BTEC National Diploma in Engineering

Level 3
Unit 8
Engineering Design

Student Name:
Assessor Name:

Paul Mulder

Document Revision & Date:

Rev 1 (30/7/12)

Students to initial the box in the Submitted row below to show that an
assignment is being submitted for assessment.
Learner Declaration:
By initialling the submission box below, I confirm that the work submitted to
complete the given tasks is my own. I have indicated where research and other
sources have been used to confirm the conclusions reached within the
submission and have listed those sources in a bibliography.

Outcom
e

P1

P2

P3

P4

P5

P6

P7 M1 M2 M3 D1 D2

Submitte
d
Achieved
Referred
Resubmitt
ed

Unit 8 BTEC Level 3 - Eng. Design

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Unit 8 BTEC Level 3 - Eng. Design

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Task(s)

Assignment Deadline
Outcome
Assignment Brief
Evidence

Assignment Guidance

P1
Describe the operation of the design process in an engineering company
Written Assignment
All engineering companies are different in the procedure they use when
designing a new product. However, some basic steps should always
applied to ensure a successful outcome. Describe the various stages of the
design process which may take place within an engineering organisation
including those listed below. Include in your assignment Finite Element
Analysis (FEA), rapid prototyping, the approval process, packaging, etc.

Task Requirement

Task completed to
the required
standard?
YES
NO

As a minimum your assignment should describe the points listed below:

Design idea/concept.
Design brief.
Market research.
Create a specification.
Design ideas.
Development, including the use of FEA where appropriate.
Prototyping.
Design evaluation.
Finalise design.
Production.
Assessor Feedback:

Achieved?
YES/NO

Unit 8 BTEC Level 3 - Eng. Design

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Task(s)

Assignment Deadline
Outcome
Assignment Brief
Evidence
Assignment Guidance

P2
Interpret the requirements of a given customer and produce a product
design specification
Written Assignment
Produce a PDS (product design specification) that will be used for the
design and development of a new electronic, digital, mobile music system.
Your design brief should be original and include features note readily
available at present.

Task Requirement

Task completed to the

required standard?
YES
NO

As a minimum your PDS should consider and include the points listed
below:
Overall size
Screen and button sizes
Style, colour and finish
Position of headphone socket
Switching, including power on/off, volume control, track selection, locking
the buttons while the device is being carried, connectivity for loading tunes.
Battery life, recharging and accessing battery.
Branding
Packaging
Target market, which will be effected by sales price.

Assessor Feedback:

Achieved?
YES/NO

Unit 8 BTEC Level 3 - Eng. Design

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Task(s)

Assignment Deadline
Outcome
Assignment Brief
Evidence
Assignment Guidance

P3
Describe the appropriate legislation and standards which apply to the
design of two different products
Written Assignment
Describe the appropriate legislation and standards which apply to the
design of two different products, in this case your assignment should focus
on an electric kettle and the games console and handset as described in
the PDS used for P5.

Task Requirement

Task completed to the

required standard?
YES
NO

Ensure that your assignment describes each of the areas listed below:
Investigate, list and briefly describe the standards which are specifically
required for a kettle. It may be plastic, metal or both.
Investigate, list and briefly describe the standards which are specifically
required for a games console.
Investigate, list and briefly describe the standards which are generically
required for electrical products connected to the UK mains electricity supply
such as 13A plug regulations, earthing requirements, CE marking and
complying with the WEEE directive, etc.

Assessor Feedback:

Achieved?
YES/NO

Unit 8 BTEC Level 3 - Eng. Design

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Task(s)

Assignment Deadline
Outcome
Assignment Brief
Evidence
Assignment Guidance

P4
Describe the environmental, sustainability and manufacturing constraints
which influence the design of a given product.
Written Assignment
Describe how constraints outside of your control might influence the design
of an electric kettle. Consider environmental, sustainability and
manufacturing constraints and describe ways in which a designer may
overcome these restrictions.

Task Requirement

Task completed to the

required standard?
YES
NO

Ensure that your assignment describes each of the areas listed below:
Environmental constraints such as:
The power used to boil water
The carbon footprint
Recycling the kettle at the end of its working life.
Sustainability constraints such as:
The materials being used for all the components of the
kettle.
Where the materials come from including where they are
made and air miles to get them to the assembly line.
Do parts come from renewable or recycled sources?
Manufacturing constraints such as:
Manufacturing cost, how this effects market price and
therefore sales of the kettle
Serviceability. Is it even necessary?
Meeting British Standards, European standards and
recyclability targets. Detail what the standards are.
Achieving a good energy rating.

Assessor Feedback:

Achieved?
YES/NO

Unit 8 BTEC Level 3 - Eng. Design

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Task(s)

Assignment Deadline
Outcome
Assignment Brief
Evidence

Assignment Guidance

P5
Produce design proposals which meet the requirements of a given PDS
Sketches and notes
Produce a series of free-hand isometric and orthographic sketches that will
show your design proposals for the games console and controller as
specified in the PDS. A written explanation should accompany each sketch
along with details of proposals for materials to be used. Include detailed
views, where necessary, showing close ups of certain features or fixings.
The PDS is enclosed on the next 6 pages of this document.

Task Requirement

Task completed to the

required standard?
YES
NO

Ensure that your assignment meets each of the areas listed below:
All generic design ideas with a short explanation of why they were rejected
or progressed onwards.
A series of free-hand sketches showing the development of your design
ideas including colours and finishes where appropriate.
An indication as to where each pre-set part from the PDS will be fitted,
including close-up auxiliary views where necessary.
Notes about how parts will be fixed together, such as screws, clips, etc.

Assessor Feedback:

Achieved?
YES/NO

Unit 8 BTEC Level 3 - Eng. Design

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Product Design
Specification
(PDS)

Product:
Game Station Hand
Controller

Contents:
1. Focus
2. Planning
3. Specification

Unit 8 BTEC Level 3 - Eng. Design

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4. Packaging

Unit 8 BTEC Level 3 - Eng. Design

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1. Focus
1.1 Our market research team has identified a number of features that the
game station hand controllers currently on the market either dont have,
or need to be improved. For this reason Canterbury College has decided to
design, manufacture and market our own gaming station hand controller.
Main design focus areas will include:

Ergonomics, to reduce the risk of repetitive strain injury (RSI).

New technology, with features not currently marketed.

1.2 Customer satisfaction is our top priority. Therefore, essential market

research has been carried out and will continue to be carried out on an
ongoing basis, focussing on the following data:

What do customers like and dislike about current game stations

hand controllers?

Which game stations hand controllers do they currently use, and

why?

What image do customers have of our business and products?

What concerns would customers have about buying from Canterbury

College?

How can we make their gaming experience more enjoyable?

Using sales data to identify the products that sell well and which are
in decline.

Using sales data to identify regional and seasonal trends.

Identifying target age group and gender of main customer base.

2. Planning
2.1 A project team will manage the design process.

Specific, quantified design objectives will be set out in section 3 of

this document.

Unit 8 BTEC Level 3 - Eng. Design

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While no specific manufacturing cost target has yet been set, good
engineering practice should be used at all times to constrain
manufacturing costs to a minimum, but without compromising
quality.

Milestones for this project should be carefully recorded and

managed.

The target completion date for the completed design portfolio is 14

June 2012.

This document will contain design constraints and considerations

and must be adhered to, as set out in section 3.

The design should allow for all parts to be manufactured in a cost

effective manner and comply with legal and health and safety
requirements.

This product is primarily to be designed for the UK market, although

alterations or enhancements will be considered for worldwide
markets at a later date.

Unit 8 BTEC Level 3 - Eng. Design

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2.2 From design to manufacture to market.

The product launch date is set for 1st November 2013 and sufficient
units need to be manufactured, assembled and tested prior to this
date to ensure take-up demands are met. Further details of initial
quantities will follow.

Specific parts used in the building of this product such as the

wireless transceiver, the volume control switch and the vibrate
control on/off switch will be sourced from existing manufacturers.
The make or buy decision for other parts will be made on a cost
effectiveness basis. See 3.2 for a full list.

All parts will be assembled and tested in the UK.

It is reasonable to expect that the cost of manufacturing component

parts should be kept to a minimum.

Standard components and tools should be used across a range of as

many parts as possible, such as screws, rather than more expensive
custom-made items.

Any additional design ideas to improve this product may be used

provided the design requirements are met and approval is granted.

2.3 Intellectual property.

Protecting the intellectual property of this product is paramount
throughout this project. Therefore, all employees who are involved in any
way with this project must sign a Canterbury College confidentiality
agreement prior to any information being disseminated to them from any
source, written or verbal.
This action is being taken to prevent competitors from copying the unique
design features which this product will have. In so doing, the following
points must be adhered to:

If additional expertise is required from third parties, they must sign

a Canterbury College confidentiality agreement prior to being given
any information on this product, however small.

No information must be imparted to third parties, including family

members and friends, outside of Canterbury College without the
written consent from the department manager and the individual
signing of the afore mentioned confidentiality agreement.

Unit 8 BTEC Level 3 - Eng. Design

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Patent protection for new and innovative products will be applied for
wherever possible.

Design registration to protect the shape, appearance and function of

this product will be applied for.

Registered trade-marks which distinguish this product from the

competition will be applied for including marketing names, logos,
etc.

Unit 8 BTEC Level 3 - Eng. Design

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3. Specification
Different types of design present different opportunities and problems.
The following is a list of design features that are required as a minimum.
However, extra value added ideas maybe incorporated into the design
subject to approval.
3.1 The key features and functions of the hand controller design are as
follows:

The handset will be used for many hours and must be durable in
design.

The handset will be designed using ergonomic principles to ensure

that it is comfortable to use.

The handsets will be wireless.

The handset will incorporate the following control options:

2 gaming joysticks
10 gaming buttons

Each button on the hand controller will be identified by a symbol or

alpha-numeric character which will be logical to understand.

The handset will incorporate an LED battery life indicator.

The handset will contain 2 x 1.5V AA rechargeable batteries which

should be accessible for changing/upgrading if necessary.

The hand controller will contain a cavity to house the PCB.

The circuit board may be any shape but will be 1.5mm thick and
have a surface are of 3000mm 10%. You will also need to allow a
minimum of 5mm on the top of the circuit board for surface
mounted components.

The hand controller will of a minimum weight and be as light as it is

practically possible to make it.

3.2 Preset design features for hand controller.

Unit 8 BTEC Level 3 - Eng. Design

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The following parts are pre-determined and a digital file will be

provided for each part to the designer. The designer will ensure that
the hand controller and base unit incorporates appropriate
apertures and fixing points to ensure that these parts fit correctly.
Hand controller LED battery life indicator
1.5V AA Battery

3.3 The visual appearance:

The hand controller will be designed to look aesthetically pleasing in

a domestic environment, in both colour and style.

The colour of the hand controller will be determined by the designer.

3.5 Quality standards must be used and stated in the project portfolio

All parts must conform to the relevant British Standard.

4. Packaging
The packaging should be made from materials which can easily be
recycled and the graphics should include recycling information.
4.1 The hand controller will be packaged as a single unit.
The hand controller will be packaged in such a way as to withstand
transportation vibration, a drop test from 1.5m and stacking as part of
transportation and storage.

Unit 8 BTEC Level 3 - Eng. Design

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Task(s)

Assignment Deadline
Outcome
Assignment Brief
Evidence
Assignment Guidance

P6
Extract reference information from component manufacturers catalogues
and materials and design databases
Written Assignment
All materials and fixings for your games console and hand controller should
be sourced from both electronics catalogues and the internet, as well as
paper catalogues. Ensure that you reference correctly the source including
date, suppliers name, web address or catalogue issue and any other
relevant information.

Task Requirement

Task completed to the

required standard?
YES
NO

Your assignment must include the data listed below according to whether
the part is referenced from a paper or online source. The items that you
must source are shown in the table at the bottom of this page.
For paper based catalogue information the following details should be
included in the assignment:
A copy of the page(s) referenced with the appropriate item being
highlighted.
The name of the suppler
The date that the catalogue was published or its period of validity
The price for the item(s) required including break prices where appropriate
For web based supplier information the following details should be included
in the assignment:
A print out of the page(s) referenced with the appropriate item being
highlighted.
The name of the supplier
The exact I.P address (webpage link) for the online catalogue being
referenced
The date the webpage was accessed and data recorded
The price for the item(s) required including break prices where appropriate
Finally, write a conclusion about your experience of sourcing these parts
comparing the 2 methods, listing the advantages and disadvantages of
each.
Assessor Feedback:

Achieved?
YES/NO

Paper based items to source:

Fan 120mm 240V 94CFM
Green diffused LED 25mA 5mm
Pozi Csk. Self-Tapping Screws No.6 13mm ()

Online items to source:

Pozi Csk. Self-Tapping Screws No.4 x 6.5mm
5mm 5v Green LED
SKF 6009-2RS1 1 row radial ball bearing 45mm ID

Single row radial ball bearing,25mm ID

Black rubber mains plug,13A

Black re-wireable straight plug,10A 250Vac

M4 x 30 Socket Cap Head Screw Zinc Plated

Fan 120mm 240V 94CFM

M4 x 12mm stainless steel grub screw (socket set

Unit 8 BTEC Level 3 - Eng. Design

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screw)

Unit 8 BTEC Level 3 - Eng. Design

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Task(s)

Assignment Deadline
Outcome
Assignment Brief
Evidence

Assignment Guidance

P7
Use a range of techniques to present a final design solution which meets
the requirements of a given PDS and relevant legislation and design
standards
CAD generated drawings, screen shots and written assignment
Produce a 3D CAD model of a games controller as specified in the PDS.
The digital files as well as prints of each part from at least 4 views must be
submitted including screen shots and engineering drawings of the
assembly. A written explanation of the materials to be used, their
specification data. The submission must also include a written assignment
justifying your design, the material(s) used. Also explain why your design is
suitable for manufacturing and how your design conforms to the required
standards, including what those standards are.

Task Requirement

Task completed to the

required standard?
YES
NO

Ensure that your assignment submission contains each of the items listed
below:
A series of 3D SolidWorks generated parts which are assembled to make
the games controller
Does the design include all of the pre-set parts?
A document containing screen shots of the completed design
A 3rd angle orthographic drawing showing a minimum of 3 views of your
design with the width, depth and height dimensions shown and including an
isometric view.
Your written assignment should include the following:
Justification for your design
Justification, explanation and specification of the materials used
The suitability of your design for manufacture
The standards your design conforms to and why it conforms.
Assessor Feedback:

Achieved?
YES/NO

Unit 8 BTEC Level 3 - Eng. Design

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Task(s)

Assignment Deadline
Outcome
Assignment Brief
Evidence
Assignment Guidance

M1
Explain the possible impact of a poor customer design process on
customer relationships and requirements
Written Assignment
In general terms explain the possible impact of a poor design process on
customer relationships and requirements. Also, specifically focus on the
recall of the early PS2s, in September 2005 as an example and explain
why and how this poor design affected customer relationships including the
impact it may have had on consumer confidence.

Task Requirement

Task completed to the

required standard?
YES
NO

Your assignment should include the following elements:

An explanation of the impact or poor design as it effects each of the
following areas:
Customer returns
The cost of repairing or replacing faulty goods
The cost of sending replacement parts
How this effects the profitability of a company
Consumer confidence and future sales
Specifically concerning the problems with the PS2s, include the following
areas:
Scale of the problem
Injury to customers and damage to their property
What choices did customers have?
Did this problem effect Playstations market position?
Dont forget to include a conclusion
Assessor Feedback:

Achieved?
YES/NO

Unit 8 BTEC Level 3 - Eng. Design

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Task(s)

Assignment Deadline
Outcome
Assignment Brief
Evidence

Assignment Guidance

M2
Explain the importance of using a range of accurate design reference
materials when developing design proposals
Written Assignment
Describe the process of designing using accurate design reference
materials when developing a design for a roof, the beams of which need to
have certain load bearing properties and as such are defined as mission
critical. Describe the documented reference sources that could and should
be used in such circumstances. Describe how dimensions and material
specification are vital in this scenario.

Task Requirement

Task completed to the

required standard?
YES
NO

Your assignment should include a description of the following factors as a

minimum:
Identify and explain the different types of roof design commonly used,
include pictures to aid this and reference the source.
Define the term mission critical as it applies to a roof structure.
Define what constitutes a live load and why it is important to factor it in?
Define what constitutes dead or passive loads and why it is important to
factor it in?
How do climatic conditions play a part in the design process?
Describe the need for accurate design calculations when calculating the
load bearing of a roof
Explain why the use of tables would be an advantage when designing a
roof.
Explain how/if CAD would be an advantage when designing a roof.
What British Standards are commonly applied to roof design and why?

Assessor Feedback:

Achieved?
YES/NO

Unit 8 BTEC Level 3 - Eng. Design

Page 20

Task(s)

10

Assignment Deadline
Outcome
Assignment Brief
Evidence
Assignment Guidance

M3
Explain the issues which influence whether a design proposal should be
developed into a final solution suitable for manufacture
Written Assignment
On the basis that you need to work around the constraints mentioned in
P4, explain the issues which influence whether a design proposal should
be developed into a final solution suitable for manufacture such as
manufacturing cost, market demand, competitors products and life cycle.

Task Requirement

Task completed to the

required standard?
YES
NO

Your assignment should include an explanation of the following points as a

minimum:
Whether a design should be developed or not based on environmental
considerations, not only for manufacturing, but end of life recycling also.
Whether a design should be developed or not based on material
sustainability considerations, which also needs consider end of life
recycling.
Whether a design should be developed or not based on manufacturing
constraints such as legislation and standards, both current and likely
forthcoming changes.
Whether a design should be developed or not based on manufacturing
costs, which may include geographical considerations
Whether a design should be developed or not based on market demand
and competitors products
Whether a design should be developed or not based on anticipated life
cycle
Assessor Feedback:

Achieved?
YES/NO

Unit 8 BTEC Level 3 - Eng. Design

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Task(s)

11

Assignment Deadline
Outcome
Assignment Brief
Evidence
Assignment Guidance

D1
Evaluate the impact of legislation and standards on the design process in
relation to the profitability of the business
Written Assignment
Using the example of the games controller designed in conjunction with P3
(task 3) the PDS in P5 (task 5) and P7 (task 7), identify and evaluate the
impact of the legislation and standards which apply to the design process
of the games controller, the materials used and the effects in relation to the
profitability of the business.

Task Requirement

Task completed to the

required standard?
YES
NO

Your assignment should include the identification and evaluation of the

following elements as a minimum:
Have the legislations and standards been identified and described?
Has the effect on the design of each of these legislations and standards
been identified and described?
Has the legislations and standards and how they apply to each of the game
controllers materials and components been identified and described?
Has the legislations and standards and how they impact the profitability of
the business in terms of profit and added cost been identified and
described?
Has the legislations and standards and how they safeguard the profitability
of the business in terms been identified and described?
Assessor Feedback:

Achieved?
YES/NO

Unit 8 BTEC Level 3 - Eng. Design

Page 22

Task(s)

12

Assignment Deadline
Outcome
Assignment Brief
Evidence

Assignment Guidance

D2
Evaluate a final design solution against customer requirements and a PDS,
and suggest improvements
Written Assignment
Students will be paired up to assess how the games controller design of
the other student meets the PDS. Produce a written report evaluating the
design of another students game console and controller against the PDS.
The report should be objective and consider good and bad areas of the
design including choice of materials and colours. The report should make
recommendations for improvements where appropriate. The report needs
to be objective and honest.

Task Requirement

Task completed to the

required standard?
YES
NO

Your assignment should include the evaluation of the following elements as

a minimum:
Has the assessment form on the next page been completed in full?
Does the assignment consider how the evaluated design meets, or does
not meet, each area of assessment?
Is the assignment objective and honest?
Does the assignment make recommendations for improvements?
Does the assignment have a conclusion?

Assessor Feedback:

Achieved?
YES/NO

Unit 8 BTEC Level 3 - Eng. Design

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Product Design Specification (PDS) Assessment for Gaming Controller

Designer:-

Assessor:Very
Poor

Poor

Satisfactory

Good

Excellent

The handset will be used for many hours and

must be durable in design

The handset will be designed using ergonomic

principles to ensure that it is comfortable to use

The handsets will be wireless

The handset will incorporate 2 gaming joysticks

The handset will incorporate 8 gaming buttons

Each button on the hand controller will be

identified by a symbol or alpha-numeric character
which will be logical to understand

The handset will incorporate an LED battery life

indicator

The handset will contain 2 x 1.5V AA

rechargeable batteries which should be
accessible for changing/upgrading if necessary

The hand controller will house the PCB with at

least 5mm above the surface of the board and the
board will be of approx. 3000mm 10%

The hand controller will of a minimum weight and

be as light as it is practically possible to make it

Both the base unit and the hand controller will be

designed to look aesthetically pleasing in a
domestic environment, in both colour and style

The colour of the hand controller and the base

unit are to be determined by the designer

Key features and functions of Game Controller

SCORE:

Column total:
Overall score:

Signed (Assessor):

Unit 8 BTEC Level 3 - Eng. Design

Signed (Verifier):

Page 24