Design Process

1
Design Process

• Design process is a collection of procedures and
  habits that help teams design better products

2
The Process of Design

• Designing is the process of making many decisions
  that converts an abstract concept into a hardware
  reality.

Concept
Product
3
7-Step Design Process

• Problem definition (PDS)
• External Search (Research)
• Internal Search (Brainstorming)
• Evaluation and Selection
• Detail Design (Engineering)
• Prototyping
• Documentation

4
What Product?ToyTown Top Executives
Water Balloon
Rope Climber
Can Crusher
Better Mouse Trap
Coin Sorter
Nail Driver
Rope Climber
5
Product Design SpecificationsCustomer Needs

• Climbs fast
• Affordable as a birthday present
• Fully assembled
• Uses batteries for power
• It is safe
• Looks good
• Plays music as it climbs
• Glows in the dark
• Last a long time

6
Product Design SpecificationsEngineering Specs

• Climbs at 1 ft/s or faster
• Retail cost is to be less than 30
• Uses 2 AA batteries (not included)
• Has no removable small parts
• Music loudness between 20-30 db
• Luminosity is to be more than 5 W
• Works for more than 3 hours on 2 AA

7
External Search

• Level-I
• Rope climbing toys / machines
• Rope climbers (sports or circus)
• Nature (spiders, bats, etc)
• Level-II (Team uses friction wheels)
• Hoists
• Trolleys
• Ski Lifts

8
Internal Search Evaluation

• Brainstorming
• Generate many ideas
• Evaluate against PDS
• Select one to engineer

9
Detail Design (Engineering)
More Abstract
Engineering
Less Abstract
10
Design Process

• Top-level problem definition is called PDS
  (Product Design Specifications)
• Problem definitions at lower levels derive from
  PDS
• Sub-system design specifications.
• Component design specifications.
• Feature design specifications.

11
Product Development Process
Product Planning
Design Brief (Mission Statement)
Market Research
Product Design Specifications QFD
12
Product Development Process
PDS
Candidate Design
Concept Synthesis
Detail Design
Prototyping
Concept Evaluation
Release for Production
Candidate Design
13
Detail Design
Candidate Design
Components No Numbers
System-Level Design
Parameter Design
Numbers
Prototype Testing
Release for Production
14
Customers

• People who are affected by the product

Team
Globe (External)
Company (Internal)
15
External Customers
Buyers
Retailer
End Users
Maintenance
EXTERNAL
Government Standards
Society
16
Internal Customers
Manufacturing Procurement
Management
Marketing
Internal
Shipping
Legal
17
What Do They Want?

• End Users
• Performance Functionality
• Affordability
• Ease of use including ergonomics
• Reliability and Long life
• Versatility
• Safety
• Low maintenance and easy assembly
• Esthetics

18
External Customers

• Buying managers
• Low Cost/Performance
• Safety
• Ruggedness (abuse resistance)
• Ergonomics
• Long warrantees
• Reliable with Low downtime
• Low operating cost

19
External Customers

• Retailers
• Small and attractive packaging
• Long shelf life
• Low cost/performance and Exciting features
• Maintenance
• Ease of maintenance

20
External Customers

• Government / Standards / Society
• Conformance to laws and regulations
• Promotion of public health and safety
• Protection of environment
• Solution to chronic problems in society
• Traffic
• Energy
• Noise
• Drugs, abuse and other crimes
• Diversity / Social tolerance / Security

21
Internal Customers

• Management
• Make a big profit
• On time delivery
• Low failure risk
• Documentation
• Process Conformance to company product
  development process

22
Internal Customers

• Marketing
• Attractive features to target buyers
• Low production cost
• Esthetics
• Attractive packaging
• On time delivery
• Long Warrantees

23
Internal Customers

• Manufacturing
• Manufacturability using standard methods and
  schedules.
• Conformance to company documentation formats.
• Use of products from preferred vendors.

24
Internal Customers

• Legal
• No patent infringements
• Safety
• All required safety warnings and labels
• Designed protection against reasonable abuse
• Codes and regulations

25
Internal Customers

• Shipping and Packaging
• Ease of user assembly
• Small packaged size
• Ability of locking or fixing sensitive components
• Resistance against damage due to dropping,
  vibrations, moisture, heat, and cold.

26
(No Transcript)
27
Product Design Specification

• Elements of PDS
• Performance (User)
• Speed,
• Capacity,
• Power,
• Accuracy,
• etc.

28
Elements of PDS

• Environment (User)
• Temperature range, humidity, dust and dirt, etc.
• Life in service (User)
• 10 years, 5000 cycles, etc.
• Maintenance (User)
• What is the market policy, what customers accept
• Target production cost (User)
• Cost of comparable products and company policy.

29
Elements of PDS

• Shipping
• Package sizes
• Damage resistance

30
Elements of PDS

• Quantity (Manufacturing)
• Determined by market analysis.
• Manufacturing facility (Manufacturing)
• Is the design constrained by existing facility?
• Are parts to be contracted and assembled
  in-house?
• Does the company policy dictate certain
  facilities?

31
Element of PDS

• Size and shape (Marketing)
• Weight (Marketing)
• What is the desired weight?
• Should handles or lifting points be provided?
• Should it be modular for better handling?
• Aesthetics (Marketing,User)
• Color, shape, form, texture, finish.
• Market research.

32
Elements of PDS

• Materials (Marketing, Codes, Regulations)
• Left to designers unless company guidelines or
  regulations restrict certain materials (asbestos,
  lead).
• Product life span (Marketing, Manufacturing)
• Life of a product as a marketable entity.
  Several months or several years?

33
Elements of PDS

• Laws, Codes, and standards (Government)
• Ergonomics (User)

34
Elements of PDS

• Quality and reliability (Marketing)
• Company policy regarding warranties
• Competitors warranty policies
• Testing (Marketing, QA)
• What tests would be performed to verify
  performance
• Standard tests

35
Elements of PDS

• Shelf life (storage) - Retail
• Possibility of rust, decay, deterioration
• Processes (company guidelines)
• Use of certain standards (GDT for example)
• Use of certain procedures
• Time-scales (deadlines) - Management
• Whole design project, milestones

36
Elements of PDS

• Safety (User, Government, Legal)
• What safety requirements are mandated by
  government
• Professional society's codes and standards
• Need for warning labels
• Likely degrees of abuse or misinterpretation of
  operating procedures.

37
Elements of PDS

• Company constraints (Management)
• Compatibility with other products
• Documentation (Management Legal)
• A product design must include a full formal
  documentation per company guidelines.
• Safety, Operation, and Service documents.
• Etc.

38
Elements of PDS

• Legal (Lawyers)
• What product liability law suits are associated
  with similar products and why.
• Note the legal terms
• defect of specification
• defect of design
• defect of manufacture
• Relevant patents

39
Element of PDS

• Installation (Installers)
• Many products must interface with other products
  or be assembled with other products.
• Disposal (Society)
• Should any parts by recyclable?
• bio-degradable?

40
Wording of the PDS Document

• Format of most statements in PDS
• The device must ..
• The device is to
• The device is desired to .
• Avoid mixing requirements.
• One sentence per requirement.
• Cast PDS statements in a positive format

41
PDS is a Dynamic Document

• A design statement usually begins as a vague
  statement
• The device is to be easy to use
• The device is to be safe
• The device is to be inexpensive
• The device is to be rugged and reliable
• The device is to be portable

42
Wording of the PDS Document

• Example ESCOs Pin Remover
• The pin-remover is to be light.
• The pin-remover must work in a wet, cold, and
  dusty environment.
• The Pin-remover must be safe
• The Pin-remover must have a 3-year warranty.

43
PDS Example

• The PR is to be rugged.
• must work with air pressure.
• is be easy to use.
• is to pass HTS tests.
• is to last 5 years in normal usage.
• is to be easy to carry.

44
PDS Example

• is to sell for less than 150.
• is to costless than 50 to make.
• is to have low maintenance needs.
• is to be difficult to use as a hammer.
• must not infringe on patented devices.
• Production volume is to be 300 per year

45
PDS Example

• is to be tested by June 2006.
• is to be released by Sep. 2006.
• is to be used with Dredge Point models.
• is to work faster than the hammer

46
Engineering Specifications

• What is
• Fast, accurate, high-performing?
• Light, Small, portable?
• Easy to use?
• Safe?
• Stylish?

47
Engineering Specifications

• Verifiable PDS statements
• Developed for important PDS statements
• Have associated target numbers (Yes/No OK)

48
Engineering SpecificationsTips

• Set up metrics and targets so the designer has
  maximum options in accomplishing the PDS

49
Engineering SpecificationsTips

• PDS The Dog Feeder must not tip over when bumped
  or pushed by a dog.
• Bad The DF must weigh 50 lbs
• Good The dog feeder must withstand 30 lbs
  applied to its top from side

50
A Typical PDS Page

• Requirement PR is to be easy to maintain
• Primary customer End users
• Priority High
• Metrics and Targets
• Daily maintenance None
• Weekly maintenance lt 10 minutes field
• Yearly maintenance lt 1 hour Shop
• Cost of weekly maintenance lt 10c
• Cost of yearly maintenance lt 10

51

Engineering Requirements
Competition
IMPORTANCE
Customer Needs PDS Statements
Relation Between Engineering and Customer
Requirements
Competition
Target