Chapter 1 The Product Design Process

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Chapter 1The Product Design Process

• The Four Cs of Design
• A Simplified Approach
• A Problem Solving Methodology
• Consideration of A Good Design

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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 shapes
• Compromise
• Requires balancing multiple and sometimes
  conflicting requirements

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What is Design?Design establishes and defines
solutions to and pertinent structures for
problems not solved before, or new solutions to
problems which have previously been solved in a
different way

• Difference between Design and Discovery
• Discovery is getting the first sight of something
  but design is the product of planning and work
• Good design requires both analysis and synthesis
  (Analysis is to breakdown complex problems to
  manageable parts and synthesis involves the
  identification of the design elements that will
  compromise the product and the combination of the
  part solutions into a total workable system)

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The Design Process- A Simplified Approach

• 
  General information

Specific information
Design Operation
Outcome
NO
Evaluation
yes
Feedback loop
Go to the next step
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Scientific Method vs Design Method

• State of the art

• Existing knowledge

Scientific curiosity
Identification of need
Hypothesis
Acceptance
Conceptualization
Communication
Logical analysis
Feasibility analysis
Production
Proof
Scientific Method
Design Method
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Consideration of Good Design

• Design Requirements
• Functional performance (F, s, power, deflection)
• Complementary performance (life of design,
  robustness, reliability, ease, economy, safety of
  maintenance)
• Total Life Cycle
• Material selection, productivity, durability
• Regulatory and Social Issues
• ASTM, ASME standards, codes of ethics, EPA
  requirements

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Design Process

• I. Conceptual Design
• II. Embodiment Design
• III. Detail Design
• IV. Planning for Manufacture
• V. Planning for Distribution
• VI. Planning for use
• VII. Planning for Retirement of the Product

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I. Conceptual Design

• Identification of customer needs
• Problem definition
• Gathering information
• Conceptualization
• Concept selection
• Refinement of product design specification
• Design review

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II. Embodiment Design

• Product architecture
• Configuration design of parts and components
  (feature present like holes, ribs, splines, and
  curves are configured). Modeling and simulation
  may be performed. The generation of physical
  model of the part with rapid prototyping
  processes may be appropriate)
• Parametric design of parts and components (exact
  dimensions and tolerances, materials and
  processes, robustness)

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III. Detail Design

• In this phase the design is brought to the stage
  of a complete engineering description of a tested
  and producible product.

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IV. Planning for Manufacture

• Designing specialized tools and fixtures
• Specifying the production plant that will be used
• Planning the work schedules and inventory
  controls
• Planning the quality assurance systems
• Establishing the standard time and labor costs
  for each operation
• Establishing the system of information flow
  necessary to control the manufacturing operation

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V. Planning for Distribution

• Shelf life consideration
• System of warehouses for distribution of the
  product needs to be designed
• Marketing efforts on advertising and news media
  techniques must be selected
• For technical activities specialized sale
  brochures and performance test data must be
  generated.

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VI. Planning for use

• Ease of maintenance, reliability, product safety,
  convenience in use (human factors engineering),
  aesthetic appeal, economy of operation, and
  duration of service are some of the questions to
  be answered in a consumer oriented product.
• Acquisition of reliable data on failure, service
  lives, and consumer complaint and attitudes to
  provide a basis for product improvement in the
  next design is an important phase VI activity.

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VII. Planning for Retirement of the Product

• The final step in the design process is the
  disposal of the product when it has reached the
  end of its useful life.
• Useful life may be determined by actual
  deterioration and wear or it may be determined
  by technological obsolescence.
• Industrial ecology considerations dictate a plan
  for either disposal of the product in an
  environmentally safe way or, better, the
  recycling of its materials, or remanufacture or
  reuse of product components.