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Design Process

Design Process. Design process is a collection of procedures and habits that help teams design better products. The Process of Design. Designing is the process of making many decisions that converts an abstract concept into a hardware reality. Concept. Product. 7-Step Design Process.

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Design Process

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  1. Design Process Design process is a collection of procedures and habits that help teams design better products

  2. The Process of Design • Designing is the process of making many decisions that converts an abstract concept into a hardware reality. Concept Product

  3. 7-Step Design Process • Problem definition (PDS) • External Search (Research) • Internal Search (Brainstorming) • Evaluation and Selection • Detail Design (Engineering) • Prototyping • Documentation

  4. What Product?ToyTown Top Executives Water Balloon Rope Climber Can Crusher Better Mouse Trap Coin Sorter Nail Driver Rope Climber

  5. Product Design SpecificationsCustomer Needs • Climbs fast • Affordable as a birthday present • Fully assembled • Uses batteries for power • It is safe • Looks good • Plays music as it climbs • Glows in the dark • Last a long time

  6. Product Design SpecificationsEngineering Specs • Climbs at 1 ft/s or faster • Retail cost is to be less than $30 • Uses 2 AA batteries (not included) • Has no removable small parts • Music loudness between 20-30 db • Luminosity is to be more than 5 W • Works for more than 3 hours on 2 AA

  7. External Search • Level-I • Rope climbing toys / machines • Rope climbers (sports or circus) • Nature (spiders, bats, etc) • Level-II (Team uses friction wheels) • Hoists • Trolleys • Ski Lifts

  8. Internal Search & Evaluation • Brainstorming • Generate many ideas • Evaluate against PDS • Select one to engineer

  9. Detail Design (Engineering) MoreAbstract Engineering Less Abstract

  10. Design Process • Top-level problem definition is called PDS (Product Design Specifications) • Problem definitions at lower levels derive from PDS: • Sub-system design specifications. • Component design specifications. • Feature design specifications.

  11. Product Development Process Product Planning Design Brief (Mission Statement) Market Research Product Design Specifications & QFD

  12. Product Development Process PDS Candidate Design Detail Design Concept Synthesis Prototyping Concept Evaluation Release for Production Candidate Design

  13. Detail Design Candidate Design Components No Numbers System-Level Design Parameter Design Numbers Prototype Testing Release for Production

  14. Customers • People who are affected by the product Team Globe (External) Company (Internal)

  15. External Customers Buyers Retailer End Users Maintenance EXTERNAL Government & Standards Society

  16. Internal Customers Manufacturing & Procurement Management Marketing Internal Shipping Legal

  17. What Do They Want? • End Users • Performance & Functionality • Affordability • Ease of use including ergonomics • Reliability and Long life • Versatility • Safety • Low maintenance and easy assembly • Esthetics

  18. External Customers • Buying managers • Low Cost/Performance • Safety • Ruggedness (abuse resistance) • Ergonomics • Long warrantees • Reliable with Low downtime • Low operating cost

  19. External Customers • Retailers • Small and attractive packaging • Long shelf life • Low cost/performance and Exciting features • Maintenance • Ease of maintenance

  20. External Customers • Government / Standards / Society • Conformance to laws and regulations • Promotion of public health and safety • Protection of environment • Solution to chronic problems in society • Traffic • Energy • Noise • Drugs, abuse and other crimes • Diversity / Social tolerance / Security

  21. Internal Customers • Management • Make a big profit • On time delivery • Low failure risk • Documentation • Process: Conformance to company product development process

  22. Internal Customers • Marketing • Attractive features to target buyers • Low production cost • Esthetics • Attractive packaging • On time delivery • Long Warrantees

  23. Internal Customers • Manufacturing • Manufacturability using standard methods and schedules. • Conformance to company documentation formats. • Use of products from preferred vendors.

  24. Internal Customers • Legal • No patent infringements • Safety • All required safety warnings and labels • Designed protection against reasonable abuse • Codes and regulations

  25. Internal Customers • Shipping and Packaging • Ease of user assembly • Small packaged size • Ability of locking or fixing sensitive components • Resistance against damage due to dropping, vibrations, moisture, heat, and cold.

  26. Product Design Specification • Elements of PDS • Performance (User) • Speed, • Capacity, • Power, • Accuracy, • etc.

  27. Elements of PDS • Environment:(User) • Temperature range, humidity, dust and dirt, etc. • Life in service:(User) • 10 years, 5000 cycles, etc. • Maintenance:(User) • What is the market policy, what customers accept • Target production cost:(User) • Cost of comparable products and company policy.

  28. Elements of PDS • Shipping: • Package sizes • Damage resistance

  29. Elements of PDS • Quantity(Manufacturing) • Determined by market analysis. • Manufacturing facility (Manufacturing) • Is the design constrained by existing facility? • Are parts to be contracted and assembled in-house? • Does the company policy dictate certain facilities?

  30. Element of PDS • Size and shape (Marketing) • Weight (Marketing) • What is the desired weight? • Should handles or lifting points be provided? • Should it be modular for better handling? • Aesthetics (Marketing,User) • Color, shape, form, texture, finish. • Market research.

  31. Elements of PDS • Materials (Marketing, Codes, Regulations) • Left to designers unless company guidelines or regulations restrict certain materials (asbestos, lead). • Product life span (Marketing, Manufacturing) • Life of a product as a marketable entity. Several months or several years?

  32. Elements of PDS • Laws, Codes, and standards (Government) • Ergonomics (User)

  33. Elements of PDS • Quality and reliability (Marketing) • Company policy regarding warranties • Competitors warranty policies • Testing (Marketing, QA) • What tests would be performed to verify performance • Standard tests

  34. Elements of PDS • Shelf life (storage) - Retail • Possibility of rust, decay, deterioration • Processes (company guidelines) • Use of certain standards (GD&T for example) • Use of certain procedures • Time-scales (deadlines) - Management • Whole design project, milestones

  35. Elements of PDS • Safety (User, Government, Legal) • What safety requirements are mandated by government • Professional society's codes and standards • Need for warning labels • Likely degrees of abuse or misinterpretation of operating procedures.

  36. Elements of PDS • Company constraints (Management) • Compatibility with other products • Documentation (Management – Legal) • A product design must include a full formal documentation per company guidelines. • Safety, Operation, and Service documents. • Etc.

  37. Elements of PDS • Legal (Lawyers) • What product liability law suits are associated with similar products and why. • Note the legal terms: • “defect of specification” • “defect of design” • “defect of manufacture” • Relevant patents

  38. Element of PDS • Installation (Installers) • Many products must interface with other products or be assembled with other products. • Disposal (Society) • Should any parts by recyclable? • bio-degradable?

  39. Wording of the PDS Document • Format of most statements in PDS: • The device must …….. • The device is to …… • The device is desired to …. • Avoid mixing requirements. • One sentence per requirement. • Cast PDS statements in a positive format

  40. PDS is a Dynamic Document • A design statement usually begins as a vague statement • The device is to be easy to use • The device is to be safe • The device is to be inexpensive • The device is to be rugged and reliable • The device is to be portable

  41. Wording of the PDS Document • Example: ESCO’s Pin Remover • The pin-remover is to be light. • The pin-remover must work in a wet, cold, and dusty environment. • The Pin-remover must be safe • The Pin-remover must have a 3-year warranty.

  42. PDS Example • The PR is to be rugged. • … must work with air pressure. • … is be easy to use. • … is to pass “HTS” tests. • … is to last 5 years in normal usage. • … is to be easy to carry.

  43. PDS Example • … is to sell for less than $150. • … is to costless than $50 to make. • … is to have low maintenance needs. • … is to be difficult to use as a hammer. • … must not infringe on patented devices. • … Production volume is to be 300 per year

  44. PDS Example • … is to be tested by June 2006. • … is to be released by Sep. 2006. • … is to be used with Dredge Point models. • … is to work faster than the hammer

  45. Engineering Specifications • What is • “Fast, accurate, high-performing”? • “Light, Small, portable”? • “Easy to use”? • “Safe”? • “Stylish”?

  46. Engineering Specifications • Verifiable PDS statements • Developed for important PDS statements • Have associated target numbers (Yes/No OK)

  47. Engineering SpecificationsTips • Set up metrics and targets so the designer has maximum options in accomplishing the PDS

  48. Engineering SpecificationsTips • PDS: The Dog Feeder must not tip over when bumped or pushed by a dog. • Bad:The DF must weigh 50 lbs • Good:The dog feeder must withstand 30 lbs applied to its top from side

  49. A Typical PDS Page • Requirement: PR is to be easy to maintain • Primary customer: End users • Priority: High • Metrics and Targets • Daily maintenance: None • Weekly maintenance: < 10 minutes – field • Yearly maintenance: < 1 hour – Shop • Cost of weekly maintenance < 10c • Cost of yearly maintenance < $10

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