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

2. 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.

3. 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

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

5. 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

6. 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?

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

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

9. 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

10. 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

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

12. 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.

13. 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

15. 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

16. 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

17. 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

18. ROLE OF PRODUCT DESIGN AND DEVELOPMENT IN TOTAL SYSTEM

19. GENERALIZED PRODUCT LIFE CYCLE FOR COMMON CUSTOMERS