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Design & Manufacturing of Materials

Design & Manufacturing of Materials. 6 Lectures, Trinity Term 2003 2 nd year Materials: Engineering Applications of Materials Dr Ian Stone (5 lectures) & Dr Paul Butler (1 lecture). Synopsis. Further Reading. Product Development. Product Development Team

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Design & Manufacturing of Materials

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  1. Design & Manufacturing of Materials 6 Lectures, Trinity Term 2003 2nd year Materials: Engineering Applications of Materials Dr Ian Stone (5 lectures) & Dr Paul Butler (1 lecture) Synopsis

  2. Further Reading

  3. Product Development Product Development Team Marketing Provides market assessment Identifies market opportunities Manufacturing Assesses production process Assesses manufacturing costs and quality Design Defines product form and function Engineering Design Industrial Design ProductDevelopmentType Developmenttime 1-10 years depending on product Developmentcost $100k-$5B depending on product Developmenttype Generic/Market pull Technology push Technology platform Process limited Customised Company Innovation Large companies vs SMEs (small and medium size enterprises)

  4. Product Development Team Manufacturing Engineer Marketing Professional Purchasing Specialist Finance TEAM LEADER Sales Legal Industrial Designer Electronics Designer Mechanical Designer Extended Team (including suppliers)

  5. Product Development Type

  6. Product Development Examples

  7. Innovation in Firms

  8. Total Design Market Assessment • is a systematic activity: • Identification of the market need → sale of product to meet that need. • Product, Process, People, Organization, etc. • Design Core • Market Analysis • Specification • Concept Design • Detailed Design • Manufacturing • Sales • Product Design Specification (PDS) • Envelopes all stages of the design core Specification Concept Design Detail Design Manufacture Sell THE DESIGN CORE

  9. The Design Core Market Assessment Specification MARKET ASSESSMENT Interviews, Questionnaires, Focus Groups Intellectual Property and Literature Searches Competitive Benchmarking parametric analysis, needs matrix Concept Design Detail Design Manufacture Sell

  10. Market Analysis: Example 1 Tristar 333 A rough terrain telescopic handler with parallel lift

  11. Market Analysis: Tristar 333

  12. Market Analysis: Example 2 Microm 160 A microscope manipulator for opthalmology

  13. MATRIX ANALYSIS

  14. MATRIX ANALYSIS cont’d

  15. The Design Core Market Assessment • SPECIFICATION • Product Design Specification (PDS) • Develop Specification (8 stages) • Construct customer needs matrix • Develop performance measures • Cross correlate (needs-measures matrix) • Construct competitive benchmark chart to assess market position (based on customer needs and performance measures) • Define an initial set of target specifications • Carry out engineering design analysis to assess technical feasibility • Develop a bill of materials for initial cost assessment • Redefine the set of specifications Specification Concept Design Detail Design Manufacture Sell

  16. Product Design Specification (PDS) Patents Environment Shelf life Packing Testing Competition Safety Weight Legal Maintenance Quantity Materials Politics Ergonomics Plant Disposal Aesthetics DESIGN CORE Installation Shipping Size Service life Standards Processes Customer Performance Quality assurance Storage Timescale

  17. Element to be considered: In Out Partial PDS Patents Environment Shelf life Packing Testing Competition Safety Weight Legal Maintenance Quantity Materials Politics Ergonomics Plant Disposal Aesthetics DESIGN CORE Installation Shipping Size Service life Standards Processes Customer Performance Quality assurance Storage For individual components, sub-assemblies, different stages of the design core. Timescale

  18. Design Specification: Stage 1 Stage 1: Customer needs matrix

  19. Design Specification: Stage 2 Stage 2: Develop performance measures

  20. Design Specification: Stage 3 Stage 3: Cross correlate (needs-measures matrix)

  21. Design Specification: Stage 4 Stage 4: Construct competitive benchmark chart to assess market position (based on customer needs)

  22. Design Specification: Stage 4 cont’d Stage 4: Construct competitive benchmark chart to assess market position (based on performance measures)

  23. Design Specification: Stage 5 Stage 5: Initial set of target specifications

  24. Geometry Materials Properties Fastening Methods Surface finish Fatigue Model Cycles to Failure DESIGN MODELS (Model Inputs) METRICS (Model Outputs) Design Specification: Stage 6 Stage 6: Engineering design analysis to assess technical feasibility

  25. Design Specification: Stage 7 Stage 7: Develop a bill of materials for initial cost assessment

  26. Design Specification: Stage 8 Stage 8: Refined set of specifications

  27. Example A Mountain Bike Suspension Fork Stage 1: Customer needs matrix

  28. Stage 2: Develop performance measures

  29. Stage 2: Develop performance measures (cont’d)

  30. Stage 3: Cross correlate (needs-measures matrix)

  31. Stage 4: Construct competitive benchmark chart to assess market position (based on customer needs)

  32. Specification: A Mountain Bike Suspension Fork Stage 4: Construct competitive benchmark chart to assess market position (based on performance measures)

  33. Stage 4: Construct competitive benchmark chart to assess market position (based on performance measures) (cont’d)

  34. Stage 5: Initial set of target specifications

  35. Stage 5: Initial set of target specifications (cont’d)

  36. Suspended Mass Unsprung Mass Orifice Diameter Spring Constant Oil Viscosity Attentuation at 10 Hz Estimated Monster g’s Dynamic Model of Suspension Performance (Analytical) Support Geometry Materials Properties Tube Geometry Mounting Points Lateral Stiffness Static Model of Brake Mounting Stiffness (Analytical) Fork Geometry Materials Properties Fastening Methods Suspension Geometry Cycles to Failure Fatigue Model of Suspension Durability (Physical) Assess Technical Feasibility DESIGN MODELS (Model Inputs) METRICS (Model Outputs) Stage 6: Engineering design analysis to assess technical feasibility

  37. Stage 7: Develop a bill of materials for initial cost assessment

  38. Stage 8: Refined set of specifications

  39. Stage 8: Refined set of specifications (cont’d)

  40. The Design Core Market Assessment CONCEPT DESIGN Concept Generation Clarify problem analyse into sub-problems determine basic requirements External search interview users, consult experts, patent search Internal search brainstorming, analogy, inversion, staff consultation Combination Concept Analysis Controlled convergence Rating & weighting method Specification Concept Design Detail Design Manufacture Sell

  41. Concept Design: Car Horn

  42. Concept Design: Evaluation

  43. Concept Design: Evaluation/Generation Initial number of concepts based on PDS Apply controlled convergence (CC) Initial number reduced Apply concept generation (CC) New ones added CC Further reduction (FR) CG Further addition (FA) CC FR CG FA CC CONCEPT SELECTED

  44. Concept Design: Rating & Weighting Example: Design of a machine to make bottle brushes

  45. The Design Core Market Assessment Specification DETAIL DESIGN Concept Design Detail Design Manufacture Sell

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