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- 1. S RENOLD ELSEN ASSOCIATE PROFESSOR Department of Design & Automation-SMEC Mobile: 9994304360 Mail ID: renoldelsen.s@vit.ac.in Cabin No:- SJT 612 25A SCHOOL MECHANICAL ENGINEERING DEPARTMENT OF DESIGN AND AUTOMATION MEE3502 DESIGN PROCESS PLANNING & MANAGEMENT
- 2. Define Empathy Ideate Prototype Launch Test INTRODUCTION INTRODUCTION Course Contents Course Objective Course Outcome Assessment Mode Rubrics Text Book
- 3. Define Empathy Ideate Prototype Launch Test COURSE CONTENTS COURSE CONTENTS Module I CAD/CAM/CAE Module II Assembly Of Parts And Product Data Exchange Module III Document preparation with policies, procedures and guidelines Module IV Organization work place procedures and policies Module V Managing Health and Safety Module VI Data and Information Management Module VII Learning and Self Development Module VII Contemporary Discussion
- 4. Define Empathy Ideate Prototype Launch Test Impart students skills to apply CAD/CAM/CAE tools to develop products, manage product data and information. Train students to excel in document creation, team work, health, safety, self and work management COURSE OBJECTIVES COURSE OBJECTIVES
- 5. Define Empathy Ideate Prototype Launch Test 1. Apply CAD/CAM/CAE tools efficiently to design and develop new products 2. Analyze accuracy of assemblies and execute data exchange as per standards 3. Excel in document creation and work in line with the organization's policies and procedures 4. Evaluate knowledge, skills and competence regularly and take appropriate action 5. Implement organization’s health, safety and security policies and procedures 6. Develop e-governance and manage digital data and information COURSE OUTCOME COURSE OUTCOME
- 6. Define Empathy Ideate Prototype Launch Test Having a clear understanding of the subject related concepts and of contemporary issues and apply them to identify, formulate and analyse complex engineering problems Having design thinking capability Having an ability to design a component or a product applying all the relevant standards and with realistic constraints, including public health, safety, culture, society and environment Having an ability to design and conduct experiments, as well as to analyse and interpret data, and synthesis of information Having an ability to use techniques, skills, resources and modern engineering and IT tools necessary for engineering practice STUDENT LEARNING OUTCOMES STUDENT LEARNING OUTCOMES
- 7. Define Empathy Ideate Prototype Launch Test ASSESSMENT & RUBRICS ASSESSMENT & RUBRICS Assessment Title Max Mark Wt% Due date CAT - Continuous Assessment Test - I 50 15 CAT - Continuous Assessment Test - II 50 15 Digital Assignment - Digital Assignment - I 10 10 ___________ Digital Assignment - Digital Assignment - II 10 10 ___________ FAT - Final Assessment Test 100 40 Quiz - 1 10 10 __________ Additional Learning 10 10 110
- 8. Define Empathy Ideate Prototype Launch Test Karl T. Ulrich and Steven D. Eppinger, Product Design and Development, , McGraw-Hill International Edns. 2011. Radhakrishnan P, Subramanyan S and Raju V,. CAD/CAM/CIM, 2nd Edition, New Age International (P) Ltd, New Delhi, 2008. TEXT BOOK(S) TEXT BOOK(S)
- 9. Define Empathy Ideate Prototype Launch Test REFERENCE BOOK(S) REFERENCE BOOK(S) Amitav ghosh and Asok kumar malik, “Theory of mechanism and machines”, EWLP, Delhi, 2000. Kevin Otto and Kristin Wood, Product Design Techniques in Reverse Engineering and New Product Development, Pearson Education (LPE). 2001 Dieter, George E., “Engineering Design – A Material and Processing Approach”, McGraw - Hill, International Editions, Singapore, 2000.
- 10. Define Empathy Ideate Prototype Launch Test Identify a consumer product as needed by the market, develop concept, CAD model, simulate in CAE environment, optimize, and develop tooling. Prototyping and testing cost evaluation categories of cost BOM. Make a physical prototype. Prepare detailed documentation with standards. Areas of Focus Automation, Robotics, Cyber Physical System, Advanced Mechanisms Design, CAM, Rapid Prototyping, Automobiles Engineering, Metal Casting, Forging, Tool Design. PROJECTS PROJECTS
- 11. MEE3501 PRODUCT DEVELOPMENT AND MANAGEMENT L T P J C 2 0 2 4 4 Module CAD/CAM/CAE Lecture Hours 1 Review of : Product cycle- Design process- sequential and concurrent engineering- Computer aided design CAD system architecture- Computer graphics Introduction to CAM- NC/CNC Machines, Manufacturing Planning, Manufacturing control, Manufacturing methods, Introduction to CAE. 7
- 12. Define Empathy Ideate Prototype Launch Test CAD is the usage of computer systems to perform certain functions in design process. CAM is the usage of computer systems to plan, manage and control the operations of manufacturing plant. this can be done by either direct/ indirect interface with the plants production resources. CAD/CAM/CAE CAD/CAM/CAE
- 13. Define Empathy Ideate Prototype Launch Test Drafting and documentation design Generation of shaded images and animated display Engineering Analysis (FEA/CFD) NC Part programing Process Planning CAD / CAM IN ENGINEERING PRACTICE CAD / CAM IN ENGINEERING PRACTICE
- 14. Define Empathy Ideate Prototype Launch Test The expectations of today’s customer Superior quality Performance, Higher technological capabilities On time delivery. Reduced costs Because of global competition faced by the manufacturing industries NEED FOR CAD / CAM NEED FOR CAD / CAM
- 15. Define Empathy Ideate Prototype Launch Test Geometric Modeling Design Computer Graphics CAD DISCIPLINES CAD DISCIPLINES
- 16. Define Empathy Ideate Prototype Launch Test CAD AUTOMATION MANUFACTURING CAM DISCIPLINES CAM DISCIPLINES
- 17. Define Empathy Ideate Prototype Launch Test CAD/CAM Design Geometric Modeling Computer Graphics MANUFACTURING AUTOMATION CAD CAD / CAM CAD / CAM
- 18. Define Empathy Ideate Prototype Launch Test Recognition of need Definition of problem Synthesis Analysis and optimisation Evaluation CONVENTIONAL DESIGN PROCESS CONVENTIONAL DESIGN PROCESS
- 19. Define Empathy Ideate Prototype Launch Test Recognition of need Definition of problem Synthesis (Geometric modeling) Analysis & Opti (Engg Analysis) Evaluation (Design Review & Evaluation) CONVENTIONAL DESIGN PROCESS VS CAD CONVENTIONAL DESIGN PROCESS VS CAD
- 20. Define Empathy Ideate Prototype Launch Test Geometric modelling Engineering analysis Design review & evaluation Automated drafting Parts classification and coding TASK OF CAD SYSTEM TASK OF CAD SYSTEM
- 21. Define Empathy Ideate Prototype Launch Test • Flexibility • Reduced lead times • Reduced inventories • Increased productivity • Improved quality • Better product design • Reduced cost • Reduction of machine tools ADV OF CAD/CAM ADV OF CAD/CAM
- 22. Define Empathy Ideate Prototype Launch Test CAD TOOLS FOR DESIGN PROCESS CAD TOOLS FOR DESIGN PROCESS DESIGN PHASE REQUIRED CAD TOOLS Design conceptualization Geometric modelling technique; graphics aid; manipulation and visualization Design Modeling and simulation Geometric modelling technique; graphics aid; manipulation and visualization, animation; assemblies; special modelling package. Design analysis Analysis packages; customized programs and packages Design optimization Customized application; structural optimisation. Design evaluation Dimensioning; Tolerance; BOM; NC Design communication and documentation Drafting and detailing
- 23. Define Empathy Ideate Prototype Launch Test CAD / CAM IN INDUSTRY CAD / CAM IN INDUSTRY Geometric modeling of conceptual design Check for design evaluation Design testing & evaluation Check for Drafting Documentation Process planning Check for manufacturing issue in CAD data NC programing Machining Inspection Assembly Develop own package
- 24. Define Empathy Ideate Prototype Launch Test A product is something sold by an enterprise to its customers. A product is something that is created through a process that provides benefits to a market PRODUCT PRODUCT
- 25. Define Empathy Ideate Prototype Launch Test Set of activities • begins with the perception of a market opportunity • ends in the production, sale, and delivery of a product. PRODUCT DEVELOPMENT PRODUCT DEVELOPMENT
- 26. Define Empathy Ideate Prototype Launch Test • To meet the requirements of customers • To continue in business for a long time • Too much competition in the existing product lines • Reduction in profit margins • Survival & Growth strategy of an organization NEED FOR A NEW PRODUCT NEED FOR A NEW PRODUCT
- 27. Define Empathy Ideate Prototype Launch Test PRODUCT LIFE CYCLE PRODUCT LIFE CYCLE Phase 1 - Product Development Phase 2 - Introduction / Launch Phase 3 - Growth Phase 4 - Maturity Phase 5 - Decline Sales Sales & Profit Time Product Development Introduction Growth Maturity Decline
- 28. Define Empathy Ideate Prototype Launch Test PRODUCT CYCLE PRODUCT CYCLE Design Need Design Definition specification, & requirements Collecting relevant design information and feasibility study Design Conceptualization Design Modeling and simulation Design Analysis Design optimization Design evaluation Design Communication and documentation Synthesis Analysis Process Planing Order material Production Planning Design & procurement of new tools NC, CNC, DNC programming Production Quality control Packaging Shipping CAM PROCESS Marketing CAD PROCESS
- 29. Define Empathy Ideate Prototype Launch Test PRODUCT CYCLE IN MANUFACTURING PRODUCT CYCLE IN MANUFACTURING Need Forecast Product Concept Design Preparing part prints Customer Feedback Order Tooling Process Planning Order Material & Machine Marketing Tool Tryout Scheduling Manufacturing operations Establishing Work Standards Quality Control Actual Production
- 30. Define Empathy Ideate Prototype Launch Test PRODUCT CYCLE IN AN COMPUTERIZED ENVIRONMENT PRODUCT CYCLE IN AN COMPUTERIZED ENVIRONMENT Geometric Modeling Finite Element Analysis Computer Aided Design Product Simulation Computer Aided Drafting Order New Equipment Computer Aided Process Planning Computer Aided Tool Design Tool Manufacturing And Tryout Material Requirement planning Computer Aided CNC Part Programing Generation Computer Aided Scheduling Computer Aided Work Standards CNC Machines Robots and other Material Handling Equipment's Computer Aided Inspection & QC Actual Production Marketing Customer Feedback Product Concept Need Forecast
- 31. Define Empathy Ideate Prototype Launch Test Sequential engineering is a type of engineering production method where a project is completed in a linear format. In sequential engineering, each step is worked on in a certain order. All attention is put toward completing the first step of the project until it is complete. Once the first step is complete, the engineering team will then move on to the second step of the project. DEFINITION SEQUENTIAL ENGINEERING DEFINITION SEQUENTIAL ENGINEERING
- 32. Define Empathy Ideate Prototype Launch Test Traditional / Over-the-wall SEQUENTIAL ENGINEERING SEQUENTIAL ENGINEERING
- 33. Define Empathy Ideate Prototype Launch Test A systematic approach to the integrated, concurrent design of products and their related processes, including manufacture and support. This approach is intended to cause the developers, from the outset, to consider all elements of the product life cycle from conception through disposal, including quality, cost, schedule, and user requirements. DEFINITION C.E DEFINITION C.E THE ROLE OF CONCURRENT ENGINEERING IN WEAPONS SYSTEM ACQUISITION
- 35. Define Empathy Ideate Prototype Launch Test Personal – Team formation & Training Multi Functional & Cross Disciplinary Process – Open to change Technology – S/W, H/W & Networking ELEMENTS ELEMENTS
- 36. Define Empathy Ideate Prototype Launch Test Change in market pace Faster decisions Reduced repetition of tasks Faster response Reduced cost Efficient operations NEED NEED
- 37. Define Empathy Ideate Prototype Launch Test * Improving the quality of designs which resulted in dramatic reductions of engineering change orders (greater than 50 percent) in early production. * Product development cycle time reduced by as much as 40 to 60 percent through the concurrent, rather than sequential, design of product and processes. * Manufacturing costs reduced by as much as 30 to 40 percent by having multifunction teams integrate product and process designs. * Scrap and rework reduced by as much as 75 percent through product and process design optimization. REPORTED BENEFITS REPORTED BENEFITS
- 38. Define Empathy Ideate Prototype Launch Test • Product development time reduced up to 60%. • Production spans reduced 10%. • AT&T reduced the total process time for the ESS programmed digital switch by 46% in 3 years. • Deere reduced product development time for construction equipment by 60%. • ITT reduced the design cycle for an electronic countermeasures system by 33% and its transition-to- production time by 22%. DEVELOPMENT AND PRODUCTION LEAD TIMES DEVELOPMENT AND PRODUCTION LEAD TIMES
- 39. Define Empathy Ideate Prototype Launch Test • Yield improvements of up to four times. • Field failure rates reduced up to 83%. • AT&T achieved a fourfold reduction in variability in a polysilicon deposition process for very large scale integrated circuits and achieved nearly two orders of magnitude reduction in surface defects. • AT&T reduced defects in the ESS programmed digital switch up to 87% through a coordinated quality improvement program that included product and process design. • Deere reduced the number of inspectors by two-thirds through emphasis on process control and linking the design and manufacturing processes. MEASURABLE QUALITY IMPROVEMENTS MEASURABLE QUALITY IMPROVEMENTS
- 40. Define Empathy Ideate Prototype Launch Test • Engineering changes per drawing reduced up to 15 times. • Early production engineering changes reduced by 15%. • Inventory items stocked reduced up to 60% • Engineering prototype builds reduced up to three times. • Scrap and rework reduced up to 87%. ENGINEERING PROCESS IMPROVEMENTS ENGINEERING PROCESS IMPROVEMENTS
- 41. Define Empathy Ideate Prototype Launch Test • McDonnell Douglas had a 60% reduction in life-cycle cost and 40% reduction in production cost on a short-range missile proposal. • Boeing reduced a bid on a mobile missile launcher and realized costs 30 to 40% below the bid. • IBM reduced direct costs in system assembly by 50%. COST REDUCTION COST REDUCTION
- 42. Define Empathy Ideate Prototype Launch Test * Reduced bid in company proposals. * Reduced costs in the design phase. * Reduced costs during fabrication, manufacture, and assembly * Costs reduced by parts reduction and inventory control. * Costs reduced by reducing scrap and rework. REPORTED COST REDUCTIONS REPORTED COST REDUCTIONS
- 43. Define Empathy Ideate Prototype Launch Test • Competitive advantage • Faster time to market • Enhanced Quality • Enhanced Productivity • Decrease design and development time GAINS GAINS