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
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face,
technological or user driven products based on ID.
 Establishing Product Function

• Functional decomposition
• FAST method
• Creating function structure
• Function structure modeling process

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 Establishing Product Function
o Here, our aim is to transfer the customer need into a product function.
o The methods to carry out market needs or customer needs are widely accepted.
o However, the transition from customer need to a concrete solution is seen more of an art
than science.

A product function helps us in mapping customer needs to functional description.

Advantages of a functional description of a product:

1) A component or form-independent expression of design task is generated to search for
solutions.
2) Helps in defining clear boundaries to associate assemblies or sub-assemblies of the final
design solution.
3) Creativity is enhanced.
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 Establishing Product Function
Function modelling basics:
1) A component or form-independent expression of design task is generated to search for solutions.
2) Helps in defining clear boundaries to associate assemblies or sub-assemblies of the final design solution.
3) Creativity is enhanced.

Energy Product Energy

Material represented as a Material
Information functional system Information
Function:
Fig. Generic black box model
A clear and reproducible relationship
between input and output of a product
independent of any form.
A noun + An active verb Hand motion Sound, KE
Ex: Clip nails, Play music, Make copies Finger nail Clip nail Debris, Nail
Long nail Good
appearance
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Fig. Generic black box model of fingernail clipper
Establishing Product Function

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 Establishing Product Function
Function modelling basics:

Functional decomposition:

Sub-function:

Functions and Constraints:

Function:

Constraint:

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 Establishing Product Function
Function modelling : Overview of what the system is supposed to do.

Fig. Functional structure of hair dryer [Kevin Otto] 8

 Functional Modelling Process (Functional Decomposition)
There are two approaches to functional decomposition:

Top-Down
approach
Hierarchical (FAST Method)
tree/Function tree
approach Bottom-Up
Functional approach
Decomposition
Function structure (SOP Method)
approach
(Task-listing)

• Function trees are fast and simple to construct.

• However, in this, the interconnecting links between the sub-function black boxes are not
considered.
• Less effective approach than function structure approach.
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 Establishing Product Function

Function Tree/Hierarchical Tree Approach

(a) Top-Down Approach (FAST Method)

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 Function Analysis and System Technique (FAST)

The FAST diagram 11

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 Function Analysis and System Technique (FAST)
1. Construct two vertical dashed lines. One to the extreme left and one to the right. These lines define the scope of
the product development objective.
2. Place the basic function to the right of the left-hand scope line. Pose the question, “Why is the basic function
being performed? “ A higher-order function will answer this question. Place this function to the left of the basic
function and connect with a line, beginning the critical path.
3. Generate functions to the right of the basic function. These functions should always follow a how and why
answering scheme and represent the secondary functions. Connect these functions with lines to define the
furtherance of the critical path.
4. The critical path will end with an “assumed function,” outside the right scope line. This function is external to the
product. Such as “supply electricity” in the case of an Iron box.
5. Generate the remaining secondary functions by placing them under the functions that relate to the basic or critical
path secondary functions. These functions either occur at the same time or are caused by the functions on the
critical path.
6. State the objective of the development effort above the basic function. In addition, add one-time or all-time
functions to the top of the diagram.

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 Function Analysis and System Technique (FAST)

The FAST diagram for Iron box 14

 Establishing Product Function

Function Tree/Hierarchical Tree Approach

(b) Bottom-Up Approach (Subtract and Operate Procedure)

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 Subtract and Operate procedure
Assumption: Actual product/ Form concept exists already

• Uncover technology and architecture

Product teardown • Uncover working principle
• Uncover cost

Subtract and operate procedure (SOP)

1. Disassemble one component of assembly.
2. Operate the system through its full range.
3. Analyze the effect.
4. Deduce sub-functions of the missing components.
5. Replace the component and repeat ‘N’ times.

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 Subtract and Operate procedure Explanation
1. Disassemble one component of assembly.

2. Operate the system through its full range.

3. Analyze the effect.

4. Deduce sub-functions of the missing components.

5. Replace the component and repeat ‘N’ times.

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Subtract and Operate procedure Example

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Subtract and Operate procedure

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Subtract and Operate procedure

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