METHODOLOGY FOR PRODUCT DESIGN

Sasi Kumar Gera

Scientist/Engineer “E”
NIELIT, Aurangabad
CASE STUDY: IN-LINE SKATES
Manufacturing
Graphic Design

Industrial Design Market Analysis

Packaging
Plastics Design
Design

Mechanical
Ergonomics
Design

Technical
Fluid Design
Documentation
CASE STUDY: PERSONAL COMPUTER
Electomechanical
Heat Transfer Design

Graphic Design Software Engg.

Industrial Design Manufacturing

Packaging Market Analysis

Design

Plastics Design
Ergonomics

Technical Mechanical
Documentation Design
TOTAL DESIGN
 Total Design is a systematic methodology to achieve integration of
the technological as well as non-technological subjects material with
the goal of creating successful products and processes.

Consumer Product

 TOTAL DESIGN is distinguish from “partial design” in which TOTAL

DESIGN requires the input from people of many disciplines, both
engineering and non-engineering, in a mix that is almost unique to
the product under consideration.
PRODUCT DESIGN CORE Market

Specifications

Conceptual Design

Detail Design

Manufacturing

Sales
PRODUCT DESIGN CORE Market

Information Specifications
Electrical Stress

Hydraulics Conceptual Design

Mechanisms

Mechanical Stress Detail Design

Manufacturing
Technology Dependent
Tools
Sales
PRODUCT DESIGN CORE
Market
Technology
Dependent Tools
Specifications
Information

Electrical Stress
Conceptual Design
Hydraulics
Optimisation
Mechanisms
Detail Design
Mechanical Stress Cost Patterns

Manufacturing Market Trends

Info
Sales
Technology
Independent Tools
MARKET
Market All design starts with a need that,
when satisfied, will fit into an existing
market or create a market of its own.
Specifications

Conceptual Design The outcome of this design activity is

a statement of need or a „brief‟.
Detail Design

Manufacturing

Sales
MARKET
Market All design starts with a need that,
when satisfied, will fit into an existing
market or create a market of its own.
Specifications

Conceptual Design
The outcome of this design activity is
a statement of need or a „brief‟.
Detail Design

Manufacturing Example:
Design a machine for material
handling capable of manoeuvring over
Sales rough terrain
MARKET
Market All design starts with a need that,
when satisfied, will fit into an existing
market or create a market of its own.
Specifications

Conceptual Design
The outcome of this design activity is
a statement of need or a „brief‟.
Detail Design

Manufacturing Example:
Design a machine for material
handling capable of manoeuvring over
Sales rough terrain
 The outcome of this design activity is the
SPECIFICATIONS PDS
Product Design Specification

Changes D/W Requirements

Market
D Throughput (mixed flow) max.10 l/min @ 2 bars
Max pressure 10 bars
D Temp of water standard 600C
W To fit hose basin Specifications
D Light Operation (Children)
D No Extra energy
D Smooth, easily cleaned contour, no sharp edges
W Conceptual Design
Changes D/W Requirements
D Throughput (mixed Flow) max... 10 l/min. @ 2 bars
D
W
max.. Pressure 10 Bars
Temp. of Water standard 60ºC
Detail Design
D To fit hose basin
D Light Operation (Children)
D
W
No Extra energy
Smooth, easily cleaned contour, no sharp edges
Manufacturing
Changes D/W Requirements
D Throughput (mixed Flow) max... 10 l/min. @ 2 bars Sales
max.. Pressure 10 Bars
D Temp. of Water standard 60ºC
W To fit hose basin
GENERAL STRUCTURE OF PDS
Title:________________ Date:_______________

Changes D/W Requirements Responsible

D Throughput (mixed flow) max.10 l/min @ 2
bars
D Max pressure 10 bars
W Temp of water standard 600C
D To fit hose basin
D Light Operation (Children)
D No Extra energy
W Smooth, easily cleaned contour, no sharp
edges
CHARACTERISTICS OF THE PRODUCT DESIGN
SPECIFICATION (PDS)
 PDS is the fundamental control mechanism that allows this success
to manifest itself.
 PDS must be comprehensive and unambiguous.
 At the end of the design process the product must be balanced with
the PDS
 Poor PDS leads to poor design that will fail in the market.
 Good PDS does not guarantee good design but make the goal more
attainable.
 PDS set the design context which are a comprehensive set of
constrains.
CONTENTS OF A PDS: PERFORMANCE
Webster‟s Dictionary
perï for ïmance \pe(r)-ífo r-men(t)s\ n
(15c)
1a: the execution of an action
b: something accomplished: DEED, FEAT
2: the fulfillment of a claim, promise, or request: IMPLEMENTATION
3a: the action of representing a character in a play
b: a public presentation or exhibition Ea. benefit performance
4a: the ability to perform: EFFICIENCY
b: the manner in which a mechanism performs engine performance
5: the manner of reacting to stimuli: BEHAVIOR
6: linguistic behavior - compare COMPETENCE 3
- per for ma to ry \-me-, to r -e , -, to r-\ adj p

“Performance should be fully defined, e.g., how fast, how slow, how often,
continuously vs. discontinuous, energy requirements- electrical, hydraulic vs.
pneumatic, tolerances, etc.”
REMEMBER

±0 tolerance-> ∞$

“A common failing in specifying performance is to

ask for the ultimate, rather than which is
obtainable from economical point of view.”
CONTENTS OF PDS : ENVIRONMENT
 temperature range
 pressure range (altitude)
 humidity ï shock loading (gravity forces)
 dirt or dust - how dirty? - how clean?
 corrosion from fluids - type of fluid or chemical
 noise levers
 Insects
 vibration
 type of labour or person who will use the
equipment - likely degree of abuse?
 any unforeseen hazards to customer, user or
the environment - for example inclusion of
CFCs?
CONTENTS OF PDS : ENVIRONMENT
 During manufacturing - exposure to cutting
fluid, solvents, fluxes, acids, etc.
 During storage - in the plant
 During assembly - assembly forces,
contamination from sweating hands?
 During packaging
 During transportation
 During storage - at a wholesaleís
warehouse
 During display
 During use
PDS: GUIDE LINES
 The PDS is a control document
 It is a use document

 Never write a PDS in essay format

 Try to quantify parameters from the beginning

 Always date the document and to an issue number

 Clearly mention the document amendments

CONCEPTUAL DESIGN Market

 It is the phase of design primarily Specifications

concerned with the generation of solutions
to meet the stated nee, i.e., the PDS
Conceptual Design

Detail Design

Manufacturing

Conceptual design is Synthesis Sales

CONCEPTUAL DESIGN Market

 It has two major Components Specifications

1. Generation of solutions to meet the

Conceptual Design
stated need, i.e., PDS

Detail Design
2. The evluation of these solutions to
select the one that must be suited Manufacturing
to match the need
Sales
CONCEPTUAL DESIGN
1. The generation of solutions to meet the PDS

In order to generate solutions or ideas to solve a given design

problem, you must be “creative”
CONCEPTUAL DESIGN
1. The generation of solutions to meet the PDS
Yes but how do I become “creative”?

Everybody is creative. All we need to do is watch out

for “Mental Blocks”
CONCEPTUAL DESIGN
 Recognising and dealing with Mental Blocks

1 “The Right Answer”

CONCEPTUAL DESIGN
 Recognising and dealing with Mental Blocks

2
“That is not Logic”
CONCEPTUAL DESIGN
 Recognising and dealing with Mental Blocks
“Follow the Rules”
3
CONCEPTUAL DESIGN
 Recognising and dealing with Mental Blocks

4
“Be Practical”
CONCEPTUAL DESIGN
 Recognising and dealing with Mental Blocks

5
“Play is Frivolous”
CONCEPTUAL DESIGN
 Recognising and dealing with Mental Blocks

6
“That is not my area”
CONCEPTUAL DESIGN
 Recognising and dealing with Mental Blocks

7
“Avoid Ambiguity”
CONCEPTUAL DESIGN
 Recognising and dealing with Mental Blocks

8
“Don‟t be foolish”
CONCEPTUAL DESIGN
 Recognising and dealing with Mental Blocks

9
“The err is wrong”
CONCEPTUAL DESIGN
 Recognising and dealing with Mental Blocks

10
“I‟m not Creative”
CONCEPTUAL DESIGN
Idea Generation: Tips
CONCEPTUAL DESIGN
Idea Generation: Tips
Concepts are best generated by
individuals
CONCEPTUAL DESIGN
Idea Generation: Tips
Concepts are best generated by
individuals
Avoid at all cost the temptation to „cut
and run‟ and start engineering and
developing the ideas further
CONCEPTUAL DESIGN
Idea Generation: Tips
Concepts are best generated by
individuals

Avoid at all cost the temptation to „cut

and run‟ and start engineering and
developing the ideas further

You need as many ideas as you can

CONCEPTUAL DESIGN
Idea Generation: Tips
Concepts are best generated by
individuals
Avoid at all cost the temptation to „cut
and run‟ and start engineering and
developing the ideas further
You need as many ideas as you can
Stay with the laws of physics
CONCEPTUAL DESIGN
Idea Generation: Tips
Concepts are best generated by
individuals
Avoid at all cost the temptation to „cut
and run‟ and start engineering and
developing the ideas further
You need as many ideas as you can
Stay with the laws of physics
Always keep the PDS as a reference
CONCEPTUAL DESIGN
Idea Generation: Tips
Use the following techniques:
1. Brain Storming

Combinations
2. Analogies

3.
+ =
CONCEPTUAL DESIGN
An idea is not an idea, if you can not communicate it.
• 3D Sketching
• Diagrams
• Circuit Diagrams
• Block Diagrams
• World Description
• Ladder-logic Diagrams
• Mathematical Expressions
• Analytical Drawings
Note: Concepts or ideas must be titled, numbered and ionized so they can be cross
referenced later.
CONCEPTUAL DESIGN

Concepts generated at this phase should never be arbitrarily

discarded as not been good. Particularly because a third party
does not like them.

“Gut-feeling” design is out of the question.

CONCEPT EVALUATION
To effectively evaluate a concept, an agreed set
of criteria is needed.

 This Criterion comes from the PDS

 This is carried out in groups (never along)

 It should be written down

CONCEPT EVALUATION
The Controlled Convergence Matrix
A methodology for sorting out ideas

Example:
Brief: “Design a car horn”
PDS:
CONCEPT EVALUATION
The Controlled Convergence Matrix
D/W Criterion
D Able to produce 105-124 DbA
D Able to produce 2000-5000Hz
D Corrosion, erosion, and water resistant
D Resistance to vibration, shock and acceleration
D Temp range -500F to 2000F
D Time response: 250 ms
D Small number of stages
W Power consumption less than 35W
PDS for Car Horn W Low maintenance
W Weight less than 2lbs
W Size: less than 6inx6inx6in
W Low number of parts
D Life in service: more than 10 years
W Mng costs less than $3.00
D Easy installation
W Self life: 20 years
Thank you