Transcript Chapter 2

Chapter 27
The Engineering Design Process
Learning Objectives
• Describe the various factors that are changing the
design process
• Discuss the steps in design analysis
• Explain the importance of creativity and
innovation
• Explain concurrent engineering
• Define design models and processes
Part I
The Changing Face of
Engineering Design
Designer vs. Knowledge Worker
• Designer
– Design fundamentals
– Materials science
– Manufacturing
processes
• Knowledge Worker
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Design fundamentals
Materials science
Manufacturing processes
Market trends
Safety
Data management
Teaming
Packaging,distribution,
and storage
Impacts on Design
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State and federal regulations
Environment
Consumer perceptions
Demographics
Socio-economic needs
Cultural trends
Changing Business Model
Part II
Engineering Design Models
Concurrent Engineering
• Integrated
• Emphasizes advantages of simultaneous
product design
– Focus on all aspects of design at once
• Special emphasis on customer and their
needs
Life Cycle Engineering
• Entire life of product evaluated at beginning
of process
• Address up front
– Performance
– Costs
– Reliability
– Maintainability
– Disposal
– Market trends
Integrated Product Development
• Designed and developed to satisfy all
conditions in product’s life
• Contingency planning in design
Knowledge-based Engineering
• Use of computer models
• Simulation of processes
• Data used to develop comprehensive plan
– CADD
– Manufacturing
– Tooling
– Structural
Total Quality Management
• Integration of all organizational activities
• Goal is to “serve customers”
– Establishing process standards
– Maximizing production efficiency
– Implementing quality improvement processes
– Employing integrated teams
• Effectively design customer-driven products
Part III
Creativity and Innovation
Creativity
• Ability to produce through imaginative skill
• See patterns and relationships through
diverse information
• Bring into existence something new
Being Creative
• See relationships and patterns
• Believe you are creative
• Look at problem from a different
perspective
• Dream and brainstorm
• Work in a flexible, open, autonomous
environment
Innovation
• Process of transforming a creative idea into
a tangible product
• Improving the quality of a specific thing
• Allowing for more and better choices
Part IV
Engineering Design Process
Phases
• Pre-phase 1
– Needs assessment
– Business Case
• Phase 1
– Concept
• Phase 2
– Development
• Phase 3
– Execution
Phases
Needs Assessment
Execution
Conceptualization
Development
Needs Assessment
• Extensive research
– Advanced research
• Are areas of technology currently not being utilized?
• Work with specific industry partners to exploit
technology
• Create barriers to market entry
– Existing product research
– Focus groups
Business Case
• Articulates need
• States plan
– Concept to implementation
• Allows for termination
– Costs rise
– Other specific criteria not met
Concept
• Industrial design
– Work within engineering, manufacturing, and
cost constraints
– Must be creative
Concept
• Initial direction
– Problem communicated to team
– Alternative sketches produced
• Solution chosen from alternatives or generated as a
hybrid from several alternatives
– Engineering communicates production path
Concept
• Quality Function Deployment
– Introduces impartiality into design
– Helps highlight customer needs
– Uses analytical approach to ranking customer
wishes
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Surveys
Interviews
Focus groups
Analysis of customer feedback
Concept
• Design Specification
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Dimensions
Weight
Materials
General shape
Power requirements
Voltage requirements
Amperage
specifications
– Product life and
durability
• Design Specification
– Required agency
approvals
– Performance
requirements
– Included and optional
accessories
– General and special
features
– Environmental factors
Development
• Creation and testing of prototype
• Checking intellectual properties
– Patents
– Copyrights
– Invention disclosure
• Product bill of materials
– Establishes final product cost
– Organizes manufacturing process
Development
• Failure Mode Element Analysis (FMEA)
– Determine possible failures
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Potential effects
Probability of occurrence
Potential causes and triggers
Verification of testing and observation
– Eliminate or minimize failures
Development
• Finite Element Analysis (FEA)
– Mathematical solutions
• Structural and thermal problems
– Computer model generated
• Stresses placed on model and analyzed
Execution
• Pre-production build of limited run of
product
– Validation of manufacturing processes and
conformance to expected performance
• Securing of regulatory approvals
– Flame retardant ability
– Durability
– Ergonomics
Execution
• Receipt of UPC
– Universal Product Code
• Completion of technical literature
• Target inventory levels are made
Summary
• The traditional engineering design model
does not take into account many factors in
the 21st century market
• Cross-functional teams help the design
process through greater cooperation and
communication
• The multi-phase model of design begins at
a needs assessment and cycles through
implementation, only to be revisited