Design and Manufacture Design Analysis Design Analysis Think

Design and Manufacture Design Analysis

Design Analysis Think of a product: We are all going to have that product in our minds for a while, so make sure you are know all about it and are very familiar with it.

Design Analysis I have picked a Lawnmower! Your turn now Unfortunately you cannot have the same product as anyone else in the class. There a few products you can’t pick. These are things like mobile phones, MP 3 players, DVD players, televisions, computers or any other gaming platform. Try to think of a product from the kitchen, your bedroom, the bathroom, the garden or something you use for a hobby.

Design Analysis Now that we have chosen, we are going to carry out a series of tasks to help us understand the main design issues we need to learn about. Surprise, surprise they are: FEEDSCAMP

Design Analysis FEEDSCAMP Function Ergonomics Environmental Concerns Durability Safety Cost Aesthetics Materials Production

Function can be split into two main areas. Primary function and Secondary function

Function Primary function This is the main purpose of the product. ‘What the product is designed to do’ e. g. Lawnmower: to cut grass shorter

Secondary function This is another job that the product does. e. g. Lawnmower: to collect grass clippings

Secondary function(s) Some products have more than one secondary function e. g. Lawnmower: to collect grass clippings and to make stripes on the cut grass

Function Your turn: Write down the primary and secondary functions of your product and explain what they are. At this point you should realise why we asked you not to pick a mobile phone, etc: Too many different functions!

Function What did you write? Let us take some of the answers and discuss.

ERGONOMICS THE THREE ASPECTS

ERGONOMICS • Anthropometrics • Physiology • Psychology

Anthropometrics • The study of human dimensions • This area of ergonomics looks into the sizes of the human body

Standard deviation curve Population Dimension / size

Anthropometrics • • 5 th percentile (tiny people) 50 th percentile (average Joe) 95 th percentile (huge people) 100 th percentile (largest person) E. g. 100 th percentile stature = tallest person in the world.

Anthropometrics • • Adult male Adult female 95 th%ile 50 th%ile 5 th%ile Older adult Child data

A A: Hand Breadth Female 16 years of age 5 th: 75 50 th: 80 95 th: 85 Male 16 years of age 5 th: 80 50 th: 90 95 th: 100 B Measure your own hand at ‘A’ and write down what dimension you get. B: Hand Length Female 16 years of age 5 th: 160 50 th: 175 95 th: 190 Male 16 years of age 5 th: 170 50 th: 185 95 th: 200 Measure your own hand at ‘B’ and write down what dimension you get.

Anthropometrics What dimensions did you get? What percentile range does that put you in? Does that mean you have a big hand or a small hand?

Anthropometrics Lawnmower, Anthropometrics: The 5 th %ile adult female hand grip diameter has been researched so that the handles to push and pull can be held by most users. The 95 th %ile adult male palm width has been researched so that the cord pull handle fits in most users hands safely.

Ergonomics Anthropometrics What did you write? Let us take some of the answers and discuss.

Physiology • Physiology is the study of human limitations (and interactions with products) • Task: Write down as many physical action verbs as you can think of that link to the use of a kettle (verbs are doing words)

Physiology Lifting Pouring Filling Holding Switching Pressing Turning Cleaning Grabbing Gripping Carrying Moving Opening Closing Emptying Reading Note these are things that you do – not things that a kettle does e. g. boiling, heating are not in the list.

Physiology

Physiology It is best to try to link the doing word to the part of the kettle to make sense of what you are saying. e. g. When pressing the switch on the kettle it should be easy with little effort to get it to go on.

Physiology When I am pulling the pull cord to switch the lawnmower on, I am strong enough to do it. When I am turning the petrol cap to fill the tank it is easy to turn with little strength.

Physiology Lawnmower, Physiology: The wheels on the lawnmower make moving around the garden more easy. The rubber grips on the handles add comfort when holding them.

Physiology Task: Write down three sentences relating to your product in terms of physiology. Remember to link the part of product to the physical action verb.

Ergonomics Physiology What did you write? Let us take some of the answers and discuss.

Psychology • The study of human behaviour and emotional interactions with products. • A sense of reactions linked to the use of a product

Psychology • Kettle Satisfying click (knowing it is on) Reassuring light (knowing it is on or off) Viewing window (knowing how full it is) White / silver colour (hygienic)

Psychology

Psychology When we talk about psychology we try to link the emotion to the part of the product. e. g. When I press the switch on the kettle to go on I know that it is on because the click noise/feeling and the light going on. I can see how full the kettle is by reading the fill level and I know it is safe to boil.

Psychology Lawnmower, Psychology: The red colour of the petrol tank cap makes it easy to see it is a dangerous part of the mower. The hot surface symbol on the engine grill makes the user aware of the danger of a burn from this part.

Psychology Task: Write down three sentences relating to your product in terms of Psychology. Remember to link the part of product to the emotion or feeling.

Ergonomics Psychology What did you write? Let us take some of the answers and discuss.

Design Analysis Environmental concerns What are environmental concerns? ‘designing a product to be friendly to the planet’

Design Analysis Can you think of any issues related to environmental concerns? Discuss in your group and make a list in your jotters of the issues you can think of. (timed task 4 minutes use stopwatch)

Design Analysis Environmental concerns • • • Reduce / reuse / recycle Recycled Recyclable CFCs Greenhouse cases Landfill Carbon footprint Carbon monoxide (car exhaust) Fossil fuels / finite resources Alternative energy solutions Sustainable forests

Environmental concerns (EC) When we think about EC we have to think about the three stages of a product during its life cycle. • Birth (manufacturing stage) • Life (daily use) • Death (disposal at end of useful life)

Product Life Cycle Sales Time What could be the impact on the environment at these times?

Environmental concerns (EC) Birth (manufacturing stage) When a product is manufactured, it is important to think about the materials and processes used to make it. The materials used should be sustainable and not finite. e. g. wooden garden bench should be made of sustainable wood. It could take a lot of energy and power to make certain products and this could be harmful to the environment. e. g. cast car engine parts should be manufactured using as little energy as possible.

Environmental concerns (EC) Life (daily use) When a product is being used it should have little impact on the environment. Low energy use, non-toxic. Get energy symbol for fridge / bulb / kettle measure etc.

Environmental concerns (EC) Life (daily use) Energy efficiency symbol Old, energy wasting light bulb Energy efficient light bulbs

Environmental concerns (EC) Death (disposal at end of useful life) When a product reaches the end of its useful life, can it be: • recycled (materials used for another product, great!) • up-cycled (product use changed, whoopee!) • land fill (product thrown away and buried, boo!)

Environmental concerns (EC) Death (disposal at end of useful life) All recyclable rubbish is separated Landfill site (smelly!)

Up-cycling!

Environmental concerns (EC) Your turn now! Think of your product now and describe in sentences the three areas of EC. e. g. Lawnmower: Birth: The lawnmower is mostly made of metal (steel) and there are many processes used to make the parts. To make steel into different shapes and forms takes a lot of energy and machine processes.

Environmental concerns (EC) e. g. Lawnmower: Life: The lawnmower uses petrol to make it work and this is a finite resource. That makes the lawnmower poor for the environment. It also gives off fumes when it is in use and this is also bad for the environment. e. g. Lawnmower: Death: The lawnmower is mostly made from steel and this can be recycled. I could take it to the local recycling centre where it will be taken away and the metal can be reused.

Environmental Concerns What did you write? Let us take some of the answers and discuss.

Durability When we talk about Durability we are talking about time. The duration (lifespan) of time for which a product is designed to last. There are many factors that influence the lifespan of a product. Some products are designed to last shorter lifespans (obsolescence)

Durability Lifespan of a product. e. g. Lawnmower: When I am moving the lawnmower around the garden it will bump into the fence or the hedge. It must be strong enough so that the wheels do not fall off when it gets hit by the fence. When I empty the box for clippings it must not bend or break with repeated use. etc.

Durability Lifespan of a product. Your turn! Write down some sentences that describe lifespan (durability) issues about your product. (timed task 4 minutes)

Durability What did you write? Let us take some of the answers and discuss.

Durability Lifespan of a product. Are some products designed to last longer than others? What (other design issues) might this affect? Cost / materials / environmental concerns / etc!

Safety This one is easy, but it is not just about no sharp corners. We have to make sure we do not fall into the trap about talking in general terms (see frying pan rule) ‘designing a product to be non-hazardous to users’

Safety Images CE mark: European equivalent of kite mark Safety during manufacture British Standards Institute: Kite Mark

Safety I could start talking about the lawnmower and saying that is must be safe to use and not cut you when you use it. I could also say that the materials should be non-toxic and not harm the user. These statements are all correct, but they are of no use to you as a product designer. They could be used with any product on the planet!

Safety We need to be specific when we talk about products and safety. e. g. Lawnmower: When I use the lawnmower, it must not burn my hand when I go near the engine. There is a guard in the way to let the heat go out and not let my hand in to touch the hot parts. When I am moving forwards the blades are well out of reach of my feet so I do not cut my foot off! There is a safety release lever that I must hold at all times, or the engine cuts out. This means when I let go it stops and doesn’t run off and cause danger to anyone!

Safety Your turn again. Write down some sentences that describe the safety issues about your product. Remember to be specific. It must be safe is no use!!!!!! (timed task 4 minutes)

Safety What did you write? Let us take some of the answers and discuss.

Cost When we talk about cost we are mainly interested in value for money. How would we describe value for money?

Cost Value for money could be broken down into a simple mathematical equation! Number of years the product lasts divided by the purchase cost. e. g. Gola trainers 1 year £ 30 = £ 30 per year. Nike trainers 2 years £ 90 = £ 45 per year.

Cost Gola trainers £ 30 per year Nike trainers £ 45 per year This shows that Gola trainers are better value for money! I am sure you disagree, why? Branding is the answer, we did not bring in the branding factor, which we can’t put a price on. The value of feeling good about a brand that you like cannot be quantified in an equation.

Cost There are many other influences on cost before the product reaches the sale shelves these include: • • Material costs Manufacturing costs Labour costs Advertising costs Marketing costs Transport costs Profit for manufacturer / retailer.

Cost Lawnmower: The lawnmower is good value for money because it has a very robust steel frame and body, this means it will last a very long time and therefore the purchase price of £ 250 will be worth it in the long term. It is guaranteed for two years, so the minimum cost per year is £ 125. That is about £ 2. 40 per week. This is great when you compare it to getting someone else to cut your grass! The brand of Qualcast is well known and I trust that brand to work for many years.

Cost Your turn again. Write down some sentences that describe the cost (value for money) issues about your product. Remember to be specific. (timed task 4 minutes)

Cost (value for money) What did you write? Let us take some of the answers and discuss.

Aesthetics is concerned with the visual and tactile design of a product. ‘designing a product to appeal to potential purchasers’ When you go into a shop to get a product you will only buy something if you like the look of it. You will look at the brand the style etc.

Aesthetics • Which one do you prefer the look of ? • Why?

Aesthetics • Which one do you prefer the look of ? • Why?

Aesthetics • Which one do you prefer the look of ? • Why?

Aesthetics There are many areas of aesthetics we need to learn and these are listed below. • • • Colour (yellow blue red, green, violet, orange) Shape (2 D, circle, square, rectangle, triangle) Form (3 D, sphere, cylinder, cube, cuboid, prism) Texture (rough, smooth) Line (angular, sleek) Pattern (not design, this is added decoration) Proportion (in or out of proportion for effect) Symmetry / Asymmetry Contrast (in all!!!!)

Aesthetics e. g. Lawnmower: The lawnmower has two main colours (green and red) that contrast with each other really well. This makes the parts stand out and look really good. The round shape of the base suits the function of the product and it looks the way a lawnmower should look. The cylinder forms of the frame and levers look modern and stylish.

Aesthetics Your turn again. Write down some sentences that describe the Aesthetic considerations about your product. Remember to be specific. (timed task 4 minutes)

Aesthetics What did you write? Let us take some of the answers and discuss.

Materials are concerned with selecting the correct materials for use in a product. ‘selecting the most suitable materials for a product’

Materials Why porcelain and not paper?

Materials Cardboard products: Would these work?

Materials It may be really confusing for me to ask you what properties a material may have, but we have a strategy to cope with this question. Try to think about what the product needs to be able to do and these will be the properties of the material!

Materials e. g. Plastic bottle made from low density polythene (LDPE). This means the properties of LDPE are: • • • Flexible, Waterproof Available in lots of colours Does not require a finish Non-toxic Can be moulded

Materials Your turn again. Write down some sentences that describe the materials considerations (properties) about your product. Remember to be specific. (timed task 4 minutes)

Materials What did you write? Let us take some of the answers and discuss.

Production: ‘what processes are used to manufacture a product? ’ How it’s made! Are we making one (bespoke) or one million (mass production).

Production Bespoke Production

Production Mass Production

Production Lawnmower, Production: The lawnmower is a mass produced product, which has many different components (parts). Some of the steel parts are cast (sand cast / die cast), some are press formed and some are extruded. Most of the metal parts are held together with standard components (nuts/bolts/screws/washers).

Production Your turn again. Write down some sentences that describe the production processes used to manufacture your product. Remember to be specific. (timed task 4 minutes)

Production What did you write? Let us take some of the answers and discuss.