1. Chapter 1 The Product Design Process
The Four C’s of Design
A Simplified Approach
A Problem Solving Methodology
Consideration of A Good Design

2. The Four C’s of Design Creativity Complexity Choice Compromise
Requires creation of something that has not existed before or not existed in the designer’s mind before
Complexity
Requires decisions on many variables and parameters
Choice
Requires making choices between many possible solutions at all levels, from basic concepts to smallest detail of shapes
Compromise
Requires balancing multiple and sometimes conflicting requirements

3. What is Design? Design establishes and defines solutions to and pertinent structures for problems not solved before, or new solutions to problems which have previously been solved in a different way
Difference between Design and Discovery:
Discovery is getting the first sight of something but design is the product of planning and work
Good design requires both analysis and synthesis (Analysis is to breakdown complex problems to manageable parts and synthesis involves the identification of the design elements that will compromise the product and the combination of the part solutions into a total workable system)

4. The Design Process- A Simplified Approach
General information
Specific
information
Design Operation
Outcome NO
Evaluation
yes
Feedback loop
Go to the next step

5. Scientific Method vs Design Method
Existing knowledge
State of the art
Scientific curiosity
Identification of need
Hypothesis
Acceptance
Conceptualization
Communication
Logical analysis
Feasibility analysis
Production
Proof
Scientific Method
Design Method

6. Consideration of Good Design
Design Requirements
Functional performance (F, σ, power, deflection)
Complementary performance (life of design, robustness, reliability, ease, economy, safety of maintenance)
Total Life Cycle
Material selection, productivity, durability
Regulatory and Social Issues
ASTM, ASME standards, codes of ethics, EPA requirements

7. Design Process I. Conceptual Design II. Embodiment Design
III. Detail Design
IV. Planning for Manufacture
V. Planning for Distribution
VI. Planning for use
VII. Planning for Retirement of the Product

8. I. Conceptual Design Identification of customer needs
Problem definition
Gathering information
Conceptualization
Concept selection
Refinement of product design specification
Design review

9. II. Embodiment Design Product architecture
Configuration design of parts and components (feature present like holes, ribs, splines, and curves are configured). Modeling and simulation may be performed. The generation of physical model of the part with rapid prototyping processes may be appropriate)
Parametric design of parts and components (exact dimensions and tolerances, materials and processes, robustness)

10. III. Detail Design
In this phase the design is brought to the stage of a complete engineering description of a tested and producible product.

11. IV. Planning for Manufacture
Designing specialized tools and fixtures
Specifying the production plant that will be used
Planning the work schedules and inventory controls
Planning the quality assurance systems
Establishing the standard time and labor costs for each operation
Establishing the system of information flow necessary to control the manufacturing operation

12. V. Planning for Distribution
Shelf life consideration
System of warehouses for distribution of the product needs to be designed
Marketing efforts on advertising and news media techniques must be selected
For technical activities specialized sale brochures and performance test data must be generated.

13. VI. Planning for use
Ease of maintenance, reliability, product safety, convenience in use (human factors engineering), aesthetic appeal, economy of operation, and duration of service are some of the questions to be answered in a consumer oriented product.
Acquisition of reliable data on failure, service lives, and consumer complaint and attitudes to provide a basis for product improvement in the next design is an important phase VI activity.

14. VII. Planning for Retirement of the Product
The final step in the design process is the disposal of the product when it has reached the end of its useful life.
Useful life may be determined by actual deterioration and wear or it may be determined by technological obsolescence.
Industrial ecology considerations dictate a plan for either disposal of the product in an environmentally safe way or, better, the recycling of its materials, or remanufacture or reuse of product components.