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Session 2: Product Development Agenda

Session 2: Product Development Agenda. Questions from last lecture Product Development Process Example – SQUID SBIR Program “Muddiest Points” Input Sheets Homework Due Session 3. Commercialization Model. User. Project Operator. Business Development Process. Project Owner.

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Session 2: Product Development Agenda

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  1. Session 2: Product DevelopmentAgenda • Questions from last lecture • Product Development Process • Example – SQUID SBIR Program • “Muddiest Points” Input Sheets • Homework Due Session 3

  2. Commercialization Model User Project Operator Business Development Process Project Owner Project Developer Project Development Process System Producer Product Development Process Equipment Producer Technology

  3. Product Development Starts with a Need Customer Need

  4. Simple Product Development Model Customer Need Design Fab & Assembly Testing Production

  5. Expanded Product Development Model Customer Need Detailed Design Conceptual Design Preliminary Design Fab & Assembly Dev. Testing Qual. Testing Production Delivery and Support Design broken into Conceptual, Preliminary, and Detailed Testing broken into Development and Qualification

  6. Product Development Model with Rework Customer Need Detailed Design Conceptual Design Preliminary Design Fab & Assembly Dev. Testing Qual. Testing Production Delivery and Support Rework • Rework is required during development testing • Re-design • Drawing changes • Fabrication & assembly • Re-test

  7. Testing During Design Reduces Rework Customer Need Detailed Design Conceptual Design Preliminary Design Fab & Assembly Dev. Testing Qual. Testing Production Delivery and Support Testing Testing Testing Rework • Component testing during design reduces development rework

  8. Integrated Product Development & Support (IPDS) Model Phase 1 Pre-Concept Customer Need Phase 2 Concept Phase 3 Product Definition Phase 4 Detailed Design Phase 5 Fabrication, Assembly, Test & Readiness Phase 6 Initial Delivery, Support, and Improvement Detailed Design Conceptual Design Preliminary Design Fab & Assembly Dev. Testing Qual. Testing Production Delivery and Support Testing Testing Testing Rework

  9. IPDS Model with Major Deliverables Phase 1 Pre-Concept Customer Need Proposal Phase 2 Concept Phase 3 Product Definition Phase 4 Detailed Design Phase 5 Fabrication, Assembly, Test & Readiness Phase 6 Initial Delivery, Support, and Improvement Detailed Design Conceptual Design Preliminary Design Fab & Assembly Dev. Testing Qual. Testing Production Delivery and Support Testing Testing Testing Rework Solid Model Trade Studies Detailed Drawings Specifications Qualified Prototype Production Drawings Production Units Support Resources Requirements Sketches Trade Studies

  10. Integrated Product Development & Support (IPDS) Phase 1 Pre-Concept Customer Need Proposal Phase 2 Concept Phase 3 Product Definition Phase 4 Detailed Design Phase 5 Fabrication, Assembly, Test & Readiness Phase 6 Initial Delivery, Support, and Improvement Detailed Design Conceptual Design Preliminary Design Fab & Assembly Dev. Testing Qual. Testing Production Delivery and Support Testing Testing Testing Rework Solid Model Trade Studies Detailed Drawings Specifications Qualified Prototype Production Drawings Production Units Support Resources Requirements Sketches Trade Studies

  11. The Concept of Commercialization Phase 1 Pre-Concept Customer Need Proposal Phase 2 Concept Phase 3 Product Definition Phase 4 Detailed Design Phase 5 Fabrication, Assembly, Test & Readiness Phase 6 Initial Delivery, Support, and Improvement Detailed Design Conceptual Design Preliminary Design Fab & Assembly Dev. Testing Qual. Testing Production Delivery and Support Testing Testing Testing Rework Solid Model Trade Studies Detailed Drawings Specifications Qualified Prototype Production Drawings Production Units Support Resources Requirements Sketches Trade Studies Commercialization Proof-of-Concept

  12. Phase 1 – Pre-Concept Customer Input • Customer Needs - Opportunity Assessment • Opportunity ID - Decision to Pursue Phase 2 – Concept • Bus & Pgm Plans - Risk Abatement • Conceptual Design - Proposal Phase 3 – Product Definition/Process Development • Detailed Plans - Detailed Layouts • Trade Studies - PDR Phase 4 – Detailed Design • Design Definition - Key Characteristics • Manufacturing Definition - CDR Phase 5 – Fabrication, Assembly, Test & Readiness • Hardware Fab - Production Readiness • Development Testing - Qualification Testing Phase 6 – Initial Delivery, Support, and Improvement Customer Satisfaction • Manufacturing - Problem Resolution • Customer Support - Customer Data

  13. IPDS Key Points • Life Cycle of Project in Six Phases • Each Phase has Exit Criteria • Phases can Overlap for Fast Cycle Time • Integrated with a Multi-functional Team • Program Kickoff is Key • Setting the Vision • Input from all Team Members

  14. Design Problems are not Textbook

  15. Design Encompasses Many Activities

  16. Design follows “Controlled Convergence”

  17. Product Development is … • A primary engineering function. • A primary business process. • Both design and implementation. Product Development Summary

  18. Integrated Product Development is… • State-of-the-art, generic approach. • Factors all requirements into the design early. • Uses a multifunctional team to integrate. Product Development Summary

  19. Integrated Product Development and Support (IPDS) is… • Specific process developed by AlliedSignal. • A six-phased approach that features • Exit criteria for each phase • Ability to overlap phases to achieve Fast Cycle Time • Use of a multi-functional team • Detailed procedures and deliverables for each phase. Product Development Summary

  20. Using a FMEA and Requirements to drive detailed analyses • Using a simplified model to evaluate trades • Integrating component tests early in design process • Using simple equations to validate more detailed models • Learning to bound the problem Areas Where Students Have Trouble

  21. Establishing Need through a “Voice of the Customer” process • Translating VOC into measurable engineering requirements • Creating an expanded requirements list • Establishing a method to verify each engineering requirement • Performing trade studies • Understanding the distinction between features and benefits Areas Where Students Have Trouble

  22. Example Project Non-Lethal Stopping Device Home Land Security Small Business Innovative Research (SBIR) by Engineering Sciences Analysis Corp. (ESA) SQUID Example.ppt

  23. Safe Quick Undercarriage Immobilization Device • Stored Configuration • 14-inch Diameter • 4-inches high • Less than 50 lbs • DOT approved • All-Weather Capability • Rugged Construction • Hi-Temperature Resistant

  24. Manufacture Product/ Customer Support Logistics VOC Technology Assessments Development Concepts Concept Definition Preliminary Design Review (PDR) Validation Test Report/ Review Critical Design Review (CDR) Overall Schedule SBIR Phase I Proven Feasibility - 6mos SBIR Phase II DHS Prototype SQUID - 24mos Stops representative vehicle Phase III SQUID to Mkt 12-18mos after Phase II

  25. Problem Formulation • Identify and Characterize Problem • Voice of Customer • Requirements

  26. Vehicle proximity is hazardous Officer proximity is hazardous Problem and Opportunity Current methods are ineffective • 1994-1998 stats - one officer killed every 11 weeks as a result of pursuit • Collateral damage - 42% of persons killed or injured are innocent bystanders • The SQUID is the solution to these problems

  27. VOC Overview • Police departments • Sheriffs’ offices • Border Patrol • DPS/Highway Patrol • DoD/National Guard Users

  28. Phase I - Requirements • DHS Solicitation – Develop new vehicle stopping technologies / techniques • Compact, Lightweight, easily transportable & Deployable • Weigh less than 150 lbs • Inexpensive & Safe • Deployable by ground-based personnel or helicopter (air assets) • Stop a 5,000 lb vehicle • 50 MPH – Off-road • 120 MPH – Hard Surface • Complete stop within 500 ft from initial engagement • Incapacitate for 30 min or more

  29. Concept Design • Abstract Embodiments • Proof-of-Concept Testing • Evaluation and Selection • Verify there are no “Show Stoppers” • Analysis • Testing • Conceptual Design Definition

  30. Concept DesignCandidate Abstract Embodiments Stop-Stick Variant Net Variant Axle Wrap

  31. Baseline Concept Functional Block Diagram

  32. Baseline Concept Functional Block Diagram • Identified basic physics to be employed • Indicated potential “show stoppers” that guided analysis and testing tasks • Basic Principle: Straps absorb kinetic energy • Redesign: Controlled skid absorbs kinetic energy

  33. Proof-of-Concept Test Stand

  34. Tendril Windings Proof-of-Concept Testing Example • Secondary Tendrils Launch • Ensnare rotating component • Leader pulls in secondary net

  35. Pressure Volume Gas Generator Winding Cavity Pressure boundary Frangible top & bottom Pressure Volume Gas Generator Winding Cavity Pressure boundary Frangible sides Gas Generator Projectile / Plugs Pressure Volume Directional Ball Valve Pressure channel Packaging Concept Study Concept 1 Concept 2 Concept 3

  36. CAD Drawing of Baseline Concept Gas Generator • Key Components Activation Electronics Frangible Balls & Adhesives Straps wrapped around perimeter Tendril Windings

  37. Phase 1 Program Schedule & Deliverables

  38. Configuration Design • Functional Block Diagram • Component Trade Studies • Bench Testing • Component Analyses • Evaluation and Selection • Baseline Configuration Design Definition

  39. Phase 2 Goals • Prototype works – stops Durango SUV • Production design – meets DTC target • Commercialization Plan • MOU with a manufacturer • Patent • Phase 3 Plan

  40. 1 2 3 4 5 6 7 8 Overall Phase 2 Schedule Component Testing System Testing Preliminary Design Detailed Design Fab/Test Deliver DHS Test Prototype Design-to-Cost Hi-Spd Test Hi-Spd Testing Deliver Final Report Program Management and Commercialization Planning Monthly Progress Reports

  41. Functional Block Diagram Functional Block Diagram (FBD) created as part of the Failure Modes and Effects Analysis process 41

  42. Trade Study (How many studied) Primary choice is boxed Secondary choice Design Area Configuration Trade Studies Housing Connection (3) Syringe Nipple Deployment (2) Warm Gas CO2 Cartridge Outer Strap Material (6) Twaron Nylon Strap Configuration (3) Accordion Party Favor Bladder (8) Polyolefin Silicone Barbs (6) Roofing Nail Drywall Screw Event 1 Barb Orientation (5) Elastic Foam Weighted Base Unfurl Pressure (Range) 350 psi 120-350psi Barb Attachment (4) Grommets Clip-on Muzzle Inclination (Range) Vertical Only Multiple angles 30º-90º Firing Mechanism (2) 22 Ca Primer Shell Warm gas Sticky Substance (7) Glissopal (PIB) Carbotac (Acrylic) Event 2 Delay Control (2) DIP switches Rotary IR Sensor (3) Optek Keyence Squib Circuit (2) SCR SCR/Relay Electronics Legend Material (2) Aluminum Steel/Plastic Housing

  43. Parametric Design • Models • Performance • Sizing • Cost • Optimization Studies • Subsystem Testing • Evaluation and Selection • Baseline Preliminary Design Definition

  44. Parametric Design Model

  45. Parametric Design Example 100 400 80 LEGEND Strap Strength Skid Distance 300 60 * Initial Speed of Vehicles = 50 mph Required Strap Strength, 1000s lbf Skid Distance, ft 200 40 100 20 0 0 0 10 20 30 40 50 60 70 Truck Weight, 1000s lbm

  46. Design-to-Cost (DTC) Analysis

  47. Prototype Development

  48. Prototype Development Movie

  49. Detailed Design • Phase 3 Activity • Emphasis on Commercialization • Prototype Detailed Design Package • Prototype Build and Test Program • Detailed Design for Production

  50. Project Management • Project Plan • Weekly Team Meetings • Metrics • Schedule • Budget • Performance • Focus on Deliverables

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