12ME4710 PRODUCT DESIGN AND DEVELOPMENT L T P C

3 0 0 3

Objective(s):
To learn knowledge on design of product and their specifications.

UNIT – I INTRODUCTION 09 Hrs.

Design theory, design materials, human factors in design, man-machine system, applied
ergonomics, characteristics of successful product development, challenges to product
development.

UNIT – II PRODUCT SPECIFICATIONS 09 Hrs.

Establishing the product specifications- target specifications -refining specifications,
concept generation - clarify the problem - search internally - search externally - explore
systematically.

UNIT – III PRODUCT ARCHITECTURE 09 Hrs.

Concept selection- screening - scoring, product architecture - implication of architecture-
establishing the architecture - related system level design issues.

UNIT – IV INDUSTRIAL DESIGN 09 Hrs.

Need for industrial design - impact of industrial design - industrial design process -
management of industrial design process - assessing the quality of industrial design -
design for manufacturing - cost considerations, impact of DFM decisions on other
factors.

UNIT – V PRINCIPLES OF PROTOTYPING AND ECONOMIC ANALYSIS 09 Hrs.

Principles of prototyping - planning for prototypes - economics of product development
projects - elements of economic analysis - base-case financial model - sensitivity
analysis - influence of the quantitative factors.

Total Hours: 45 Hrs.

Text Books:
1. Karal, T.UlrichstevenD.Eppinger, “Product Design and Development”, McGraw
Hill, International Editions, 2003.
2. George Dietor, “A material and processing approach”, McGraw Hill ,2000.

References:
1. Moustapha I., “Concurrent Engineering In Product Design And Development”,
New age International Pvt. Ltd., 2006.
2. Chitale A. K., R. C. Gupta, "Product Design and Manufacturing”, - 2007.
3. Chitalagupta, “Product design and development”, PHI learning, 2013.
4. Boothroyd, “Product design and development”, book world, Bombay, 2013.
 UNIT – I INTRODUCTION

Product design Product development

Product design is the process of creating Product development is the set of
a new product to be sold by a business to activitieslike
its customers. Perception of a market opportunity
It is essentially the efficient and effective Production
generation and development of Sale
ideasthrough a process that leads to new Delivery of a product.
products.
The essential requirements of a good Characteristics of product development
product design are listed as follows: depends on
It must optimally perform its main
function (task). Product quality
It must be easy to repair at a low cost. Product Cost
It must be very reliable to use. Development time
It must follow principles of aesthetics. Development Cost
It must be a durable one. Development Capability.
It can be easily produced in large numbers
at minimum production cost.
It must be simple to produce and use
(handle).
It must also be compact.
 Conceptual design is to develop  Idea generation
concepts to meet design specifications.  Idea screening
 Detailed design determines all detailed  Concept development & testing
parameters including dimensions,  Marketing Strategy development
tolerances and other design parameters  Business Analysis
of all components where a product is  Product development
described by engineering drawings or  Test marketing
 Commercialization
geometric models.
 Configuration design refines design
concepts to concrete product
architectures and components.

• Morris Asimov proposed 7 phases of design

1. Conceptual Design
2. Embodiment Design
3. Detail Design
4. Planning for Manufacture
 5. Planning for Distribution
6. Planning for Use
7. Planning for Retirement

DESIGN MATERIALS

Material selection is a step in the design process of any physical object. In

the product design, the main goal of material selection is to minimize cost
while meeting product performance goals.

Stages of Materials Selection

 Analysis of material performance requirements

Creating alternative material and process solutions for the

optimum concept
Initial Screening (Ashby’s method of screening – Density Vs
Youngs Modulus)
 Use the critical requirements of each part to define the
performance requirements of the material. Start with all
materials available and narrow down the choices on the
basis of the rigid requirements.
 Selection of Optimum Solution

Use the optimum materials and matching manufacturing

processes to make detail designs.
Compare alternative combinations taking into account the
elements of cost.
Select optimum combination of design-material-
manufacturing process.

The selection of materials for designing a product depends on following

requirements.
o Service requirements– sustainability, resistance to service
conditions
o Fabrication requirements - material’s melting point, density,
moisture content, porosity, and surface texture, dimensional
stability, corrosion resistance, adequate strength, hardness,
toughness, heat resistance and dissolution
o Economic requirements – sustainability, Aesthetics, Product
Cost
o Reliability requirements

The selection of materials depends on the following properties

 Physical properties - (material’s melting point, density, moisture
content, porosity, and surface texture);
 Chemical properties (resistance to corrosion and dissolution);
 Thermal properties (heat conductivity, heat resistance);
  Electrical properties (materials’ conductivity and resistance to
electrical charges);
 Acoustical properties (materials’ reactions to sound), and
 Optical properties (materials reactions to light)

HUMAN FACTORS IN DESIGN

Human factors are basically a rigorous, systematic, and data

based science. One human factors exercise is called task analysis. Task
analysis is a simple, step-by-step description of human interaction with
a device. The analysis describes what the user is expected to perceive
(see, hear, feel, etc.), understand, and physically manipulate (press,
move, etc.).
The discipline of human factors engineering focuses on the
combination of user- and device related problems.

MAN-MACHINE SYSTEM

Man–machine system is a system in which the functions of a human

operator (or a group of operators) and a machine are integrated.

The human machine systems consists of three main systems

 First component: is the human component which includes all

human characteristics, like anatomical, physiological and
psychological elements.

 Second component: is the machine component like chairs, tools

and equipment with which the human-being interacts

 Third component: is the environment, it is the place and the

circumstances in which the work is carried out and it includes
physical and social aspects

Classification of Man-Machine Systems:

Depending upon size and complexity, man machine systems are of
following three types:

(1) Manual Systems:

They are essentially man directed systems. These are flexible in nature
and small in size. Simple tools and equipment are used and the
efficiency is dependent upon the human factor. A large variability is
possible in a manual system as every worker may select different
method to do the same job.
(2) Mechanical Systems:
They are more complex and inflexible in nature than manual systems.
The machine component is power driven and human activity is
information processing, decision making and controlling occasionally
knows semi automatic systems, they have components which are well
integrated. This is the feature which renders these systems rather
inflexible. An automobile and a machine tool operated by driver or
operator are good examples of his class.
(3) Automatic Systems:
A complex system in which all operational functions are performed by
automatic devices is known as automatic system. Operational
functions are sensing information processing decision making and
action. It is completely inflexible in nature and cannot be adapted to
uses other that the one for which it has be designed.

APPLIED ERGONOMICS
It is the application of the data and principles of human factors to the specification,
design, evaluation, operation, and maintenance of products and systems that are
intended for safe, effective, satisfying use by individuals, groups and organizations.
These are classified into reducing stress, designing the machines, matching the job –
demands with the people abilities and improving the people’s knowledge about their
environment.

Two concepts are used

1- Fit man to job - like pilot who drive fight airplane (this need highly
qualified person)
2- Fit job to man - like carrying objects (it does not require much training)

CHARACTERISTICS OF SUCCESSFUL PRODUCT

DEVELOPMENT
 • Product quality
– How good is the product resulting from development?
– Does it satisfy customer needs?
– Is it robust and reliable?
– Product quality is reflected in market share?
• Product cost
– What is the manufacturing cost?
– It includes capital equipment and tooling?
• Development time
– How long did the Product Development effort take?
• Development cost
– How much spent in PD effort?
• Development capabilities
– Did the team/firm acquire any experience for future projects?

Challenges to product development

• Trade-offs: An airplane can be made lighter, but this action will
probably increase manufacturing cost. One of the most difficult
aspects of product development is recognizing, understanding,
and managing such trade-offs in a way that maximizes the
success of the product.
• Dynamics: Technologies improve, customer preferences
evolve, competitors introduce new products, and the
macroeconomic environment shifts. Decision making in an
environment of constant change is a formidable task.
• Details: The choice between using screws or snap-fits on the
enclosure of a computer can have economic implications of
millions of dollars. Developing a product of even modest
complexity may require thousands of such decisions.
• Time pressure: Any one of these difficulties would be easily
manageable by itself given plenty of time, but product
development decisions must usually be made quickly and without
complete information.
• Economics: Developing, producing, and marketing a new
product requires a large investment. To earn a reasonable return
on this investment, the resulting product must be both appealing
to customers and relatively inexpensive to produce.
• Creation: The product development process begins with an
idea and ends with the production of a physical artifact. When
viewed both in its entirety and at the level of individual activities,
the product development process is intensely creative.
• Satisfaction of societal and individual needs: All products
are aimed at satisfying needs of some kind. Individuals interested
in developing new products can almost always find institutional
settings in which they can develop products satisfying what they
consider to be important needs.
• Team diversity: Successful development requires many
different skills and talents. As a result, development teams
involve people with a wide range of different training, experience,
perspectives, and personalities.
• Team spirit: Product development teams are often highly
motivated, cooperative groups. The team members may be
collocated so they can focus their collective energy on creating
the product. This situation can result in lasting camaraderie
among team members.