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 – – – – – – – – Design fundamentals Materials science Manufacturing processes Market trends Safety Data management Teaming Packaging,distribution, and storage Impacts on Design • • • • • • 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 • • • • Surveys Interviews Focus groups Analysis of customer feedback Concept • Design Specification – – – – – – – 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 • • • • 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