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

2. The Process of Design Designing is the process of making many decisions that converts an abstract concept into a hardware reality. ConceptProduct

3. 7-Step Design Process 1. Problem definition (PD) 2. Product design Specification (PDS) 3. External Search (Research) 4. Internal Search (Brainstorming) 5. Evaluation and Selection 6. Detail Design (Engineering) 7. Prototyping 8. Documentation

4. Product Design Specification Elements of PDS –Performance (User) Speed, Capacity, Power, Accuracy, etc.

5. Elements of PDS –Environment: (User) Temperature range, humidity, dust and dirt, etc. –Life in service: (User ) 10 years, 5000 cycles, etc. –Maintenance: (User) What is the market policy, what customers accept –Target production cost: (User) Cost of comparable products and company policy.

6. Elements of PDS Shipping: –Package sizes –Damage resistance

7. Elements of PDS Quantity (Manufacturing) –Determined by market analysis. Manufacturing facility (Manufacturing) –Is the design constrained by existing facility? –Are parts to be contracted and assembled in-house? –Does the company policy dictate certain facilities?

8. Element of PDS Size and shape (Marketing) Weight (Marketing) –What is the desired weight? –Should handles or lifting points be provided? –Should it be modular for better handling? Aesthetics (Marketing,User) –Color, shape, form, texture, finish. –Market research.

9. Elements of PDS Materials (Marketing, Codes, Regulations) –Left to designers unless company guidelines or regulations restrict certain materials (asbestos, lead). Product life span (Marketing, Manufacturing) –Life of a product as a marketable entity. Several months or several years?

10. Elements of PDS Laws, Codes, and standards (Government) Ergonomics (User)

11. Elements of PDS Quality and reliability (Marketing) –Company policy regarding warranties –Competitors warranty policies Testing (Marketing, QA) –What tests would be performed to verify performance –Standard tests

12. Elements of PDS Shelf life (storage) - Retail –Possibility of rust, decay, deterioration Processes (company guidelines) –Use of certain standards (GD&T for example) –Use of certain procedures Time-scales (deadlines) - Management –Whole design project, milestones

13. Elements of PDS Safety (User, Government, Legal) –What safety requirements are mandated by government –Professional society's codes and standards –Need for warning labels –Likely degrees of abuse or misinterpretation of operating procedures.

14. Elements of PDS Company constraints (Management) –Compatibility with other products Documentation (Management – Legal) –A product design must include a full formal documentation per company guidelines. –Safety, Operation, and Service documents. –Etc.

15. Elements of PDS Legal (Lawyers) –What product liability law suits are associated with similar products and why. –Note the legal terms: “defect of specification” “defect of design” “defect of manufacture” –Relevant patents

16. Element of PDS Installation (Installers) –Many products must interface with other products or be assembled with other products. Disposal (Society) –Should any parts by recyclable? –bio-degradable?

17. 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

18. PDS Example … is to sell for less than $150. … is to costless than $50 to make. … is to have low maintenance needs. … is to be difficult to use as a hammer. … must not infringe on patented devices. … Production volume is to be 300 per year

19. Engineering Specifications What is –“Fast, accurate, high-performing”? –“Light, Small, portable”? –“Easy to use”? –“Safe”? –“Stylish”?

20. Engineering Specifications Tips –Set up metrics and targets so the designer has maximum options in accomplishing the PDS

21. Engineering Specifications Tips PDS: The Dog Feeder must not tip over when bumped or pushed by a dog. –Bad: The DF must weigh 50 lbs –Good: The dog feeder must withstand 30 lbs applied to its top from side

22. Product Design Specifications Engineering Specs (Ex:Rope Climber) Climbs at 1 ft/s or faster Retail cost is to be less than $30 Uses 2 AA batteries (not included) Has no removable small parts Music loudness between 20-30 db Luminosity is to be more than 5 W Works for more than 3 hours on 2 AA

23. Assignments due by Wednesday 09/23 Read Chapter 3 of the textbook Note your opinions of the sections in your journal Note questions, issues or perspectives you have/gained Homework #3: Group Assignment - Step 2 in the Engineering Design Process For your selected project topics, write down your specifications and constraints along with a cover page with your names and an abstract.