Design Example

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 Content
 What is Design?
 Design Process
 Design process For Automotive
 Design process For automotive with
respect to Human Factors

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 Introduction to Design
 A goal- directed problem solving activity (Archer 1965).

 Design is a interplay between what we want to achieve

and how we want to satisfy them (Suh 1990).

 Design is a process of converting information that

characterize the needs and requirements for a product
into knowledge about the product (Mistree 1992).

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 Definition of Design
 Design is

– An art, not a science

• Problem solving, Decision making, Applying science
– Creativity & imagination vs Heuristic search
– Directing, leading & organizing
• Dealing with people & team-building
• Negotiating to achieve a satisfactory solution &
optimizing
• Foresight towards production, assembly, testing and
other processes
• Considering the "bottom line" of costs and profit,
• Satisfying needs & satisfying the customer
– Ethical and professional conduct

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 Various Design
 New Design: New tasks and problems are solved by new solution
principles.
 Revised Design: The embodiment design is customized/adapted to
fit new requirements. The employed solution principles are known
and field-proven .
 Variant Design: Size and/or structure of parts and assemblies are
varied within the limits of the already planned system.
 Repeat Design: A new start of the production run with an
unchanged design.
 Robust design: A systematic engineering based methodology
(which is part of quality engineering process) that developes and
manufactures high reliability products at low cost with reduced
delivery cycle.

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 Over the Wall Engineering
Product concept Product specs. Design specs. Manufacturing specs.

Customers Marketing Design Manufacturing Production

engineering engineering

Roles of system engineer

Need identification & customer linkage, Management (spec, process, risk,
information), System design, Integration, R&D, leading & coordinating

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 Integrate Product Design
 Integrate People
– Build concurrent engineering teams R&D

– Negotiation in engineering design

Manufac- Marketing
 Integrating Processes turing

– Process Modeling Design

– Process Reengineering
Suppliers Customers
 Integrating Information
– Database Management Systems Finance

– Information and data mining

 Building a Concurrent Engineering Design Process

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 Design Process
 System, subsystem and component design
 Sequential & iterative process
 Starts and Ends with the customer
 Comparison and contrast to scientific method
– Need  Concepts  Feasibility  Produce  Sell
– Time and cost as key factors
 Process of converting information that characterizes the needs
and requirements for a product into knowledge about the
product and its implied processes.

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Engineering Models of Design

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 Design process 1
 Recognition of a customer’s need
– Market research identifies customers and needs
– R&D creates ideas that are relevant to an organization’s capabilities
– Needs arise from dissatisfaction
– Technology push (examples : computers, audio)
 Definition of a problem or Task
– Design specification
– Selecting product ideas
– Compiling the requirement list
– Acquire & apply technical knowledge
– Identify resources
– Prioritize design goals & continue to refine

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Designs vs Needs

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 Design process 2
 Product definition
– Function SOURCES

CONSUMER COMPANY
– Preliminary requirements list
– Solution requirements SITUATION ANALYSIS

– Cost target and budget PROCEDURE FOR SEARCH

DEFINE THE PRODUCT

QUALITATIVE DESCRIPTION

DESIGN

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 Design process 3
 Conceptual design
– This phase looks at the function requirement of the Product.The
function are listed & complex functions are broken into simpler sub-
functions.
– Determines the Principle of Solution.
– It is preceded by a Decision
 Procedure
– Abstract to identify essential problems
– Establish function structures
– Search for working principles to fulfill the sub-functions
– Combine working principles into working structures
– Select suitable combinations
– Evaluate against technical & cost criteria

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 Design process 4
 Design embodiment
– It starts from the concept and develops the definitive layout for the
project
– Evaluate against Technical & Economic criteria
– Preliminary layout
– Optimize and complete form designs
– Check for errors and disturbing factors
– Prepare preliminary part list and production documents
 Embodiment design is characterized by repeated deliberation and
verification.
 This requires approach that is progressive as well as iterative.
 The checklist
– Function, Working Principle, Layout, Safety, Ergonomics,
Production, Assembly, Transport, Recycling, Maintenance, Costs,
Quality control
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 Design process 5
 Prepare production documents :
– Elaborate detailed drawings and parts list
– Complete production,assembly,transport and operating
instructions
– Check all documents
 Design review
– Review and redesign focuses on achieving the performance,
producibility, reliability and cost (As compared to what)
objectives.
– Competitive benchmarking
– Reverse Engineering of competitor’s products
– Early bird gets the profit

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Example design process: Jack
 My car was not in very bad condition, but the original jack was so
slender, that I didn't dare creep under the car when it was lifted by this
jack. There was no space for me, anyway! The floor of the car was
badly rusted, because the car had been effected by some sewer gas in
the garage. I had to cut large sections out of the floor and cover them
with new steel plate.

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 Information
 Space below of car

 Jack point & car size

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Available Means

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List of Demands

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 Definition of Problem
 We must design a jack, which is able to lift a car, which has a
weight of 1300 kg, a width of 1800 mm an a wheel base of 2700
mm. The jack must be safe enough, that repair and service
operations below the lifted car are possible.
 We must design a system, which makes repair and service
operations possible below a car.
 Functions

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 Decomposing into subsystem
Ones muscle power has
to be transformed to
lifting force with the sub
function 1. Sub function 2
is used to transmit the
combination of lift and
lifting force directly or in
transformed form into the
connection points of the
car. Sub function 3 makes
the connection with the
car. Sub function 4 keeps
the system steady on the
ground. Sub functions 5
and 6 secure the lift and
they make operations
below the car safe.

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Alternative subsystems

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Possible combinations

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Decision Table

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Embodiment design

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Detail design

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Review of Design

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Results

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