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Unit 1

The Product Design Process

The Four Cs of Design


A Simplified Approach
A Problem Solving Methodology
Consideration of A Good Design
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
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)
The Design Process- A
Simplified Approach
General information

Specific Design Operation Outcome


information

NO yes
Evaluation
Feedback loop
Go to the next step
Scientific Method vs Design Method

Existing knowledge State of the art

Scientific curiosity Identification of need


Communication

Acceptance
Hypothesis Conceptualization

Logical analysis Feasibility analysis

Production
Proof
Scientific Method Design Method
Consideration of Good Design
Design Requirements
Functional performance (F, , 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
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
I. Conceptual Design
Identification of customer needs
Problem definition
Gathering information
Conceptualization
Concept selection
Refinement of product design specification
Design review
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)
III. Detail Design
In this phase the design is brought to the
stage of a complete engineering
description of a tested and producible
product.
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
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.
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.
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.

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