1. Unit no-1 Introduction to product design and development
Design establishes and defines solutions to and pertinent structures for problems not solved
before, or new solutions to problems which have previously been solved in a different way
The Four C’s of Design
1)Creativity 2)Complexity 3)Choice 4)Compromise
Decisions made in the design process cost very little in terms of the overall product cost but
have a major effect on the cost of the product.
You cannot compensate in manufacturing for defects introduced in the design phase .
Types of Design
1) Original design 2)Adaptive design 3)Redesign 4)Industrial Design
Description of design process-
Phase-I conceptual Design-
1)Identifi cation of customer needs :2) Problem defi nition 3) Gathering information
4) Conceptualization 5) Concept selection 6) Refi nement of the PDS 7) Design review
Phase-II Embodiment Design
1) Product architecture 2) Confi guration design of parts and components 3) Parametric
design of parts
2. Phase-III Detail Design
1) Detailed engineering drawings suitable for manufacturing 2) Verifi cation testing of
prototypes 3) Assembly drawings and assembly instructions 4) A detailed product
specifi cation 5) detailed cost estimate 6) design review
Phase-IV Planning for manufacture
1)Designing specialized tools and fixtures
2)Specifying the production plant that will be used (or designing a new plant)
3)laying out the production lines
4)Planning the work schedules and inventory controls (production control)
5)Planning the quality assurance system
6)Establishing the standard time and labor costs for each operation
7)Establishing the system of information flow necessary to control the manufacturing
Phase-V Planning & Distribution
Provide for the effective distribution to the consumer of the products that have been produced
Phase-VI Planning for use
The following specific topics can be identified as being important user-oriented concerns
in the design process: ease of maintenance, durability, reliability, product safety, convenience
in use (human factors engineering), aesthetic appeal, and economy of operation
Product Development Process
Product development process is the entire set of activities required to bring new concept to a
state of market readiness. This set includes everything from the initial inspiring new product
vision to business case analysis activities, marketing efforts, technical engineering design
activities development of manufacturing plans and validation of product design to confirm
these plans. It also includes development of distribution channels for strategically marketing
and introducing new product.
Product development and design is closely linked with industrial activity and production.
When a new product is planned the designer has to bear in mind the available resources of
plant and the possible impact of firm having to acquire, modify or substitute existing
machines and equipment or buy various components from other supplier.
The detail process of product development is explained in six phases as per below diagram
3. Phase 0:
Product planning is usually done in two steps. The first step is a quick investigation and
scoping of the project to determine the possible markets and whether the product is in
alignment with the corporate strategic plan. It also involves a preliminary engineering
assessment to determine technical and manufacturing feasibility. If things look promising
after this quick examination, the planning operation goes into a detailed investigation to build
the business case for the project
Phase-1 Concept Development
product design specifi cation (PDS) are developed in this phase by understanding customer
needs by customer survey and by using tools like quality function deployment (QFD).
Phase 2 , System-Level Design (embodiment design)
Functions of the product are examined, leading to the division of the product into various
subsystems. In addition, alternative ways of arranging the subsystems into a product
architecture are studied
Phase 3 , Detail Design
It is the phase where the design is brought to the state of a complete engineering description
of a tested and producible product
At the end of Phase 3, a major review is held to determine whether it is appropriate to let
contracts for building the production tooling.
Phase 4 , Testing and Refinement,
It’s concerned with making and testing many preproduction versions of the product. The first
prototypes are usually made with production-intent parts. These are working models of the
product made from parts with the same dimensions and using the same materials as the
production version of the product but not necessarily made with the actual processes and
tooling that will beused with the production version
Phase 5 , Production Ramp-Up,
At this stage manufacturing operation begins to make and assemble the product using the
intended production system
For certain products the manufacturing process places strict constraints on the properties of
the product, so product design cannot be separated from the design of the production process.
Examples of process-intensive products are automotive sheet steel, food products,
semiconductors, chemicals, and paper
4. Major Activities of Modern product development process are
1)Identify opportunity-
i)Develop a vision ii)Market opportunity Analysis iii)Customer need Analysis iv)Competitive
analysis
2)Development of Concept:
i)Portfolio planning ii)Functional modeling iii)Product architecture development iv)concept
engineering
3)Implementation of concept-
i)Embodiment Engineering ii)Physical and analytical modeling iii)Design for X iv)Robust
design
Standardization ,simplification and specialization in product design .
Advantages of standardization-
i)Reduction of material waste and obsolescence
ii)Reduction in inventories
iii)Concentration of manufacturing efforts
iv)Reduction in book keeping
v)Lowering the grades of skill required
vi)Reduction in price
vii)Reduction in repair and maintenance cost
Advantages of simplicity-
i)Reduction in inaccuracy
ii)Reduction in equipment
iii)Save of storage space
iv)simplify inspection and control
v)shorten or eliminate order ques
Advantages of variety-
i)Satisfy wide range of demand
ii)Enable better contact with market to study its taste and requirement
iii)create demand
structure of Product Development team:
A team may be defined as two or more persons engaged in a common goal who are
dependent on one another for results and who have joint accountability for the outcomes.
Various team roles includes
1)Administrator 2)Troubleshooter 3)Producer/test pilot 4)Manager/coordinator
5)Councilor or critic 6)Investigator 7)Performer 8)visionary 9)strategist 10)Need Identifier
11)Entrepreneur 12)Diplomat 13)Simulator
5. Product Development versus Product Design
Sr
no
Product Development Product design
1 It is a process which contains entire set of
activities required to bring new concept to
a state of market readiness
It is a process which contains technical
activities within product development
process that works to meet market and
business requirements.
2 This set includes everything from initial
inspiring new product vision to business
case analysis ,commercialization activities
It includes refinement of product vision in
to technical specifications
3 Includes marketing efforts and technical
engineering design activities
It only includes technical activities
4 Includes financial activities Do not include
5 Includes design for
manufacture(DFM),Design for
assembly(DFA)
Do not include
6 Independent process It’s a part of Product development
Product Verification and product validation:
Sr
no
Product verification Product validation
1 It is the evaluation process of determining
whether or not a product ,services or
system satisfies the requirements,
regulations and complies with
specifications or not those are imposed or
for which it has made
It is assurance of product ,services or
system which requires and satisfies
different customer needs. Customer needs
are validated or not it often involves
acceptance
2 It is a process to check product services or
system need a set of initial design
specifications or not
validation is a technique to check that
development and verification procedure
for service. or system result in initial
specifications or not
3 It involves performing special test on
model. This performance is reviewed or
analysis of modeling result is done
It involves modeling the entire flow and its
verification using simulation to product.If
any gap is generated during the process it
may lead to incomplete verification or
development of product
4 It is internal process of verification It is external process of validation
6. Product testing:
Product testing, also called consumer testing or comparative testing, is a process of
measuring the properties or performance of products. The theory is that since the advent of
mass production manufacturers produce branded products which they assert and advertise to
be identical within some technical standard. Product testing seeks to ensure that consumers
can understand what products will do for them and which products are the best value.
Product testing is a strategy to increase consumer protection by checking the claims made
during marketing strategies such as advertising, which by their nature are in the interest of the
entity distributing the service and not necessarily in the interest of the consumer. The advent
of
product testing was the beginning of the modern consumer movement. Product testing might
be accomplished by a manufacturer, an independent laboratory, a government agency, etc.
Often an existing formal test method is used as a basis for testing. Other times engineers
develop methods of test which are suited to the specific purpose. Comparative testing
subjects several replicate samples of similar products to identical test conditions.
In India bodies like ARAI (Automotive Research Association Of India) performs crash test
which is a form of destructive testing .It is performed in order to ensure safe design standards
in crashworthiness and crash compatibility for various modes of transportation (see
automobile safety) or related systems and components like safety belts and Helmets.
