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

 Designing is the process of making many decisions that converts a need into a hardware reality. NeedProduct

1.Product Design Specifications (PDS) 2.External Search (Research) 3.Internal Search (Brainstorming) 4.Concept Evaluation and Selection 5.Detail Design (Engineering) 6.Prototyping and Testing 7.Documentation

StepOutcome Product Design SpecificationsPDS 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

Rope Climber Can Crusher Coin Sorter Better Mouse Trap Water Balloon Nail Driver Rope Climber

 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

 START Expensive Patents Battery Life Slow Unsafe No Glow Silent Indoors Only

Desired Boundary Retail < $45 Acceptable Boundary Retail < $50

High Priority Plays Music Low Priority Glow in the dark

 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

 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 db  Luminosity is to be more than 5 C  Works for minimum 3 hours on 2 AA

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

 Brainstorming ◦ Generate many ideas ◦ Evaluate against PDS ◦ Evaluate risks ◦ Select one to engineer

More Abstract Engineering Less Abstract

 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

Concept Synthesis PDS Concept Evaluation Candidate Design Detail Design Candidate Design Release for Production Prototyping

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

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

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

 A successful product: 1)Sells well and makes a lot of profit 2)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)

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

Internal Marketing Legal Manufacturing & Procurement Management Shipping Packaging

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 –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 –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 the Noble Prize

Product Design Specification Elements of PDS –Performance (Primary customer: End User) Speed, Capacity, Power, Efficiency, Accuracy, Return on investment etc.

Elements of PDS –Environment: (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

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 –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) –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 is to be released by Sep 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 Customer Needs PDS Statements Engineering Requirements Competition IMPORTANCEIMPORTANCE Relation Between Engineering and Customer Needs Target