1. Defining and solving design problems Designing products and process plants Product anatomy Components: standard vs. special purpose Process plant anatomy Component decomposition diagrams Types of design Tinkering Summary

2. 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?

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

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

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

6. 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 Other example components

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

8. Final design (not included in text) 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.

9. Process plant - definition A process plant is a combination of systems used to process energy or materials (both organic and inorganic).

10. Component decomposition of a frozen food processing plant Frozen Vegetable Plant Washing System Packaging System Freezing System Spraying ConveyingCooling Conveying Inspecting Chilling Blanching System Parboiling Inspecting Wrapping Weighing Plant System Equipment

11. Component decomposition of process plant Equipment 5 Plant System BSystem A Equipment 3 Equipment 2 Equipment 1 Sub-system B1 Equipment 4

12. Why bother preparing Component Decomposition Diagrams? Learn pros & cons of existing products or processing plants 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.

13. 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

14. Detail Design Parametric Design Configuration Design Detail Design Parametric Design Detail Design Formulation Concept Design Detail Design Parametric Design Configuration Design variant design selection design original design part design Types of design related to phase

15. (http://www.m-w.com/cgi-bin/dictionary) “Tinker” Real engineers do not tinker. Real engineers predict how a product will perform before building it, reducing the need to “cut and try” or “fiddle.” Date: 1592 ---to work in the manner of a tinker; especially : to repair, adjust, or work with something in an unskilled or experimental manner: to FIDDLEFIDDLE

16. Summary Products and process plants have an anatomy of components Components include parts & subassemblies Process plant components include systems and equipments Components can be standard or special purpose Component decomposition diagrams are very useful Types of design include: original, variant, selection, adaptive, redesign Tinkering is really not engineering design