Design Engineering 1 Design Engineering KTU Syllabus Module

Design Engineering 1 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

How to convert decriptive model into a prescriptive model ? Simplest model descriptive has three phases. 1 Generation- the designer generates or creates various design concepts. 2 Evaluvation- designer test the chosen design aganist matrices. Should reflect clients objectives, specifications. 3. Communication- designer communicates final design to client & to manufactures. 2 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

Another three staged model • 1. Conceive • 2. Design • 3. Implement. • Both models are very abstract but donot provide any useful information in generating designs. 3 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

Prescriptive Model Output of each design phase serve as the input to next phase. ( Stages= rectangles& stage output as Ovals) • 1. • Problem defenition: • • clarify clients requests. clarify objectives. • identify constraints. • gathering other information. • 4 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

• Input: Original Problem statement. • Tasks: • Revise clients problem. Clarify objectives. • Identify constraints. • • Establish principle functions. • Outputs: Customer requirements • revised problem statement. • Initial list of final objectives. • Initial list of principal functions. 5 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil •

• 2. Conceptual design: • Input: Output of problem defenition. • Tasks: Establish functional specifications. • • establish means for functions. write limits or constraints. develop constraints. generate design alternatives. refine & apply matrices to design alternatives estimate design alternatives. choose a design concept • Output: a choosen design. • analysis, test, & evaluvation results for choosen design. • 6 • • • Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

• 3. Preliminary Design: ( we identify the preleiminarily size/ estimating the priciple attributes of the choosen design). • Is more technical design. ( computer calculations). • Input: a choosen design. specifications. • Tasks: model and analyze choosen design. • test & evaluvate chosen design. • Output : Analysis, testing , evaluvation of choosen design. 7 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil •

• 4. • Detailed Design: • refining the preliminary design into dimentions. • We use detailed design knowledge, rules, formulas, algorithems. ( handbooks, databases, catalogs. ). Input: • analyzed , tested, evaluated design. • Tasks: • • Refine , optimize the chosen design. • assign & specify the design deatils. • Output : Proposed Design & design details. 8 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

• 5 • Design Communication: • Documentation is done here. • Document the fabrication specification & their justification Input: Proposed design & design Details. • Tasks: Document the final design • Output: Final written, oral reports to client containing • A. Desription of design process. • B. Drawings & design details. • C. Fabrication Specifications. • • 9 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

Design Process • 5 Phases. • 1. Needs Assessment • Need for the solution is first established. • Identify objective. • Who will benefit ? • Begin with end in mind 10 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

• 2. problem Formulation Ask if the real problem differs from the problem already presented • . • Structure the search for the solution. • • Identify the resources. • Prioratize the design goals, design specifications. 11 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

• 3. Abstaction & Synthesis: • Develop general concepts or approaches through which the problem can be solved. • Recall related solved problems. • Expand your thinking. • Seek to develop solutions that are fully acceptable to all involved • Be crative, Be adaptable, combine ideas. 12 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

• 4. Analysis • Compare & evaluate alternative designs. • Recognize weaknesses, shortcomings. . • Consider implementation requirements. • Eliminate alternatives that donot satisfy design goals. • Anticipate & avoid failures. • Construct prototype. 13 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

• 5. Implementation: • Develop final solution & distribute to clients. • After testing and valuation proceed with full production. • After distribution to user take feed back for next generation. 14 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

• Steps towards design. CClarity on the problem, searching for concepts or ideas for a solution, finalizing the concept and proceeding with the design. • larity on the problem, searching for concepts or ideas for a solution, finalizing the concept and proceeding with the design • 15 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

• What is a good design Quality of the design is based on how the artifact meets the user demands • . • • 16 This primarily depends on how best the steps towards design have been taken Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

• Is there a difference between Design and Problem solving? • By designing one cannot solve the problem. • Engineered design only solves the problem. 17 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

Functional Vs Strength Functional Design Here the function of the product is important and the strength considerations are secondary. Assures that each modular part of a device has only one responsibility and performs that responsibility with the minimum of side effects on other parts. E. g. Watch, Ball point pen, an amplifier, a software. Strength Design Here forces acting and environmental factors are critical to the design, in addition to the function. E. g. Automobile, Dam, Crane, Ship, Rocket. In many designs, both are of importance. 18 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

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Taxonomy or classification of Problems (need gaps) There are two main classifications and under each a sub classification: 1. Design Problems : - New artifact By Structured Design Process By Design Selection (Selection from known alternatives) 2. Design Improvement Problems By Tuning of subsystems: - changing the variables, experimentation. 23 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

Introduction to Design Two other types of problems are: Crisis Problems – Fokushima disaster Key strengths-Experience and Resources • • “Eternal” Problems- Territory disputes, Wars, ( conflicting goals of stakeholders) Key strengths-Special skills, specialization, practice, patience. 24 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

Thinking outside the box We are all in a box. We are surrounded by things that are well known to us. We see how people behave, how they react, what they say, what they use, how they use and so on. Such a surrounding envelopes us. WE ARE IN A BOX ! If you want to be different ( creative) then thinking and doing differently is the only option. So think outside the box. 25 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

Thinking outside the box To be creative, step out of the box, change your mindsets and attitudes, leave all your experiences behind and start to look at things from different perspectives. Think of crazy ideas that are non workable at the first thought. Bring in negative approaches to look at the situation. 26 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

Thinking outside the box Be uninhibited and unbiased and open for suggestions. Go against the tide- question the popular approaches “Every cloud has a silver lining. ” Why not it be “ Every silver lining has a cloud behind it. ” 27 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

• Quality Function Deployment (QFD) • is a structured approach to defining customer needs or requirements and translating them into specific plans to produce products to meet those needs. The "voice of the customer" is the term to describe these stated and unstated customer needs or requirements. transform qualitative user demands into quantitative parameters • described by Dr. Yoji Akao, who originally developed QFD in Japan in 1966, • 28 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

• Japanese car maker cut down cost of launching a new car by 60%. Time taken reduced by 33%. • QFD is accomplished by house of Quality. ( similar to house). • • Focus on 1. Needs of customer • 2. How manufacturing industry planning to satisfy such needs. • • Cascading Method HOQ Chart is prepared to access the specifications of the product against its initial requirements. • After that another Ho. Q chart is prepared to evaluate the conceptual design against specifications • 29 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

• Region 1: • Prioratised needs are listed • Region 2: • All specifications of the product are listed as columns. • Region 3: Each specification is graded as a correlation to each requirement( how closely each specification focus on requirement). • No correlation =0 ( rating) • Feeble =1 • Moderate =3 • Strong= 9 • 30 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

• Region 4: Correlation Matrix: Blade of a fan when moving is likely to have faster speed. • The interaction between blade which is moving , speed is fast can shown as a roof of matrix. • Shows specifications which conflict with each other ( 1, 3, 9, _ ) • - shows conflict • Region 5: • Shows target values of specifications. • Region 6: • • shows absolute importance ratings of specificatons rated against prioratised requirements. ( here specification rating is multiplied by its corresponding requirement importance rating & respective columns are added up) 31 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

• Region 7: Shows relative importance ratings. • Highest absolute rating is considered as benchmark value and given importance of 9. All other specifications are compared to this value. • • Region 8: • The bench mark value of each requirement is rated against close rival producta in the market. 32 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

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• Ultimately the goal of QFD is to translate often subjective quality criteria into objective ones. • that can be quantified and measured and which can then be used to design and manufacture the product. • It is a complimentary method for determining how and where priorities are to be assigned in product development. • The intent is to employ objective procedures in increasing detail throughout the development of the product 36 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

• The 3 main goals in implementing QFD are: • 1. Prioritize spoken and unspoken customer wants and needs. • 2. Translate these needs into technical characteristics and specifications. • 3. Build and deliver a quality product or service by focusing everybody toward customer satisfaction. 37 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

Helps companies in • • Plan new products • Design product requirements • Determine process characteristics • • Control the manufacturing process • • Document already existing product specifications 38 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

Engineers and scientists are comfortable with units and quantities for all specifications. But the consumers of their products are ordinary individuals who can express their needs only in simple terms. “ I need a silent air conditioner that is good ” This is the specification for the product by the user. Now how to convert this into engineering specifications that are quantified. 39 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

• 40 This is achieved through the House of Quality Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

41 Quality Function Deployment [QFD] Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

Ideation • process of generating, developing, and communicating new ideas. Ideation comprises all stages of a thought cycle, from innovation, to development, to actualization • Problem solution : • • This is the most simple method of progress, where someone has found a problem and as a result, solves it. • Derivative idea : • This involves taking something that already exists and changing it. • Symbiotic idea : • A symbiotic method of idea creation is when multiple ideas are combined, using different elements of each to make a whole. • Revolutionary idea : • A revolutionary idea breaks away from traditional thought and creates a brand new perspective. 42 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

• Serendipitous discovery: • solutions are ideas which have been coincidentally developed without the intention of the inventor. • Targeted innovation: • intensive research in order to have a distinct and almost expected resolution • Artistic innovation: Artistic innovation disregards the necessity for practicality and holds no constraints • . • • Philosophical idea: • The philosophical idea lives in the mind of the creator and can never be proven. • Computer-assisted discovery: 43 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

Ideation • Method of generating , developing new ideas. Form of structured brainstorming. • Systematic sequence of actions. • • 1 Clearly defined event goals. ( why we are doing this? ) • 2 Measureable event objectives( what we will walk away with? ). • 3 Specific event inputs & outputs( document deliverables) • 4 Standard process actions, inputs, outputs are adaptable different changing goals. . • Best mehod is to ask questions? 44 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

• Design an egg container How big the container Be. . ? • What container shapes are good at absorbing impact? • How fast will the contained be travelling at impact? • What other technologies are desined to minimize impact. ? • 45 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

Evaluation and choosing a design • 46 Design Evaluation: Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

• 47 A SWOT analysis (alternatively SWOT matrix) is a structured planning method used to evaluate the strengths, weaknesses, opportunities and threats involved in a project or in a business venture. Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

Indian Economy 48 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

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Evaluation and choosing a design Design Strengths: What are the idea’s advantages? What can the idea be successful in? What are the current existing idea resources? How others may see the strength of the idea? The idea that starts the design. 53 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

Evaluation and choosing a design Design Weaknesses: How can the idea can be improved? ( Methods). What does the idea lack in term of experience, team and resources? What can prevent the idea from success? How do others see the idea in terms of weaknesses? 54 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

Evaluation and choosing a design Design Opportunities: What opportunities does the idea have in the market? How the company can help the idea to succeed? 55 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

Evaluation and choosing a design Design Threats: What are the obstacles that face the idea? Do the idea weakness represent any threat to its success? What are the financial needs that may face the idea? It is also possible to quantify these to compare designs Always remember that no design is final. Designs are always evolving. 56 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

Communication in Design is a cognitive process. However it needs inputs and outputs that are oral, written or sketched out. For this communication skills are to be honed in all the three. While the oral and the written segments give critical inputs to design, drawings are the medium for design outputs. What cannot be expressed orally or in writing can be well communicated through drawings. 57 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

Communication in Design Hence the significance of sketching and drawing in design. Design emerges through sketches which in turn changes to free hand drawings and later to Computer Aided Design and Drafting (CAD). CAD system with freeform software can do clay modeling. Designs need additional details for its realization or manufacturing. 58 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

Communication in Design is a cognitive process. However it needs inputs and outputs that are oral, written or sketched out. For this communication skills are to be honed in all the three. While the oral and the written segments give critical inputs to design, drawings are the medium for design outputs. What cannot be expressed orally or in writing can be well communicated through drawings. 59 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

Communication in Design Hence the significance of sketching and drawing in design. Design emerges through sketches which in turn changes to free hand drawings and later to Computer Aided Design and Drafting (CAD). CAD system with freeform software can do clay modeling. Designs need additional details for its realization or manufacturing. 60 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

Communication in Design CAD systems available are capable of providing all these to the designer. Visualization of the design through solid modeling is providing a new angle to design. This was not possible earlier and today this is often the starting point of a conceived design 61 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

Though the Solid model gives a better comprehension of the object than 2 D views, 2 D drawings are essential to provide details on the design as well as for the part manufacture. In certain domains of design, instead of sketches pictorial representations could be used. Examples: Circuit diagrams; Flow charts; Block diagrams. 62 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

Ultimately • So seeing is believing! • (Eyes believe what they see, the ears believe what others say) 63 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

Communications of all types play a major role in engineering design. User manual, Safety standards, Assembly and packaging instructions, and of course in marketing. Communications could change the mind set of people. Instead of stating that i Phone is “Made by Apple“ it is written as “Designed by Apple”. At different stages of design, designers have to convince other team members about their ideas clearly- both orally and in writing. 64 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

Concept to Configuration The strength of a designer lies in the ability to transform the design concept to a workable configuration. The complexity of the product poses major challenges. The only consolation is that all designs are evolving and one can have a reference of an older version for a new one. This is the reason why new designs are only starting points Complex designs needs sub system designs. • Designs are configured out of such subsystem. 65 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

Sketching, Drawing, Modeling A good designer initially starts off with sketches. With experience on can directly do this 3 D CAD. Sketching give the designer ample of opportunity to transform the design concept as a visible soft design. Many CAD systems now allow this to be done directly. 66 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

While the soft designs can be visualized in 3 D as well at different view angles, there is still the need for a physical model as the perception on the screen is not real enough. Now virtual reality (VR) do assist us to a certain extend. (designing the work space) Full scale physical models are attempted in certain products to realistically evaluate the design for its finer aspects like colour, shape, finish etc. 67 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

Complex is Simple Many engineering designs are complex in nature. They have large number of sub assemblies and in turn a very large number of parts. Final product realization is through assembly. Assembly is still manual. Manual assemblies take time and cost escalation. Designs should reduce the number of assemblies to reduce the time. Here comes the concept of “Complex is Simple” 68 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

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Science Engineering and Technology Science gives the Principle for temperature measurement -Thermal expansion of solids and liquids • Engineering uses this principle to design a thermometer • Technology allows to realize thermometer. 74 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

National Conference on “Role of Open Source Software's in Libraries” Cochin University of Science & Technology November 24 -25, 2009

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Evaluvation & choosing a design. - 4 Steps • 1. Pass Fail evaluvation method. Can be used for evaluvating large number of ideas in short time. • Includes question such as • • A) does the idea comply with company strategy? Yes/no • B) does it talk company target audience. ? Yes/no • C)does the idea budget acceptable? YES/NO. 77 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

2. Evaluvation Matrix • Here reviewers compare the ideas with a specific matrix or a set of criteria. ( includes the following). • 1. the idea contribution in company’s overall strategic outcome. 2. the idea’s potential impact. • 3. expected stakeholders. • 4. expected budget to apply the idea. • • 5. timelines to implement the idea. Then a specified score is given to each criterion. • Example: the idea contribution in company’s startegic outcome can include the following score set. • 78 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

• The comparison factor reflect the project requirement using a score rate. • This score measures sucess of the idea based on a number of factores. • After evaluvation total score is assigned to each idea. • Each evaluvator provides feedback to each idea. 79 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

• Score 0 - No expected contribution in company’s strategic outcome. • Score 1 - Direct contribution in one strategic outcome. • Score 2 - Direct contribution in two strategic outcome. • Score 3 - Direct contribution in three strategic outcome • Score 4 - Direct contribution in four strategic outcome Score 5 - Multiple contribution in the organisations wide strategic outcomes • The score measures the potential sucess of the idea • After evaluvation score number is assigned to each idea. . • 80 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

3. SWOT analysis 81 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

4. Approval & implementation. • 82 Once the above methods are completed it becomes ready to taken to next stage of implementation Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

Communication in design • Communication requires cognition. • Cognition Is a set of all mental abilities & processes related to knowledge, attention, memory & working memory • Judgement & evaluvation, • Reasoning & computation • Problem solving & decision making • What cannot be decribed orally can be well communicated through design & drawings. 83 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

• Design is a client service. Designer needs info from client to complete the job. • Being able to communicate in simple & understandable manner is a good skill. • • Steps to improve communication with clients. • 1. Easily accessible • 2. Avoid Jargon ( use basic ways so any one can understand) • 3. Encourage feedback through process 84 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

Complex is simple • Any engineering design assembly of parts are required. • Reduce the no of parts. • Reason – error can happen in each part. • as part icreases the probability of error increases, fabrication cost increases. • Automation becomes more difficult. • Costs related to purchasing, stocking & servicing also increases • 85 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

Design Detailing • Final step in Engineering Design before manufacturing. Here all the details are brought together, decisions are finalized and decision is made by management to release the production. • Here we want to calculate • • • Static/dynamic loads Stress Force Temperature Pressure Fluid dynamics • Electric current • Resistance • Chemical reaction. • 86 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

Activities in detailed design phase • Make/ buy decision. ( inhouse / purchase it) • • Selectiong & sizing of components. Engineering drawings Bill of materials. Revise the product design specification Prototype testing Cost estimation. Project report. Project review. • Design to manufacturing • • • 87 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

Factors influencing make or buy decision. Volume of production. • Cost • Utilization of production capacity. • Availability of Manpower. 88 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

Selecting & sizing components • If design is complex a design freeze is imposed prior to completion. • No change in design is allowed unless they go through a formal review. 89 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

Engineering Drawings • Standard views like top, front, side. . • Auxillary views such as sections. . • Visualizing the component. • Dimensions. • Tolerances. • Material specification. • Manufacturing detail. 90 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

Bill Of material • Listing of all of the assemblies, sub assemblies, parts & raw materials that are needed to produce one unit of the finished product. • Includes Product name • Use • Date of preperation. • Item numbers. • Sub assembly part numbers. • Quandity requirements. • Material used in each part. • 91 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

Product design specification • Gives design team gains knowledge about the design of the product. • In detailed design the PDS will be updated to include all current requirements that the design must meet. 92 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

Prototype Testing • 93 Once the design is finalized a beta prototype is built & verification tested to ensure that the design meets the product design specification. Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

Cost Estimation • Detailed drawings allow to estimate cost. • cost estimation is possible as we knowledge of material, diamensions, tolerances. 94 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

Project report • Written at the conclusion of the project to describe the tasks undertaken & to discuss design in detail. • Vital document discuss about the teams involved. . • Patent ligitation etc. . . 95 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

Design review Ensures quality of manufacturing, quality issues, reliability , safety , prelimainary costs. . etc. 96 Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil

Design to Manufacturing • 97 The release of the product design to manufacturing ends the design process. Design Engineering- KTU Syllabus- Module 2 - Varghese S Chooralil