18.02.

2011

Engineering
Design &
The Design
Process

Engineering Design
What is Design…… ?

As many definitions as many there are designs because

process of design is such a common human experience

As per Webster‟s Dictionary

“To fashion after a plan”

Is this definition complete…?

If Yes…..What is missing in it….?

“the essential fact that to design is to create

something that has never been”

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Engineering Design
Engineering Designer, artist, sculptor, a composer, a
playwright and other creative members practice
design by this definition
Professional practice of Engineering is concerned
with Design

Then what is the …Formal Definition of Design..?

“Design establishes and defines solutions to and

pertinent structures for problems not solved before or
new solutions to and which have previously been solved
in a different way”

Conclusion : Essence of Engineering is „DESIGN‟

Engineering Design
Ability to Design is both a Science and an Art
Science : is learned through techniques and
methods used
Art : is best learned by doing design
Discovery : is getting the first sight of, or first
knowledge of something
We can discover what has already existed but has
not been known before
“Design should not be confused with Discovery”
Design is the product of “Planning and Work”
Invention:
“Design may or may not involve invention as some
are truly inventive but most are not”

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Engineering Design
What is a Good Design…… ?
“Good design requires both Analysis and Synthesis”
Analysis
Decomposing problem into manageable parts
To understand performance/behavior of parts in
service using appropriate discipline of
science/engineering and computational tools
Usually involves simplification of real world problems
through models
Synthesis
Identification of Design Elements that will comprise
Product
Its decomposition into parts
Combination of part solutions into a total workable
system

Engineering Design
What is a Real World Problem that you intend to design…?
Rarely neat and defined
May need many engineering (fluid, solid mechanics etc)
and non-engineering discipline (economics, finance,,
law etc)
Input data may be best but out of the scope of the
individual
Constraints may be time, money, societal,
environmental or energy regulations etc.

What is Final Design…… ?

Is it the best, most efficient. Only time will tell….!!!!!
Rarely known the correct answer
One is hopeful that “His Design will Work”

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Engineering Design
Conclusion
“Engineering Design extends beyond the boundaries of
Science”
As Design Engineer during professional career you may
have the opportunity
To create dozens of designs
Have satisfaction of seeing them become working
reality
As Scientist during professional career you may have
the opportunity
To make one creative addition to human knowledge in
your whole life and many never do so
Can discover a new star but can not make one
Have to ask an Engineer to do it for him

Engineering Design
It is the systematic, intelligent generation and
evaluation of specifications for artificats
whose form and function achieve stated
ojectives and satisfy specified constraints.

Artifacts : human made objects

Form : shape, geometry
Function : the artifact is supposed to do
Specification : precise description
(fabrication spec.s= set of plans for making the
designed artificat)
(design spec.s = evaluation benchmarks)

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What is design?
Design is a process in which information is
added to an artifact, a process, or a system.
• Think about the word, information, and its root word
inform
• What does it mean to inform someone or something?
• What do we do when we injection mold plastic, or form
a piece of sheet metal?
• Where does the information come from?
• What other information is involved in the process?

Engineering Design

Engineering Design is the organized,

thoughtful development and testing of
characteristics of new objects that
have a particular configuration or
perform some desired functions that
meets our aims without violating any
specified limitations.

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Engineering Design
Design Problems are

a) Open-ended
Because of having several acceptable solutions
b) Illstructured
Because their solutions can not normally be
found by applying mathematical formulas or
algorithms in a routine or structured way

The Design Process

Designers concerned with the product’s
life cycle (purchase, support, use, and
maintenance).
Designers and manufacturing specialits
work together, so that they are
collectively and concurrently designing
an artifact.
It demands teamwork.
CONCURRENT ENGINEERING

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The Design Process

There are a lot of questions in simple design
problem :
How is it to be used ?
How much should it cost ?
Is there a market for it ?
Will it be made of steel, aluminum ?
What is thje design load?
Is the design economically feasible ?
Is there a more efficient design ?
And so on ...

The Design Process

Asking questions to elaborate the meaning
of a client’s statement is part of the
design process.
They can not be answered by applying usual
mathematical models.
There are not any equations to define the
meaning of safe or marketability.

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The Design Process

Asking questions for solving them :
Clarifying the objectives (color, cost)
Establishing user requirements
Identifying constraints
Establishing functions
Establishing design specifications
Generating design alternatives
Modeling / Analysing the design
Testing & elavuating the design (test model)
Refining & optimizing the design (optimize features)
Documenting the completed design (fabrication specs)

Problem
Customers identification

Preliminary ideas Modify the

problem & its
constraints
Refinement
process
No

Analysis & decision Criteria

Satisfied
processes ?

Yes
Implementation

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An Idea Sketch
• Tools:
• Pencil and paper
• Computer work-sheet:
• Rhinocerus
• …

The Design Process

Idea Feasibility Product Yes Preliminary
generation study feasible? design

No

Final Process
Prototype
design planning

Design & Manufacturing

Specifications

Manufacturing

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The Design Process (3-stages)

Descriptive = linear =
Client
Synthesis Statement

Look for different

Conceptual design concept schemes
to achieve the
Several competing client’s objectives
concepts
Preliminary design
Analyses

Final choise from

among them
Final
Detailed design
Design

The Conceptual Design

Conceptual design

Is design no
feasible ?

Is there an
yes

unkown or vague
no Build/model/
component simulate/prototype

yes
Add detail research Will concept
no
discard design work?

yes
Acceptable concept Discard concept

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The Conceptual Design

DO NOT MARRY
YOUR FIRST
DESIGN IDEA !!

No sufficient data
to desicard any
concepts.

The Design Process (5-stages)

Extended = linear =
Client Problem Definition
Statement

Conceptual design

Preliminary design

Fabrication specs &

Detailed design documentation

Final
Design Communication Design

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The Design Process (5-stages)

Prescriptive
Client Problem Definition #1 clarify objectives
Statement #2 establish user reqir.s
#3 identify contraints
#5 establish design specs
Conceptual design #4 establish functions
#6 generate alternatives

#7 model / analyze design

Preliminary design
#8 test & evaluate design

#9 refine & optimize design Detailed design Fabrication specs

& documentation
Final
#10 document design Design Communication Design

The Design Process (5-stages)

Prescriptive with Feedback
Client Problem Definition
Statement
Verification

Validation

Conceptual design

Preliminary design
Product
Detailed design

Final
Design Communication Design

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The Design Process

Computer based models are used widely in
all engineering disciplines and they
become even more important as a design
project moves into detailed design.

Refering to such tools as discipline-

specific CADD systems.

The Design Process

Problem identification Specifications
(market analyst-design brief)

Conceptual design Concepts

(Product designer)

Embodiment design Layouts

(Design Analyst)

Detail design Drawings

(Development & Research Engineer)

Manufacture Product
(Process Planner and Production Engineer)

Morphology of Design - (Seven phases of design)

1. Conceptual design 2. Embodiment design 3. Detail design 4. Planning for manufacture
5. Planning for distribution 6. Planning for use 7. Planning for retirement of product

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Design Process
Define Gather Concept Evaluation
Problem Information Generation of Concepts

Problem Internet, Brainstorming Pugh concept

statement Patents Functional Selection
Bench marking Trade decomposition Decision
PDS, QFD Morphological
Literature matrices
Project planning
chart
Conceptual design

Product Configuration Parametric Detail

Architecture Design Design Design
Arrangement Prelim. Selection Robust design
of physical
of matls. & mnfg. Tolerances Detailed drawings
elements to
carry
Modeling & sizing Final dims. &
out function of parts DFM Specifications

Preliminary / Embodiment design

Design For X
DFA Design For Assembly
DFM Design For Manufacturability
DFD Design For Disassembly
DFI Design For Install ability
DFM Design For Maintainability
DFML Design For Material Logistics
DFP Design For Portability (Software)
DFQ Design For Quality
DFR Design For Redesign
DFR Design For Reliability
DFR Design For Reuse
DFS Design For Safety
DFS Design For Simplicity
DFS Design For Speed
DFT Design For Test
DFE Design For Environment
DFESD Design For Electrostatic Discharge
DFEMC Design For Electro-Magnetic Compatibility

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Design For X
A growing emphasis on Concurrent
Engineering, as it involves cross-functional
teams, parallel design and vendor
partnering etc.
• A successful design must satisfy
requirements
functionality,
appearance, and cost
durability and reliability

Design For Manufacture & Assembly

(DFMA)
Processes or procedures for integration of design and
manufacture, with the goals of reducing manufacturing costs
and improving product quality are termed as DFM. Associated
with this for assembly is DFA.
DFM Guidelines

Minimizing Standardize Use Design parts to Design parts Avoid too Avoid Utilize the
total components common be multi- for ease of tight secondary special
number of parts functional fabrication tolerances operations characteristics
parts across of processes
product
lines

Assembly process
DFA Guidelines
consist of two parts
• Handling
Minimizing Minimizing Avoid Minimize Maximize Minimize
-Manual total assembly separate assembly compliance in handling in
-Automated number of surfaces fasteners direction assembly assembly
parts
- Robotic
• Insertion

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Design Process
Product Design Complex Engineering System
Consumer goods Electric power generating system
Appliances, missiles, jets, planes Petrochemical plants
Building/bridge design
Importance of design process
100
Conceptual
development
Percentage of product cost commited

design
Market

Product cost
commitment

Manufacturing
during phases of
design process
Functional

Product use
design

70~80% = for Design

commitment
25% = for manufacture
Cost incurred
5% = for design
95% = for material,
manufacture, labor,
capital
0 Time (nonlinear)

The Traditional Product Development

Process

Detailed design
Customer requirements Conceptual design
and analysis
(sales and marketing) (Industrial designers)
(engineering)

Distribution Support and

Manufacturing and Sales Service

Disposal
(not our problem)

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