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PROCESS OF INDUSTRIAL DESIGN
As engineers follow an established design procedure to generate
and evaluate concepts for the technical functioning of a product,
industrial designers follow similar procedure.
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While this is the end of the industrial design process,
some industrial design companies offer comprehensive
engineering services including:
detailed design,
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AESTHETIC
Design for aesthetic is being given greater emphasis and is being
applied more often to technically oriented industrial products -
often this is considered as styling.
Industrial design deals with the aspects of a product that relate to
the user. (Caplan)
The First major role of industrial design is the aesthetic appeal.
o Aesthetics is a science concerning with the interaction of
product with human senses: how it looks, smells, or sounds.
o For most of the products the visual appeal is very important -
deals with shape, proportions, surface texture, colour of
elements, etc.
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Proper attention to aesthetics in design can instil a pride of
ownership and a filling of quality & prestige.
Appropriate styling elements can be used to achieve product
differentiation in a line of similar products: car models, variety of
cloths prints, etc.
Proper attention to industrial design is essential to develop and
bring to the public a corporate image about the product that the
company makes & sells.
Many companies take this to the point where they have developed
a corporate style that embodies their products i.e. in the
letterheads, souvenirs, etc.
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The second major role of industrial design is in making sure that the
product meets the user human interface, a subject called
Ergonomics or Usability.
Ergonomics deals with the user interactions with the product, making sure that
it is easy to use and maintain (March)
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Visual Aesthetics
Hierarchy of human responses to visual stimuli:
At the bottom level of the hierarchy there is order of visual
forms, with their simplicity and clarity.
The base level of visual aesthetics hierarchy deals with the visual
neatness.
The second level of hierarchy is concerned with recognition of
functionality or utility of the design.
The highest level of visual esthetics hierarchy deals with the group
of aesthetic values derived from fashion, taste, or culture.
These are the class of values usually associated with styling.
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It was found that people react better to symmetric shapes
with closed boundaries.
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Another way of enhancing perception is reducing the
number of design elements and clamping them into more
compact shapes.
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Patterns showing a tendency towards visual separation from the base
suggest a sense of mobility or action (Lewalski)
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A streamline shape suggests speed, like in racing cars, high
speed trains, airplanes, fighter jets etc.
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The Honda jet plane - good example of a streamliner for high
speed flights.
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The highest level of visual esthetics hierarchy deals with the
group of aesthetic values derived from fashion, taste, or culture.
These are the class of values usually associated with styling.
There are close links between these values and the state of
available technology.
For example:
The high strength steel wires made possible the
construction of suspension bridges & TV towers.
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The availability of steel beams and reinforced concrete
columns made possible the construction of skyscrapers,
dams, large industrial buildings, oil platforms, wind-mill
electric generators & the like.
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Eiffel tower in Paris, France (325m) - 1889
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Burj Khalifa ("Khalifa Tower") -
known as Burj Dubai
Dubai, United Arab Emirates,
The tallest man-made structure in the
world
829.8 m - 2010
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HUMAN FACTORS DESIGN
Human Factors Engineering or Ergonomics - deals with
the study of the interaction between people and the products
and systems, in which they work or live.
Human Factors Design applies information about human
characteristics to create objects, facilities, and environment that
people use or work in.
Industrial designers have a good knowledge about human
factors design and they focus on the ease of using products,
while the engineers focus on the design of the production
systems for productivity and safety.
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Human interacts with products in four ways:
1. As an occupant of the work space (cab or chair),
2. As a power source (usually muscle power),
3. As a sensor, looking for a warning light or sound,
4. Acting as a controller of the machine.
Products that score high marks in human factors and safety are
regarded as quality products, since they work well with the user.
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Creating a User-Friendly Design (UFD)
There are several approaches to create UFD:
1. Fit the product to the user physical attributes & knowledge
2. Simplify tasks
3. Make the controls & their functions obvious
4. Use mapping
5. Utilize constrains to prevent incorrect action
6. Provide a feedback
7. Provide good display
8. Make controls easy to handle
9. Anticipate human errors
10. Avoid heavy & extreme motions for the user
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1. Fit the product to the user physical
attributes and knowledge:
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User-friendly design also require to incorporate the
Normans concept which states:
The design must incorporate the general knowledge
of the majority of peoples population.
Examples:
red light means stop,
higher numbers on a dial are shown in the CW direction,
knobs, or screws are tightened when turned in CW
directions, etc.
The designer should also not presume too much knowledge &
skill by the user about the product.
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2. Simplify tasks:
Control operations should have a minimum number of
operations and should be clear and straightforward.
The learning of users must be minimal and the use of
microelectronics into the product will simplify the sequence of
operations.
The product should look simple and have a minimum number of
controls and indicators.
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Selection of the controller for a product should match the
intension of the operator with the response of the system.
Design should be such that when the person interacts with the
product there must be only one obvious and correct thing to
do.
Display should be clear, visible and large enough to be read easily
without mistakes.
Analog displays are used when quick reading is required.
They also show changing conditions.
Examples: car speedometer, tachometer providing the engine speed,
fuel meter, etc.
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8. Make controls easy to handle:
Make knobs and handles of controls of different shape and size
so as they can be distinguished easily by look and by touch.
Minimize complexity by organizing controls in groups.
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10. Avoid heavy & extreme motions for
the user
Twisting or long arm movements, bending & large
movement of the spine are not allowed.
Especially when the these motions are repetitive - leading to
cumulative trauma disorder.
11. Standardize:
It is important to standardize controls because it improves
the user knowledge.
Example: Placement of accelerator, brake and clutch pedals in a vehicle
are standard for all passenger cars and lories irrespective of the motion
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DESIGN FOR SERVICEABILITY
to keep their
performance within acceptable limits.
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There are two types of maintenance:
Preventive maintenance
Breakdown maintenance
Preventive maintenance
routine service required to avoid failures, such as changing oil
and filters of an engine, greasing bearings, etc.
Breakdown maintenance
service that must be done when failure or decline in
performance has occurred.
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Greater concern for the environment in product design requires
strong emphases on the life-cycle design of the product,
achieved through:
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Life-cycle assessment (LCA) - adopted way of assessing
effects that products & processes have on environment.
Stages of LCA:
1. Inventory analysis:
The flow of energy and materials to and from the product
during its life is determined quantitatively.
2. Impact analysis:
Consideration of all potential impacts on the environment of the
above flows.
3. Improvement analysis:
The results of the above two steps are translated into specific action
that reduces the impact of the product and the processes to the
environment.
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General approach used in LCA
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Design for Environment (DFE)
is divided into two broad categories:
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Design for Environment (DFE)
Principles:
1. Design for material recovery and reuse
2. Design for disassembly
3. Design for product waste minimization
4. Design for waste recovery and reuse in processes
5. Design for Packaging recovery
6. Avoid the use of hazardous and undesirable materials
7. Consider the environmental hazard on production workers
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1. Design for material recovery and reuse:
Traditionally the recycling and reuse of materials is governed
by economics & special regulations.
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2. Design for disassembly:
Avoid the use of screws & welds but use snaps, clips, and
other means for quick disassembly.
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3. Design for product waste
minimization:
Minimize the amount of material used by avoiding
overdesign of the components.
Learn, which materials are incompatible in recycling in
order to separate & segregate them.
Keep the number of different materials to minimum to
reduce the recycling cost.
Understand, which paints, labels, adhesives can cause
contamination when recycled & avoid them.
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4. Design for waste recovery and
reuse in processes:
The waste of a product is usually a small fraction from the
waste generated by the processes that produce it
(electroplating, alloying, painting).
Consider the environmental implications in
manufacturing and selecting the processes.
Be aware of the ways of reducing process waste.
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5. Design for Packaging recovery:
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6. Avoid the use of hazardous and
undesirable materials
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Material cycle:
Mining of minerals, pumping oil, harvesting wood and
agricultural fibers such as cotton, etc.
Processing, refining, & extracting bulk materials e.g. a
steel ingot, which is further processed into finished
engineering material such as steel sheets, profiles such as bars,
pipes, beams, etc.
Then the engineers design a product that is manufactured
from the material and the product is put into useful service.
In the process of usage the product wears out or become
obsolete, because a better product comes on the market, e.g.
The products of the digital electronics has replaced the analog
ones: that is LCD, LED TVs replaced the Tube one, etc.
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Benefits of material recycling:
Contribution to the supply of bulk materials.
Reducing the consumption of natural resources.
Reduction of the solid waste that has to be disposed of, in a
landfill, thus contaminating.
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A good alternative to recycling is remanufacturing:
Instead of disassembling the product for recycling materials the
product is restored to a new condition. This is done by
replacement of worn parts.
Some secondary materials are generated in the material
processing & the utilization cycle by using:
o Home scrap: the material is recovered from primary material
production: Cropped tops of ingots or sheared edges of sheets,
plates, bars, etc.
o Industrial scrap or new scrap is generated during the
manufacture of products: e.g. stamping scrap, bundles of turning,
or spinning, etc.
o Old scrap is scrap generated from a product that has completed
its useful life. Its also called obsolete or post consumer scrap, e.g.
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a scraped car, fridge, or any machines.
Recyclability
Refers to the ease with which a material can be recovered
from a used product.
Buy-back centers
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Separation usually follows one of two
paths:
1. Selective dismantling
E.g. toxic materials like engine oil and lead batteries are first
removed and then given special treatment. High value materials such
as copper, gold, etc. are removed & segregated.
2. Shredding
The product is subjected to multiple high-energy impact to batter to
small irregular pieces.
Shredded material is further sorted into different materials using
special techniques such as:
o Magnetic separation
o Vibratory sieves
o Air sorting, and
o Wet flotation
o Plastics are sorted by using the principle of Raman
spectroscopy, much like a barcode scanner.
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Identification of materials, sorting and
reprocessing
After sorting, the recycled material is sold to a secondary materials
producer
o Metals are re-melted in Marten furnace - ingots
o Plastics are ground and processed into pallets
Thermoplastic polymers can only be recycled, in contrast to thermosets,
which cannot be recycled.
Usually recycled plastics can be used for less critical applications, but
today's technology allows engineering plastics to be recycled 3-4 times
losing only 5-10% of their original strength
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