Design Process Design process is a collection of procedures and habits that help teams design better products

The Process of Design Designing is the process of making many decisions that converts a need into a hardware reality. Need Product

7-Step Design Process Product Design Specifications (PDS) External Search (Research) Internal Search (Brainstorming) Concept Evaluation and Selection Detail Design (Engineering) Prototyping and Testing Documentation

Design Process Outcomes Step Outcome Product Design Specifications PDS Document External Search (Research) List of existing related products and technologies Internal Search (Brainstorming) A lot of solution ideas Concept Evaluation / Selection Pros and Cons / Decision Matrix Selection of one idea to implement Detail Design (Engineering) Determination of all details needed to build the product Prototyping and Testing Comparisons to PDS target Improvement recommendations Documentation Final Design Report BOM + Production Drawings All other reports

What Product? ToyTown Top Executives Water Balloon Rope Climber Can Crusher Better Mouse Trap Coin Sorter Nail Driver Rope Climber

Customer Input Climbs fast Affordable as a birthday present Fully assembled Uses batteries for power No small parts – is safe Looks good Plays music as it climbs Glows in the dark Lasts a long time Would not violate any patents

Graphical Representation of PDS START Patents Battery Life Slow Silent Expensive No Glow Unsafe Indoors Only

PDS Compromises Desired versus Required Desired Boundary Retail < $45 Acceptable Boundary Retail < $50

PDS Compromises High Priority Plays Music Low Priority Glow in the dark

Customer Needs Cannot be taken apart Has no small parts or sharp edges Only to be used indoors It is light and compact Does not use toxic materials Fits into a small box for shipping Has attractive packaging Design and testing finished in 4 months Quantity 1 Million

Engineering Specifications Climbs at 1 ft/s or faster Retail cost is to be less than $45 Uses 2 AA batteries Has 0 removable small parts Music loudness between 20-30 db Luminosity is to be more than 5 C Works for minimum 3 hours on 2 AA

External Search Level-I Level-II (friction wheels selected) Rope climbing toys / machines Rope climbers (sports or circus) Nature (spiders, bats, etc) Level-II (friction wheels selected) Hoists Trolleys Ski Lifts

Internal Search & Evaluation Brainstorming Generate many ideas Evaluate against PDS Evaluate risks Select one to engineer

Detail Design (Engineering) More Abstract Engineering Less Abstract

Design Process Applies to Top-level decisions Applies to lower levels decisions Define requirements Search for existing ideas/technologies Brainstorm for solutions Pick a candidate Determine the details

Product Development Process PDS Candidate Design Detail Design Concept Synthesis Prototyping Concept Evaluation Release for Production Candidate Design

Detail Design Candidate Design System-Level Design Parameter Design Components No Numbers System-Level Design Parameter Design Numbers Prototype Testing Release for Production

Complexities of Developing a PDS Document Level-I: Goal is clear, “Design a X to do Y” specifications are known, priorities are known, no mass production concerns, IP issues not important, limited customer base Example: one-of-a-kind equipment.

Complexities of Developing a PDS Document Level-II: Goal is specific “Design a X to do Y”, Specifications are unknown, Priorities are unknown, Mass production concerns, IP issues are important, expanded customer base Example: Most consumer products

Complexities of Developing a PDS Document Level-III: Goal is unclear, “Design ? To do ? There is a general statement of need Not easy to get to: “Design X to do Y” Example: Oceans are rising

Customers People who define the PDS People who influence product success People you cannot ignore Team Globe (External) Company (Internal)

What is a successful Product? Sells well and makes a lot of profit Would not violate any laws/regulations What about: Safer than law requires? Solves some problems of humanity? Is green (energy efficient, recycles, etc)? Lasts more than warranty period? Perform better than required? Only when they relate to 1) or 2)

Product Design Customers The design team and its members are not customers Every PDS statement must be associated with at least one customer Internal customers are within the organization (management, marketing) External customers are outside the organization(end users)

External Customers Company Buyers Retailer End Users Maintenance Government & Standards Society (Marketing)

Internal Customers Manufacturing & Management Procurement Marketing Shipping Packaging Legal

What Do They Want? End users want Performance & Functionality Affordability Ease of use including ergonomics Reliability and Long life Robustness Versatility Safety Low maintenance and easy assembly Esthetics

External Customers Buying managers want Low Cost/Performance Safety Ruggedness (abuse resistance) Ergonomics Long warrantees Reliable with Low downtime Low operating cost

External Customers Retailers want Maintenance wants Small and attractive packaging Long shelf life Low cost high profit Exciting features Maintenance wants Ease of maintenance Low cost of maintenance

External Customers Government wants Standards want Conformance to laws and regulations Standards want Conformance to industry standards Conformance to codes

Internal Customers Management wants Make $$$ On time delivery Low risk of financial failure Proper Documentation Process: Conformance to company product development process

Internal Customers Marketing wants Attractive features to target buyers Low retail price Esthetics Attractive packaging Ease of user assembly/maintenance On time delivery Long Warrantees

Internal Customers Manufacturing / Purchasing want Available materials Manufacture-able at low cost. Conformance to company documentation formats. Use of products from preferred vendors.

Internal Customers Legal wants No patent infringements Safety All required safety warnings and labels Protection against reasonable abuse Safety manual Conformance to laws and regulations

Internal Customers Shipping and Packaging Small (standard) package sizes Ability of locking or fixing sensitive components Resistance against damage due to dropping, vibrations, moisture, heat, and cold.

Product Design Specification Is this a PDS item? Is there a customer associated with it? Does the information limit the design selections and choices? Can the requirement be designed into the product? High resale value Win a Prize PDS is important because most product failures (to be successful) can be traced to one of the elements in PDS. A design engineer that understand the importance of PDS and is efficient in developing one is much more successful in his/her career than those who go after “Eureka” type blank-sheet designs. As a starting engineer, you will be much more impressive and valuable to company management if you do a good job on this task. We have many many examples of this being true. Performance:Beware of “over-specification”. Care must be exercised to set attainable specification requirements to keep the cost down. Environment: All aspects of the product’s likely environment such as: Temperature/Pressure/Humidity Shock loading / Vibration Dirt / Dust / Corrosive media / insects Exposure during manufacturing, storage / packaging Maintenance: Specify ease of access and frequency and kind of maintenance called for for the product. Need or desirability of any special tools or spare parts.

Product Design Specification Elements of PDS Performance (Primary customer: End User) Speed, Capacity, Power, Efficiency, Accuracy, Return on investment etc. PDS is important because most product failures (to be successful) can be traced to one of the elements in PDS. A design engineer that understand the importance of PDS and is efficient in developing one is much more successful in his/her career than those who go after “Eureka” type blank-sheet designs. As a starting engineer, you will be much more impressive and valuable to company management if you do a good job on this task. We have many many examples of this being true. Performance:Beware of “over-specification”. Care must be exercised to set attainable specification requirements to keep the cost down. Environment: All aspects of the product’s likely environment such as: Temperature/Pressure/Humidity Shock loading / Vibration Dirt / Dust / Corrosive media / insects Exposure during manufacturing, storage / packaging Maintenance: Specify ease of access and frequency and kind of maintenance called for for the product. Need or desirability of any special tools or spare parts.

Elements of PDS Environment: (User) Life in service: (User) Temperature range, rain, humidity, dust. Life in service: (User) 10 years, 5000 cycles, etc. Maintenance: (User) The market policy, what customers accept Retail/Production cost: (User) Consistent with comparable products Rule of thumb 4:1

Elements of PDS Shipping/packaging: Package sizes + Weights Damage resistance

Elements of PDS Quantity (Marketing) Determined by marketing Manufacturing facility (Management) Does the company policy dictate certain facilities?

Element of PDS Size and shape (Marketing) Weight (Marketing) What is the desired weight? Handles for lifting points? Modular? Aesthetics (Marketing) Color, shape, form, texture, finish. Market research.

Elements of PDS Materials (Marketing, Codes, Regulations) Left to designers unless company guidelines or regulations restrict certain materials (asbestos, lead). Product life span (Marketing) Designed life Ergonomics All products interact with human users at least to some degree during use and maintenance. It is important to describe the nature of this interface and record design requirements for ease of use, transportation, and handling.

Elements of PDS Laws, Codes, and standards (Government) Ergonomics (User + Marketing + buyers)

Elements of PDS Quality and reliability (Marketing) Company policy regarding warranties Failure rate during warrantee period Testing (Marketing) Tests to perform to verify performance and other PDS requirements Industry standard tests

Elements of PDS Shelf life (storage) - Retail Processes (Mangement) Possibility of rust, decay, deterioration Processes (Mangement) Conformance to certain standards (GD&T or ISO 9000 for example) Use of company procedures Time-scales (deadlines) - Management Whole design project, milestones

Elements of PDS Safety (User, Government, Legal) Safety requirements mandated by government Professional society's codes and standards Need for warning labels Design against acceptable degrees of abuse

Elements of PDS Company constraints (Management) Compatibility with other products Documentation (Management – Legal) Full documentation (Guard against possible litigation) Safety, Operation, and Service documents.

Elements of PDS Legal (Lawyers) Product liability law suits associated with similar products and why. Relevant patents

Element of PDS Installation (Installers) Disposal (Marketing) Connection geometry. Various models to install Disposal (Marketing) Recyclable? bio-degradable? Green

Other Element of PDS Other possible PDS items to include Rugged Easy to use Reliable Quiet Portable Source of energy

Before you Interview Sponsors Prepare your questions (PDS) Let them do most of the talking Take notes Ask for clarification Do not be annoying (you can always ask more questions later if deemed important)

Wording of the PDS Document Format of most statements in PDS: The device must …….. The device is to …… The device is desired to …. Avoid mixing requirements. One sentence per requirement. Cast PDS statements in a positive format

PDS is a Dynamic Document A design statement usually begins as a vague statement The device is to be easy to use The device is to be safe The device is to be inexpensive The device is to be rugged and reliable The device is to be portable

Wording of the PDS Document Example: ESCO’s Pin Remover The pin-remover is to be light. The pin-remover must work in a wet, cold, and dusty environment. The Pin-remover must be safe The Pin-remover must have a 3-year warranty.

PDS Example The Pin Remover is to be rugged. must work with air pressure. is to be easy to use. is to pass “ASME standard” tests. is to last 5 years in normal usage. is to be easy to carry.

PDS Example is to sell for less than $150. is to cost less than $50 to make. is to have low maintenance needs. is to be difficult to use as a hammer. must not infringe patented devices. Production volume is 3000 per year

PDS Example is to be tested by June 2013. is to be released by Sep. 2013. is to be usable with all Dredge models. is to work faster than a hammer

Engineering Specifications Engineers cannot design for vague criteria “Fast, accurate, high-performing” “Light, Small, portable” “Easy to use” “Safe” “Stylish” (maybe)

Engineering Specifications Verifiable PDS statements Developed for important PDS statements Have associated target numbers BUT Do not push the customer for numbers

A Typical PDS Page Requirement: PR is to be easy to maintain Primary customer: End users Priority: High Metrics and Targets Daily maintenance: None Weekly maintenance: < 10 minutes – field Yearly maintenance: < 1 hour – Shop Cost of weekly maintenance < 10c Cost of yearly maintenance < $10

Methods of setting targets Some targets are specified by: Marketing Management Regulations /standards Users / buyers / retailers etc

Methods of setting targets Benchmarking + parametric Studies Technology capability Field experts Experimentation Educated guesses Select ranges for targets from Barely acceptable to highly desirable

HoQ Engineering Requirements Competition IMPORTANCE Customer Needs PDS Statements Relation Between Engineering and Customer Needs Competition Target