ENGINEERING DESIGN
UNDERSTANDING
DEFINING THE FUNCTIONALITIES OF THE COMPONENTS
In engineering design, before building or assembling a product/system, it's essential to define what each component
is supposed to do. This step ensures that every part contributes to the overall operation of the system effectively.
What it means:
•Identify each component in the system.
•Determine the purpose or role of that component.
•Describe the input-output behavior of the component.
•Understand how it interacts with other components.
Example (Click Pen)
How to Define Component Functionalities ?
1.Identify the Component
Start with listing all components in your product/system.
2.Understand the Role
What is its purpose? What problem does it solve?
3.Specify Input and Output
What does it receive and what does it deliver?
4.Determine Interaction
With which components does it communicate or connect?
5.Consider Functional Conditions
Under what conditions or modes does it operate?
Classification: Types of Component Function
Component functions are broadly classified into 3 main types:
Function Type Description Examples
The main role the component plays
Primary Function A gear transmits torque; a fan cools
in the system
Additional roles to assist primary A casing provides alignment,
Supporting/Secondary Function
functions sealing, and safety
Functions that limit or control A stopper limits rotation; a bushing
Constraining Function
movement or behavior restricts axial play
FUNCTIONAL NETWORK DIAGRAM
A Functional Network Diagram (FND) in engineering design is a visual representation that describes how a
system or product performs its intended operations by illustrating the logical flow and relationships between its
various functions.
Rather than focusing on physical components or specific hardware, the diagram focuses on the functions — or
actions — that the system must perform to meet its design goals. Each function is represented as a block, and arrows
are used to indicate the flow of material, energy, or information between these functions.
The FND is created during the early stages of the engineering design process to help engineers and designers:
•Break down the overall task of a system into subfunctions
•Understand the sequence and dependency of operations
•Identify how inputs are transformed into desired outputs
•Define functional boundaries and interfaces between subsystems
By doing this, the FND serves as a foundation for concept generation, risk analysis, and system architecture,
ensuring that the final design meets the functional requirements before physical components are selected or built.
DEFINING THE FAILURES OF THE SYSTEM
In engineering, a system failure refers to the inability of a system or any of its components to perform its
intended function within the specified performance criteria. These failures can be mechanical, electrical, structural,
software-related, or functional in nature.
Why Define Failures in Engineering Design?
• To ensure safety of the product or user
• To improve reliability and durability
• To reduce costs of rework and warranty claims
• To ensure compliance with regulatory standards
• To identify critical failure modes early in the design stage
TYPES OF FAILURES IN THE SYSTEMS
Design Failures
Arise from flaws or oversights in the design phase.
•Causes:
•Inadequate factor of safety
•Overcomplicated design
•Ignoring tolerances
•Lack of consideration for manufacturability or assembly
•Example: Gearbox designed without allowance for thermal
expansion, leading to seizure.
Functional Failures Mechanical Failures
The system or component does not perform its intended function.
Failure of mechanical components like gears, shafts, bearings, or fastene
Example: A hydraulic pump fails to generate pressure. •Causes: Overload, misalignment, improper fits, manufacturing defects.
Cause: Design miscalculation, improper specifications. •Example: Bearing seizure due to lack of lubrication
Structural Failures Electrical Failures
Failure due to mechanical stress, fatigue, overloading, or
Any malfunction in electrical or electronic components of the system
material weakness. •Types:
•Subtypes:
•Short circuits
•Fracture: Cracks or complete breakage.
•Open circuits
•Buckling: Collapse under compression.
•Overheating
•Fatigue: Repeated stress over time.
•Insulation failure
•Creep: Slow deformation under constant load.
•Voltage spikes
•Example: Bridge beam cracks under repeated loading
•Example: Inverter failure in an electric vehicle.
aterial Failures
lures due to poor material selection or degradation over time.
ypes:
•Corrosion
•Erosion
•Oxidation
•Wear & tear
•Thermal degradation
xample: Rusting of a steel shaft in a humid environment
What is a Subsystem in
A subsystem is a smaller, self-contained Engineering Design?
unit within a larger system that has its own distinct function but also
interacts with other subsystems.
For example, in an Electric Scooter, subsystems include the battery unit, motor drive, braking system,
suspension, frame, and control unit.
Why Define Failures at the Subsystem Level?
• Pinpoint exact failure origins
• Improve design clarity and modularity
• Enable targeted testing and validation
• Simplify maintenance and upgrades
• Facilitate root cause analysis
Why–Why
Analysis
The Why–Why Analysis is a root cause analysis tool
used in engineering design to identify the underlying
reason for a failure. It is typically performed after a
subsystem or component has failed, and the goal is to
dig deep into the true source of the problem, rather
than stopping at the surface-level cause.
Why–Why helps engineers:
• Prevent repeating failures
• Improve design robustness
• Ensure safety, reliability, and compliance
STRUCTURE OF WHY–WHY ANALYSIS
Process Flow:
1.Define the Failure Clearly
• Identify the subsystem
• Describe exactly what failed (what, where,
when, how)
2.Ask “Why did this failure happen?”
• Start with the immediate cause
3.Keep asking “Why?” (Usually 5 times)
• Trace deeper into the chain of events until
a root cause is found
4.Identify the Root Cause
• Usually something related to design,
material, process, or human error
5.Verify and Validate
• Ensure the cause is not just a symptom
• Check if removing this cause will prevent
the failure
6.Implement Corrective Action
• Feed back into design, manufacturing, or
testing process
FAILURE NETWORK DIAGRAM
A Failure Network Diagram (FND) is a structured graphical tool used in engineering design and systems analysis to
visualize how individual component or subsystem failures can propagate and lead to overall system-level failure. It
helps engineers identify not just what can fail, but how and why those failures occur in a sequence or combination,
enabling proactive measures to improve reliability and safety.
Purpose of a Failure Network Diagram
The main objective of a Failure Network Diagram is to map the interdependencies between components and identify
potential failure paths. This is crucial for complex systems where a single fault in a minor component can cascade and
trigger a chain of failures. The diagram visually represents these sequences, supporting root cause analysis, risk
assessment, and the design of mitigation strategies.
BRAKE LEVER PLAY
INCOMPLETE FORCE
TRANSMISSION
REDUCED HYDRAULIC PRESSURE
AT CALIPER
BRAKE FLUID LEAK AIR BUBBLES IN LINE
INSUFFICIENT CLAMPING
DELAYED BRAKE RESPONSE
FORCE
BRAKE PADS SLIP/GLAZE INCREASED STOPPING TIME
POOR BRAKING FORCE SYSTEM FAILURE NOTICED
ENGINEERING DESIGN
APPROACH
PRODUCTION ENGINEERING PROCESS
Engineering Design Approach: Production Engineering Process
The Production Engineering Process is a crucial part of the engineering design approach. It involves planning,
designing, and optimizing the manufacturing system that will produce the designed product effi ciently and cost-
effectively.
MANUFACTURING
OPERATIONS
PRODUCTION
PROCESSES
ASSEMBLY OPERATIONS
PRODUCTION
QUALITY CONTROL
ENGINEERING
PROCESS PLANNING
PRODUCTION
SYSTEMS
PRODUCTION PANNING
& CONTROL
Phases of the Production Engineering
Process
Stage Description Key Activities
- Material selection
1. Design for Manufacturability Ensures product can be manufactured
- Tolerance analysis
(DFM) with available technology
- Standard part usage
- Process flow charts
Selection of the best methods for
2. Process Planning - Selection of machines, tools
production
- Sequence of operations
- CNC programming
3. Tooling & Fixture Design Designing jigs, dies, molds, and fixtures - Die and mold design
- Welding fixtures
- Prototype testing
4. Prototype & Trial Production Early product built to validate processes - First-article inspection
- Design iteration
- Layout planning
5. Production Setup Prepare machines, tools, and workforce - Production line balancing
- Operator training
- Lean manufacturing
Continuous improvement during
6. Process Optimization - Six Sigma
production
- Quality control checks
- Mass production
7. Full-Scale Production Full-volume manufacturing - Inspection
- Maintenance
- SPC (Statistical Process
Validate that products meet Control)
8. Quality Assurance & Feedback
specifications - Defect tracking
- Feedback loop to design
STAKEHOLDERS AND RESPONSIBILITIES
In engineering design, stakeholders are the individuals, teams, or organizations that have an interest or influence in the
development of a product, system, or process. They play a critical role throughout the design lifecycle—from initial concept to
final production and beyond. The primary stakeholders typically include design engineers, who are responsible for creating
and optimizing the technical aspects of the design, and manufacturing engineers, who ensure that the design is feasible and
efficient to produce. Project managers act as coordinators who align the efforts of different teams, manage timelines, and
ensure deliverables meet objectives. Testing and quality assurance teams verify that the product performs safely and
reliably under various conditions. In parallel, customers and clients provide the foundational requirements, offer feedback
during development, and ultimately approve the final design based on performance and usability. Regulatory bodies are
crucial external stakeholders, ensuring the product complies with safety, environmental, and industry-specific standards.
Suppliers and vendors impact the design by influencing component availability, quality, and lead times. Finally, senior
management oversees strategic direction, budget allocation, and risk management. Each stakeholder has distinct
responsibilities, but their goals must align to achieve a successful, safe, and market-ready product. Collaborative
communication and continuous feedback among stakeholders are essential to identify risks, avoid design flaws, and ensure the
final product meets all technical, functional, economic, and safety expectations
Design Engineers Electrical Engineers Embedded Manufacturing
Engineers Engineers
Suppliers/ Maintenance
Maintenance Procurement
Quality Assurance Suppliers/Vendors Procurement Team
Vendors Technicians
Technicians Team
Stakeholder Role/Responsibility in Engineering Design
- Translate requirements into technical specifications
Design Engineers - Create CAD models, simulations
- Ensure functionality and manufacturability
- Develop manufacturing process plans
Manufacturing Engineers - Validate tolerance, materials, and methods
- Coordinate with suppliers for feasibility
- Plan timelines, track progress
Project/Product Managers - Allocate resources and manage risks
- Facilitate communication across teams
- Conduct performance, durability, and safety tests
Testing & Validation Teams - Analyze failures and suggest design changes
- Ensure compliance with test standards
- Monitor process and product quality
Quality Assurance (QA) - Implement inspection protocols
- Ensure adherence to ISO/industry standards
- Define performance and usability expectations
Customers/Clients - Provide feedback during design stages
- Validate final product performance
- Supply components/materials as per specification
Suppliers & Vendors - Provide technical support and lead time details
- Influence design through manufacturing limitations
- Impose safety, environmental, and compliance rules
Regulatory Bodies - Evaluate and certify products
- Ensure legal adherence to national/international standards
- Set strategic direction and budget limits
Senior Management - Approve design phases and gate reviews
- Assess ROI and business viability
NEW PRODUCT DEVELOPMENT AND CONCEPT DEVELOPMENT
Introduction to New Product Development in
Engineering Design
New Product Development (NPD) is a systematic and strategic
engineering process used to transform an idea into a market-ready
product. It involves multiple stages, from identifying market needs
to concept development, detailed design, prototyping, testing, and
finally, launching the product. Within this framework, concept
development is one of the most critical early stages. It connects
the creative aspects of innovation with the technical foundation of
engineering design, acting as a bridge between what should be
built and how it will be built.
Steps in New Product Development (NPD)
1.Idea Generation
2.Concept Development
3.Product Design and Engineering
4.Prototype Development
5.Testing and Validation
6.Manufacturing Planning
7.Product Launch
8.Feedback and Continuous Improvement
CONCEPT DEVELOPMENT
What is Concept Development?
Concept development is the initial stage of the product development lifecycle where ideas are transformed into
viable product concepts that align with business objectives, technical feasibility, and user needs. It defines what the
product will do, how it might look, and why it will succeed in the market.
STEPS IN CONCEPT DEVELOPMENT
Stage Details
Conduct surveys, interviews, or market analysis to
understand what the user wants. Use tools like Voice of
1. Identify Customer Needs
the Customer (VOC) and Quality Function Deployment
(QFD).
Convert needs into clear technical challenges or functions
2. Define Problem Statements
the product must address.
Study competitors’ products for performance, materials,
3. Benchmarking
design ideas, and weaknesses.
Brainstorm multiple concepts using sketches, mood
4. Generate Concepts boards, and early CAD models. Include both innovative
and proven ideas.
Use decision matrices, SWOT analysis, or Pugh charts to
5. Evaluate Concepts compare alternatives based on cost, feasibility,
performance, etc.
Choose the concept that best balances design goals,
6. Select Best Concept(s)
manufacturing feasibility, customer satisfaction, and ROI.
Create early prototypes (e.g., foam models, 3D printed
7. Refine and Iterate
parts) to test form, function, and ergonomics.
PRODUCT REQUIREMENTS AGAINST
SPECIFICATIONS
Introduction to Product Requirements and Specifications
In the field of engineering design, clearly defining product requirements and translating them into precise specifications is a
critical step toward successful product development. Requirements describe what the product must achieve, while specifications
define how those requirements will be met through engineering decisions. This process ensures the end product aligns with
customer needs, regulatory standards, and performance expectations. Understanding the difference and relationship between
these two aspects is essential for design engineers, product managers, and quality assurance teams.
Product Requirements: Understanding What the Product Should Do
Product requirements are broad, descriptive statements that identify the functions, capabilities, and constraints of a product
from a user or system-level perspective. These are usually derived from customer expectations, market research, safety norms,
and business goals. They do not provide technical details but describe what the product is expected to deliver. For example, in
an electric two-wheeler, a product requirement might state that "the scooter should travel 80 km on a single charge" or "the
braking system should stop the vehicle safely at high speeds." These requirements help the design team focus on end-user
satisfaction, safety, and product utility.
Product Specifications: How Requirements are Technically Achieved
Specifications, on the other hand, are precise and measurable technical details that explain how each requirement will be
fulfilled. These are developed by engineers and designers during the design process and are used for modeling, simulation,
prototyping, and testing. Specifications might include parameters such as dimensions, materials, voltage, weight, torque,
temperature range, tolerances, or regulatory compliance figures. For the earlier example of range, the corresponding
specification might be "Battery capacity: 4.4 kWh with a voltage of 72V and motor efficiency ≥ 90%." Such measurable
figures help guide engineers during product development and ensure every aspect can be validated and tested.
Introduction to Specifications in Engineering Design
In engineering design, specifications are the precise, technical descriptions of a product’s characteristics, functions,
dimensions, performance limits, materials, and other parameters. They serve as a bridge between the product concept and the
actual implementation by engineers, technicians, and manufacturers. Specifications act as detailed blueprints that guide the
product’s development, assembly, testing, and quality assurance processes. They are essential in ensuring that the final design
fulfills the intended product requirements.
Role and Purpose of Specifications
The primary role of specifications is to clearly communicate what is expected from each component, system, or assembly of
a product. This prevents ambiguity and reduces the possibility of errors during design and manufacturing. Specifications provide
objective, measurable criteria that can be used to verify whether the product meets the functional requirements, industry
standards, and user expectations. They also enable teams to conduct simulations, tolerancing, performance analysis, and
ensure interchangeability between parts in complex assemblies.
Types of Specifications
Specifications can be categorized based on their function:
•Functional Specifications: Describe what a system or component must do (e.g., "must withstand 100 kg load").
•Performance Specifications: Define measurable performance criteria (e.g., "motor must deliver 4.5 kW power at
4300 RPM").
•Material Specifications: Specify material types and properties (e.g., "use AISI 1020 steel with yield strength ≥ 350
MPa").
•Geometric Specifications: Include sizes, shapes, tolerances, and surface finishes (e.g., "shaft diameter 40 mm ± 0.05
mm").
•Environmental Specifications: Mention conditions under which the product should perform (e.g., "operating
temperature: -10°C to +45°C").
•Regulatory/Compliance Specifications: Define legal or safety standards the product must meet (e.g., "must comply
with AIS 156 battery standards").
Example of Specifications in an EV Scooter Design
Let's consider an electric two-wheeler as an example. Below are
some sample specifications derived during design:
•Battery Capacity: 4.4 kWh, Voltage: 72 V
•Motor Type: Brushless DC hub motor, 4.5 kW, 140 Nm torque
•Chassis Material: Mild steel (AISI 1020), 2.5 mm wall thickness
•Brake Disc Diameter: 220 mm front, 180 mm rear
•Tire Size: 90/90-12, Diameter: 466 mm
•Suspension Travel: Telescopic fork, 110 mm travel
•Ingress Protection Rating: IP67 for electronics
•Frame Load Capacity: 180 kg with FOS ≥ 2.5
In the engineering design approach, defining clear and measurable product specifications from high-level requirements
ensures that:
• The final product aligns with customer expectations
• All components are engineered with precision
• The design is testable, manufacturable, and compliant
This bridge between "what is needed" and "how it’s delivered" is what turns an idea into a functional product.
Maps each requirement to one or more Translates customer voice into
measurable specifications engineering terms
Requireme Quality
nt Function
Specificati Deployme
on Matrix Tools and nt (QFD)
Methods to
Align
Requirement
s and
Specification
s Failure
System Mode and
Engineerin Effects
g V-Model Analysis
(FMEA)
Ensures every requirement is validated Evaluates risks in failing to meet specs
by testing a corresponding specification derived from critical requirements
SUBSYSTEMS – DEFINING THE FAILURES
HOW
HOW USING THE BEST
MATERIALS THAT MEET
THE SYSTEM
USING HIGH QUALITY SUITABLE MATERIALS
SPECIFICATIONS
COMPONENTS &
MATERIALS
USING NON-
USING HIGH PRECISED
CONVENTIONAL
COMPONENTS
MACHINING PROCESSES
HOW USING IOT SENSORS
AND ACTUATORS
REDUCING FAILURES USING REAL-TIME
IN SUBSYSTEM MONITERING SYSTEMS
USING AI TO FIND
ERRORS
SHEDULED CHECKS
DEFINE AND FOLLOW
PREVENTIVE
MATAINENCE REPLACEMENT OF
CONSUMABLES IN TIME
FAILURE MODE AND EFFECTS ANALYSIS (FMEA) IN SUBSYSTEM FAILURES
1. Definition & Purpose
FMEA (Failure Mode and Effects Analysis) is:
•A preventive risk analysis method used during product and process
development.
•It helps identify possible failure modes, assess their effects, and prioritize
actions to eliminate or reduce risks.
•Widely used across automotive, aerospace, electronics, and
manufacturing sectors.
Types of FMEA
There are mainly two types:
•Product FMEA: Focuses on design-level risks (e.g., parts failing,
interactions not working).
•Process FMEA: Focuses on process-related failures (e.g.,
assembly steps, equipment issues).
Key Evaluation Metrics
•Severity (S): Impact of the failure (1 to 10).
•Occurrence (O): Likelihood of the cause occurring (1 to 10).
•Detection (D): Ability to detect before it reaches the customer
(1 to 10).
RPN (Risk Priority Number) = S × O × D
The higher the RPN, the higher the priority to address the risk.
Product
FMEA
Product FMEA is a structured method used during the design
phase of a product to identify:
•Potential failure modes in the product’s design,
•The effects of those failures,
•Their causes and likelihood,
•And to take preventive actions before manufacturing begins.
What It Focuses On:
• Material selection
• Geometry/dimensions
• Tolerance stack-ups
• Thermal, mechanical, or vibration loads
• Functional fit between components
• Customer and regulatory requirements
RISK PRIORITY NUMBER
RPN stands for Risk Priority Number. It is a numerical value used in FMEA to prioritize
potential failures based on their risk level. RPN is calculated by multiplying three factors:
Severity, Occurrence, and Detection.
Each factor is rated from 1 to 10, so RPN values range from 1 (lowest risk) to 1000 (highest
risk). A higher RPN means a higher priority for taking corrective action. RPN helps teams
focus on the most critical issues first
Severity (S)
What it means:
How serious the effect of a failure would be if it happens.
•Rated from 1 (no effect) to 10 (dangerous or catastrophic). SEVERITY OCCURRENC
•Higher severity = more impact on safety, function, or customer.
Example:
E
If brake failure causes an accident, Severity = 10.
RPN
Occurrence (O)
What it means:
How likely the failure is to happen.
•Rated from 1 (rare) to 10 (very frequent).
•Based on past data, experience, or estimates.
Example:
If a bolt loosens once in 1,000 bikes, Occurrence = low (e.g.,
2–3).
Detection (D)
DETECTION
What it means:
How likely the failure will be detected before reaching the
customer.
•Rated from 1 (very likely to detect) to 10 (not detectable).
•Lower rating means better control or testing system.
Example:
If a testing machine easily finds a defect, Detection = 1–2.
If there's no test for it, Detection = 9–10.
Process FMEA
(PFMEA)
Purpose:
To identify and reduce risks in manufacturing or
assembly processes before production begins.
Focus Areas:
•Assembly errors
•Equipment malfunctions
•Human/operator errors
•Tool wear or improper calibration
•Incorrect process parameters (e.g., temperature,
pressure)
Example:
In assembling an EV bike:
•A PFMEA might identify a risk of over-torquing bolts
during motor mounting, which could damage
components or cause vibration issues.
Benefits:
•Improves process reliability
•Reduces scrap, rework, and downtime
•Ensures consistent product quality
