DESIGN AND DEVELOPMENT

PROCESS

–R&D department
LEEL Bhiwadi.
 DESIGN PROCESS ?

Design process is a collection of

procedures and habits that help teams
design better products
 The Process of Design
 Designing is the process of making many
decisions that converts an abstract concept
into a hardware reality.

Concept Product
 R&D DEPARTMENT

 NPD ( new product development)

 C&D ( continuous and derivatives)
 ONGOING PROJECTS
 NPD
– DMRC HVAC 14 TR Unit
– BMRC HVAC 14 TR Unit
– RMVU Ventilation Unit
– GETS CAB HVAC Unit
– ICF Ventilation Unit
– Hot case

 C&D ( continuous and derivatives)

– RMPU 407c
– RMPU reverse cycle
– LHB
GUIDING PRINCIPLES FOR NPD
PROCESS DESIGN
–Develop a comprehensive process that caters to
various types of projects undertaken by Lloyd
Electrical and Engineering Limited.

–Ensure that the process is easy to understand and

is user friendly

–Define clear scope of the NPD process and clarify

project initiation point

–Enable fact based and timely decision making at

appropriate levels (senior management, functional
heads, and project team) during project execution.
– Define business and technical criteria for effective
decision making

–Provide clarity on process deliverables, their

ownership, timing for completion, and related inputs.

–Improve NPD quality by integrating design for

functional excellence (DFS, DFM,DFA) and design for
six sigma (DFMEA, PFMEA) concepts in the process

–Enable cross-functional and concurrent execution of

projects.

–Integrate Qualicon process and leverage the materials

wherever relevant
 Lloyd’s 7-Step Design Process
1. Project definition (management/Engg.)
2. External Search (Research)
3. Internal Search (Brainstorming)
4. Evaluation and Selection (Engineering)
5. Detail Design (Engineering)
6. Prototyping (Testing)
7. Documentation (Engineering)
 NPD Process gate structure for leel
( following IRIS standards)
Identification of GATE 1
design inputs

Design activity
planning GATE 2
Designing

Design review
and verification

GATE 3 Drawing release

and changes

Design Validation

GATE 3 Documentation
 IDENTIFICATION OF DESIGN
INPUTS
Following design inputs are considered while
planning the design and development activities:-

 Customer’s functional & performance requirements /

specifications and relevant standards
 Information from previous similar designs.
 Material selection charts.
 Engineer’s Design’s Hand books.
 Technical Literature on similar products
 Feed back from customer on product quality on
previously designed similar product.
 Statutory & Regulatory requirements related to the
product.
 DESIGN ACTIVITY PLANNING
Design activity planning involves identification
of design stages including review, verification ,
validation and responsibility & authority for
each design stage.

 Project plan will be made

 Target dates
 Responsibilities
 DESIGNING
Product Design and its modification is evolved by
qualified and experienced design engineers, using
Auto CAD / Design-PRO/Solid works software.

 General arrangement drawing is prepared and positioning of

components and their matching is seen on 3-D scales with
the objective to visualize the fitment and placing of parts

 Following analyses are applicable to ensure the design;-

Thermal analysis (CFD)
Structure analysis (FEA)
Airofoil analysis
Shock and vibration analysis

 Component selection from rolling stock approved vendors

only.
 DESIGN REVIEWS &
VERIFICATION
–Design reviews are conducted at each stage of design by the
R & D engineer, to evaluate the ability of the results of design
and to identify any problem. Where ever appropriate,
representatives of Production Deptt., Marketing, Purchase &
Quality Assurance also attend design review meetings. Design
outputs are approved by Head Design / Design Engineer,
before these are released for procurement & production..

–Internal brain storming sessions for design review.

–Problem identification and their root cause analyses.
 DESIGN RELEASE &
SUBSEQUENT CHANGES
–Design Outputs, Related data, Material
specifications are frozen after Design Verification
and are released for procurement of materials and
implementation. Changes to technical data made
during design sequences & design reviews are
recorded in corresponding product file.
 DESIGN VALIDATION

–Design validation is done after commissioning of

the machine as per customers usage condition. Type
test for the designed parameters are conducted and
report is prepared which acts as Validation Record.

–Validation design and performance target

achievement through proto build.
–Factory tests
–Field trials
–Report preparation.
–Customer approval
–Work station release
 DOCUMENTATION

–After design validation and performance target

achievement through proto build these documents to
be prepared

–Service manuals
–Test reports
–Installation drawings
–Training presentation
–Final BOM
LIST OF DELIVERABLES AS
PER IRIS STANDARD
–GATE 1

–GATE 2 FROM AJAY

–GATE 3

–GATE 4
 Product Design Specifications
Customer Needs
 Cooling capacity
 Affordable as a birthday present
 Fully assembled
 Uses alternate power source for emergency
 It is safe
 Looks good
 Heating capacity
 Automatic controls
 Last a long time
 Product Design Specifications
Engineering Specs
 Climbs at 1 ft/s or faster
 Retail cost is to be less than $30
 Uses 2 AA batteries (not included)
 Has no removable small parts
 Music loudness between 20-30 db
 Luminosity is to be more than 5 W
 Works for more than 3 hours on 2 AA
 External Search
 Level-I
 Rope climbing toys / machines
 Rope climbers (sports or circus)
 Nature (spiders, bats, etc)
 Level-II (Team uses friction wheels)
 Hoists

 Trolleys

 Ski Lifts
 Internal Search & Evaluation

Brainstorming
Generate many ideas
Evaluate against PDS
Select one to engineer
 Detail Design (Engineering)

Lift and Drag Coefficients

(as effected by ground promimity)

0.35
0.3

Coefficient
0.25
0.2 Drag Coefficient
0.15 Lift Coefficient
0.1
0.05
0
0 0.05 0.1 0.15
h/L

More Abstract Engineering Less Abstract

 Design Process
 Top-level problem definition is called PDS
(Product Design Specifications)

 Problem definitions at lower levels derive

from PDS:
 Sub-system design specifications.
 Component design specifications.
 Feature design specifications.
Product Development Process

Product Planning

Design Brief (Mission Statement)

Market Research

Product Design Specifications & QFD

Product Development Process

PDS
Candidate Design

Detail Design Concept Synthesis

Prototyping Concept Evaluation

Release for Production

Candidate Design
Detail Design

Candidate Design

Components
No Numbers
System-Level Design

Numbers Parameter Design

Prototype Testing

Release for Production

 Customers
 People who are affected by the product

Team

Globe
Company
(External)
(Internal)
 External Customers

Buyers
Retailer

End
Users
Maintenance EXTERNAL

Government
Society &
Standards
 Internal Customers

Manufacturing
& Management
Procurement

Marketing Internal

Shipping
Legal
 What Do They Want?
• End Users
– Performance & Functionality
– Affordability
– Ease of use including ergonomics
– Reliability and Long life
– Versatility
– Safety
– Low maintenance and easy assembly
– Esthetics
 External Customers
• Buying managers
– Low Cost/Performance
– Safety
– Ruggedness (abuse resistance)
– Ergonomics
– Long warrantees
– Reliable with Low downtime
– Low operating cost
 External Customers
• Retailers
– Small and attractive packaging
– Long shelf life
– Low cost/performance and Exciting features

• Maintenance
– Ease of maintenance
 External Customers
• Government / Standards / Society
– Conformance to laws and regulations
– Promotion of public health and safety
– Protection of environment
– Solution to chronic problems in society
• Traffic
• Energy
• Noise
• Drugs, abuse and other crimes
• Diversity / Social tolerance / Security
 Internal Customers
• Management
– Make a big profit
– On time delivery
– Low failure risk
– Documentation
– Process: Conformance to company
product development process
 Internal Customers
• Marketing
– Attractive features to target buyers
– Low production cost
– Esthetics
– Attractive packaging
– On time delivery
– Long Warrantees
 Internal Customers
• Manufacturing
– Manufacturability using standard
methods and schedules.
– Conformance to company documentation
formats.
– Use of products from preferred
vendors.
 Internal Customers
• Legal
– No patent infringements
– Safety
• All required safety warnings and labels
• Designed protection against reasonable
abuse
– Codes and regulations
 Internal Customers
• Shipping and Packaging
– Ease of user assembly
– Small packaged size
– Ability of locking or fixing sensitive
components
– Resistance against damage due to
dropping, vibrations, moisture, heat, and
cold.
 Performance cost Ease of use Reliability Safety

Users ***** ***** ***** ***** *****

Buyers **** ***** ** ***** *****

Retailers *** *** *** ** **

Govrnmnt ****

Mangmnt ** **** ** ** ***

Marketng **** ***** *** **** ***

 Product Design
Specification
• Elements of PDS
– Performance (User)
• Speed,
• Capacity,
• Power,
• Accuracy,
• etc.
 Elements of PDS
– Environment: (User)
• Temperature range, humidity, dust and dirt,
etc.
– Life in service: (User)
• 10 years, 5000 cycles, etc.
– Maintenance: (User)
• What is the market policy, what customers
accept
– Target production cost: (User)
• Cost of comparable products and company
policy.
 Elements of PDS
• Shipping:
– Package sizes
– Damage resistance
 Elements of PDS
• Quantity (Manufacturing)
– Determined by market analysis.
• Manufacturing facility (Manufacturing)
– Is the design constrained by existing facility?
– Are parts to be contracted and assembled in-
house?
– Does the company policy dictate certain
facilities?
 Element of PDS
• Size and shape (Marketing)
• Weight (Marketing)
– What is the desired weight?
– Should handles or lifting points be
provided?
– Should it be modular for better
handling?
• Aesthetics (Marketing,User)
– Color, shape, form, texture, finish.
– Market research.
 Elements of PDS
• Materials (Marketing, Codes, Regulations)
– Left to designers unless company
guidelines or regulations restrict certain
materials (asbestos, lead).
• Product life span (Marketing, Manufacturing)
– Life of a product as a marketable entity.
Several months or several years?
 Elements of PDS

• Laws, Codes, and standards (Government)

• Ergonomics (User)
 Elements of PDS
• Quality and reliability (Marketing)
– Company policy regarding warranties
– Competitors warranty policies
• Testing (Marketing, QA)
– What tests would be performed to verify
performance
– Standard tests
 Elements of PDS
• Shelf life (storage) - Retail
– Possibility of rust, decay, deterioration
• Processes (company guidelines)
– Use of certain standards (GD&T for
example)
– Use of certain procedures
• Time-scales (deadlines) - Management
– Whole design project, milestones
 Elements of PDS
• Safety (User, Government, Legal)
– What safety requirements are
mandated by government
– Professional society's codes and
standards
– Need for warning labels
– Likely degrees of abuse or
misinterpretation of operating
procedures.
 Elements of PDS
• Company constraints (Management)
– Compatibility with other products
• Documentation (Management – Legal)
– A product design must include a full
formal documentation per company
guidelines.
– Safety, Operation, and Service
documents.
– Etc.
 Elements of PDS
• Legal (Lawyers)
– What product liability law suits are
associated with similar products and
why.
– Note the legal terms:
• “defect of specification”
• “defect of design”
• “defect of manufacture”
– Relevant patents
 Element of PDS
• Installation (Installers)
– Many products must interface with
other products or be assembled with
other products.
• Disposal (Society)
– Should any parts by recyclable?
– bio-degradable?
 Wording of the PDS
Document
• Format of most statements in PDS:
– The device must ……..
– The device is to ……
– The device is desired to ….
• Avoid mixing requirements.
– One sentence per requirement.
• Cast PDS statements in a positive
format
 PDS is a Dynamic
Document
• A design statement usually begins as
a vague statement
– The device is to be easy to use
– The device is to be safe
– The device is to be inexpensive
– The device is to be rugged and reliable
– The device is to be portable
 Wording of the PDS
Document
• Example: ESCO’s Pin Remover
– The pin-remover is to be light.
– The pin-remover must work in a wet,
cold, and dusty environment.
– The Pin-remover must be safe
– The Pin-remover must have a 3-year
warranty.
 PDS Example
• The PR is to be rugged.
• … must work with air pressure.
• … is be easy to use.
• … is to pass “HTS” tests.
• … is to last 5 years in normal usage.
• … is to be easy to carry.
 PDS Example
• … is to sell for less than $150.
• … is to costless than $50 to make.
• … is to have low maintenance needs.
• … is to be difficult to use as a
hammer.
• … must not infringe on patented
devices.
• … Production volume is to be 300 per
year
 PDS Example
• … is to be tested by June 2006.
• … is to be released by Sep. 2006.
• … is to be used with Dredge Point
models.
• … is to work faster than the hammer
 Engineering
Specifications
• What is
– “Fast, accurate, high-performing”?
– “Light, Small, portable”?
– “Easy to use”?
– “Safe”?
– “Stylish”?
Engineering Specifications
– Verifiable PDS statements
– Developed for important PDS
statements
– Have associated target
numbers (Yes/No OK)
Engineering Specifications
Tips
– Set up metrics and targets
so the designer has
maximum options in
accomplishing the PDS
Engineering Specifications
Tips
• PDS: The Dog Feeder must not tip
over when bumped or pushed by a dog.
– Bad: The DF must weigh 50 lbs
– Good: The dog feeder must
withstand 30 lbs applied to its
top from side
 A Typical PDS Page

• Requirement: PR is to be easy to
maintain
– Primary customer: End users
– Priority: High
– Metrics and Targets
• Daily maintenance: None
• Weekly maintenance: < 10 minutes – field
• Yearly maintenance: < 1 hour – Shop
• Cost of weekly maintenance < 10c
• Cost of yearly maintenance < $10
 Engineering Requirements Competition

I
Customer M
Needs Relation Between
P Engineering and
PDS O Customer
R Requirements
Statements T
A
N
C
E
Competition
Target