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

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.

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

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

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

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

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

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

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

Other example components 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

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

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.

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

Types of design (i.e. decisions and activities) Redesign –   Selection design – Variant design – Adaptive design – Original design – Artistic design - Part design – 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

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

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

ROLE OF PRODUCT DESIGN AND DEVELOPMENT IN TOTAL SYSTEM

GENERALIZED PRODUCT LIFE CYCLE FOR COMMON CUSTOMERS