1. Product Design and Development
Final exam review Fall 2011

3. MULTIPLE CHOICE QUESTIONS
AND SHORT ANSWERS
Multiple choice questions cover all material including detailed design. Make sure you know good CAD modeling practices, views, dimensioning rules (over dimensioning, under dimensioning), weld types, differences between part and assembly drawings etc.
Review guest lectures.

4. Clearance fit Transition fit Interference fit Sample question:
Identify fits A, B, C
ec001.SLDASM
hole
shaft
hole
shaft
hole
shaft
Clearance fit
Transition fit
Interference fit

5. Line fit Transition fit Interference fit Sample question:
Identify fits A, B, C
Line fit
Transition fit
Interference fit

6. Identify some commonly used features:
Have many sketches they need?
Which one may or may not be the first feature in Feature Manager Design Tree?

7. USE SI UNITS ON EXAM
DO NOT CONFUSE UNITS OF MASS AND FORCE
PRICE/COST IS NOT A DESIGN SPECIFICATION

8. PRODUCT DESIGN TECHNIQUES - KNOW WHAT ARE THEY
AND WHEN THEY ARE USED
MATERIAL SELECTION
FAILURE MODES AND EFFECT ANALYSIS
GO/NO-GO SCREENING
SIMULATION
BRAINSTORMING
CRITICAL PATH METHOD
MORPHOLOGICAL ANALYSIS
FAULT TREE ANALYSIS
ENGINEERING MODELS
DFE
PRODUCT LIFE CYCLE
QUALITY FUNCTION DEPLOYMENT
DFM
FEASIBILITY JUDGMENT
FEA
GANTT’S CHARTS
DFA
PRELIMINARY HAZARD ANALYSIS
PATENT SEARCH
TECHNOLOGY READINESS ASSESSMENT
FUNCTIONAL DECOMPOSITION
DESING FOR DISASSEMBLY
DECISION MATRIX METHOD
DFR
DESIGN FOR RECYCLING
CUSTOMER SURVEY
CAD
RISK ENGINEERING
DESIGN FOR HUMAN FACTORS

9. PRODUCT DESIGN TECHNIQUES - SPECIFICATION DESIGN
CUSTOMER SURVEY
QUALITY FUNCTION DEPLOYMENT
GANTT’S CHARTS
CRITICAL PATH METHOD
Specification Development
Planning Phase

10. PRODUCT DESIGN TECHNIQUES - CONCEPTUAL DESIGN
FUNCTIONAL DECOMPOSITION
BRAINSTORMING
MORPHOLOGICAL ANALYSIS
Concept generation
FEASIBILITY JUDGMENT
TECHNOLOGY READINESS ASSESSMENT
GO/NO-GO SCREENING
DECISION MATRIX METHOD
Concept Selection

11. PRODUCT DESIGN TECHNIQUES - DETAILED DESIGN
CAD
Best Modeling Practices
Part Modeling
Assembly Modeling
Drawings
MATERIAL SELECTION
ENGINEERING MODELS (form, shape, function)
SIMULATION

12. PRODUCT DESIGN TECHNIQUES - DETAILED DESIGN
DFM
DFA
DFR
Preliminary Hazard Analysis
Fault Tree Analysis
Failure Modes and Effect Analysis
Risk Management (Risk engineering)
DESIGN FOR HUMAN FACTORS
DFE
Design for Disassembly
Design for recycling
Product life cycle

13. KNOW WHAT QFD IS AND WHAT IT IS USED FOR
Quality Function Deployment is a technique developed in Japan during the mid-1970's for better understanding the design problem, in particular of customer needs.
Deployment: The distribution of forces in preparation for battle or work.

14. Quality Function Deployment (QFD)
General Comments:
No matter how well the design team thinks it understands a problem, it should employ the QFD technique for all mechanical design projects, because in the process the team will learn what it doesn't know about the problem.
The customer's requirements must be translated into measurable design targets before a large amount of time and resources are invested in the design effort.
It is important to first consider what needs to be designed and, only after that is fully understood, to worry about how the design will look and work.

15. Quality Function Deployment (QFD)
The eight basic steps in the Quality Function Deployment technique are:
1. Identify the customers: Who are they?
2. Determine the customers' requirements: What do the customers want?
3. Determine relative importance of the requirements: Who versus what
4. Generate engineering specifications: How will the customers' requirements be met?
5. Relate customers , requirements to engineering specifications: Hows measure whats?
6. Identify relationships between engineering requirements: How are the "hows" dependent on each other?
7. Identify and evaluate the competition: How satisfied is the customer now?
8. Set engineering targets: How much is good enough?

16. Quality Function Deployment (QFD)
COMPETITION
Easy to inflate
Small size defl.
Easy to maneuver
Comfortable paddle
Bounces off rocks
Self bailing
Stable
Fast
Lightweight
Affordable
Cargo space
Weight
Length
Width
Multi chamber
Chamber vol
Strength mat.
Canadian Coast 1 9 4
Customer importance 9 A B C 4 4 5 3 4 3 9 4 2 1 1 3 9 2 5 2 3 9 2 2 2 1 1 4 3 3 2 2 3 2 9 3 9 3 5 5 2 9 1 1 2 4 9 5 3 5 2 9 3 3 3 1 4 2 2 2
units kg m 1 m3
N/m %
Absolute importance
219 85 27 27 43 1 18 18
relative importance % 39 12 12 20 8 8

17. Functional Decomposition Technique
UNDERSTAND WHAT IS FUNCTIONAL DECOMPOSITION AND MORPHOLOGICAL ANALYSIS AND HOW THEY WORK TOGETHER TO GENERATE CONCEPTS
Morphological matrix shows alternative means of achieving given functionality

18. Morphological * Analysis
Morphological analysis is used to identify the necessary product functionality and explore alternative means and combinations of achieving that functionality. For each element of product function, there may be a number of possible solutions. The morphological chart is prepared and used to develop alternative combinations of means to perform functions and each feasible combination represents a potential solution.
* Morphology: The science of the form and structure

19. CONCEPT EVALUATION TECHNIQUES
Type of Comparison
Technique
Basis of Comparison
Numerous
Concepts
KNOW CONCEPT SELECTION TECHNIQUES
Feasibility Judgment
Gut Feeling
Technology Readiness Assessment
Absolute
State of Art
Go/no-go Screening
Customer Requirements
Relative
Decision Matrix Method
Best Concept(s)

20. PROJECT PLANNING TECHNIQUES
CPM
GANTT CHARTS

21. PRELIMINARY HAZARD ANALYSIS FAILURE MODES AND EFFECT ANALYSIS
DESIGN FOR RELIABILITY TECHNIQUES (DFR)
PRELIMINARY HAZARD ANALYSIS
FAULT TREE ANALYSIS
FAILURE MODES AND EFFECT ANALYSIS

22. FAULT TREE ANALYSIS Be able to calculate probabilities in Fault Tree
The output fault occurrence probabilities for AND gate is:
where
FAND is the probability of occurrence of the AND gate output fault event
m is the number of independent input fault events
Fi is the probability of occurrence of input fault event i, for i=1, 2, …m
OUTPUT EVENT
FAND
Example:
F1 = 0.1
F2 = 0.05
FAND = 0.1 * 0.05 = 0.005
AND
INPUT EVENTS F1 F2

23. FAULT TREE ANALYSIS Be able to calculate probabilities in Fault Tree
The output fault occurrence probabilities for OR gate:
where
FOR is the probability of occurrence of the OR gate output fault event
m is the number of independent input fault events
Fi is the probability of occurrence of input fault event i, for i=1, 2, …m
FOR
OUTPUT EVENT
Example:
F1 = 0.1
F2 = 0.05
FOR = 1 – ( )*( ) = 0.145 OR F1 F2
INPUT EVENTS
Note: For small (i.e. less than 10 percent) occurrence probabilities of input fault events of the OR gate, the above equation reduces to:

24. RANKING PROCEDURE FOR FMEA
Be able to calculate RPN and discuss/justify all numbers
Risk Priority Number
RPN = R occurrence x R severity x R detection
RPN = 1 failure is highly unlikely and unimportant
RPN = 30 it is OK
RPN = 100 failure will occur
RPN = hazardous and harmful failure will occur

25. Be able to calculate I.P. The improvement potential I.P. Where:
NA is the actual number of components
NT is the theoretical minimum number of components
Rate the product on the worksheet:
If I.P.  10%, then current design is outstanding
If 10% < I.P.  20%, then current design is very good
If 20% < I.P.  40%, then current design is good
If 40% < I.P.  60%, then current design is fair
If I.P. > 60%, then current design is poor

27. EXAM PROBLEM Imagine a photo of some common household object is given.
You may be asked to:
Perform DFA (13 rules) and DFM on it.
Identify failure modes and perform FMEA
Next you’ll propose a redesign to make it suitable for people with arthritis* by identifying customer needs and linking them to design specifications (QFD)
You’ll then develop two concepts complete with sketches, evaluate them and perform DFA on the winning concept and DFM on selected components..
The above is not “all inclusive”. You don’t have to memorize the 13 DFA rule but you must know how to use them in the table format to calculate scores.
* Definition of Arthritis
Arthritis is a disease that causes pain and loss of movement of the joints. The word arthritis literally means joint inflammation, and refers to more than 100 different diseases.
Description of Arthritis
Arthritis affects the movements you rely on for everyday activities. Arthritis is usually chronic. This means that it can last on and off for a lifetime.

28. EXAMPLE: A FLOUR SIFTER NEEDS TO BE REDESIGNED TO MAKE IT SUITABLE FOR USE BY PEOPLE WITH ARTHRITIS IN HANDS

29. EXISTING FLOUR SIFTER
DFA?

30. EXISTING FLOUR SIFTER
FAILURE MODES AND EFFECT ANALYSIS

31. DESIGN OF A NEW FLOUR SIFTER
CUSTOMER REQUIREMENTS FOR PEOPLE WITH ARTHRITIS 1 2 3 4 5 6 7 8

32. DESIGN OF A NEW FLOUR SIFTER
HOW TO TRANSLATE CUSTOMER REQUIREMENTS INTO ENGINEERING TARGETS?

33. DESIGN OF A NEW FLOUR SIFTER
CREATE TWO CONCEPTS: CONCEPT 1, CONCEPT 2
WHAT TECHNIQUES CAN WE USE FOR CONCEPT CREATION?
BE PREPARED TO SKETCH YOUR CONCEPTS ?

34. Customer Requirements
DESIGN OF A NEW FLOUR SIFTER
WHAT TECHNIQUES CAN WE USE FOR CONCEPT EVALUATION? ?
Decision-Matrix Form
Concepts to be compared
Concepts for Comparison 3
Customer Requirements
Weights
Scores 4 1 2
Totals 5
The relative importance of requirements found using pair-wise comparison technique

35. DESIGN OF A NEW FLOUR SIFTER
Relative importance of requirements
The winner
Evaluation Based on Decision Matrix

36. DESIGN OF A NEW FLOUR SIFTER
We have selected our concept, is it better or worse as compared to the existing sifter?
DFM?
DFA?

37. DESIGN OF A NEW FLOUR SIFTER
Performance requirements of the material in our proposed flour sifter? ?
Material properties associated with the above performance requirements?
Any design recommendations inspired by DFE?

38. PAST EXAMS

39. PAST EXAMS

40. GOOD LUCK ON YOUR EXAMS!