Course on

Design & Engineering

(BE 102)
A Presentation

Introduction to the Course

&
General Observations

Introduction
This course is a generic one, meant for all
branches of engineering.
It has been introduced to allow the students to
understand and appreciate the creative aspects of
engineering, before getting deeper into their areas
of specialization.*Module1- Creative Designs.pptx
This course is formulated to excite the student
about design and engineering which are the
ultimate objectives in any engineering profession.

Introduction
To make this course a success, it should be offered
in an interactive way whereby students
participation enriches the delivery.
Teachers have to bring in excellent examples to
augment the course delivery.
Students are to be excited about the course from
day one by allowing them to be a part of the course.
The course outcome given in the syllabus is to be
met so that the students are confident about what
they can achieve from the course.

General
This presentation is formulated to give the
teacher an overview of the course as well as on
its delivery.
It gives the course coverage as per the course
plan, in that sequence.
Modules and sub modules are taken up and the
topics are dealt in detail.
At every stage it is important to have good
examples to substantiate the topics covered.

General
Contents of lectures and some examples of
Designs that could be associated with the modules
are mentioned in this presentation.
Teacher has to make efforts to identify other
common and interesting examples to supplement
the lectures. Such examples are to be discussed
and not lectured.
Evaluation of the this course is planned through
Open Book examinations- internals as well as the
semester examination. The weightage for this
course is now 2/3rd internal and 1/3rd Semester.
(100 and 50 marks)

General
This course is an interesting and engaging one if
done with enthusiasm. So make the introduction to
this course interesting and inspiring !
Throw up some challenging problems that make
the students think.
Let them form groups and design. Allow students
to formulate their own projects.
Organize design competitions, set innovative
questions and value the answers carefully. *
Module1- Why such designs.pptx

Module 1 a
Number of Lectures- 2
Practice - 2

Contents
Introduction
Design and its Objectives
Design Constraints and Design Functions
Role of Science, Engineering & Technology in design.
Engineering A Business Proposition
Design - Form, Function and Strength
Functional and Strength Designs
Introduction to Designs- Why such a design?
Give a simple design problem and discuss designs.

Introduction
Design The starting point in Engineering
Why do we design? To meet a need / find a
solution.
What are some of the common individual needs?
What are the organizational needs?
What are the national needs?
What are the universal needs? * Module1- Intro.pptx

Introduction
Which came first? Science, Engineering or
Technology?
Today most of the advances in E &T come from
advances in science.
This evolution happens often in parallel.
Technology at times prompts engineering and in
turn prompts science to give the clue.

Introduction
Science gives the clue, Engineering Plans(designs)
and Technology delivers.
Technology transforms these solutions into realities
like products, processes, systems that can be
implemented.
While science is basically a knowledge driven
entity, engineering and technology are often seen
as business entities. Reason?
As E&T encompasses many areas, it was natural to
have different thrust areas in the field.

Design and its Objectives

In Engineering, every thing is about Design.
But, Design is not every thing about Engineering.
Design is a common terminology used in all
branches of engineering as well as in some
specific areas of sciences (drug design).
Primary aim of engineering is to design and
realize a product, process or a system.

Design and its Objectives

Design Objectives
This is the most important aspect to be
understood before initiating design.
Objectives are often not what the design should
do, but what the design should be.
Objectives are normally expressed verbally.
Example: Portable drilling machine

Design Constraints
Design is not an open field. It has many constraints.
An engineer has to carefully understand these
constraints and work out a design that fits the
situation.
This at times puts a break on creativity. Such
challenges are there in all designs.
One major constraint in engineering, is the
regulatory frame work.
What is this? Solicit examples from students.

Design Constraints
Constraint is a restriction on design, in many fronts.
They could be on some of the features or attributes
of the design.
Many a time these constrains can be considered as
yes or no types.
Examples:
Should a design work at high temperature?
Should the product be portable?
Should it meet the environmental regulations?

Design Constraints
Note that Design objectives and Constraints are
related, but different.
Objectives allows us to have wider choices.
(Wider Design Space)
Constraints limit the choices in design.
(Drill weight not to exceed 1.5kg - Reduced Design
Space)
Can one think of an example - satellites?

Design Functions
This is about the specifics, the design is planned
to do.
The drill should work in high humidity ( in rain)
The drill should switch off if the load exceeds.
Some of the functions can lead to constraints.
( specifying the maximum load)

Design Means
It is about the approaches to make it function as
proposed.
One may look at other drill designs.
At times do some small survey of similar activities.
Do some research to see the workability.
Borrow some features from other designs.

Design Form
Form is the shape of the design.
This has not much to do with the function.
For the same function the shape could be different.
(Automobiles) * Module1- Form.pptx
However, often the design starts with form.
A building design starts with sketches.*
Module- Design sketches.pptx
Functions creep in slowly together with the means.

Science, Engineering and Technology

They are closely related, but are different.*
Module1Intro 2.pptx
Science is about understanding the physical world.
Sciences give us unique solutions.
Engineering gives us choices.
It applies scientific, technological and practical
knowledge in solving the needs of the society to
its satisfaction, creatively and economically. *
Module1- Science-Eng-Tech.pptx

Engineering- A business Proposition

Engineering is not all about designing things.
Engineering is not a curiosity shop to try different
products, processes, technology etc.
Engineering is Business. To succeed it has to pay
back.
There are some exceptions to this - Strategic
products.
Examples of designs- Faded and Sustaining ones*
Module1- Design and Business.pptx

Functional and Strength Designs

Function and Strength are the two important
aspects of any design.
Software designs are always functional.
Designs in electronics are predominantly functional.
However most designs consider these two aspects
often together.
Engineers tend to be more oriented towards
strength designs. *
Module1- Function & Strength.pptx

Desirable qualities of a Design Engineer

Problem solving skills- able to identify and define
the problem to be solved.
Scientific temper and proficiency in STEM
[ Science, Technology, Engineering and
Mathematics]
Technical and Computer skills.
Ethical, moral and professional values.

Desirable qualities of a Design Engineer

Business and managerial acumen.
Excellent communication skills.
Cultural exposure- sensitivity, understanding,
etiquettes and manners.
Self confidence and optimism.
Concern for the environment and safety.

Module 1 b
Number of Lectures- 3
Practice - 2

Contents

Design An introduction
Initiating the Thinking process
Need identification
Problem Statement
Market survey- customer requirements
Design attributes and objectives
Ideation, Brain storming
Solutions and Closing on Design

Design An introduction
Design is the most creative part of engineering or
Technology. *Module1- Creative Designs.pptx
Engineers have a wide spectrum of design
requirements.
Research and development is the focus of all
thriving engineering organizations.
Output from these provide a wider area for creative
design.
In brief , believe it or not, we are a lot more creative
than many.

Design- a definition
One definition of Design is: Design is conceiving and giving form to artifacts
that solve problems or meet the needs
Conceiving in this context means imagining,
visualizing a solution to a problem or need.
Form means shape, physical appearance,
formulation or a procedure.

Design? What is it?

Artifacts standard definition:
An object produced or shaped by human craft, e
specially a tool, weapon, or ornament of archaeo
logical or historical interest.
Artifacts in design could be a product, software,
building, dress, a process, a dam, graphics etc.

Design? What is it?

Based on the final artifacts, Designs have different
domains of existence.
Examples: Architectural Design; Building Design;
Interior Design; Fashion Design; Lighting Design;
Software Design; Product Design; Engineering
Design; Automobile Design; Machine Design; Web
Design; Logo Design- to name a few.

Design? What is it?

While these are diverse designs, they are all
designs. There is a commonality in design across
all domains.
So the term Design, is a common frame work to
achieve solutions and meet the needs.

Initiating the Thinking process

How to initiate creative designs?
In this course we deal mostly with physical objects.
However the same process is applicable to the
design of a business model or the design of a
software.
If one encounters a totally new problem, the
solution ought to be termed as creative !
If one solves the problem differently with an
improvement then also it can be termed as
creative.

Initiating the Thinking process

However today there are many designs
available to us, in all segments of engineering.
So how one can be creative in design?
Look at an existing design and think of a new
way of meeting the requirement. *
Module1- Evolving Design.pptx

Initiating the Thinking process

Start with a creative idea for a new artifact. *
Module1- Roomba.pptx
Look for any inventions that can be harnessed to
develop a new artifact . *Module1- velcro.pptx
For this we have to initiate the thinking process.
What is the thinking process involved in design?

General Design Framework

Need Identification
Design starts with need identification.
Whose need? User , Client or Customer;
Aircraft- Designer Boeing or Airbus
Client- Air India or IndiGo
User: Passengers
At times the user, the client and the customer could
be the same or different.
User - The entity that has the need to use the
design.

Designer User and Client

Need Identification
To start with, the Designer has to meet the
needs of the Client as well as the User.
They provide the synergy for a good design.
In addition the Designer should be aware of
professional and social ethics and values.

Need Identification
For any Design to be taken up, there should be
a need gap or a problem that needs a solution.
This gap or need could be identified by the user,
an observer or by an organization.
Is design same as invention?
When you design a new product with a novel
idea it could be an invention. 3M glue! *
Module1- 3M postit.pptx
All inventions require design to realize them.

Need Identification
Often the need or the need gap are only
vaguely identified by the user.
Design requires clearly defined needs. This is
termed as Problem definition and identification
of Design goals.
Problem definition is easier when the user is the
designer.
Otherwise we need market survey and informal
interviews.

Problem Statement
Problem statementStudents need an easy way to take their books
to school.
Now there is the need to define this problem a bit
more in detail.
Who are the students?
What is meant by easy?
Make the problem definition as best as possible.
Identify the Product attributes/functions and
assign weightages.

Problem Statement
Formatting the Objective Tree

Market survey- customer requirements

Identification and Defining the Problem

Market Survey/Research Objectives
Design of the Survey
Samples
Data collection
Data Analysis
Survey outcome

Design Objectives and Attributes

Objectives :- These are the desired deliverables
from the design. They often include design
attributes and operation that the user wants in the
design.
Constraints:- These could be from the product angle
, user angle, regulatory angle, or from the
scientific/technical angle.
Functions:- are entities a design is supposed to do.
Requirements:- are specifications (functional or non
functional) that are specified by the user/ standards.

Design Attributes
Designs have both soft and hard objectives.
Presently many products rule the markets based
on their soft attributes like novel design, styling
and the image they bring to the user.
Aesthetics
Feel, Form
Texture, Colour

Perception
Style
Cheap
Contemporary
Delicate

Module 2 a
Number of Lectures- 2
Practice - 2

Design Process

Introduction to Design
Initiating Design
Structured Design Process
Defining the Design Space
Analogies
Thinking outside the box
Quality Function Deployment
Design Evaluation
Choosing a Design

Introduction to Design
Steps towards design.
Clarity on the problem, searching for concepts
or ideas for a solution, finalizing the concept
and proceeding with the design.

Introduction to Design
What is a good design?
Design being the result of substantial cognitive
effort requires multiple iterations and the
outcome is not always perfect or optimal.
Quality of the design is based on how the artifact
meets the user demands.
This primarily depends on how best the steps
towards design have been taken.

Introduction to Design
Is there a difference between Design and Problem
solving?
This is not easily understood as both of them follow
the same process to achieve the objective.
Design process results in a plan of action.
Realization of the design only will solve the problem.
For this the design is to be engineered (produced).
By designing one cannot solve the problem.
Engineered design only solves the problem.

Introduction to Design
Functional Design
Here the function of the product is important and
the strength considerations are secondary.
E.g. Watch, Ball point pen, an amplifier, a software.
Strength Design
Here forces acting and environmental factors are
critical to the design, in addition to the function.
E.g. Automobile, Dam, Crane, Ship, Rocket.
In many designs, both are of importance.

Introduction to Design
Taxonomy or classification of Problems (need gaps)
There are two main classifications and under each a
sub classification:
1. Design Problems :- New artifact
By Structured Design Process
By Design Selection (Selection from known alternatives)
2. Design Improvement Problems
By Tuning of subsystems:- changing the variables,
experimentation.

Introduction to Design
Two other types of problems are:
Crisis Problems Fokushima disaster
Key strengths-Experience and Resources

Eternal Problems- Territory disputes, Wars,

( conflicting goals of stakeholders)
Key strengths-Special skills, specialization, practice,
patience.

Introduction - Initiating Design

Design is a cognitive process requiring
knowledge in many areas.
Such a background allows to think of ways of
meeting the design goals.
For this the staring point is to have as many
ideas as possible for the problem to be solved.

Introduction - Initiating Design

Ideas are available from different sources as
well as from different people.
To extract this we resort to brain storming.
Such a systematic procedure allows to close
on to a workable design.

Structured Design Process

Most of the design problems we undertake as
professionals do require a structured process of
design.
The advantage of this may not be seen first but in
the long run it shows its advantages.
An elegant design is the ultimate goal of a
designer. It is a design that is original, appealing,
cost effective, user friendly, safe and green.
Example: Bifocal spectacles *
Module1- Bi-focal glasses.pptx

Structured Design Process

Design process has many stages
1.
Product or Problem identification
2.
Problem Definition
3.
Design goals and functions
4.
Gather sufficient data or
get new knowledge through
research
5.
Brainstorming and ideation
6.
Evaluation of potential solutions
7.
Conceptual design
8.
Design Detailing

Structured Design Process

8. Standardization needs

9. Prototyping
10. Testing
11. Design Modifications
12. Freezing the design
13. Cost analysis
14. Realization/Manufacturing
15. Quality Assurance
16. Feed back analysis for design improvement.

Product / Problem Identification

Here the need gap is the focus.
This is often spelt out in a vague and general
fashion - Need something to lift a very heavy
box.
In certain cases instead of problem identification
one can focus on product identification.
- Need a container for 25 l of mineral water.
One cannot proceed much with such vague
problem identification.
Clear problem definition is critical to design.

Problem Definition
Clarity on the problem can be obtained by
questioning.
Problem: Transportation of 30l of mineral water.
Vague definition:- A container is to be designed.
Why a container is required?
Where is it be used?
How much weight is to be transported?

Problem Definition
Is the water in one or more bottles?
What is the size limitation for the container?
Is container lifted, pushed, turned? If so how?
Are the containers transported in a truck?
Has the truck any provisions for this? *
Module1- Defining the problem.pptx

Problem Definition
What?, Why?, When?, Who?, Where? are the
questions to be clarified at every stage of the
design process.
From the answers to these, one can define the
problem with more clarity.
This is essential for proceeding with the design.
Otherwise, at later stages, one may encounter
design gaps.

Design Functions
They are the things that a designed
device(system) is supposed to do.
Examples lift a load, turn a lever, deliver a
voltage etc,.
Functions are classified as Basic and Secondary.
Basic function is the main objective of the
design.*Module1- Design functions.pptx

Design Functions
To have that, there has to be many secondary
functions.
While doing the function the design may produce
unwanted secondary functions. (heat, noise,
smell)
Discuss the design function, secondary functions
and unwanted functions produced by a product.*
Module1- Design functions.pptx

Design Functions
Functional Analysis:Like functions in mathematics, it is the
transformer of inputs to out puts.

Example: Electric Drilling machine

Inputs: Energy, Clamping force, Control
Output: Rotating Drill , Heat, Noise, Vibration.

Design Functions
Functional Analysis:To focus on the design one has to further
understand the functions based on the input to
achieve the output.
In the case of the drill, Power is an input. One
function will be to get the power connection using
wires.
Conversion of electrical power into mechanical
power- another function
Control- Control by a switch
Force To hold the drill bit by a suitable method.

Design Functions
Known functional designs- Electric motor
Listing all sub functions for achieving the final
function.
Speed changes for the drill- gears, shifting gears.
Function Means Trees
This is a simple graphical representation of a
designs basic and secondary functions and the
ways of achieving them.

Design Functions
Function Means Trees

Specifying Functions
Functional needs are to be well defined for
achieving the design objectives.
For this we have to specify the functions.
In engineering this is termed as Specifications.
These could be in any of the following ways.
Specify the values Drilling machine- Wattage.
Specify the procedures As per IS -21X
Specify performance level Should drill concrete.

Defining the Design Space

This is an imaginary space for design alternatives for
a problem. Simply this means the vastness of the
possibilities.
Now that the design requirements have been clearly
spelt out, all the design options available should be
explored.
A large design space means there are many design
options available.
Totally new designs may have small design space.
Buildings for example have a large design space.
Give an example of a product with limited design
space.

Defining the Design Space

Design space is generated by the functions and
means discussed earlier.
By having a table incorporating these two one can
assess the design space.
A chart can be made that can show the different
possibilities for a design.*

Defining the Design Space

To generate a good design, we need divergent ideas
and later converge on the ideas.
Generating ideas is an intellectual exercise.
Thinking without constraints, allows to bring in a lot
of ideas (workable or not) - Brain storming.
Sitting around a table and writing ideas in brief and
then circulating them among the members for their
short written comments and further exploring based
on the comments can provide different ways of
looking at the solution.
( One can also use black boards, or slips of paper )

Defining the Design Space

Brain Storming:No criticism or evaluation of ideas
Uninhibited approach to thinking
Bring in ideas fast and spontaneous
Here at the initial stage, Quantity is desired over
quality
Combine or modify ideas
Build upon another s ideas
Bring in the solutions to similar problems
AT THE END CRITICIZE, EVALUATE AND RANK
THE OPTIONS.

Defining the Design Space

For a totally new product the design space is limited.
If the design space is small, to get workable solutions
one has to do through study of many other systems or
products that are similar and look for ideas.
At times innovative ideas are to be experimented and
decided upon.
Designs in advanced areas often need research
inputs.
In brief the Design Space allows us to explore the
possibilities and evaluate their suitability for a good
design.

Analogies in Design
Design by Analogy:
Analogy is the process of connecting two
seemingly different domains that share something
in common.
Make use of existing examples to initiate ideas to
solve a new problem.
Creative people use analogical reasoning to arrive
at solutions.

Analogies in Design
This involves relating the existing problem to some
segments of solved problems.
This gives possible solutions from existing
solutions.
Certain plant seeds (Arctium plants) have clinging
properties as an excellent mechanism for seed
propagation. From this came the invention of
Velcro.
A GOOD DESIGNER HAS TO BE KEEN
OBSERVER.

Analogies in Design

Analogies in Design
Wind Turbines generating electricity need to be
quiet as people who live near demand quiet
operation.
Owls are famously silent predators, able to surprise
their prey thanks to sound dampening wings.
Blade design can be analogues to the wings of
owls.
Such analogies from nature are also termed as
biomimentics.

Thinking outside the box

We are all in a box. We are surrounded by things
that are well known to us. We see how people
behave, how they react, what they say, what they
use, how they use and so on.
Such a surrounding envelopes us.
WE ARE IN A BOX !
If you want to be different ( creative) then
thinking and doing differently is the only option.
So think outside the box.

Thinking outside the box

To be creative, step out of the box, change your
mindsets and attitudes, leave all your experiences
behind and start to look at things from different
perspectives.
Think of crazy ideas that are non workable at the
first thought.
Bring in negative approaches to look at the
situation.

Thinking outside the box

Be uninhibited and unbiased and open for
suggestions.
Go against the tide- question the popular
approaches.
Every cloud has a silver lining.
Why not it be Every silver lining has a cloud
behind it.

Quality Function Deployment [QFD]

Engineers and scientists are comfortable with units
and quantities for all specifications.
But the consumers of their products are ordinary
individuals who can express their needs only in
simple terms.
I need a silent air conditioner that is good
This is the specification for the product by the user.
Now how to convert this into engineering
specifications that are quantified.

Quality Function Deployment [QFD]

This is achieved through the House of Quality
[HOQ] There are excellent examples of how to
workout HOQ

http://www.webducate.net/qfd/qfd.html

Quality Function Deployment [QFD]

Evaluation and choosing a design

Design Evaluation:

Evaluation and choosing a design

Design Strengths:
What are the ideas advantages?
What can the idea be successful in?
What are the current existing idea resources?
How others may see the strength of the idea?

Evaluation and choosing a design

Design Weaknesses:
How can the idea can be improved?
What does the idea lack in term of
experience, team and resources?
What can prevent the idea from success?
How do others see the idea in terms of
weaknesses?

Evaluation and choosing a design

Design Opportunities:
What opportunities does the idea have in the
market?
How the company can help the idea to
succeed?

Evaluation and choosing a design

Design Threats:
What are the obstacles that face the idea?
Do the idea weakness represent any threat to its
success?
What are the financial needs that may face the
idea?
It is also possible to quantify these to compare
designs
Always remember that no design is final.
Designs are always evolving.

Module 2 b
Number of Lectures- 3
Practice - 4

Contents

Communication in Design
Concept to Configuration
Sketching, Drawing, Modelling
Concept of Complex is Simple
Design for Function and Strength
Material Selection

Contents

Design visualization Solid Modeling

Detailing- 2D drawings
Tolerancing
Standard item in Design
Research needs in Design
Energy needs

Communication in Design
Design is a cognitive process.
However it needs inputs and outputs that are oral,
written or sketched out.
For this communication skills are to be honed in all
the three.
While the oral and the written segments give
critical inputs to design, drawings are the medium
for design outputs.
What cannot be expressed orally or in writing can
be well communicated through drawings.

Communication in Design
Hence the significance of sketching and
drawing in design.
Design emerges through sketches which in
turn changes to free hand drawings and later
to Computer Aided Design and Drafting
(CAD).
CAD system with freeform software can do
clay modeling.
Designs need additional details for its
realization or manufacturing.

Communication in Design
CAD systems available are capable of
providing all these to the designer.
Visualization of the design through solid
modeling is providing a new angle to design.
This was not possible earlier and today this is
often the starting point of a conceived design.

Communication in Design
Though the Solid model gives a better
comprehension of the object than 2D views, 2D
drawings are essential to provide details on the
design as well as for the part manufacture.
In certain domains of design, instead of sketches
pictorial representations could be used.
Examples: Circuit diagrams; Flow charts; Block
diagrams.

Communication in Design
So seeing is believing!
Was die Augen sehen, glaubt das Herz;
Die Ohren glaubt was anderan sagt
(Eyes believe what they see, the ears believe what
others say)

Communication in Design
Communications of all types play a major role in
engineering design.
User manual, Safety standards, Assembly and
packaging instructions, and of course in marketing.
Communications could change the mind set of
people.
Instead of stating that i Phone is Made by Apple it
is written as Designed by Apple.
At different stages of design, designers have to
convince other team members about their ideas
clearly- both orally and in writing.

Concept to Configuration
The strength of a designer lies in the ability to
transform the design concept to a workable
configuration.
The complexity of the product poses major
challenges.
The only consolation is that all designs are
evolving and one can have a reference of an
older version for a new one.

Concept to Configuration
This is the reason why new designs are only
staring points. *
Module1- Changing design with Experience.pptx
Complex designs needs sub system designs.
Designs are configured out of such subsystem.
Discuss an example for this- A bicycle.

Sketching, Drawing, Modeling

A good designer initially starts off with sketches.
With experience on can directly do this 3D CAD.
Sketching give the designer ample of opportunity
to transform the design concept as a visible soft
design.
Many CAD systems now allow this to be done
directly.

Sketching, Drawing, Modeling

While the soft designs can be visualized in 3D as
well at different view angles, there is still the need
for a physical model as the perception on the
screen is not real enough.
Now virtual reality (VR) do assist us to a certain
extend. (designing the work space)
Full scale physical models are attempted in certain
products to realistically evaluate the design for its
finer aspects like colour, shape, finish etc.

Complex is Simple
Many engineering designs are complex in nature.
They have large number of sub assemblies and in
turn a very large number of parts.
Final product realization is through assembly.
Assembly is still manual. Manual assemblies take
time and cost escalation.
Designs should reduce the number of assemblies
to reduce the time.
Here comes the concept of Complex is Simple *
Module1- Simple is Complex.pptx

Module 3 a
Number of Lectures- 2
Practice - 2

Contents
Prototyping
Rapid Prototyping (3D Printing, Additive
Manufacturing)
Product Testing and Performance Evaluation
Design Modifications
Freezing the Design
Cost analysis

Prototyping
Prototype is the first fully functional model of a
design.
This is not a model but a full fledged product made
as per the design.
However models are used in certain designs to
understand the specific performance of that part or
product. (Aircraft, buildings, ships, rockets etc.)
At times prototyping is done for some parts of a
design to check certain requirements.
These include assembly, clamping,

Prototyping
Prototyping is done using the materials
specified so that their performance is also taken
into account.
Conventionally few prototypes are made for a
planned evaluation of the product from various
angles.
Producing a prototype is a costly procedure as
the requirements are limited.
Regular prototyping is done by making the
design through conventional approaches.

Prototyping
Time taken for this could be at times few weeks.
This delays the freezing of the design.
Currently 3D printing technologies have shown
their worth in this. Most of the parts could be
produced by this process and each may take
only a few hours to produce.
3D printing was earlier known as Rapid
Prototyping as they were ideally suited for this.
Currently RP or AM technologies allow metals to
be used in the process.

Testing and Evaluation

Before the product is introduced it is to be
tested fully for all the designed function.
Other requirements that are taken into account
in the design are to be evaluated (safety,
environmental issues, etc)
In novel design the Proof of concept tests are to
be done to ascertain the workability of the
design.
Such studies are done using DoE procedures.

Freezing the Design

Any set backs seen in the design is used to
improve the design. These modified designs are
again tested till satisfactory results are seen.
Then the design is frozen for and it is handed
over for production.
Frozen design are improved further, based on
customer feed back.
So design are never frozen, but are always
evolving

Module 3 b
Number of Lectures- 3
Practice - 2

Contents

Engineering the Design- Prototype to Product

The many Ms
Supply Chains
Planning
Scheduling
Handling
Manufacturing/Construction/ Realization
Storage, Packaging, Shipping, Marketing,
Design feed back
Role of Standards in Design

Engineering the Design

For the design to be realized it has to be
engineered.
Design changes may be required to engineer the
design economically.
Prototype gets changed to manufacturing designs.
Here comes the significance of value engineering,
group technology, standard parts, modularity,
interchangability,
Decision on materials, manufacturing approaches,
assembly techniques are finalised at this stage.

Engineering the Design

Cost of design is relatively low for a product.
However design is significantly responsible for
the cost of its realization.
A good design always brings down the cost.
Hence a good design should focus on cost
aspects of the product beyond its function and
strength.
This should be taken care of during every
phase of design.

Engineering the Design

Cost of designed product is an important factor.
Cost estimates are to be worked out at every stage
and suitable changes made to contain the cost.
Apart from materials, tooling, manpower, energy
requirements and overheads are to be taken into
account.
Production costs can be further reduced by
adopting the best practices used in industries.
Quality is to be ensured to achieve product Value.

Engineering the Design

There are many M s in manufacturing a product.
Cost of these affect the product cost.
Time is money. Any material waiting for conversion
as value added item is a waste. Wasting means
loosing time and money.
Trimming waste and quick conversion of raw
materials into products brings down the cost.

Engineering the Design

Role of standard items in a design is important in
reducing the cost as well as in its life time
management.
What is a standard? Who formulates it?
What are the advantages of standard items?
For students:Name few standards; Get the details of one
specific standard and explain its relevance and
details.

Module 4
Number of Lectures- 4
Practice - 4

Design for X
There are many other factors to be considered
in the design to make it competitive in the
market.
These needs are grouped under Design for X
Here X stand for specific design objectives
other than those discussed earlier.

Design for X
Design for Manufacturing/Construction
Design for Assembly/Fitting
Design for Safety and Reliability
Design for Maintenance & Serviceability
Design for Logistics
Design for Disassembly and Recycling

Design for XDesign for Manufacturing/Construction

Main objective is to make the cost of realization of
the product low.
Reduction in parts and their costs.*
Module1- Part reduction.pptx
Use of standard parts/subcontracted items.
Design using Group Technology.
Change in materials if possible.*Module1- TiN
Coating.pptx
Use wider tolerances wherever possible.

Design for XDesign for Assembly (DFA)

Assembly is often the costly part in manufacture.
Assembly automation to reduce the time and cost
is not easy.
Manual assembly is very costly.
However by designing the product suitably many
assembly operations can be automated.
Vertical assembly is good for ease of assembly.*
Reduction in screws and quick location of parts
make the assembly quick.*Module1- DFA 2.pptx

Design for XDesign for Assembly (DFA)

Minimize number of parts
Provide self locating features on parts
Design parts with self-clamping features
Avoid reorientation of parts during assembly
Use Top down approach for assemblies
Use standard parts in the design
Think of modular design

Design for XDesign for Safety and Reliability

Product safety is to be ensured in design.
This covers the materials used, design aspects
on safety in operation, fool proofing, warning
systems etc.
What safety system is needed in a rocket ?
What safety systems are needed in an
automobile and in an airplane?
Discuss this with reference to any common
product.

Design for XDesign for Safety and Reliability

Reliability is the probability that a product will
perform its function under normal use for a
specific period (product life span).
Normally for simple understanding reliability can
be specified as Mean Time Between Failures
(MTBF).
In order to improve the reliability redundant
systems are used in specific designs.

Design for XDesign for Maintenance & Serviceability

Product maintenance is an important aspect to
be taken during design.
Products should be simple and easy to maintain.
Part replacement requirements, spare part
needs, spare part availability.
Easy Access for part replacement.
Part interchangeability between models
Self diagnosis (Laser Printer).

Design for XDesign for Logistics

Design for packaging, handling, transportation
and storage.
Design for seamless transportation.*
Optimal packaging to save space and damage.
Provision for product handling with safety.

Design for XDesign Disassembly & Recycling

Design for easy disassembly.

No welded joints
No dissimilar materials joined together.
Common materials as far as possible
Easy segregation of parts of the same material.
Automated disassembly
Easy cleaning and compaction requirements.
Handling of dangerous materials.

Design for XDesign using Group Technology.

In Group Technology Parts are grouped based
on their similarity in design attributes and
manufacturing.*
Module1- Group Technology.pptx
Such parts form a family or a group.*
By grouping similar parts a single manufacturing
solution can be used.
This reduces the cost.

Module 5 a
Number of Lectures- 2
Practice - 3

Product centered and User Centered

Design
Product Centered Design
Function, Strength, Handling, Transport etc.
User Centered Design
Aesthetics, Style, Elegance
Ergonomics
User Friendliness
Safety, Reliability

Aesthetics
Aesthetics is the human perception of beauty,
including sight, sound, smell, touch, taste, and
movement not just visual appeal.
Aesthetics is the aspect of design and
technology which most closely relates to art
and design, and issues of colour, shape,
texture, contrast, form, balance, cultural
references and emotional response are
common to both areas.

Product Styling and Elegance

Here the form is the focus in the design.
The same function can be met through different
forms
Some countries are well known for stylish designs.
It has more to do with art than engineering.
Product of personal use need styling and
elegance.
Automobiles, Watches, Mobiles, etc.
Industrial designers do styling design.

Product Styling and Elegance

Elegance is not about styling.
It is about the ability of the design to stand out
among its competitors.
While styling counts, many subtle features of
the design contributes to its elegance.

Style and Elegance

Ergonomics
Some times named - Human factors
engineering.
This area is concerned with human well being
while using the design.
Examples are many in this area.
Driving cars, Using Laptops, Operating
Machines etc.

Ergonomic Design

User Friendliness
Is this user friendly?

Module 5 b
Number of Lectures- 4
Practice - 3

Contents

Value Engineering
Concurrent Engineering
Reverse Engineering
Culture based Design
Architectural Designs
Motifs
Design and Tradition

Value Engineering
Value Engineering is the study of functions to
satisfy the user needs of a quality product at
low life cycle cost through well planned
design with creativity.

Value Engineering
Value Equation: V= P/C
V- Value
P- Performance
C Cost)

Value Engineering
Poor Value results from:Poor collaboration within the design group
Badly conceived design objectives
Wrong assumptions based on poor
information
Fixation with previous design concepts
Failure to assess the challenge in design

Value Engineering
Aims at Value addition in design
Value can be enhanced through better performance
and cost reduction.
Adding features that enhances the value of the
product with marginal increase in cost.
Examples:- Reduction of parts during design,
introduction of simple design modifications that
could assist in manufacture or assembly. Choosing
materials that can replace costly ones and improve
the performance.

Value Engineering

Value Engineering
What the product is supposed to do?
What else can it do?
What else is needed to enhance the value?
Will these secondary functions add value ?
What are the value added feature you notice in
a stapler?
Can one think of any additional functions that
can add value to it?

Value Engineering

Think of value addition to the following:Laser printer

A Ladder
A Jacket for winter

Concurrent Engineering

Concurrent or simultaneous engineering.

Serial operations are done in parallel.
This is possible using IT .
Saves cost and time.
This has a lot of relevance to Design
IT has allowed this to happen as the evolving
designs are seen by all concerned.

Reverse Engineering
A nice modern term for copying a design.
How to reverse engineer?
Manual
Computer Assisted
One can digitize any product and create its
CAD model.
This model can now be easily modified to
create new designs of the same product

Reverse Engineering
An existing product can be redesigned
through reverse engineering.*
Module1- Fringe Projection.pptx
Products are digitized and designs are
revealed. The design can be modified using
the digital data.
Good for making spare parts that are not
available. Modify an existing design.

Culture based Design

Architecture
Home grown products
Artistic background of the population
Bright and mellow colors in design
Motifs
Traditional designs

Architecture
Architectural design are excellent examples of
culture based designs
These design have evolved over years and
they are often long standing products.
Design modifications based on the cultural
backgrounds are often seen in many products.
It is true that art and culture has a say in
design.*Module1- Architectural Design.pptx

Design and Tradition

Home grown products

Design and Tradition

Artistic Background

Design and Tradition

Bright and Mellow colors

Design and Tradition

Motifs
Motifs are repeated features forming a
pattern.
Mostly used for decorative items, clothing
and in murals.
Product designs based on motifs are also
there.
They include ornaments, watches, furniture,
toys etc.

Module 6
Number of Lectures- 3
Practice - 6

Contents

Modular Design
Design Optimization
Product Design trends
Intelligent and Autonomous Products
User Interfaces
Communication between products
Internet of Things
Advanced Products and Human psychology
Design as a Marketing Tool
Intellectual Property
Product Liability

Modular Design
The product is realized in different variations at
the assembly end using modular concepts.
Modules can be bought and assembled.
Many design can be based on well conceived
Modules.
These modules could be:
Independent parts (often standard items)
Modular subsystems ( fuel injection)
Modular Assemblies
Modular design reduces, cost, inventory, time,
spares. (Ask for examples)

Design Optimization
Optimization should have only a single
objective to be dealt with.
Multi objective optimization approaches are
basically trying to cover more than one
important factors.
These could be quality, cost, time, weight etc.
Analytical tools are used for such
optimization.

New Designs
Intelligent Products Current products are
mostly user interactive. E.g. Mobile phones,
computers, robots.
This came about by integrating IT with the
design of new products.
Roomba Robot an intelligent robot for
cleaning.

Intelligent Product Designs

Intelligent products are the ones that are
capable of dynamic interaction from a user
angle.
In addition to meaningful interaction, they can
store and process user-specific information
which can be used to enhance user
performance and the quality of interaction.
IT and Information based control strategy
gave the main thrust in this direction.

Evolution of an Intelligent Product

In the forties and fifties, many lathes were connected
to a single motor drive through belt drives.

Evolution of an Intelligent Product

By early sixties designs were changed and a motor for
each lathe became the norm and all drives and controls
were coupled to this single motor drive unit through belts,
gears, clutches, screws etc.

CNC Machine

An Elegant CNC Machine

Evolution of an Intelligent Product

Soon with cheap microprocessors, Numerical
Control became economically viable . This lead to
CNC with individual drives for every activity
associated with the machine.
Application of IT allowed different functions of the
product to be decoupled from a single drive
source resulting in distributed control strategy.
This concept is now extended to many products
like cameras, printers, medical equipment etc.

Autonomous and Intelligent Products

Autonomous productsCan manage well without constant user
interaction- a robot
Intelligent ProductsInteract intelligently with the user.
An intelligent product could recognize who
the user is and be aware of user preferences.
Soon it may even exceed these limits.

Autonomous and Intelligent Products

Intelligent ProductsEstablishing and building a sense of trust
between the product and user is central to
the design of systems that can help the user
perform a task in a collaborative manner.
This is important to keep the user in control
while delegating tasks to the system.
To make a system subservient to the user
and at the same time interact intelligently is a
tough task.

Intelligent Products
The system should be able to monitor the
user's behavior, learn, and make suggestions
towards creating a more satisfying user
experience.
Examples of such a products is the car
navigation systems.
In this context, the physical product design,
interaction style and embedded intelligence
form a composite user experience.

Deceptive Designs
These designs trick you into thinking the
product has something it doesnt.
Its a smart way to design products (from a
business perspective) as it will make your
products seem better than they actually are,
all done artificially through appearance rather
than function

Deceptive Designs
Gone are the metallic edges around the sides
of the note book screen.
Mobiles have black full screens.
Forms are shaped to achieve the desired
objective without doing the job.

Deceptive Designs

Deceptive Designs

Internet of things
Products of the future
Able to interact between themselves as well
as with the user.
Can cover industrial machines , house hold
gadgets, Surgical equipments, Kitchen
equipment etc.

Design as a Marketing tool

We are familiar with Made in ----- for many
products.
Now we do not make products in one location
or in one country.
So the emphasis is slowly shifting to
Designed in (by) ---
Design has emerged as a marketing
proposition

IPR- Intellectual Property Rights

Design is a cognitive process and needs
protection from copying.
Hence IPR are critical to their survival.
Patents, Copy rights, Trade marks and Trade
secrets are used for this objective.

IPR- Intellectual Property Rights

Patent is the rights granted to an inventor by
the state for a specified period of time. Patent
enables the inventor to safe guard against quick
duplication of the design / product.
To get the patent an application giving sufficient
details of the invention is to be filed and got
approved.
Patent infringements are offences and are dealt
by the patent laws of the country.

IPR- Intellectual Property Rights

Copy Right: Exclusive rights given to the original
work which is creative, intellectual, or artistic forms,
or "works.
Trade mark: A recognizable sign, design or
expression which distinguishes products or services
of a particular trader from similar product or
services of other traders.
A Trade Secret: A formula, practice , process,
design Instrument , pattern , or compilation of
information which is generally not known or
reasonably ascertainable, by which a business can
obtain economic advantage over competitors or
customers.

Product Liability
Product liability is the area of law in which
manufacturers, distributors, suppliers, retailers, and
others who make products available to the public
are held responsible for the injuries those products
cause.
Types of Liability:
Design defect,
Manufacturing defect,
Failure to warn (also known as marketing defects).

Design Assignments
Here are a set of design needs:Bring out creative designs to meet the need.*
Module1- Design Assignments.pptx
Automatic switching of street lights.
Simple noise level recording in specific city areas.

Student interaction
At every stage of this course students are to be given
simple cases to be solved through proper design.
How to identify the need for a new design?
Can one improve the existing design?
If so how?
How standardization works?
Check on the standards available in different areas.
Give examples and encourage thinking on this.
Give a product and ask to study the design from all
angles.