Product Design

DEZG541/MMZG541

BITS Pilani Subramaniam J

Pilani|Dubai|Goa|Hyderabad
Highlights of last lecture

• Conceptual Design
• Generating Concepts – Basic Methods (Part II)

2
Roadmap

• Modelling of Product Metrics

• Design for Manufacturing and Assembly
• Design for Environment
• Physical Prototypes and Models Experimentation

3
Why Performance Specs are important?

• Developing product models help to understand how a product would

perform under all circumstances and operating conditions
• Can be a Physical, Analytical or Mathematical Model
• Facilitates embodiment decisions by understanding the impact on
performance

4
Model Preparation and Selection Method

• Map or relate the customer need weights to the product function

• Identify the functions that strongly relate to the customer’s needs
• Choose the metrics which may be used to quantify the material, energy or
sign flows for these functions
• Identify target values by using any benchmarking technique

5
Product Application: Model Preparation and Selection

• Idea is to clarify and hon a product concept to apply the engineering

principles
• Systematically select a metric and modelling approach to instill the
confidence on the team
• Static Vs Quasi Static Vs Dynamic
• Analytical Vs Numerical
• All the models start with customer needs

6
Mathematical Modelling Vs Physical Prototyping

Analytical Physical
Simulations Hardware
"Virtual" Prototyping Material and Physical property corelation
Computer Animations Experimental Setups
Optimizations Fully Functional Mock-ups

7
Focused Vs Comprehensive

Focused Comprehensive
Testing Limited Performance Full-Scale, fully functional
Just representative to Answer the question As representative as possible
As Cheap as possible As true to the real product

8
How detailed should be a model?

• Completely a project management decision

• Simple Vs Complex comparison is made first, then in conjunction with the
level of detail required, and the cost associated with it
• Resources (Time & Money) to be leveraged – Always synonymous with the
success or failure of the outcome
• Clarity of information – More detailed doesn’t mean better results
• Scope of experimentation – Revision and alteration for betterment doesn’t
always yield better results
• Customer Expectations – Baseline would be what the customer wants

9
How detailed should be a model?

10
What is a Product Model?

• Always an Abstract – Based on approximations and calculations

• Informal Models
• Designers interpretation of the customer needs, engineering
requirements and all the associated aspects along with the conceived
solution.
• Formal Models
• Computable model design problem, more realistic to the actual result.
There would be a provision for choosing amongst the alternatives. This
would comprise of the object set and the property set

11
Product Metrics - Conceptual

• Design Space (D) – Set of considered possible alternative Configurations,

defined using the design variables
• Performance Space/Performance Metric (P) – Evaluated performance at
each point of design Space
• Noise Space (N) – A set of possible configurations described using Noise
Variables, used to evaluate any point of performance space

12
Model Completeness

• Performance Metric
• One to one correspondence between the metric and the objective
• Target value association with the objective
• Measurable
• Design Space
• Accurate reflection of the concept
• True to the interpretation
• Distinguishable with the configurable options
• Noise Space
• One to one correspondence with the environmental disturbances
• Comprehensive to the intensity
• Measurable

13
Basic Modelling Approach

• Identify a flow for the informal effect/Customer Need

• Identify the balance relationship for the flow
• Identify the boundary for the balance relationship
• Formulate an equation for the balance relationship
• Use the resulting model to explore design configuration options

14
Advanced Modelling Approach

• Identify the Customer Need

• Identify a flow
• Identify the Physical Mechanisms
• Target the precisions
• Construct the Boundary and Balance relationship
• Apply similitude/Dimensional Analysis
• Embody the model computationally
• Interrogate the model
• Display and use the model

15
Advanced Modelling Approach

16
Design for Manufacture and Assembly

• Design for Manufacture & Assembly is the most effective methodology to

reduce product cost.
• The basic techniques to improve a design are mostly a collection of
common sense rules
• One can determine the most effective approach for design through stacked
up cost analysis
• Modularize to minimize the part count, design for top-down insertion with
alignment features
• Think thoroughly and simplify the fabrication difficulty of each feature on
every part

17
Basic Methods – DFA Guidelines

18
DFA Guidelines (Contd..)

• System Guidelines
• Handling Guidelines
• Insertion Guidelines
• Joining Guidelines
• Theoretical minimum number of parts

19
Potential Conflicts between DFA & DFM

• While, minimization of parts can be good for DFA – this may not actually be
aiding the manufacturing process or integration function
• Focus is on complexity, cost and functionality
• Have to come to a trade-off which balances the requirements versus output

20
Manufacturing Cost Analysis

• Two types
• Fixed – Cost of Equipment
• Variable – Material Cost

21
Manufacturing Cost Analysis

Selling Price

Manufacturing Cost Distribution Cost Retail Cost

Pierce Parts Assembly Overhead

OEM
Labour Tooling
Parts/Custom
Parts

Material Tooling Setup Processing

22
 Thank You

BITS Pilani
Pilani|Dubai|Goa|Hyderabad