Course Title: Introduction to Design and Innovation

Credit Structure L T P C
4 0 0 4
Prerequisites

By: Kamlesh Joshi

Department of Mechanical and Aerospace Engineering

(Institute of Infrastructure Technology Research and Management)
 Detailed Syllabus
Introduction: Introduction to design, modern product development process, reverse engineering and redesign, examples of product
development process.

Product Development Process Tool: Product development teams, team structures, team building, team valuation, product development
planning, scheduling tools.

Scoping Product Development: What to develop? Mission statement, Technical questioning, technical feasibility, S curve, Concept of ideal
design, conceptualizing product: Identifying the customer needs, understanding the customer needs, organizing & prioritizing customer needs,
affinity diagram, customer use pattern

Establishing Product Function: Functional decomposition, FAST method, creating function structure, function structure modeling process.

Product tear down and experimentation: Tear down process, tear down methods, application of product tear down.

Benchmarking & Engineering Specification: Benchmarking approach, example, supporting tool for benchmarking, intended assembly cost
analysis, function form diagram, setting product specifications, specification process, house of quality/quality function deployment(QFD).

Concept generation: Concept generation process, traditional brainstorming, brain ball method, C sketch/6-3-5 method, example.

Concept selection: Concept selection process, Pugh concept selection chart, concept screening and concept scoring.

Concept embodiment: process of concept of embodiment, advanced method, FMEA

Industrial design: Goal, importance of ID, assessment of quality of product based on ID, ID process, design challenges that ID
2
face,
technological or user driven products based on ID.
 Modern Product Development (PD)
A typical product development A reverse engineering and
process redesign PD process
•Develop a vision • Select a product
Understanding • Market opportunity Reverse • Develop a vision
• Customer need • Customer need
an opportunity Engineer
•Competitive analysis • Market opportunity

• Portfolio Planning • Competitive analysis

Develop a • Functional modeling Develop a • Functional modeling
concept • Product architecture Redesign • Product architecture
•Concept Engineering •Concept Engineering

• Embodiment Engg. • Embodiment Engg.

Implement a • Physical and analytical Implement a • Physical and analytical
concept Modeling Redesign Modeling
• Design for ‘X’ • Design for ‘X’
• Robust Design • Robust Design
Dr. Kamlesh Joshi, Assistant Professor, Dept. of ME (IITRAM) 3
 Benchmarking and Engineering
Specifications

• Benchmarking:
Definition, approach.

• Support tools for benchmarking process.

• Specification process:
Basic methods like specification sheets and the house of quality.

4
 Benchmarking
It is a process of measuring the performance of a company’s products, services, or
processes against those of another business considered to be the best in the industry.

It is done to: Stay in business, Delight the customer, Become world class leader.

A benchmarking approach:
Step 1: Form a list of design issues.

Step 2: Form a list of competitive products.

Step 3: Conduct an information search.

Step 4: Tear down multiple products in class.

Step 5: Benchmark by function.

Step 6: Establish ‘Best-in-class’ competitors by function.

Step 1: Form a list of design issues. (Continually revised and updated)

Ex: Coffee Mill: [Krups Mill]

Design issues: Price, Noise level, Size, Grind time. (From customer need)

Step 2: Form a list of competitive/related products.

Braun, Molinex, Salton, Bosch } Competitors to Krups Mill

Step 3: Conduct an information search.

Any printed article that mentions about the product, its features, materials, manufacturing
company, manufacturing locations, customer group, market share.

Libraries, Thomas register of companies, Market share reporters, National Bureau of Standards,
Census of Manufactures, Moody’s Industry review, Trade magazines, Patents.

The objective of this step is to find a list of successful products in the market along with
key design issues (for teardown).
Step 4: Tear down multiple products in class. (Using methods from Chapter 6)

Note: We must benchmark our products with only ‘Best-in-class’ products.

Ex: Krups coffee Mill:

Design issues:
Mill cost,
Noise level,
Size,
Grind quality,
and Grind time.

Products to teardown:
Braun, Cuisinart, Procter- Silex

Top competitors in North American market

Step 5: Benchmark by function. (Not by component)

Benchmark by component: Comparison of products by components/product form/parts

Problem: Any component in one product may not be functionally equivalent to similar component
in another product.

Ex: The cover lid in (in one coffee mill machine) may additionally serve as a switch in one
machine, but may not in another machine

Solution: Benchmark by functional equivalency approach (Focus on functions)

Step 6: Establish ‘Best-in-class’ competitors by function.
For each function: a) Highest performing solution (Best-in-class)
b) Least expensive solution (Best-in-class)

Benchmarking by technical solutions: (Product performance) Develop ‘S’ curve

Benchmarking of competitors: (Company performance)
 Support tools for the benchmarking process
1. Indented Assembly cost analysis:
2. Function-Form Diagrams:

10
 Support tools for the benchmarking process
1. Indented Assembly cost analysis:

11
 Support tools for the benchmarking process
2. Function-Form Diagrams:

12
 Setting Product Specifications
After benchmarking competitive products, the next step is to use the information gathered
for setting product specifications (and targets) for developing a new product.

Information Setting of Product

Benchmarking
Specification

Understanding Develop a
the opportunity Concept

First phase of Second phase of

product product
development development
(Complete) (Start)
13
 Setting Product Specifications
Specifications:- Specifications for a new product are quantitative, measurable criteria that
the product should be designed to satisfy.

(Measurable goals of the design teams)

• What is the meaning of quantitative? How it is different from the term qualitative? Discuss.

There are two aspects of specification:

➢ It should have dimensions (can support units)

Ex.: Meters, Degree Celsius, Horse Power

➢ It should have a target value

Ex.: Specific value:- 1, 5, 7
Range:- 30-42, ≤ 70 etc.
14
Note: Specifications can change or refined from an initial phase (preconception phase) to the final phase (embodiment phase)
 Basic method of establishing engineering Specifications
1. Specification sheets
2. House of Quality

Specification sheets
• Customer needs provide the foundation to focus design efforts.

• Apart from customer needs, other important criteria that compliments or supplements
customer needs are engineering requirements.

• These engineering requirements includes aspects like manufacturing, standard, ethics etc.
which the customer may not even perceive.

• The design teams should consider both customer needs and engineering requirements for
product development.
15
 Basic method of establishing engineering Specifications
Specification sheets
• One way to do this is by making use of specification sheets, or generation of specification
list.

• This approach focuses on specifications that are latent ( the customer do need them, but
they do not think to express them)

Ex.: Safety issues, environmental effects

The level of importance of each specification is given by classifying them as:-

-> Required demand (D) or
-> Desirable wish (W)

16
Basic method of establishing engineering Specifications

17
Basic method of establishing engineering Specifications

18
 Basic method of establishing engineering Specifications
Quality function deployment
Help transform customer needs into engineering specification
(QFD)

•Developed by Yoji Akao in Japan (1966).

• First applied in 1970 by Mitsubishi.
• Adopted in a number of industries including automotive and electronics.

House of Quality Basic design tool for Quality function deployment

• Identifies and classifies customer needs (desires) and their importance.

• Engineering specifications are identified and correlated with customer needs.
• The output of house of quality is a matrix which help us understanding design targets.
19
 House of quality
(Quality function Deployment)

Figure:
House of quality
(Template)
Source:
(https://www.lucidchart.
com/blog/qfd-house-of-
quality
 House of quality
(Quality function
Deployment)

Figure:
House of quality
(For mobile phone)
Source:
(https://www.lucidchart.
com/blog/qfd-house-of-
quality