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Defining and solving design problems

Designing products Product anatomy Components: standard vs. special purpose Component decomposition diagrams Types of design. Defining and solving design problems. Product Design - defined. Product design – the process of defining all of the companies product characteristics

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Defining and solving design problems

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  1. Designing products Product anatomy Components: standard vs. special purpose Component decomposition diagrams Types of design Defining and solving design problems

  2. Product Design - defined Product design – the process of defining all of the companies product characteristics • Product design must support product manufacturability (the ease with which a product can be made) • Product design defines a product’s characteristics of: • tolerances, and • performance standards. • appearance, • materials, • dimensions, Process Selection – the development of the process necessary to produce the designed product.

  3. The Product Design Process Idea development: all products begin with an idea whether from: • customers, • competitors or • suppliers Reverse engineering: buying a competitor’s product

  4. Product Design Process • Idea developments selection affects • Product quality • Product cost • Customer satisfaction • Overall manufacturability – the ease with which the product can be made

  5. The Product Design Process Step 1 - Idea Development - Someone thinks of a need and a product/service design to satisfy it: customers, marketing, engineering, competitors, benchmarking, reverse engineering Step 2 - Product Screening - Every business needs a formal/structured evaluation process: fit with facility and labor skills, size of market, contribution margin, break-even analysis, return on sales Step 3 – Preliminary Design and Testing - Technical specifications are developed, prototypes built, testing starts Step 4 – Final Design - Final design based on test results, facility, equipment, material, & labor skills defined, suppliers identified

  6. laser printer leaf rake paper clip paper cup penlight power lawn mower toaster oven vacuum cleaner automobile baseball bat bicycle canoe paddle coffee maker commercial jet fishing reel inflatable kayak Are all design problems the same? Imagine designing the following products

  7. Let’s start with product design A product is an item that is purchased and used as a unit (Dixon and Poli, 1995)

  8. case button spring battery bulb cap Example product…. Penlight has “components”

  9. penlight bulb battery body screw cap switch glass lens filament base anode cathode electrolyte plastic cover case spring Component decomposition diagram - penlight Parts Assemblies Standard Special purpose A diagram showing the anatomy

  10. Standard Parts Standard Assemblies Special Purpose Parts bolt, nut screw rivet key gasket gear blank lubricant seal pump electric motor clutch chain/sprocket heat exchanger brake caliper ball bearing power screw housing cover bracket link support shaft Other example components

  11. Product Standard Part Special purpose Part Sub-assembly A Sub-assembly B Special purpose part Special purpose part Standard part Sub-assembly B1 Standard part Special purpose part General product – component decomposition

  12. Final design • Communication book: letters, emails, minutes. • Technical info book: catalogs, articles. • Design book: math models, optimization problems. • Plan book: assemblies, parts, list of standard and special-purpose parts.

  13. Why bother preparing Component Decomposition Diagrams? • Understand the interaction between components • Consider standard parts versus special purpose parts (buy vs. make) • Divide the design problem into separate sub-problems, i.e. decisions. • Learn pros & cons of existing products or processing plants

  14. Types of design (i.e. decisions and activities) modifying the “form” choosing from existing standard parts/subassemblies modifying existing part/subassembly, but keeping original concept adapting known solution to new task  new concept, part never existed before modifying appearance or look vs. assembly or product design Redesign – Selection design – Variant design – Adaptive design – Original design – Artistic design - Part design –

  15. Types of design related to phase Formulation original design selection design part design Concept Design variant design Configuration Design Configuration Design Parametric Design Parametric Design Parametric Design Detail Design Detail Design Detail Design Detail Design

  16. Summary • Products plants have an anatomy of components • Components include parts & subassemblies • Components can be standard or special purpose • Component decomposition diagrams are very useful • Types of design include: original, variant, selection, adaptive, redesign

  17. ROLE OF PRODUCT DESIGN AND DEVELOPMENT IN TOTAL SYSTEM

  18. GENERALIZED PRODUCT LIFE CYCLE FOR COMMON CUSTOMERS

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