EAS 140 Engineering Solutions

1. EAS 140Engineering Solutions Lecture #11 New Design Strategies

2. Outline • Need for Innovative Design Processes • New Design Strategies

3. Need for Innovative Design Processes • Traditional design approach has been successful, but…. • What problems do you see with the traditional design process?

4. Need for Innovative Design Processes Problems include: • Long design time - sometimes called “throw-it-over-the-wall” design • Engineering dept designs product • Throw design over the wall of the cubicle to marketing dept • Marketing changes the design • Throws revised design back to engineering Example: Every blueprint page of a Boeing aircraft is revised 4.5 times on average – they design 4.5 airplanes for every model built!

5. Need for Innovative Design Processes Other problems include: • No incentive to make products easy to: • manufacture/assemble • service/maintain/support • No incentive to minimize environmental impact of products

6. New Design Strategies To address these problems, engineers have developed new design strategies, including: • Concurrent Engineering (CE) • Reverse Engineering • Reengineering/redesign

7. Concurrent Engineering • Idea: Systematic approach Consider all elements of product lifecycle, including: • End user requirements • Manufacturing • User support • Quality control • Product disposal • Key elements: Design for manufacturing (DFM) Design for assembly (DFA) Design for environment (DFE, also called Green Engineering)

8. DFM Example • Example: Mattel toy: Color Spin Child rotates red ball, other balls spin For children for 6 mo - 3 years old

9. DFM Example • Background: Mattel purchased rights to toy from Japanese manufacturer Toy is too expensive for US market

10. DFM Example • Potential savings are huge • Mattel saves $0.5 million dollars for every 1 penny savings on manufacture of Barbie • How can Mattel design to save money? What costs money to make the Color Spin toy?

11. DFM Example Main expenses in Color Spin toy: • Number of parts • originally, 55 parts • Materials • originally, made of expensive plastics • Manufacturing process • New goals: • Reduce the number of fasteners • Use standardized parts • Use unidirectional assembly

12. DFM Example • Example: Replaced 10 screws with ultrasonic welding

13. Design for Manufacturing • Example: Created symmetric roller drive - 4 less parts and interchangeable parts

14. DFM Example Overall impact: • Number of parts reduced from 55 to 27 (49% reduction) • Reduction in factory costs: 38% • Annual savings: $700,000/yr

15. Reverse Engineering • Idea: Take apart an object or system to see how it works • Uses: New ideas from competitors Fabricate copies of old parts, machinery for legacy equipment Reuse computer code

16. Reverse Engineering • Example: Saturn automotive engineers dismantle other cars to look for design ideas (worksheet below):

17. Reengineering/Redesign • Idea: Fundamental rethinking and radical redesign of a system • Applications: Engineering Computer software Business systems

18. Reengineering/Redesign • Examples: Power Mac G4 Cube (but production suspended) Boeing 777 designed using 3D CAD see text for details or http://bits.me.berkeley.edu/develop/b777/ Microsoft .NET net-based software development

19. Reengineering/Redesign • Examples continued: Boeing 777 designed using 3D CAD 2,200 workstations, 3x1012 bytes of data (3 terabytes) see text for details or http://bits.me.berkeley.edu/develop/b777/ Microsoft .NET net-based software development Boeing 777 designed using 3D CAD see text for details or http://bits.me.berkeley.edu/develop/b777/ Microsoft .NET net-based software development