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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 a need into a hardware reality. Need. 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 a need into a hardware reality. Need Product

  3. 7-Step Design Process • Product Design Specifications (PDS) • External Search (Research) • Internal Search (Brainstorming) • Concept Evaluation and Selection • Detail Design (Engineering) • Prototyping and Testing • Documentation

  4. Design Process Outcomes

  5. Customer Input • Climbs fast • Affordable as a birthday present • Fully assembled • Uses batteries for power • No small parts – is safe • Looks good • Plays music as it climbs • Glows in the dark • Lasts a long time • Would not violate any patents

  6. Customer Needs • Cannot be taken apart • Has no small parts or sharp edges • Only to be used indoors • It is light and compact • Does not use toxic materials • Fits into a small box for shipping • Has attractive packaging • Design and testing finished in 4 months • Quantity 1 Million

  7. Engineering Specifications • Climbs at 1 ft/s or faster • Retail cost is to be less than $45 • Uses 2 AA batteries • Has 0 removable small parts • Music loudness between 20-30 db • Luminosity is to be more than 5 C • Works for minimum 3 hours on 2 AA

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

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

  10. Detail Design (Engineering) MoreAbstract Engineering Less Abstract

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

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

  13. Customers • People who define the PDS • People who influence product success • People you cannot ignore Team Globe (External) Company (Internal)

  14. What is a successful Product? • A successful product: • Sells well and makes a lot of profit • Would not violate any laws/regulations • What about: • Safer than law requires? • Solves some problems of humanity? • Is green (energy efficient, recycles, etc)? • Lasts more than warranty period? • Perform better than required?

  15. Product Design Customers • Customers • The design team and its members are not customers • Every PDS statement must be associated with at least one customer • Internal customers are within the organization (management, marketing) • External customers are outside the organization(end users)

  16. External Customers Company Buyers Retailer End Users Maintenance EXTERNAL Government & Standards Society (Marketing)

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

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

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

  20. External Customers • Retailers want • Small and attractive packaging • Long shelf life • Low cost high profit • Exciting features • Maintenance wants • Ease of maintenance • Low cost of maintenance

  21. External Customers • Government wants • Conformance to laws and regulations • Standards want • Conformance to industry standards • Conformance to codes

  22. Internal Customers • Management wants • Make $$$ • On time delivery • Low risk of financial failure • Proper Documentation • Process: Conformance to company product development process

  23. Internal Customers • Marketing wants • Attractive features to target buyers • Low retail price • Esthetics • Attractive packaging • Ease of user assembly/maintenance • On time delivery • Long Warrantees

  24. Internal Customers • Manufacturing / Purchasing want • Available materials • Manufacture-able at low cost. • Conformance to company documentation formats. • Use of products from preferred vendors.

  25. Internal Customers • Legal wants • No patent infringements • Safety • All required safety warnings and labels • Protection against reasonable abuse • Safety manual • Conformance to laws and regulations

  26. Internal Customers • Shipping and Packaging • Small (standard) package sizes • Ability of locking or fixing sensitive components • Resistance against damage due to dropping, vibrations, moisture, heat, and cold.

  27. Product Design Specification • Is this a PDS item? • Is there a customer associated with it? • Does the information limit the design selections and choices? • Can the requirement be designed into the product? • High resale value (more of a reputation)

  28. Product Design Specification • Elements of PDS • Performance (Primary customer: End User) • Speed, • Capacity, • Power, • Efficiency, • Accuracy, • Return on investment • etc.

  29. Elements of PDS • Environment:(User) • Temperature range, rain, humidity, dust. • Life in service:(User) • 10 years, 5000 cycles, etc. • Maintenance:(User) • The market policy, what customers accept • Retail/Production cost:(User) • Consistent with comparable products • Rule of thumb 4:1

  30. Elements of PDS • Shipping/packaging: • Package sizes + Weights • Damage resistance

  31. Elements of PDS • Quantity(Marketing) • Determined by marketing • Manufacturing facility (Management) • Does the company policy dictate certain facilities?

  32. Element of PDS • Size and shape (Marketing) • Weight (Marketing) • What is the desired weight? • Handles for lifting points? • Modular? • Aesthetics (Marketing) • Color, shape, form, texture, finish. • Market research.

  33. Elements of PDS • Materials (Marketing, Codes, Regulations) • Left to designers unless company guidelines or regulations restrict certain materials (asbestos, lead). • Product life span (Marketing) • Designed life

  34. Elements of PDS • Laws, Codes, and standards (Government) • Ergonomics (User + Marketing + buyers)

  35. Elements of PDS • Quality and reliability (Marketing) • Company policy regarding warranties • Failure rate during warrantee period • Testing (Marketing) • Tests to perform to verify performance and other PDS requirements • Industry standard tests

  36. Elements of PDS • Shelf life (storage) - Retail • Possibility of rust, decay, deterioration • Processes (Mangement) • Conformance to certain standards (GD&T or ISO 9000 for example) • Use of company procedures • Time-scales (deadlines) - Management • Whole design project, milestones

  37. Elements of PDS • Safety (User, Government, Legal) • Safety requirements mandated by government • Professional society's codes and standards • Need for warning labels • Design against Acceptable degrees of abuse

  38. Elements of PDS • Company constraints (Management) • Compatibility with other products • Documentation (Management – Legal) • Full documentation (Guard against possible litigation) • Safety, Operation, and Service documents.

  39. Elements of PDS • Legal (Lawyers) • Product liability law suits associated with similar products and why. • Relevant patents

  40. Element of PDS • Installation (Installers) • Connection geometry. • Various models to install • Disposal (Marketing) • Recyclable? • bio-degradable? • Green

  41. Other Element of PDS • Other possible PDS items to include • Rugged • Easy to use • Reliable • Quiet • Portable • Source of energy

  42. Before you Interview Sponsors • Prepare your questions (PDS) • Let them do most of the talking • Take notes • Ask for clarification • Ask for examples • Do not be annoying (you can always ask more questions later if deemed important)

  43. 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

  44. 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

  45. 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.

  46. PDS Example • The Pin Remover is to be rugged. • must work with air pressure. • is to be easy to use. • is to pass “ASME standard” tests. • is to last 5 years in normal usage. • is to be easy to carry.

  47. 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 patented devices. • Production volume is 3000 per year

  48. PDS Example • is to be tested by June 2013. • is to be released by Sep. 2013. • is to be usable with all Dredge models. • is to work faster than a hammer

  49. Engineering Specifications • Engineers cannot design for vague criteria • “Fast, accurate, high-performing” • “Light, Small, portable” • “Easy to use” • “Safe” • “Stylish” (maybe)

  50. Engineering Specifications • Verifiable PDS statements • Developed for important PDS statements • Have associated target numbers

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