Design and Engineering - Ramachandran S
Design and Engineering - Ramachandran S
Design and Engineering - Ramachandran S
ENGINEERING
(For B.E. / B.Tech. Mechanical Engineering Students)
ISBN : 978-93-84893-67-5
Course Plan
Module
Sem.
Hrs. Exam
Contents
Marks
Design
and
its
objectives;
Design
L2
L3
attributes
and
Brain
storming
15%
II
L2
15%
L3
P4
L2
L3
P4
15%
IV
L4
15%
P4
L2
L4
evolution
of
Wet
grinders;
P6
20%
VI
and
the
20%
Contents C.1
Contents
1. DESIGN AND ITS OBJECTIVES
1.1 Design .......... .....................................................................
1.1
1.4
1.4
1.5
1.6
1.6
1.6
1.6
1.7
1.7
1.7
1.8
1.9
1.9
1.9
1.9
2. DESIGN PROCESS
2.1 Design .......... .....................................................................
2.1
2.2
2.3
2.3.1 Research.............................................................
2.3
2.4
2.3.3 Conceptualization..............................................
2.4
2.6
2.6
2.7
2.7
2.9
2.9
Contents C.3
3. PROTOTYPE TO PRODUCT
3.1 Prototyping .. .....................................................................
3.1
3.3
3.5
3.6
3.6
3.7
3.8
Contents C.5
4.1
4.3
4.3
4.3
4.4
4.6
4.9
5. VALUE ENGINEERING
5.1 Product Centered and User Centered Design .............
5.1
5.5
6. MODULAR DESIGN
6.1 Modular Design ...............................................................
6.1
6.5
6.9
Chapter 1
1.1 DESIGN
Engineering design can be defined as the process of
designing a system, component or process to meet the
desired needs. It is often an iterative decision making
process which uses basic sciences, mathematics and other
essential data to convert resources to meet a stated
objective. Based on the difficulty of the design process, it
can be classified into three types:
1. Adaptive design
It is usually the most easiest types of a design
process. It deals with creation of a design process based on
an existing similar process. Since the resources are readily
available, adaptive designs could be performed in a short
period of time. That is, the existing design can be adopted
for new design with some modifications. Example: Design
process for an elevator has been technically and
conceptually the same for a long period of time. Hence, the
Design costs
Development costs
Manufacturing costs
Distribution costs
Availability of resources
En gine ering
Co mm e rcial
D e sign
Fu nctions
Q uality
M anufacturing
working,
design
Integration
of
design
process
with
the
manufacturing and other process through ERP
systems thereby allowing transparency between
departments.
(ii)
(iii)
8-12
The
Problem analysis
Problem clarification
1.
2.
3.
4.
5.
6.
7.
8.
Rank Order
Physiological needs
Social needs
Esteem
G ro w th
Social
Physiological
B elo ng ing
Safety
A ccepta nce
S ecurity
S ocial L ife
H unger
P ro tection
Thirst
form D a ng er
Friend ship
G E N E R AL EX AM PL E S
S tatus
Friend ship
S tab ility
Food
A ccom plish me nt
A chieve me nt
P erson al
S tatus
D evelo pm e nt
R ecogn itio n
a nd love
S lee p
A chieve me nt
O R G A N IZATIO N A L E XA M P LE S
S elfa ctu alizatio n
n ee ds
E ste em need
B elo ng ingn ess n eeds
Friend s at w ork
S ecurity ne ed s
P hysiolog ical nee ds
Fig. 1.3 M aslo ws H ierarch y of Needs
P ensio n plan
B ase sa lary
Product performance
Cost of product
Quality of product
Performance of a product
Performance is measured from the primary operating
characteristics of a product. A better performing product
speaks about its intended functionality and attracts more
customers
Time to reach the Market
Time factors include all the time spent on designing
the product. A product should not take more time, to reach
the market. The efforts are being given to reduce the
product development cycle time, also known as time to
reach the product on market. Customers usually prefer the
products which reach the market at their time of need.
Cost
Cost of a product is the main aspect that should be
considered while designing. Cost determines, the buying
decision of a customer so it should not be high.
Quality
Quality of a product is another aspect which
influences the marketability. A product should satisfy the
its
torque
and
brake
power
and
computers
feature,
and
could
be
an
unique
selling
4. Durability:
Durability is the measure of a products life. It is the
amount of use one gets from a product before it breaks.
Customers are more likely to purchase a durable product.
5. Serviceability:
A failed component of a product should be easier to
repair or replace, which is called as serviceability. A better
serviceability implies quicker service time and availability
of components in market at all times. Hence universally
recognized standard components are often employed.
6. Conformance:
It can be defined as the degree to which a products
design and operating characteristics meet the customers
expectations and the
International standards. These
standards include Industrial standards, safety and
environmental standards. A product should not only fulfill
the needs and its own primary objectives, but should also
find its way to conform with several International
standards.
7. Aesthetics:
Aesthetics deals with the beauty, artistic impact and
the appearance of a product. A product which attracts the
person by its appearance, smell, taste or sound is said to
be aesthetically acceptable. The customer response in this
dimension is a matter of individual preference and personal
judgement.
8. Perceived quality:
The marketability of a product also relies upon the
reputation of the firm. Additional factors like advertising
and marketing often influence the customers point of view
1.15 IDEATION
Ideation is the process which allows to evaluate
current ideas, create new ideas and improve an idea with
other benefits. This process is very important in the process
of concept development, innovation and creativity. The
major goal of ideation should not be developing lots of idea,
but the goal should be to develop a single idea with a best
solution to satisfy the customer needs.
W h at is ou r
D e sign C o ncep t ?
H o w do w e d o it ?
C re ative
ide as
1.16 BRAINSTORMING
Brainstorming is a group creativity technique in
which a group of people are allowed to discuss about a
problem and to find a solution and conclusion for the
problem in a limited period of time. Brainstorming is a
carefully exhibited process.
This approach was first initiated in industries to solve
the problems and to implement new and creative ideas on
a system.
To stimulate various ideas, the people are divided into
groups. All groups come up with different ideas to solve
the problem. The facilitator collects the ideas from the
groups and conducts voting on each idea among the groups.
After the voting is done, the top ranked ideas are discussed
among the group members.
In brainstorming, if there is a criticism for any idea
then that idea is put on hold.
The brainstorming group keeps a target for time and
with some pressure to attain the large number of ideas.
The participants are awarded with incentives for their
unique ideas.
The ideas are collected and also recorded so that they
can be reused to design alternate procedures to meet the
objectives.
1.16.1 Guidelines
storming session
to
be
followed
during
Brain
Chapter 2
DESIGN PROCESS
Design process- Different stages in design and their
significance; Defining the design space; Analogies and "thinking
outside of the box"; Quality function deployment-meeting what the
customer wants;Evaluation and choosing of a design.
Design Communication; Realization of the concept into a
configuration, drawing and model. Concept of "Complex is simple".
Design for function and strength. Design detailing- Material
selection, Design visualisation- Solid modelling; Detailed 2D
drawings; Tolerancing Use of standard items in design; Research
needs in design; Energy needs of the design, both in its realization
and in the applications.
2.1 DESIGN
The
word
Design
represents
the
meaning
definitional challenges. Design is difficult in its own aspect
as it requires multiple number of iterations and rarely used
on the optimal process. There are few design domains that
are described by formal mathematical languages and some
by computational complexity.
The other way of thinking about design quality is to
identify the defects that will arise in the design process.
However, a large number of human problem solving is not
the really good design. In the other way, design hardly
represents the faithful execution of plan with the
application of remarkable skill and craft.
G ap
Se nse G ap
D e sign
Explore
Alternatives
Se lect Plan
Plan
Fig. 2.1
Environmental
non-operating
Test requirements
External dimensions
Reliability requirements
Design life
Maintenance
Testability provisions
Materials requirement
Packaging requirements
External marketing
situation
for
operating
and
A rtic ulate d
D e sign
H id d en
D e sign
B o un da ry
o n F ea sible
D e sign
Fig:2.2 D es ign Sp ace in n -dim en sion
2.5 ANALOGIES
Analogy is an inventive method of problem solving in
everyday life. It is the duty of the designer to recognize the
similarity between the design under study and a previously
solved problem.
Analogy is a creative solution which depends on the
degree to which the analogy leads to a new and different
designs. In one type of solution, analogy recognizes the
similarity between an existing product and its design
specification of the product which is under study.
There are four different types of analogies to generate
ideas about an existing problem. The four types of analogies
are listed below
1. Direct analogy
2. Fantasy analogy
3. Personal analogy
4. Symbolic analogy
2.5.1 Direct analogy
Direct analogy is the common approach that is used
by every one at a time or another. The analogy is direct
because in each system there are matched physical objects
behaving the same way. A direct analogy may take the form
of a similarity in physical behaviour, similar in geometrical
configuration, or in function.
Interrelationships
betw ee n
Technical D escriptors
C o un te rpart C ha racte ristics
(Tech nica l D escriptors)
(Voice of the O rganisation )
Vo ice of the
C u stom er
( C ustom er
R e qu ire m en ts)
Priority of
C u stom er
R e qu ire m en ts
Co mpe titive
Evalution
The ceiling
descriptors
of
the
house
contains
technical
Identify
voice
requirements)
of
the
customer
(customer
2.
3.
4.
5.
6.
Questions such as
illustrate
the
development
of
House
of
C overs sub je ct
G oo d
d ispilin e
Top ical
C overa ge U p-to-date
R eal-w orld
a pp lica tions
E xercises S ufficie nt
Q ua ntity
D ifficulty
C ost
L ow co st
E asy to rea d
G ood
topical
coverage
R eal-w orld
applications
Exercises Sufficient
quantity
D ifficulty
C ost
Low cost
Easy to rea d
Exam p les
illustrate the ory
Free from N o content
errors
om issions
N o typo grap hical
errors
Fig. 2.4 (b)
G oo d
to pica l
coverag e
C o ve rs sub je ct
d isciplin e
U p -to -date
R e al-w orld
a pplica tio ns
E xercise s S ufficie nt
q uantity
D ifficu lty
C o st
L ow co st
E asy to rea d
E xam p les
illustrate the ory
Fre e from N o con ten t
e rrors
o m issio ns
N o typograp hica l
e rrors
Fig. 2.4 (c)
B S p ro du ct
Targ et
value
D ifficulty
L ow co st
E a sy to rea d
C o ve rs sub je ct
d isciplin e
G oo d
to pica l
U p -to -da te
coverag e
R e al-w orld
a pp lica tio ns
E xercise s S u fficie nt
q ua ntity
C o st
C o stum er
com p etitive
e va lu atio n
AS p rod uct
* 1 Fo r w o rst
5 Fo r be st
O ur pro d uct
Fig. 2.4 (d )
AS produ ct
B S p rodu ct
D ifficulty
L ow cost
Ea sy to rea d
Techn ica l
C o stum er
com p etitive
e va lu atio n
Target
value
C o st
* 1 Fo r w orst
5 Fo r best
O u r prod uct
O ur prod uct
AS product
BS p rod uct
4 3 4 4 4 2 3 2 3 5 3
3 4 3 4 5 3 3 2 4 5 4
5 2 3 3 4 3 4 4 2 5 4
* 1 Fo r w orst
5 Fo r b est
Target value:
The target value column is used by the QFD team to
decide whether they want to keep their product unchanged,
improve the product (or) make the product better than the
competition.
Step 6: Determine
requirements
the
priorities
of
customer
* 1 F or w orst
5 Fo r best
1.5
D ifficu lty
Low cost
E a sy to rea d
1.5
E xam ple s
illu strate theo ry
F ree from N o content
errors
om issions
Tech nical
O ur product
4 3 4 4 4 2 3 2 3 5 3
AS p ro duct
3 4 3 4 5 3 3 2 4 5 4
B S pro duct
5 2 3 3 4 3 4 4 2 5 4
* 1 For w orst
5F or best
S a les point
Im portan ce
to costum er
B S product
Target
valu e
C ost
P riorities
of
custom er
requirem en ts
C ostum er
com pe titive
evaluation
AS p ro duct
M ee ts instructiona l ne eds
C om po ne nt
C haracteristics
Technica l
characteristics
C ustom e r
A ttribute s
Technical
C haracteristics
Q ua lity
C ontrol Pla n
P rocess
O pe rations
C om po nen t
C hara cteristic s
P ro cess
O pe rations
Process operations
Functions
Acquisition
Proposal
Review
Contracting
Writing
Editing
Galleys
Proofs
Page make up
Cover design
Printing
Development
Preproduction
Production
Film making
Plate exposing
Offset printing
Cutting
Folding of forms
Composing
Perfect binding
Packing
2.
3.
4.
5.
6.
7.
Consensus decision
8.
9.
10.
11.
12.
It stabilises quality.
13.
14.
15.
benefit
of
QFD
is
the
Customer
Ev aluation Ph as es
A b so lu te C riteria
G o - N o n go S c re en in g
P u gh C o nce pt S election
B e st C o ncep t
on
assessment
of
technology
Criteria
Concept
A
Cost
Comfort
Weight
Aesthetics
Availability of materials
Ease of manufacturing
Pluses
Minuses
4. Best Concept
Once all the criteria are satisfied for the required
level, then that Best concept will be proceeded for other
operation. This is how evaluation takes place.
Visual communication
Information architecture
Editing
Typography
Illustration
Web design
Animation
Advertising
Ambient media
Visual design
Performing arts
Graphic designer
Industrial designer
sufficient
fracture
Vibration
Design incorporated should withstand vibrations.
The above mentioned are functionality factors, often
called design for performance factors, deal with technical
issues that can be addressed though analysis based on
mechanics of materials, its strength issue, fluid flow or heat
transfer. More detailed analysis of critical components is
carried out in the parametric design step.
Sp he re
C o ne
Torus
C ylinder
C u bo id
K=3
R o ot M od e
L
L
L
Le af M od e
L
K
L
T ree h eigh t
Fig. 2.10
The root mode (R) has no parent and leaf mode (L)
has no children.
Advantages of CSG
1. Since the data to be stored are less, memory
required will be less.
2. Create fully valid geometrical solid model
3. Less skill is enough
Disadvantages of CSG
1.
2.
2.12.2 B-rep
This approach is widely used in most of solid
modellers.
The solid model created by using B-rep technique may
be stored in graph based on data structure.
Advantages of B-rep
1.
Combining
possible.
wireframe
and
surface
model
are
2.
3.
Disadvantages of B-rep
1.
2.
Sometimes
possible.
geometrically
valid
solids
are
not
2.
3.
4.
highlighting,
modellers.
5.
and
facilities
available
in
solid
D ecision
E ngine ering D ra w in gs
P ro totype Testin g
P ro ject R e po rt
P ro ject R e view
Cost Estimation
The detailed drawing gives clear sketch on the final
cost estimation, since knowledge of the material, the
dimensions, tolerances and finish of each part are needed
to determine manufacturing cost. Cost analysis requires
specific information about the particular machines and
process steps that will be used to make each part.
Project report
The detailed project report is written at the conclusion
of the project to describe the tasks undertaken and to
discuss the design in detail. The project report is an
important document if the products become involved in
either production or in patent.
Design Review
Design review will include initial product concept
meeting to begin the establishment of the product design
specification, a review at the end of the conceptual design
to decide whether to proceed with full scale product
development. Detailed reviews in the meeting will discuss
important issues like design for manufacturing, quality
issues, reliability, safety or preliminary cost estimates.
Final design review is the most structured and
comprehensive of the reviews.
Design for manufacturing
Design for manufacturing is the main activity of the
design personnel on that product. Manufacturing moves
ahead to develop tooling while design works on an
accelerated schedule to fix some design deficiencies. Design
input does not necessarily stop once manufacturing takes
over, because technical expertise is needed in such areas
2.
3.
4.
5.
2.
3.
4.
5.
2.15 TOLERANCING
A tolerance is the permissible variation from the
specified dimensions. The designer should decide how much
variation is allowable from the basic dimension of the
component to accomplish the desired function.
The design objective is to make the tolerance no
tighter than necessary. Since smaller tolerances increase
manufacturing cost and make assembly more difficult.
Bilateral tolerance
Unilateral tolerance
Direct
Bilateral tolerance
The variation occurs in
both directions from the
basic dimension. That is, the
upper limit exceeds the
basic value and the lower
limit falls below it
9 .975
0.005
sha ft
1 0.007
0.00 7
h ole
(i.e.) value
Fig:2.15 Bilateral To lerance
Presentation
Unilateral tolerance
The basic dimension is
taken as one of the limits
and variation is in only one
direction.
sha ft
9 .98
-0.01
1 0.000
+0.014
h ole
Direct tolerance
The
maximum
and
minimum acceptable values
for the dimensions will be
given
sha ft
9 .98
9 .97
1 0.014
1 0.000
h ole
1.
2.
3.
4.
5.
6.
Performance
Test methods
Codes of practice
many
Invention
Innovation
Diffusion
(i) Invention
It is the creative act where an idea is conceived,
articulated and recorded.
(ii) Innovation
The process by which an invention or idea is brought
into successful practice and is utilized by the economy.
(iii) Diffusion
The successive and widespread implementation and
adoption of successful innovations is called diffusion.
Of these three stages, innovation is the most difficult
most time consuming and most important.
Chapter 3
PROTOTYPE TO PRODUCT
Prototyping - rapid prototyping; testing and evaluation of
design; Design modifications; Freezing the design; Cost analysis
-Engineering the design - From prototype to product. Planning;
Scheduling; Supply chains; inventory; handling; manufacturing/
construction operations; storage; packaging; shipping; marketing;
feed-back on design. - List out the standards organizations
3.1 PROTOTYPING
Prototyping is a way to develop and test the feasibility
of ideas to help us move from abstract to product in a safe
and controlled environment,
Once the design team has a consolidated idea of how
to answer a problem, prototyping provides an opportunity
for testing some of the proposed solutions without going to
the expense of full development. Prototyping engages a wide
range of stakeholders to generate and validate ideas and
awaken new possibilities. It follows the direction "Fail
earlier and often, to succeed sooner".
Prototyping can be defined as the process of quickly
putting together a working model (prototype) in order to
test the various aspects of a design, illustrate ideas or
features and gather early user feedback.
The word prototype comes from the Latin word proto,
meaning original, and types meaning form or model. A
prototype is the result of the prototyping process and
describes a crude version of the desired result. The role of
a prototype is to assure that the product will really function
S olid
(C A D )
M od el
C onversion
to
S T L F ile
P ost P rocessing
P ro cess P lann er
(M ode l validity,
slicing, trajecto ry
p la nnin g)
A uto ma ted
Fabrication
laser beam traces the shape of each layer and hardens the
photosensitive resin.
Process
Advantages
U V Laser S ou rce
L iq uid P olym er
L iq uid
S urface
E levator
Form ed Pa rt
Vat
S upport
P latform
Fig. 3.2. S chem atic Illu stratio n o f Stereo Lithography Pro cess
Disadvantages
Po w de r
R o lle r
Pa rt
Piston go es
up for ea ch
Layer
Piston m oves
dow n for
each Layer
Fig. 3.3. S ele ctive L aser Sinterin g.
Process
Advantages
Variety of materials
Disadvantages
Complex operation
M irror
L aser
M ovin g op tics H ead
H e ate d R olle r
L ayer C on to ur
S heet
M aterial
P latform
Take up R oll
S upply R o ll
Fig. 3.4. L ayer Object Manufacturing.
Advantages
Fast method
No shrinkage or warpage
Disadvantage
Fila m en t
Fe ed e r
L iq uifie r
Fila m en t
S u pply C o il
H e ig ht
A d ju stable
P latform
Process
Advantages
No post curing
Good
range
Polycarbonate)
of
strong
materials
(ABS,
Disadvantages
L iq uid
a dh esive
sup ply
M ulti - C h an ne l
in kje t H e ad
R o lle r
...
..........
.....
...
Fa brication
P o w de r B ed (B )
O bject B eing
Fa bricate d
P o w de r
D e live ry
S ys tem
B u ild
C ylind er
Process
Advantages
Speedy fabrication
No supports necessary
Disadvantages
Limited materials
Fragile parts
Engineering
Analysis
and
Planning:RP
enables stress analysis, flow analysis etc., of the
physical model. Also fabrication of pre-production
parts for process planning and tool design is
possible.
fabrication
of
Advantages
Limitations
Identifying major
re-design work.
areas
of
concern
for
any
To identify potential
improvements
faults
and
to
make
C o ncep t
Free ze
D e taile d
d esign
Prototyping
D e sign
Free ze
Tooling
Free ze
Where design
manufactured
is
frozen,
product
can
be
of
production
Labour
Maintenance
Selling expenses
Another categorization
Direct costs
Indirect costs
Fa ctory C o st
M an ufactu rin g co st
S a le s expe n se s
Tota l co st
P ro fit
S e llin g p ric e
We have
Gross profit, Z PQQV F
F
PV
Net profit
100
Cost of investment
C a pital e m p lo yed
Profit
Sa le s
C o sts
In ven tory
C a sh a nd
re ceiva bles
Fixed
a sse ts
1,000, 000
666.67
1500
Selling pric e,
Q BEP
7000
F
3500 units.
PV 97
Q BEP
1000
14000
Rs.14 /unit
1000
Net profit
100
Cost of in vestment
300000
100
1500000
0.2 100
20%
D e ve lo pm e nt
A lph a P ha se
B e ta ph a se
P ro du ct R e le ase
P ro du ctio n
Fig.3.9. G eneral R ep resen tation
from D evelo pm en t to Prod uction :
Each Stage Representin g
D ifferent Levels of Q uality
P roduction
Inspection &
Q uality A ssuan ce
Feedb ack
A conventional product
cycle from prototype to
product is shown in Fig 3.10
De tailed D esign
P rototyp e
P ackagin g, M arketing
& S ales Literature
P roduct
Fig.3.10. Prototype to Product
Bill of Materials(BOM)
Purchase Order(PO)
Tooling
Quality
Packaging
Shipping
Storage
Other costs
P ro c ess
P lan ning
P ro du ctio n
P lan ning
D e sign &
P ro c ure m en t
o f n ew too ls &
e qu ip m e nts
P ro du ctio n
Q ua lity
C o ntrol
P a cka ging
O rd er
M aterial
N C ,C N C ,D N C
p rog ram m in g
N C - N um e rica l C o ntrol
C N C - C o m p uter N um e ric al C o ntrol
D N C - D ire c t N u m erica l C on tro l
D e sign n ee d
(D e sign P rocess )
C u stom er
Fe ed b ac k
M arke tin g
S h ip ping
3.7 PLANNING
Planning consists of identifying the key activities in
a project and ordering them in a sequence in which they
should be performed.
Now-a-days, companies are in severe demands to
produce successful and high quality products with the
smallest cycle times and investment costs. So, product
development becomes risky if improperly planned. Good
product developers seek to balance product constraints(time,
cost) with product features, and quality. Absence of
planning would lead to wastage of time and resources.
Planning considers all input variables to achieve
predetermined output goals. Control activities are necessary
for remedial action to prevent variance of output from
planned levels.
The general product and control cycle is shown in
Fig.3.12
W h e re a re
w e no w ?
Feed back
How d o we
kn ow w h en
w e h ave
arriv ed ?
W h e re d o w e
w a nt to be ?
M on itoring
O bjectives
H o w a re w e
go in g to
ge t the re ?
C o ntrol activitie s
Plann ing
in
tune
with
3.8. SCHEDULING
Scheduling is the process of arranging, controlling and
optimizing work and work loads in a production process,
where it has a major impact on the productivity of a
process. It consists of putting the plan into the time frame
of the calendar. Companies use forward and backward
scheduling to allocate plant and machinery resources, plan
human resources, plan production processes and purchase
materials.
Forward scheduling
Backward scheduling
Cost Reduction
P ro je ct N a m e
Task 1
S u btask 1.1
S u btask 1.2
W ork P ac ka g e 1 .1 .1
W ork P ac ka g e 1 .1 .2
W ork P ac ka g e 1 .2 .1
W ork P ac ka g e 1 .2 .2
Task 2
S u btask 2.1
W ork P ac ka g e 2 .1 .1
W ork P ac ka g e 2 .1 .2
Fig. 3.1 3. W ork B re ak D ow n Stru ctu re.
PERT
Program Evaluation Review Technique(PERT) is a
project management tool developed by the US Navy in the
1950s to evaluate the performance of large development
projects. It is a network of tasks needed to complete a
project, showing the order in which the tasks need to be
completed and the dependencies between them.
A PERT chart presents a graphic illustration of a
project as a network diagram consisting of numbered
nodes(either circles or rectangles) representing events or
milestones linked by labelled vectors (directional lines)
representing tasks or activities in the project. The direction
of the arrows on the lines indicate the sequence of tasks.
A PERT chart is illustrated in Fig.3.15
2
C
15
D u mm y
a ctivity
1
5
B
E
10
10
D
Materials flow
Financial flow
A generic configuration of a
manufacturing is shown in Fig.3.16
supply
chain
in
A ssem blers
R e taile rs
M aterials
P ro du ct
A ssem bly
S a le s
C u stom ers
3.10 INVENTORY
Inventory is a stock of goods, materials or held for
operations or sale or for processing before being sold
The inventory means aggregate of those items of
tangible personal property which are held for sale in
ordinary course of business.
In
a
manufacturing
organization, in addition to
the stock of finished goods,
there will be stock of partly
finished goods, raw materials
and stores. The collective
name of these entire items is
inventory.
The
types
of
inventory in manufacturing
organization is shown in
Fig.3.17
Inventories occupy the
most strategic position in the
structure of working capital of
most business enterprises as
they constitute the largest
component of current asset in
most of the enterprise. Hence,
a good inventory system is a
necessity for any modern
business or manufacturing
system.
Supp liers
M aterials
Arrived
R aw M ate rials
Inven tory
Produc e P a rts and
Suba ssem b lies
W ork in P ro cess
Inven tory
( C om po nent o r
su bassem blies )
F inished G oo ds
Inven tory
D elivering
C ustom ers
Fig.3.17 Types of Inventory
in Man ufacturing Organization s
(ii)
Forming
Separating
Joining or combining
Mechanical fastening
screws, etc.,)
Welding
Brazing
Soldering
Adhesive bonding
(rivets,
bolt
and
nuts,
3.13 STORAGE
Material storage in manufacturing system is required
for supplies coming in, work-in process parts and finished
goods. Materials must be accurately placed in appropriate
storage, so that no time is wasted looking for misplaced
products. Also, equipment tools and measurement devices
need to be stored easily for rapid retrieval while being
protected to avoid unplanned repairs / recalibrations and
prevent theft. Storage should be integrated into the working
environment depending on how a business specifically
operates and what storage solution will complement its
defined processes.
3.14 PACKAGING
Packaging is a necessity for the containment and
protection of products from the environment but also for
the protection of the environment from the products. In
addition to marketing, protection and containment, the
packaging also enables more efficient distribution and
storage of products, which means that the packaging can
help to reduce costs and cut lead-times in the supply chain.
Tailor-made packaging and product design can also
contribute to a reduction of packaging waste.
So,packaging is a pre-requisite for every product and
also plays an important logistics activity as it is the
packaged product that is transported, stored, carried, etc in
the supply chain.
3.15 SHIPPING
The move by many companies to have production
facilities at low cost manufacturing locations and
development of concepts such as focus factories, some with
a single global manufacturing point for certain products,
has had an obvious impact on the relative importance of
the different modes of transport.
Shipping is the process of transporting raw materials
and finished goods to their respective destinations. Shipping
originally referred to transport by sea but is extended to
refer to transport by land or air as well.
Multimodal transport is shipment of goods by trucks,
directly from shippers place to the destination.
Trucks and trains make deliveries to sea and airports
where cargo is moved in bulk. Ninety percent of the worlds
3.16 MARKETING
Marketing is a management process through which a
product moves from concept to customer. It is based on
thinking about the business in terms of customer needs and
their satisfaction. Communicating the value of the product
or service is a key aspect of marketing. Marketing includes
the coordination of four elements called the 4 P of
marketing.
(i)
(ii)
(iii)
Identification,
product
selection
and
development
of
(iv)
3.18 STANDARDIZATION
A Standard is a document that defines the
characteristics of a product or service, such as dimensions,
safety aspects and performance requirements. The role of
Chapter 4
(ii)
(iii)
Continuously
improved
product
reliability
performance and technology to meet customer
expectations.
(2)
(3)
M arke t
S h are
C u stom er
S a tisfa c tio n
P rice s
Q ua lity
C o sts
P ro du ctivity
P ro fits
D e sign fo r R eliability
O perating
En vironm en t L evel
System L evel
U se R edundancy a nd Fault
Tolerance , R e duce C om p le xity
C o mpo ne nt Le ve l
C o mpo ne nt Selection - U se
Proven R eliable C om ponents
rin
ee
g in
S a fe ty
En
s ig
De
Decision
making
Identification and selection
of alternative strategies.
H a za rd P reve ntion
Fig. 4.3. E ngin eering and
D esig n R elation
manufacture
or
otherwise
called
as
design
of
manufacturability. Both Design for manufacturing and
Design for assembly are similar.
Design for manufacturing (DFM) is based on the
concurrent engineering, which plays a major role in
acquiring the goals of DFM. The objectives of Design for
manufacture is to create an awareness about the design
being the base for all steps of production.
Benefits of Design for Manufacturing
Design for Manufacturing
considering the following points:
an
be
improved
by
4. Standard components
By preferring standard components, the cost is
reduced and improved quality can be seen in the design.
The cost reduction is implemented through discounts,
tooling costs, elimination of design work and better
inventory control.
5. Simple Design
Simple design will be the most reliable and the
easiest way to maintain. [For example: Instead of specifying
a heat treated alloy steel, a plain carbon steel will achieve
the performance with a bit more careful analysis].
Designing the product with the fewer parts, adjustments,
and less manufacturing steps are the best ways to reduce
the cost of manufacture.
4.5.3 Methods for DFM
Dont
Do
N o Dra ft
t
R = 3/8 t
Do
R+t
Avoid sharp corners, they
produce stress concentrations
and obstruct m aterial flow
(b)
2 m in
Add
Th ickne ss
fo r d raft
(a) A lw ays provide a d ra ft ang le fo r
e asier m old rem o va l
Dont
Do
Dont
t rib= 8
t rib
t rib
t rib=
8
Do
B e tter
voids
S ink m arks
S teppe d thickness
tra nsitio n
8
B e st
can
be
improved
by
the
the
the
are
D iffe re nt le ng th s
Do
S tan da rd le ng th
Don t
U nusua l heig ht
Do
M aintainability D esign
O pera tin g
En viro nm enta l L evel
System Le vel
C o mp onent Leve l
C o mp onent S election
(U se C om p on en ts easy to M aintain
R e place , R ecycle )
make
(iii)
(iv)
Remedial
maintenance
(repair):
Remedial
maintenance is performed after product has failed.
For example fitting new vehicle starter motor when
the existing motor has burned out.
for
Maintainability
Features/
reduced
Design for
Maintainability
Features
No
or
adjustment
reduced
Components
/ Technician fatigue / injury is
reduced
modules - quick and
easy to replace
Product availability increases
Problem identification improves
Mistake
proofing, Probability of damage to the
part or product is reduced
part/module
is
installed in one way Reliability is improved
only
Customer satisfaction improves
Self-diagnostics
or Maintenance time and costs are
reduced
built
in
test
or
indicators
to
find Diagnostic time is reduced
problems quickly
Customer satisfaction improves
No or few
hand tools.
special Maintenance
reduced
investment
is
Design for
Maintainability
Features
Standard
fasteners No. of spare parts in inventory
is reduced
and components
Product cost is reduced
Maintenance time and costs are
reduced
Reduce number of Product cost is reduced
components in final Reliability is improved
assembly
Spare parts inventory is reduced
Table 4.2 lists several metrics that can be used in
manufacturing measuring design for maintainability
benefits.
Table 4.2
Maintenance Metrics
Design
Attributes
Accessibility
Testability
Field costs
Repair costs
Total costs
Standardizat Maintenance
ion
Humanfactors
Times to
Repair
Field performance
Maintenance Work
Payroll
Maintenance
Management
Costs
Training costs
Orders / Year
Downtime
Total Maintenance
Hours
Number of
Maintenance
Personnel
Induced Failures
for
logistics
has
some
major
key
Locatio n o f S to rage,
N u m be r & type of sto ra ge
and
size of distribution d epartm ents
Inform ation
and
control
Pa cking
U n it
Tra nsport
Inven tory
Su ppliers
Bu lk delivery
R aw m ateria ls in ven tory
Pa ckaging inv entory
Tra nsfer
Prod uction
Tra nsfer
W ork -in-progres s inve ntory
and as sem bly
Tra nsfer
Fin ished g oods in ven tory
and w arehou se
Prim ary tra nsp ort
Organizational control
Managing warehouses
Manually operated
monorail, and hoist
devices
Trucks,
cranes,
(b)
(c)
(ii)
(iii)
(iv)
Don t
Do
(ii)
(iii)
(iv)
(v)
Timely production
and
thus
U se the sa me to ols
for as sem bly and
D isas sem bly
D on t
Do
Recycle S ubassembly
Pro du ct
Install R ecycled
sub assem bly
New
Su ba ssem bly
Re mo ve o ld
Su ba ssem bly
R em o ve old
S u ba s sem b ly
Recycle Comp on en ts
Pro du ct
Install R ecycled
sub assem bly
New
C o mp onent
R e mo ve p roduct a nd
recover m ate ria ls
R e cycle old
C o mp onent
Recycle M aterials
Pro du ct
Install p roduct
w ith recycled
m aterials
New
product
R e mo ve p roduct a nd
recover m ate ria ls
R e cycle
m aterials
M anufactu re
Pro du cts
Virgin M aterials
Increase profitability
Reverse engineering
Analysis
Redesign
Forward Engineering
R e de sign
A n alysis
R e - E ng in ee rin g
Chapter - 5
VALUE ENGINEERING
Product centered and user centered design. Product centered
attributes and user centered attributes. Bringing the two closer.
Example: Smart phone. Aesthetics and ergonomics.
Value
engineering,
Concurrent
engineering,
Reverse
engineering in design; Culture based design; Architectural designs;
Motifs and cultural background; Tradition and design; Study the
evolution of Wet grinders; Printed motifs; Role of colours in
Design.
functions
Product Safety
No dangerous chemicals.
Id en tify th e
N e ed
S p ecific con te ct
o f u se
E v alua tion o f
D e sign
U s er
S p ecify
R e qu ire m en t
S o lu tio n fo r
P ro du ct d es ig n
with
A
deeper
understanding
of
psychological,
organizational, social and ergonomic factors
emerges from the involvement of the users at
every stage of design and evaluation of the
product.
from
Blackberry thumb.
using
causes
P hone
R a dius
S creen
H e ight
i
S creen
R a dius
Vertical S pacing
H o rizonta l S p acing
Fig. 5.1 : Independent dim ension
variables in m obile pho ne
i.e., Value
W orth
Cost
Evaluation
Refine and select the best ideas for development.
Development
Determine the best alternatives for presentation to
the decision-maker.
Presentation
Obtain a commitment to follow a course of action for
initiating an alternative.
Implementation
Obtain final approval of the proposal and facilitate its
implementations.
5.3.2 Benefits of Value Engineering
(i)
(ii)
quality
management
and
resource
(iii)
(iv)
It
enhances
the
customer
satisfaction
by
determining the exact need and expectation of
customers.
(v)
D esign
P lan ning
M an ufactu ring
Q ua lity
M arketing
is
S e rvic ea bility
M arke tin g
D e sign
C o -ord in ator
A s sem bly
S a le s
P a cka ging
Fu nction
Rapid prototyping.
(ii)
(iii)
D ata C aptu re
S cann er
D ata S e gm en tatio n
P oin t P rocessing
3 D C A D M ode l
A pplicatio n
Fig. 5.4 Process of Reverse Enginen ering
Point Processing
(ii)
(iii)
(iv)
Social or
behavioural culture
Spiritual or ideal
culture
M OT IF S
5.9.5
Social responsibility
In traditional view, the main responsibility is to fulfil
the specific role such as work, society, family etc which is
given to us.
In design point of view, the primary responsibility is
to act in a way that supports the integrity and function of
the whole such as the planetary ecosystem, the culture or
the university.
Way of Thinking
The traditional person focuses on the details of the
situations at hand and handles it by thinking
conventionally. The designer has the holistic high level
views to study the priorities and action.
Academic research
The goal of the traditional researcher is to discover
facts within his area of specialization. The goal of designer
is to create or develop whatever is needed in order to make
our world functional and safe.
Research organization
The
traditional
researches
grow
through
specialization. The designer requires a combination of many
talents and backgrounds.
Early Development
The basic action of grinding has been used since the
beginning of time. However, over the years, the tools used
to grind material have become highly complex. The grinding
and millings has its origin in prehistoric times, humans hit
grains and nuts with stones to free the seed from the hard
protective shell. In the olden days, during the stone Age
the tool used for this operation are the mortar and pestle.
By around 2000 BC the saddlestone mill had been
invented incorporating a horizontal fixed stone over which
a moving stone was moved forward and backwards.
Around 1500 AD the grinding of
revolutionized for grinding large volumes
small particles. At this time stamp miles
to break the pebble by the impact from
hitting hammer.
minerals was
of pebbles into
were developed
a pounding or
1850 -1900
In Germany at 1870, invented the roller mill for
grains with high capacity machines for ores and cement.
Grinding machines become more precise during this time.
1900-1920
During the early twentieth century, the introduction
of electricity enhances the technology of size reduction
which leads to the invention of vertical roller mills and
pebble mills for grinding the fine particles.
In the year 1960, Wily A Bachofen introduced the
Turbula Mixer world-wide, mixer used for mixing of powder
substances of different weights and particle sizes.
Chapter - 6
MODULAR DESIGN
Modular Design, Design Optimization: Intelligent and
autonomous products: User Interfaces: Communication between
products: autonomous products: Internet of things: Human
Psychology and the advanced products.
Design as a marketing tool: Intellectual Property Rights Trade secret: Patent: copyright: Trademarks: Product liability.
Top L evel
P ro du ct
S e co n d Le ve l
L ast L eve l
N a m e s of e xp ecte d
C o m p o ne nts tha t
a re n e ed ed to
fu lfill th e fun ctio n
o f m od u les
Interactions
And
detail
Performance
layouts,
2.
3.
4.
Spatial
Interactions: Geometrical
dimensions,
degrees of freedom and tolerances that must be
maintained between the modules.
that
must
be
be
: F x objective function.
: gj x 0 ; j l, m Inequality constraints.
h j x 0 ; j l, P Equality constraints
x li xi xui : i l, n side constraints
Objective Function
The objective function is a function, with respect to
which the design is optimized.
Design Constraints
Differentiating acceptable and unacceptable designs
by design restrictions are collectively called as Design
constraints.
Design Variables
The values chosen in producing a design for different
independent variables are called design variables.
Design Space
The n-dimensional variable vector represented in
space, forms the design space.
Constraint Surface
These are the surfaces formed by the limiting
constraints.
Regional Constraints
Regional constraints are one sided constraints where
stress, geometry and cost do not exceed the limiting values.
These constraints are also called as inequality constraints
and it is denoted by gj
For eg: if a stress x must be less than yield stress
S y, then our constraint is
x S y
Converting this constraint to
x S y 0
(or) gj x 0
Now the constraint is of the form gj x 0
Equality constraints
These constraints restrict certain design variables to
be simultaneously related. It is denoted by hj. The similar
transformations are performed on equality constraints hj so
they equals zero.
h j x 0
Classical methods
Constrained Problem
Unconstrained Problem
S tart
Id en tify
D e sign Variab le s
O bjective F un ctio n
C o nstra in ts
C o lle ct d ata f o r
d escrib ing the
syste m
E stim a te
in itia l d esig n
A n alys e th e
P ro blem
Is th e con ve rge n ce
C riteria is satisfie d
b y the d esig n
NO
C h an ge th e
d esig n usin g an
o ptim ization
m etho d
YES
S top
D e cision s M aking
L ocatio n of
inte llig en ce
G ro up ing
level of
Inte lligen ce
Ag gre g ation
level o f
inte llig en ce
Location of intelligence
Each product has its own intelligence. The intelligence
of the product is not necessarily need to be located at the
object. Two extremes can be identified:
components
that
are
manufactured
by
different
organizations and that may by themselves be composed of
other parts. In the case of modern cars or other products
with sufficient information processing and communication
capabilities, a lot of decision-making can be embedded into
the product itself. However, some parts of the product may
have only one identifier, while other parts may have their
own embedded information processing capabilities. In order
to make it possible the communication interface is made
similar for all components of the product. For analyzing
this type the following separations are made.
Functionality
requirements
assembling
Assembling a list of the functions required by the
product to accomplish its goals and the potential
needs of the users.
engineering
introduction
of
new
and
production
products
from
deals
the
with
the
design
and
communication
between
production
and
organisation
can
process
new
product
design
and
introduction.
Value Engineering to optimize competing priorities of cost
and performance
Value
engineering
is
responsible
for
engaging
meetings
should
be
held
and
the
following
communication
between
Design
and
the
production
field,
the
organization
must
these
engineering
changes
performed
should
be
product
are
the
ones
that
are
of
the
attracting
results
of
the
application
of
them
with
information
and
communication
human-to-human
or
human-to-computer
interaction.
Convergence
of
wireless
technologies
Products
built
with
M2M
communication
through
cloud
resource
access
control.
Paas
provide
companies,
nowadays,
are
providing
software
Indu strial
inte rne t
C onnected
w earables
d evices
C onnected C onnected
C itie s
C onnected H om es
C ars
O il & Gas
h ea lth C are
Actions of IoT
Use
to
maximize
advantage of sensors
attached to things (eg:
temperature, pressure,
acceleration)
Sense
Actions of IoT
Efficient
Network
ed
Connects
network
Specializ
ed
Modifies
technology The IoT is fragmented
and process to specific smaller in size and is
task.
more efficient unlike
Pcs and smartphones.
Everywh
ere
Can
be
effectively More devices can be
used everywhere like connected with greater
on human body, cars, security concerns.
homes cities, factories
etc.
objects
to Some
of
the
intelligence are shifted
from cloud to the
networks edge.
assets
(ii)
(iii)
6.12 PATENT
A patent is an exclusive right granted for an
invention of a product or process that provides a new way
of doing something, or that offers a new technical solution
6.13 COPYRIGHTS
Copyrights are used to protect the expressive arts.
They provide exclusive rights to owners reproduce their
work, publicly display or perform their work and create
derivative works. In other words copyright laws grant
engineers, authors, artists and other creators, protection for
their literary and artistic creations, generally refereed to as
works. Additionally, owners are given economic rights to
financially benefit from their work and prohibit others from
doing so without their permission. It is important to realize
that copyrights do not protect ideas, only how theyre
expressed.
6.13.1 Copyrights and related rights
A closely associated field is related rights or rights
related to copyright that encompass rights similar or
identical to those of copyright, although sometimes more
limited and of shorter duration. The beneficiaries of related
rights are: performers (such as actors and musicians) in
their performances; producers of phonogram (for example,
compact discs) in their sound recordings; and broadcasting
1. Literary works
2. Musical works, including any accompanying words
3. Dramatic works, including any accompanying music
4. Mimes and choreographic works
5. Pictorial, graphic, and sculptural works
6. Motion pictures and other audiovisual works
7. Sound recordings
8. Architectural works
These works should be viewed broadly. For example,
computer programs and most compilations are considered
to be literary works; and maps and architectural plans
are considered pictorial, graphic, and sculptural works.
Adding to it, the work must be original--that is,
independently created by the owner. It doesnt matter if an
owners creation is similar to existing works or even if it
is lacking in quality, ingenuity or aesthetic merit. To be
short if the owner creates an original work without copying
from someone else, the results can always be protected by
copyright.
Finally, to receive copyright protection, a work must
be the result of some creative effort on the part of its
owner, but there are no standards as to how much
relativity is enough. For example, a work must be more
creative than a telephone books white pages, which
involves a straight forward alphabetical listing of telephone
numbers rather than a creative selection of listings.
Manufacturing
defects
Marketing defects
The spouse
The children
The estate
Indemnification
Chapter 1
Adaptive design
Development design
New design
factors
affecting
economic
Design costs
Development costs
Manufacturing costs
Distribution costs
Availability of resources
R e se arch
En gine ering
Co mm e rcial
D e sign
Fu nctions
M anufacturing
Q uality
Problem analysis
Problem clarification
observe, how the actual end users are interacting with the
product in their regular condition. Team members collect
photographs, sketches, videos and interviews during
Ethonographic study.
1.12. Graphically explain Maslows Hierarchy of Needs.
Self-Actualisation
Esteem
G ro w th
Social
Physiological
B elo ng ing
Safety
A ccepta nce
S ecurity
S ocial L ife
H unger
P ro tection
Thirst
form D a ng er
Friend ship
G E N E R AL EX AM PL E S
S tatus
Friend ship
S tab ility
Food
A ccom plish me nt
A chieve me nt
P erson al
S tatus
D evelo pm e nt
R ecogn itio n
a nd love
S lee p
A chieve me nt
O R G A N IZATIO N A L E XA M P LE S
S elfa ctu alizatio n
n ee ds
E ste em need
B elo ng ingn ess n eeds
Friend s at w ork
S ecurity ne ed s
P hysiolog ical nee ds
Fig. 1.3 M aslo ws H ierarch y of Needs
P ensio n plan
B ase sa lary
Chapter 2
Design Process
2.1. What are the major steps involved in designing?
The major designing process steps are
(i) Sense Gap
(ii) Define problem
(iii) Explore Alternatives
(iv) Select plan
2.2. Explain the term feasibility.
The feasibility study is an evaluation and analysis of
the potential of the proposed project to support the process
of decision making. It is the alternative of achieving the
desired outcome.
2.3. What is conceptualization? Explain the techniques
involved.
Feasibility study is followed by the concept study
which
is
also
called
as
conceptualization.
The
conceptualization is a phase in the design process which
involves in the process planning that includes ideas and
considering the ideas for implementation.
The most common
conceptualization are
techniques
involved
in
the
Interrelationships
betw ee n
Technical D escriptors
C o un te rpart C ha racte ristics
(Tech nica l D escriptors)
(Voice of the O rganisation )
Vo ice of the
C u stom er
( C ustom er
R e qu ire m en ts)
Priority of
C u stom er
R e qu ire m en ts
Co mpe titive
Evalution
1.
Identify
voice
requirements)
of
the
customer
(customer
2.
3.
4.
5.
6.
2.
3.
4.
5.
6.
7.
Consensus decision
8.
9.
10.
11.
12.
It stabilises quality.
13.
14.
15.
Ev aluation Ph as es
A b so lu te C riteria
G o - N o n go S c re en in g
P u gh C o nce pt S election
B e st C o ncep t
Sp he re
C o ne
Torus
C ylinder
C u bo id
2.
Combining
possible.
wireframe
and
surface
model
are
2.
3.
Disadvantages of B-rep
1.
2.
Sometimes
possible.
geometrically
valid
solids
are
not
2.
3.
4.
5.
Bilateral tolerance
Unilateral tolerance
Direct tolerance
Chapter 3
Prototype of product
3.1. Define the term prototyping.
Prototyping can be defined as the process of quickly
putting together a working model (prototype) in order to
test the various aspects of a design, illustrate ideas or
features and gather early user feedback.
3.2. Define the term prototype.
Prototype can be defined as a working model,
technically and visually complete, that is used to confirm
that the design meets all customer requirements and
performance criteria.
3.3. What is the difference between a model and a
prototype?
A model is used to demonstrate or explain how a
product will look or function, whereas, a prototype is used
to test different working aspects of a product before the
design is finalized. A prototype is much closer to the form,
fit and function of the final design than a model.
3.4. What are the Benefits of prototyping.
A prototype allows engineers and designers to explore
design alternatives,test theories and confirm performance
prior to starting production commercially.
Prototyping
S olid
(C A D )
M od el
C onversion
to
S T L F ile
P ro cess P lann er
(M ode l validity,
slicing, trajecto ry
p la nnin g)
P ost P rocessing
A uto ma ted
Fabrication
Engineering
Analysis
and
Planning:RP
enables stress analysis, flow analysis etc., of the
physical model. Also fabrication of pre-production
parts for process planning and tool design is
possible.
F
PV
ROI
Net profit
100
Cost of investment
in
tune
with
by
Work
Breakdown
Materials flow
Financial flow
3.20. Explain
the
management?
objective
of
supply
chain
(ii)
which
Chapter 4
Design for X
4.1. What do you mean by the term Design for X?
The terminology to explain a design methodology is
known as Design for X; where in a detailed design is done
to improve life-cycle, optimum cost, quality, increased
design flexibility, and increased efficiency and productivity
using the concurrent design concepts. The letter "X" in DFX
is made up of two parts, life-cycle process X and
performance measure (ability).
4.2. What are the main objectives of the Design of
Quality?
(i)
(ii)
(iii)
Continuously
improved
product
reliability
performance and technology to meet customer
expectations.
Organizational control
Managing warehouses
the
advantages
of
design
for
Increase profitability
Reverse engineering
Analysis
Redesign
Forward Engineering
Chapter 5
Value Engineering
5.1. Explain the method of Product centered design?
The product centered design is the method of
designing the product with increased efficiency and output
and by reducing the manufacturing time and cost, so that
the customer needs are met. It is a product of favorable
design.
5.2. What are the steps involved in product centered
design?
The steps involved in product centered design process
are:
Step 1: Product conceptualization
Step 2: Identification of Product Quality Factors.
Step 3: Preparation of Product Microstructure.
Step 4: Generation of alternative ways to manufacture
the product.
Step 5: Product and Process evaluation.
5.3. Define User Centered Design.
User centered design is also called as human-centered
design. It is an approach to iterative system that focuses
specially on making products usable. In other words, it is
the process of designing product such as a website or
application user interface, from the point of how it will be
understood and used by a human user.
Id en tify th e
N e ed
S p ecific con te ct
o f u se
E v alua tion o f
D e sign
U s er
S p ecify
R e qu ire m en t
S o lu tio n fo r
P ro du ct d es ig n
(ii)
quality
management
and
resource
(iii)
(iv)
It
enhances
the
customer
satisfaction
by
determining the exact need and expectation of
customers.
(v)
D esign
P lan ning
M an ufactu ring
Q ua lity
M arketing
characteristics
of
concurrent
Rapid prototyping.
(ii)
(iii)
5.14. Explain
the
steps
involved
in
engineering process with a sketch.
D a ta C aptu re
Sc an ner
D a ta Se gm en ta tio n
3 D C AD M ode l
Ap plicatio n
Fig. 5.4 Process of Reverse En gin enering
Reverse
(ii)
(iii)
(iv)
Chapter - 6
Modular Design
6.1. What is modular design?
Modular design is a technique where everything is
built using a block grid pattern. Each of the elements of
the design fits into modules in rectangular patterns.
6.2. Explain the hierarchy involved in creatures a
product architecture.
Top L evel
P ro du ct
S e co n d Le ve l
L ast L eve l
2.
3.
that
must
be
4.
Classical methods
products
are
the
ones
that
a
are
to
larger
extent,
because
eventhough
S tart
Id en tify
D e sign Variab le s
O bjective F un ctio n
C o nstra in ts
C o lle ct d ata f o r
d escrib ing the
syste m
E stim a te
in itia l d esig n
A n alys e th e
P ro blem
Is th e con ve rge n ce
C riteria is satisfie d
b y the d esig n
NO
C h an ge th e
d esig n usin g an
o ptim ization
m etho d
YES
S top
Identification
Sensor
Storage
Actuating elements
User Interface:
Industrial controls
M2M applications
Temperature Monitoring
6.12. What are trade secrets?
Trade secrets are any, confidential business
information which provides the organization a competitive
edge. Trade secrets include manufacturing or industrial
secrets and commercial secrets.
6.13. How to protect a Trade secret?
Trade secrets are protected without registration, in
other words, trade secrets are protected without any
procedural formalities. Added to it, a trade secret can be
protected for an unlimited period of time.
6.14. What is a patent?
A patent is an exclusive right granted for an
invention of a product or process that provides a new way
of doing something, or that offers a new technical solution
to a problem.
6.15. What is the need for patents?
Patents provide incentives to individuals by
recognizing their creativity and also offers material rewards
for their marketable inventions. The reason for offering
incentives is that it encourages innovation which inturn
enhances the quality of human life.
6.16. Explain the term copyrights.
Copyrights are used to protect the expressive arts. They
provide exclusive rights to owners reproduce their work,
publicly display or perform their work and create derivative
works. In other words copyright laws
grant engineers,
authors, artists and other creators, protection for their literary
and artistic creations, generally refereed to as works.
a manufacturer or seller
a defective product to a
defect could rest with any
distribution.
Design defects
Manufacturing defects
Marketing defects
Index In.1
Index
A
Academic research, 5.30
Adaptive design, 1.1
Advanced Products, 6.29
Aesthetics, 1.32
Analogies, 2.9
Architectural Designs, 5.20
Autonomous Products, 6.9, 6.20
B-rep, 2.44
Benchmarking, 1.36
C
Cloud Computing, 6.23
Communication Between
Products, 6.17
Conceptualization, 2.4
Concurrent Engineering, 5.13
Conformance, 1.32
Constraint Surface, 6.6
Copyrights, 6.39
Cost Analysis, 3.23
CSG, 2.42
Cultural background, 5.27
Culture Based Design, 5.22
Customer needs, 5.2
Customer complaints, 1.21, 1.24
Customers Requirements, 1.26
D
Defining the Design Space, 2.7
Design for Recycling, 4.31
Inventory , 3.45
F
Fantasy analogy, 2.10
Feasibility , 2.4
Feedback on Design, 3.54
Focus groups, 1.20
Freezing the Design, 3.22
Functional Constraints, 1.4
Functional Design, 1.12
Fused Deposition Modeling
(FDM), 3.15
G
Gantt charts, 3.40
Geometric Tolerances, 2.52
H
House of Quality, 2.15
Human Psychology Products,
6.29
I
Ideation, 1.34
L
Laminated Object
Manufacturing, 3.13
Legal and Ethical Constraints,
1.7
M
Maintenance, 4.8
Manufacturing constraints, 1.6
Manufacturing Operations, 3.48
Market Survey, 1.23
Marketing, 3.53
Material Handlings, 3.47
Material Selection Process, 2.49
Modular Design, 6.1
Motifs, 5.27
Motifs Features, 5.27
N
Need Identification, 1.19
New design , 1.2
O
Objective Function, 6.6
P
Packaging, 3.52
Patent, 6.36
Patent protection, 6.37
Perceived quality, 1.32
Planning, 3.36
Problem Statement, 1.22
Index In.3
Product Conceptualization, 5.2
Product Liability, 6.44
Production, 2.7
Prototyping, 3.1
Q
QFD Process, 2.28
Quality Function Deployment
(QFD), 2.12
Quality constraints, 1.6
R
Rapid prototyping, 3.7
Reliability, 1.31
Research in Design, 2.56
Research, 2.3
Research organization, 5.30
Reverse Engineering In Design,
5.16
Role Of Colours In Design, 5.33
S
Safety constraints, 1.5
Scheduling, 3.38
Selective Laser Sintering(SLS),
3.12
Sequential Engineering, 5.12
Serviceability, 1.32
Shipping, 3.52
Social responsibility, 5.29
Solid Modelling, 2.42
Standardization, 4.23, 3.54
Stereo Lithography, 3.10
Storage, 3.50
Supply Chains, 3.43
Surveys, 1.21
Symbolic Analogy, 2.11
T
The IoT Landscape, 6.24
Three Dimensional Printing
(3DP), 3.16
Time constraints, 1.6
Tolerance Allocation, 2.52
Tolerancing, 2.50
Trade Secrets, 6.34
Trade Mark, 6.42
Tradition and design, 5.29
U
User Centered Design, 5.1, 5.3
User Interface, 6.14
V
Value Engineering Methodology,
5.11
Value Engineering, 5.10
W
Warranty data, 1.21
Way of Thinking, 5.30