[BROT Wechanical Enginesting Department | @& Faculty of Tecnology & Engineering IG)! | te. s. Unversity of Barode, Vadosara, Gua, inci-200 001 ‘Website: hil naw. msvbaroda.acin ‘Subject Code: “Subject Product Design and Process Evaluation | | Branene noch | “Teaching Scheme ‘Examination Schone: Toews’ Sours perWeek | Theor Baper “tore: NI Prine Prasat 2" sylabus 4. Introduction, Denton of product, tyes of products, Role of product in society - arene “and. manufacturer approsen towards product and product development Sitestnoe of prosuet design and ‘element design sysiem approach fo the preduct design. 2, system design, general fects affecting system such as state of Technology CMikonment organization polices, eeonamic and human factors ~ cassicaton of ‘environment 3. Analyealramework for studying existing product, product fe cycle, methodology of new design various sages of design, design process. 4. Detail stucy of vatous phases of design process such a8 reorganization of need, Betntion or peoblem, Synthesis snd anaiysis and optimization, evaluation and presentation 5 _Detal study of synthesis ~ application of creatity to design, characteristic of creative Pattie ewatve prosess and ways of improving cteatiy, Enghesing analysis and Methodology of engineering anaiysis cases. 6. Consideration of various aspects of product design such as desig fr fanction, desi for (pauuctnty and relly. design for safety and maintainabiy, design fr marketbiy, 7. Materials for product, selection factors, various standard for materi, thelr physical ‘hemisa, mechanical elecrea propertes, lass an ther applicators. 8. Principles of design for plastic produc, various consideration of design. Replacement of metal by plastics. ©. Comparative study of manufacturing processes, process evaluaten for a product TRanuacutrg processes anaysia. Failure mode analysis for production processes. 40. Design methods. PABLA and Morphological method and their ilustation. Advanced predict design procesase and applications of computerin product desinn Author “Tent Raferenoe Books 1 Orr Machine Design Vol.|& 1) 2 J'Shingley Machine Design. 3. Nieman ‘Machine Design Vol. 811 4 Rec dohneon Opt Design & Synthesis 5 V. tube Phnciple of Engineering Design 3 Biterce ——_Enginserng Design: A Material & Processing Approach 7 Eary OF. Process Engineering fr Manufacturing System Design Hand Book 8 Hand Book of Production EngineeringLiernture Review | 2015, Preventive Action > Remove contamina om thefoint (rust, prease, moisture te) por wo welding 2.2, Failure Mode & Effect Analysis [A Failure mode & effect analysis (FMEA) is prevention based isk management tol that helps the organization focus onthe folowing systematically “To understand essential concept of Design PMEA & Process FMEA. |demtifping potential causes for Failures Prioritizing Failures “Teking action to reduce mitigate o eliminate failures 2Literature Review [2015 FMEA was fist developed in the 1960°s uy the Aerospace industry as a design methodology withthe obvious reliability and safety requirements, Later on the same ‘concept hasbeen edopted by various manufacturing industries. In Ol & Gas pipeline ‘manufacturing, minor file mode leads 1 a great catastrophic fills, FMEA isan essential function indesign & process, ftom concept through development. Manufacturing proceses are highly cra fr meeting the customer requirements For the paricular product. It considers of product process commercial aspect, isa very ‘much important in today’s competitive world. FNIEA enhances to proesssproduct evelopmeat. [15] FMBA includes > dentiication of process steps! Functions entiation of potential failure mode Idntisation of causes and els forthe deified potential failure mode Determination of Risk prioritizing number for te existing preventive action and suggested action ‘There isan increase in demand by the customer for the particular produc. Several other quality tools ar help only afer develapmeit or manueturing of product but in cose of FMEA, i a before acting process The concept allows us to identify the potential fulure modes, risk assessment prioritizing and implementation of CCorrectve/ Preventive action. FMEA concept is adopted for reducing the risk atthe manufacturing process and also to minimize the potential occurence of non confoemitios at customer ends Intl it involves selection of Process stepsfunetions for the patcular project, The process steps! function taken for particule product are decided from past track records and views fom the experts. The funtion taken for attaining goals will be done trough reducing the accessed ris by implementing suggested action forthe particular filure mode, The idetieaton of potential flare modes at the each and every proces forthe particular product helps ust tropbleshoot easily whenever the problem occurs. There are various root enusts for the particular fire mode and also it involves several quality tols for causes and effets of ‘emifed future mode. The analysis ulimately helps us to develop the produet/ process methodologies. It sone of key fictor for ataining operational excellence and ‘stoner delight. [15]Literature Review | 2015 STRUCTURE, Failure modes and effects analssis (FMEA) isa technique used to identify the ways in which components, systems o processes can fit full ther design iment. [13] PMBA ides All potential failure modes ofthe various parts of process ( fllre rode is whats observed to fal that ereate non conformites orto perform inert) he eases and effets these particular fires may have impact onthe process! produc Control prevention and contr monitoring fo the identified fallre mode: > > Risk Prircaing and ranking for the existing contro prevention; > Recommended aeton to mitigate the sk > Risk Prioritizing and ranking for the recommended action, In FMEA, each faukt mode identified is ranked aocording to is importance or criticality, This erticality analysis i usually qualitative or semiquantiative but may be quae using atu lure rates ES FMEA ean be used to assist in selecting desig’ process ltematives with igh aependabilcy, > nvure that al lure modes of systems and processes, and tor eles on ‘operational success have been considered, Identity human eror modes and ees, Provide a basis for planing testing and maintenance of equipments, Limprove the design of procedures and processes, Provide qualitative or quantitative information for analysis FMEA and FMECA can provide input 1 other analyses techoiques seh a5 CCause and effect diagrams, Chock sheet, Control charts at either a qualitative vy locquanttatve level__titratve view | 2015 INPUTS FMEA need information about the elements of the process in sufiient detail for meaningful analysis ofthe ways in which each element en fil [13] Information may inchde: > Deawings oF a flow chart ofthe system being analyzed and its eomponents, or the steps oF process ‘An understanding ofthe function of each sep ofa processor component of & system: Deals of environment and oter parameters, which may feet operation; ‘Anunderstndng ofthe resls of particular fires: >> Historical information on flares including flue rate dats where avilable PROCESS “The FMEA process i as follows: |A) Detine the seope and objectives of the experimental study: ') Selection of the team members: (Understand the systemiprocess to be subjected 10 the FMEA: 1D) Breakdown ofthe system ito its components or steps: ) Define the function ofeach steps oF components £) For every component or step listed identify > > > > > ‘ow can each part conceivably il? ‘What mechanisms might produce these modes of eile? ‘What could the effets be ithe ius did occur? Isthe file harmless or damaging? How ithe fur detexted? 6G) lent inherent provisions in the design to compensate forthe fireLiterature Review | 2015 There are several ways of quanting the Risk. Common methods inclode ‘The risk priority number (RPN) “Severity of Detetion (SOD) The model erat is « measure of the probability thatthe made being considered ill result flue ofthe system as a whole it is defined as Risk Priority Number (RPN) = Severity * Occurrence © Detection Incase Severity of Detection method, individual values are taken as iti. For this particular pipeline industry, RPN mth i sed [13] (14) 11s most often applied to equipment failures where each of these tems ean be ‘defined quantitatively ae flare modes all have the same consequence. ‘The ride level is obsained by combining the consequences of flare mde oocurting ‘withthe probability of ire tis used when consequences of dierent lire modes Aifer and can be applied to equipment systems or processes. Risk level ean be expressed qualitatively semi quantatively or quantitatively, 13] [14] ‘The risk peovty number (RPN) is @semi-quanttative measure of etsy obtained by multiplying numbers from rating scales (between 1 and 10) for ensequence of flue, ikelihood of filure and ability to detec the problem. (13) [14] (Once failure modes and mechanisms re denied, corrective ations canbe defined nd implemented forthe more sigifian fulure modes PMEA is documented in report that contin Details ofthe system that was analyzed, > The way the exercise was carried out; > Assumptions made in the analysis > Sources of dates > ‘The resus including the completed worksheets > ‘The evtalty (iPcompleted) andthe methodology used to define it;Literature Review | 2015, > Any recommendations for fuer analyses, design changes or atures to be Incorporated in test plans, ec ‘The system may be reassessed by another eyele of FMEA afer the aetens have been completed oureurs The primary ouput of FMEA is alist of fllure modes, the flue methanisms and effets foreach process (which may include information onthe likelihood of fll). Information is also given onthe causes of failure and the consequences to the sytem asa whole (131(14] STRENGTHS AND LIMITATIONS “The stengths of FMEA are as follows: > Widely applicable to human, equipment and system failure modes and to hardware, sofware and procedures; > , Menify component lure modes, their causes and their effets en the sytem, ‘and present them in an easily readable format Avoid the need for costly equipment modifications inservice by identifying problems early inthe design process -demtity single point failure modes and requirements for redundancy or safety > Provide input co the development monitoring programs by higightng key Features tobe monitored. Limitations nolo: > They can only be used to identify single failure modes, not combinations of failure modes; > Unless adequately controlled and focused, the studies canbe time consuming and cost: > They can be dificult and tedious For complex multi-layered systems.Experimental Work | 2015 H Brot (eas) Weston he Bror detection) son by automated como ardor itll detest enor and | Very igh jproblem * | prevent disrepant part fom , ‘being made. Error (case) pisvenon a peteton not | =H of fine deen | Machine design orp desion J | svpestle: | DiSept pr cao beds | Atox enn Emer | hecaie em has teen coe " “ proofed by. process! product Seven “Table 3.10 - Process FMEA Occurrence Evaluation Criteria (9) Rank Criteria: Occurrences of Causes Tikelivood of Faire 100 per thousand (> 1 in 10) Vers High 2f pe thousand (in 50) Sper thousand Cn 20) High 10 per thousand (1 in 100) 2 per thousand (2 in 500 15 per thovsnd (in 2000) Moderate D.01 per housand (Fin 100,000) 8.1 per thousand (I in 10,000) Low "001 per thousand {Fin 4,000,000), 9 ® 7 6 5 4 3 2 i 3.7 Experimental Test Plan for Samples Fall is eliminated tough preventive control | Ve bw ‘able 3.11 Experimental Test Plan Experimental Test Plan eins Testing (Anas Obeervatos| n Visual fnspection ‘Weld bead Qualiy 2 ‘Macro Examination ‘Weld bead Geomviry 7 "Magnets parce Test Subsurface Detees: tue Reviow [2015 2.3 Design of Experiment Approach Design ofexperiments series of teats in which purpsefl changed are made to the input variables of @ system or process and the effects on respghse variables are measured. Design of experiments is applicable to both physical processes and ‘computer simulation models. Experimental design i an efetié too! for maximizing the amount of information gained from a sty’ shite miniming the anount of data to be coleted, Factorial experimental designs investigfle the effets of many different ftors by varying them simultaneously instead gf changing enly one factor at atime, Factorial designs allow estimation oF the sensfivity to each fetor and also to the combined effest of twa or mare fcios. Expefmental design methods have been successfully applied to several Ballistic Mislf Defence sensitty suds to ‘maximize the amount of information with a minimuft aumber of compute simulation runs, In highly competitive world of esting and/evaluaton, an efficent method for testing many factors is needed [16] Design of experiments lz called experimeytal design isa structured and organized way of conducting and analyzing contofed tests to evaluate the fictors that are affecting a response variable, The desjéa of experiments specifies the particular seitng levels of the combinations of/factors at which the individual runs in the experiment are tobe conducted, Thiy/mulivaviable testing method vats the factors ‘Simultaneously. Because the factory/are varied independently ofeach other, s caus predictive model can be determifed. Data obtained from ebservatcnal studies or ‘other data not collected in secorghnce witha design of experiments apyroach ean only establish correlation, not caylity. There are algo problems with the traditional experimental method of ehyfging one factor at atime, Le. is inffceney and its inability to determine effess that are caused by several factors acting in combination. 6) BRIE HISTORY / Designo perils nas nen by Roald A. Fr inh 1926 ad 1930s at Rolland sponta Stan. nash reer aatn 28 mies rot of| Londo. In Fer’ Tt book on sign of experiments he stowed ow valid conchisions could be drawn efficinty from experiments with natwal MuctustionsExperimental Work | 2015 ‘Table 3.9 - Process FMEA Detection Evaluation Criteria (D1 ‘Opportunity For Detection ria: Likelihood of, Detection by Process Contvot Liketitood of Detection No deteston ‘opportuni No current process contol Almost impossible Wor ahi erect ay stage Failure mode and” oF Evor (cause) is not easily detected (ea random audi), Very remote Problem detection pos processing Failure mode detection post processing by operator though isualatile/aucibe means, Remote Problem detecion Fallre mode detection ‘operator through visual! ate! atibute gauging (2o!no-g, ‘mamial torque cheek! clicker Very ow Problem detection post proeessing | Future mode deacon a post processing by operator though tse of variable gauging or in station by operator through use oF atribute gauging (gono-s0 rmanval torque check’ clicker Low Problem detetion Failre Mode or eor (cause) detection in station by operator controls in-station that, crepont part and operator (igh, buzzer, Gauging performed on Set up and first piece chek (Rr se up Moderate Problem etetion pos processing Fallue mode detection pos discrepant part and lek part to prevent further processing Moderaely high Problem detetion Failure mode detection station by automated controls that wil detect dserepan part and automatically lock part in Highsuch s tmperstre, sil eontions, and ean il that iin the presence of nuisance ‘rables. The known nuisance variables usually cause systematic biases in groups of sults (ea bteh-to-batch variation, The unknown nuisance varfables usually cause ‘anvdom variability inthe results and are called inherent varabii! or ncse. Abhough content, the method has been applied suecessflly inthe military and in industry ince the 1940s. Besse the experimental design method was fist used in an agricul working at the US, Naval Experimentation Laborfory used experimental esign to solve problems suchas Finding the eause of bad/velds at «naval shipyard uring World War Il, George Box, employed by Imperia(ChemicalIndusties before coming to the United States, i leading developer of eYperimental desi procedures for optimizing chemical processes, W, Edwards Defing taught satisica! methods, including experimental design, to Japanese scents and engineer: in the early 198032 ata time when “Made in Japan” meant foor quality. Genii Taguchi the most well known of this group of Japanese sbienists, is famous fr his quality improvement methods. One ofthe companies whece Taguchi fst aplicd his methods ‘vas Toyota, Since the late 19705, US. indusyy has become interested azn in quality improvement initiatives, now known as “tal Quality” and “Sis Sigma” programs Design of experiments is considered an avanced method inthe Six Sigma programs, which were pioneered at Motorota and GP. (16) Uses: “The min uses of design of experimets are ng factors vyvyvy 2.4 Introduction to HWA Steel Highr-strength ow-alloy (HSLA) steels, or micro alloyed stl, are designed (0 provide efter, mechanical properties andlor greater resistance _tmospherie corrosion thjn conventional carbon steels. They are not considered to be Literature Review [2015Experinental Work | 2015 eee ees pe Se 3.6 FMEA Analysis ‘The analysis is done by caleultng risk evaluation by Risk priory umber (RPN), The BRPN i caleulted on control ection, The ranking for the Severity (8), Oxcurenee (0) the Table 3.8, 3.9.4 3.10 (15) ‘Then the main part of FMEA is suggested action for reducing the ris. Action involves 1nd Detection (D) are refer ‘modification oF process, inspetio, equipment up gradation as diseusson involved in the imesting, The suggested ation shall be implemented inthe stipulated ime and cam will completly involve fr implementation. ‘Table 3.8- Process FMEA Severity Evaluation Criteria) Rank| bist Gite: Sevriy of fect on Poses”) to, | Falre © mee | ay endanger opeatar (Machine or Assensir} wD satay | warming and/or | 6 | Regulatory | May endanger opesor (Machine or Assnbly with Required | warning Requirements Major | T00%aF product may ave To be appa. ne a ® Disuption | down o sop sip Signiticam | A Portion ofthe production run may have to be. scrapped. | 7 | Dann | Deviation fom pinay process inlalng eee re speedo aed man power 6 100% of production run may have to be reworked offline fd ase | preee A porion of ean an ay Fao TSN 5 offre and aceptd. ry 108% of prediction ran may Rave to Be worked sation Moderate [before i processed Sacaceleeteceeaaae of production run may have fo be reworked in) sition bef hs processed 2 | parton _| Sth convene o Paces, Operation or Orato [TO] Wo eteer Te dente ae