MORPHOLOGY OF

DESIGN
 Phase VI PLANNING FOR USE
 Consumer Oriented Process must be
incorporated in the design process
 User Oriented Process
 Ease of maintenance
 Reliabibility
 Product Safety
 Convience in Use ( Human Factor
Engineering)
 Aesthetic Appeal
 Economy of Operation
 Duration of Servivice
 Planning
for the
Retirement of product
 The final step in the design process is the disposal
of product when it has reached end of useful life
 Useful life is determined by point where design
can no longer function
 Technological obsolescence in which competitive
design cheaper performs the function better or
cheaper
 In Consumer product, it may come through
changes in fashion and taste
 Computer aided design --- CAD
 Computer Controlled Machine Tools
 CAD and CCM link is called design database in
Design of New Product
Steps Product Specification

Develop Design Concept

Analyse Critical Design Historical and Current Test

Features Data

Create Detail Design

Analyze Detail Design

Generate Detail Drawing

Build Prototype

Test Prototype

Program N /C Machine Tools and Automated

Mfg. Equipment

Manufacture Product

Test Finished Product

Ship the Product

Monitor Field Performance

 Further consideration in
Design
 The design process has followed time
sequence of events in the usual project
 To look design at another aspect, Design
factor are grouped into three categories
 Functional Requirements
 Total Life Cycle
 Further Major factors
Functional Requirements
 Design must meet performance
specification
 Performance specification in problem
defination
 Overemphasis the specification of
property values and performance
parameters
 Computer Aided Design (CAD) tool
for analytical analysis with
interactive computer graphics
 Product Liability

 Due to competitive nature business

emphasized has been given on
reliability
 Reliability
 Maintainability
 Availability

 Repairability
 Reliability

 Reliability is defined as probability

that device will be perform
adequately in service for the period
of time intended under specified
operating condition
 Maintainability

 Ease
 Economy
 Safety of performing function
 Minimize maintainace time
 Maximize time in productive service
 ANTICIPATION FAILURE
MODE OF PRODUCT

 Fault Tree Analysis

 Failure Modes and Effect Analysis
 Hazard Analysis
 Design Review

 The design review is vital aspect of

the design process
 Design Review provides a systemic
method for identifying the problems
with the design, aids in determing the
possible course of action
 Initiate action to correct problem
areas
 Design Review Team
 Team Leader Project Manager:
(technical knowledge and know how
for product)
 Design
 Manufacturing
 Marketing
 Purchasing
 Quality Control
 Reliability Engineering

Design Review Checklist
 Design requirements
 Functional requirements
 Environmental requirements
 Manufacturing requirements
 Operational requirements
 Reliability requirements
 Chapter 2
DESIGN IN A
BROADERCONTEXT
 2.1 Spectrum of
Engineering Activities
 It is defined as application of science to
the solution of problem of society at a
profit cost
 According to the ABET
 Engineering is the profession in which a
knowledge of the mathematical and natural
sciences gained by study, experience and
practice is applied with judgment to develop
the ways to utilize , economically, the
materials and forces of nature for the benefit
of mankind
 AIM OF ENINEERING

 Solution of specific society problem using

mathematics and science
 Limitation/ Constraints
 Legal
 Environmental

 Economic
 Engineering Functions
 Refer Fig 2.1 Engineering function starts with
research, closest to academic experience
 More emphasis is on financial and
administrative matters towards downwards
of hierarchy
 Research
 Development
 Design
 Production and Construction
 Operation and Maintenance
 Sales
 Management
 Research
 R & D are the glamour end of
engineering
 Research limited to scientist working in
Lab to explore the nature
 R & D Activities
 Research
 Exploratory Development

 Advance Development

 Engineering Development

 Management and Support

BASIC and Applied
Research
 DESIGN
 The design is the function of creating a
technical plan to solve a problem
 It involves both analysis and syntheses
 Needs not only calculation on computer
and lines on drawing but much
computer
 It involves planning of “how the thing
designed will be manufactured and how
it will be maintained
 Production and
Construction
 This activity translates the design into
manufacturing process , process plant or civil
structure engineering structure
 Engineers are responsible to
 Taking the design through initial production to
prove that product can be manufactured in planned
cost
 General list of employee to work with expert and
organize the schedule and complete task in
allocated cost
 To supervise the plants workforce, material's flow
and machine
 Meeting the production schedule while maintaing
the product quality

 2.2 ORGANIZATION OF
ENGINEERING FUNCTION

 There are three types of organization

structure
 Functional Organization
 Project Organization

 Project Functional Staff Organization

 Functional Organization
 Organization is grouped into separate
identifiable units based on functional
specialties
 Similar work is performed in same
organizational unit
 All R & D and design work reports to a
single vice president and manufacturing
activity is the responsibility of other vice
president
 Many functions are under a single vice
 Functional Organization
Chart

Board of
Directors

Stack Holders

President

Vice President Vice President Vice President Vice President Vice President
 Project Organization

 The functions are organized around a

single product or major system
 Functions are redistributed based on
need among a number of project
managers
 It is dynamic and time-limited since its
life is based on completion of project
objective and then people are reassigned
Project Organization
Chart
President

Vice President

Manager Manager Manager

Project X Project Y Project Z
 Line Organization
 Line organization represents a chain of
command relationship in which
supervisor reports to the manager
 Line functions are concerned with
achieving the prime objective of the
project
 Staff functions support the one or more
line organization
 SF provide special expertise and
information to achieve the objectives
of organization
 Project Functional Staff
Organization
 It is formed by merging of functional
organization and project team
 An organization consist of project team
superimposed on existing vertical
functional structure of organization
 An Engineer can switch one department
to another by providing technical
assistance
 Matrix Organization
President

Other Vice President Vice President of

Researach and Engineering

Project Mechanical Electrical System

Management Design Design Engineering

Project
X

Project
Y

Project
Z
 Chapter 3
DESIGN METHODS
 3.1 INTRODUCTION
 Successful design calls for skills in problem solving
and descision making
 Conceptualization step is the most important since
it constitute engineering and scientific principles
that constitute design
 Design methods are needed to assist complex
process
 Computer based “design tools” are being developed
using expert system, mathematical modeling and
advanced optimization technique but scope of this
chapter is simpler design methods
 Sketching or Drawing to help visulize design
concept
 INTRODUCTION (Cont…)

 Of the design methods one tries to formalize

the design procedures and externalize the
design thinking
 Aim of formalization is to prevent overlooked
factors in design process or the occurrence
of errors
 In externalization thoughts and thinking out
of designer’s head and put them in charts
and diagram
 3.2 Creativity and Problem
Solving
 Creativity is the ability to synthesize new
combinations of ideas and concepts into
meaningful and useful form
 There is myth ‘ Creative ideas arrive with flash
flash like spontaneity – the flash of lighting and
clap of thunder routine
 Ideas occur slow and can be enhanced with
study and practice
 Creative process can be viewed as moving from
amorphous/shapeless idea to a well structured
idea, from implicit to explicit
 Creative ideas can not be turned on upon
command
 Steps for Enhancement in
Creative Thinking
 Develop a creative attitude
 Develop self confidence to tackle the problem
 Build confidence with small success
 Unlock your imagination
 Come out of imagination
 Question ask again “why” and “what if”
 Thought games are designed to provide practice
in unlocking imagination
 Be persistent
 Creativity occurs with lighting strike
 It requires hard work and consistency since
problems are not solved in firs attempt
 Steps for Enhancement in
Creative Thinking
 Develop an open mind
 Receptive to ideas from any and all
sources
 Solutions are not the property of a
particular discipline
 Suspend your judgment
 Critical attitude of Engineers
 Avoid judgment at early stage

 Set Problem Boundaries

 Establish the boundaries of problem
 Chapter 4
Modeling and Simulation
 MODELING

 A model is an idealization of a real world situation

that aids in analysis of problem
 Free body diagram, electric circuit diagram,
sphere by earth
 A model may be classified as
 Descriptive : real world system or phenomenon
e-g model of an aircraft gas turbine. It does not
predict the behavior of system
 Predictive : used in engineering design in order
to understand and predict the behavior of
system
 MATHEMATICAL
MODELING

 In MM the component of system are idealized

by elements having the same characteristics
and behavior can be described by
mathematical equation
 A generalized picture of model for a system
or component is shown in Fig 4.3
 Engineering System is complex and can be
easily understood by breaking into smaller
components and modeling each of them
 Interaction of these components is to be
 Block Diagram

Power Plant
Coal Electricity

Fig 4.1 . Overall Block Diagram of

Power Plant

Combustion
Steam Boiler Steam Turbine Generator
Chamber
Coal Electricity

Fig 4.2 . Block Diagram of major components

of Power Plant
 Block Diagram Spray Water

Coal Electricity

Feeder Generator Cooling Pond

Coal
Ash Combustion Stea
Boiler Tube Turbine Condenser
Chamber Heat m

Gases Water
Water
Stock
Water Heater
Water

Pump
Water Pump
Gases

Fig 4.5 . Detailed system for a coal fired Power

Plant
 Chapter 6
Material Selection Process
 Material Selection
Process
 A Problem of material selection
involves one of two different
situations
 Selection of the materials for a new
product or new design
 Reevaluation of an existing product or
design to reduce cost, increase
reliability, improve performance
Steps in the Manufacturing
Process

 Material selection is problem

solving process
 The steps in the process can be
defined as
 Analysis of the materials
requirements
 Screening of candidate materials

 Selection of candidate material

 Analysis of material
requirements

 Determine the conditions of service

and environment that the product
must stand
 Translate then in critical material
properties
 Screening of Candidate
material
 Compare the needed properties
( responses) with large material
property data base to select a few
material that look promising for the
application
 Selection of candidate
material
 Analyze candidate material in terms
of product performance, cost ,
fabricability and availability to select
the best material for the application
 Development of Design
Data
 Determine experimentally the key
material properties for the selected
material to obtain statistically
reliable measures of the material
performance under the specific
conditions expected to be
encountered in service
 7.2 Classification of
Manufacturing Process
 Critical Path Method
 CPM is a a technique used