facilities Design
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Work Cell Floor Plan
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Emergency Room Layout
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Store Layout - with Dairy, Bread, High Drawer
Items in Corners
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Production Planning and Control
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Areas of Study Within Industrial Engineering 3.
Simulation
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(No Transcript)
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Areas of Study Within Industrial Engineering 4.
Quality Control
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• Areas of Quality
• Process Capability
• Evaluates conformance to product specifications
• Statistical Process Control
• Looks at the process stability over time
• Process Modeling
• Forms a mathematical model of the process
• How do the inputs of the system relate to the
  outputs?
• Gage Repeatability and Reproducibility (GRR)
• Evaluates the measurement system
• Diagnostics
• Identifies the sources of any problems

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Sample Industrial Engineering Courses

• Human Factors Engineering
• Work Measurements and Work Design
• Facilities Planning and Design
• Reliability Engineering
• Experimental Design For Engineering
• Production Planning and Control
• Engineering Project Management
• Integrated Manufacturing Systems
• Expert Systems in Engineering
• Industrial Robotics

• Quality Control
• Automated Inspection
• Integrated Product and Process Design
• Queuing Methods for Services and Manufacturing
• Introductory Decision Analysis for Engineering
• Simulation Modeling and Analysis
• Engineering Information Systems
• Contemporary Topics in Industrial Engineering

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Career Opportunities for Industrial Engineers

• Industrial engineers are the problem solvers in
  all organizations. Career opportunities for
  industrial engineering are limitless.
• A sample list of career opportunities for
  industrial engineers include
• Manufacturing regardless of the product
  manufactured, every manufacturing company needs
  IEs to plan the facility, perform economic
  analyses, plan and control production, manage
  people, handle safety issues, improve quality,
  evaluate performance, etc.
• Health Services hospitals and clinics need IEs
  to perform cost/benefit analyses, schedule work
  load, manage people, evaluate safety concerns,
  design and maintain facilities, etc.
• Transportation airlines, ground transportation,
  trucking, and warehousing companies need IEs to
  design the best schedules and routes, perform
  economic analyses, manage crews, etc.
• Financial banks and other savings and lending
  institutions need IEs to design financial plans,
• perform economic analyses, etc.
• Government local and federal governments need
  IEs to design and enforce safety systems,
  environmental policies, plan for and operate
  in a number of organizations.
• Consulting IEs may work as consultants to help
  design and analyze a variety of systems including
  information systems, manufacturing and service
  systems.

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What is Engineering Design?

• The systematic and creative application of
  scientific and mathematical principles to
  practical ends such as the design, manufacture,
  and operation of efficient and economical
  structures, machines, processes, and systems.

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The basic purpose of any organization is to
provide products or services to their customers.
Thus, the design of these products and services
is essential to the livelihood of a
company. But, what are the characteristics of an
Effective Design?
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Effective Design

• Effective designs provide a competitive edge by
• Bringing new ideas to the market quickly
• Doing a better job of satisfying customer needs
• Making new products easier to manufacture,
  use, and repair than existing products

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Types of Design and Redesign

• Original Design (or Inventing)
• Involves elaborating, original solutions for a
  given task. The result of original design is an
  invention.
• Adaptive Design (or Synthesis)
• Involves adapting a known system to a changed
  task or evolving a significant subsystem of a
  current product (such as antilock brakes).
• Variant Design (or Modification)
• Involves varying the parameters (size, geometry,
  material properties, control parameters, etc.) of
  certain aspects of a product to develop a new and
  more robust design.

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Product Design

• Specifies which materials are to be used
• Determines dimensions and tolerances
• Defines the appearance of the product
• Sets standards for performance.

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Design has a tremendous impact on the quality of
a final product or service.

• Quality in the design process involves
• Matching product or service characteristics with
  customer requirements
• Ensuring that customer requirements are met in
  the simplest and least costly manner
• Reducing the time required to design a new
  product or service, and
• Minimizing the revisions necessary to make a
  design workable.

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The Design Process
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Sources of idea generation

• Surveying suppliers, distributors,
• and salespersons
• Monitoring trade journals
• Analyzing warranty claims, customer complaints,
  and other failures
• Surveying potential customers
• Bench marking
• Comparing a product or process against the
• best-in-class product.
• Reverse engineering
• Carefully dismantling a competitors product
  
• in order to improve ones own product.

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Involvement of Different Functional Departments
in the Design Process

• Marketing Department takes the idea and
• Forms a product concept
• Conducts a study on the feasibility of the
  proposed product or service
• If the proposed product meets certain
  expectations, performance specifications are
  developed.

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Involvement of Different Functional Departments
in the Design Process

• Design Engineers take the performance
  specifications and
• Develop preliminary technical specifications, and
  later
• Develop detailed design specifications.
• Manufacturing Engineers take the detailed
  performance specifications and
• Develop a process plan that includes specific
  requirements for equipment, tooling, and
  fixtures.
• Production Engineers take these manufacturing
  specifications and schedule production

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The Design Process
Yes
No
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A Decision Making Process

• Idea generation pre-design planning
• Customer Requirements
• Functional Specification
• Product Specifications
• Concept Generation
• Concept Selection
• Engineering Design
• Engineering Evaluation
• Prototype and Testing
• Manufacturing Design

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Breaking Down Barriers
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Final design is concerned with how the product
will perform.

• It consists of three phases
• 1. Functional design is concerned with
  how the product will perform.
• 2. Form design refers to the physical
  appearance of a product.
• 3. Production design is concerned with the ease
  and cost of manufacturing the product.

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Form Design(How The Product Looks)
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Functional Design(How The Product Performs)

• Reliability
• probability product performs intended function
  for specified length of time
• A measure for reliability is Mean Time Between
  Failures (MTBF).
• Maintainability
• ease and/or cost or maintaining/repairing product
• A measure for maintainability is Mean Time To
  Repair (MTTR).

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DFM Guidelines

• 1. Minimize the number of parts
• 2. Develop a modular design
• 3. Design parts for multi-use
• 4. Avoid separate fasteners
• 5. Eliminate adjustments
• 6. Design for top-down assembly

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• 7. Design for minimum handling
• 8. Avoid tools
• 9. Minimize subassemblies
• 10. Use standard parts when possible
• 11. Simplify operations
• 12. Design for efficient and adequate testing
• 13. Use repeatable understood processes
• 14. Analyze failures
• 15. Rigorously assess value

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Design Simplification
(a) The original design
(b) Revised design
(c) Final design
Design for push-and-snap assembly
One-piece base elimination of fasteners
Assembly using common fasteners
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Listening to Customers
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Customers Requirements

• Normal Requirements are typically what we get by
  just asking customers what they want.
• Expected Requirements are often so basic the
  customer may fail to mention them - until we fail
  to perform them. For example, if coffee is served
  hot, customers barely notice it. If it's cold or
  too hot, dissatisfaction occurs. Expected
  requirements must be fulfilled.
• Exciting Requirements are difficult to discover.
  They are beyond the customer's expectations. For
  example, if full meals were served on a flight
  from Chicago to Indianapolis, that would be
  exciting. If not, customers would hardly complain.

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Kano Model Noriaki Kano 1984.
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Making Economic Decisions

• Engineering economy the discipline concerned
  with the economic aspects of engineering. It
  involves the systematic evaluation of the costs
  and benefits of proposed technical projects.
• Some Examples
• Choosing the best design for a high-efficiency
  gas furnace
• Recommending whether an overnight delivery
  service should be purchased or leased

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Rational Decision-Making Process

• Recognize a decision problem
• Define the goals or objectives
• Collect all the relevant information
• Identify a set of feasible decision alternatives
• Select the decision criterion to use
• Select the best alternative

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Example Equipment Process Selection

• How do you choose between Plastic Composite and
  Steel sheet stock for the auto body panel?
• The choice of material will dictate the
  manufacturing process for the body panel as well
  as manufacturing costs.

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Which Material to Choose?
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Engineering Costs General Cost Terms

• Manufacturing Costs
• Direct materials
• Direct labor
• Mfg. Overhead
• Non-manufacturing Costs
• Overhead
• Marketing
• Administrative

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Cost Components

• Material Cost
• Direct material cost Bill of Material (BOM)
• Non-formula material cost expense of
  consumables used during processing
• Conversion Cost
• Capital depreciation
• Direct labor
• MBR management budget review
• Scrap
• Tools and Dies
• Transportation

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Cost Classification for Predicting Cost Behavior

• Cost Behaviors
• Fixed costs
• Variable costs
• Average unit costs

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Fixed Costs
Fixed costs per unit of production (F/Q)
Total fixed costs (F)
Production volume (Q)
Production volume (Q)
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Variable Costs

• Def Costs that vary depending on the level of
  production or sales
• Cost behavior Increase or decrease
  proportionally according to the level of volume
• Examples Costs of raw material, packaging
  material, direct labor, machine utilities are
  main variable costs.

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Variable Costs
Variable costs per unit of production (V)
Production volume (Q)
Production volume (Q)
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Break-Even Analysis (BEA)

• The total revenue depends on the production
  level.
• The higher the production, the higher the total
  variable costs.
• In BEA, it is assumed that price of product is
  fixed.

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BEA
Price per unit (P)
Production (and sales ) volume (Q)
Production (and sales) volume (Q)
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BEA

• Therefore, the overall break-even analysis can be
  pictorially represented in the following graph

Profit
Total costs (FVQ)
BEP FVQPQ
loss
Total revenue (PQ)
Production (and sales) volume (Q)
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BEA

• Total Cost (TC) Total Revenue (TR)
• TCFVQ
• TRPQ
• At the break-even point FVQPQ
• QBEQ F/ (P-V)

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Example

• 500,000 total yearly fixed costs.
• 150 / unit variable costs
• 200 / unit sale price
• QBEQ500000/(200-150) 10000 units
• If our market research indicates that the present
  demand is gt 10000, then this manufacturing system
  is economically feasible.

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QUALITY FUNCTION DEPLOYMENT

• Quality Function Deployment
• Voice of the customer
• House of quality

QFD An approach that integrates the voice of
the customer into the product and service
development process.
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Quality Function Deployment

• Identify customer wants
• Identify how the good/service will satisfy
  customer wants
• Relate customer wants to product hows
• Identify relationships between the firms hows
• Develop importance ratings
• Evaluate competing products

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Customer Requirements
CUSTOMER COMMENTS

• Peels a variety of produce
• Works both right and left handed
• Creates minimal waste
• Saves time
• Durable
• Easy to clean
• Safe to use and store
• Comfortable to use
• Stays sharp or is sharpenable

Carrots and potatoes are very different. I cut
myself with this one. I just leave the skin
on. Im left-handed. I use a knife. This one
is fast, but it takes a lot off. How do you
peel a squash? Heres a rusty one. This
looked OK in the store.
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• Select a household product of your choice, your
  goal will be to describe how you think this
  design evolved. By looking at the product, can
  you tell
• How and why the device functions?  Can you
  describe how it works, what energy sources are
  used, and what purpose that function serves?
• How was human engineering involved? How would the
  human/machine interface affect this design? What
  safety issues would have been involved?
• Why the original designers selected the materials
  used?  What properties of the materials were most
  important in selecting them?
• What features make this product unique?  Compared
  to similar items, are there features on your
  example that would identify this as a better
  product?
• How was the production process affected by this
  design? Are there specific features that might
  have been added to make production more
  efficient?

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• As your analysis continues, choose one aspect of
  the design that intrigues you. Study the design
  used, and consider how you might improve on it.
• Develop a list of alternatives, and compare them
  to the existing design.
• Develop some criteria that may help you select
  one of your alternatives as most likely to
  succeed.
• Finally, select one alternative, and describe how
  it improves on the existing design, what its
  limitations are, and why you think this is a
  better alternative than the existing design.

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Good Luck with your designs!