EAS 140 Engineering Solutions

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EAS 140Engineering Solutions

• Lecture 11
• New Design Strategies

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Outline

• Need for Innovative Design Processes
• New Design Strategies

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Need for Innovative Design Processes

• Traditional design approach has been successful,
  but.
• What problems do you see with the traditional
  design process?

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Need for Innovative Design Processes

• Problems include
• Long design time - sometimes called
  throw-it-over-the-wall design
• Engineering dept designs product
• Throw design over the wall of the cubicle to
  marketing dept
• Marketing changes the design
• Throws revised design back to engineering
• Example Every blueprint page of a Boeing
  aircraft is revised 4.5 times on average they
  design 4.5 airplanes for every model built!

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Need for Innovative Design Processes

• Other problems include
• No incentive to make products easy to
• manufacture/assemble
• service/maintain/support
• No incentive to minimize environmental impact of
  products

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New Design Strategies

• To address these problems, engineers have
  developed new design strategies, including
• Concurrent Engineering (CE)
• Reverse Engineering
• Reengineering/redesign

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Concurrent Engineering

• Idea
• Systematic approach
• Consider all elements of product lifecycle,
  including
• End user requirements
• Manufacturing
• User support
• Quality control
• Product disposal
• Key elements
• Design for manufacturing (DFM)
• Design for assembly (DFA)
• Design for environment (DFE, also called Green
  Engineering)

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DFM Example

• Example
• Mattel toy Color Spin

Child rotates red ball, other balls spin For
children for 6 mo - 3 years old
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DFM Example

• Background
• Mattel purchased rights to toy from Japanese
  manufacturer

Toy is too expensive for US market
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DFM Example

• Potential savings are huge
• Mattel saves 0.5 million dollars for every 1
  penny savings on manufacture of Barbie
• How can Mattel design to save money? What costs
  money to make the Color Spin toy?

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DFM Example

• Main expenses in Color Spin toy
• Number of parts
• originally, 55 parts
• Materials
• originally, made of expensive plastics
• Manufacturing process
• New goals
• Reduce the number of fasteners
• Use standardized parts
• Use unidirectional assembly

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DFM Example

• Example Replaced 10 screws with ultrasonic
  welding

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Design for Manufacturing

• Example Created symmetric roller drive - 4 less
  parts and interchangeable parts

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DFM Example

• Overall impact
• Number of parts reduced from 55 to 27 (49
  reduction)
• Reduction in factory costs 38
• Annual savings 700,000/yr

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Reverse Engineering

• Idea
• Take apart an object or system to see how it
  works
• Uses
• New ideas from competitors
• Fabricate copies of old parts, machinery for
  legacy equipment
• Reuse computer code

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Reverse Engineering

• Example Saturn automotive engineers dismantle
  other cars to look for design ideas (worksheet
  below)

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Reengineering/Redesign

• Idea
• Fundamental rethinking and radical redesign of a
  system
• Applications
• Engineering
• Computer software
• Business systems

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Reengineering/Redesign

• Examples
• Power Mac G4 Cube

(but production suspended)
Boeing 777 designed using 3D CAD see text
for details or http//bits.me.berkeley.edu/develop
/b777/ Microsoft .NET net-based software
development

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Reengineering/Redesign

• Examples continued
• Boeing 777
• designed using 3D CAD
• 2,200 workstations, 3x1012 bytes of data (3
  terabytes)
• see text for details or
• http//bits.me.berkeley.edu/develop/b777/
• Microsoft .NET
• net-based software development

Boeing 777 designed using 3D CAD see text
for details or http//bits.me.berkeley.edu/develop
/b777/ Microsoft .NET net-based software
development