ASSIGNMENT 4

(INDUSTRIAL PRODUCT DEVELOPMENT)

An Assignment Report Submitted

In Partial Fulfilment of the Requirements
For the Award of the Degree of

MASTER OF TECHNOLOGY
in
CAD-CAM
By
ABHISHEK CHAUDHARY (MT21CDM002)
M.TECH 1ST YEAR
Under the Supervision of
Dr H P JAWALE
(ASSISTANT PROFESSOR)

DEPARTMENT OF MECHANICAL ENGINEERING

VISVESVARAYA NATIONAL INSTITUTE OF
TECHNOLOGY, NAGPUR.
OCTOBER 2021
 1. What do you mean by processing of designs for commercialization?
Commercialization is the process of introducing a new product or production method into
commerce making it available on the market. The meaning of processing of designs for
commercialization shows the process of commercializing the individual major components
which helps in making the commercialization process of the product come true.

2. What is a breakthrough product? Give some examples. What are the

challenges in creating breakthrough product?
Breakthrough products are the products which are technologically advanced and creatively
superior to the existing products in the market. One of the examples of the breakthrough product
is the Tesla self-driving electric sedan which took the market by a shock. The challenges in
creating the breakthrough product are that a lot of research, time and money is utilized in the
production of the product and to some extent the marketing and financing of that product is also
a challenge to the company which is producing the product.

3. What are the contents of “make cost” and “buy cost”?

The contents of make cost are as follows:
a) Purchase and maintenance cost of any production equipment.
b) The cost of raw material.
c) Labor cost.
d) Inventory cost.
e) Waste disposal cost of the waste produced by the production process.
f) Material handling cost.
g) Overhead cost.
The contents of buy cost are as follows:
a) Cost of purchasing the product/component from an outside source.
b) Transportation cost.
c) Inventory cost.
d) Sales and tax cost.
4. Elaborate about make and buy decision for parts in aggregate.
A make or buy decision is an act of choosing between manufacturing a product inhouse or
purchasing it from an external source. Make or buy decisions provides the comparison of the
costs and advantages of producing versus outsourcing. For the parts in an aggregate the make
and buy decisions can significantly reduce the cost and make the whole aggregate efficient in
terms of the capital investment. It provides enough information for the pros and cons of each
method and buy that the organisation can decide to make or buy the parts.
 5. Give the significance of generation-1 aggregates in IPD.
Generation-1 aggregates are the first produced aggregates which in coming time will help in
building the product and production process for the product. Generation-1 also determines
whether the product will be getting the nodding from the management or not. It helps in
outlining the make and buy decisions and helps in finding the cost and functionality of the
products. It is also the stage where the prototype of the product will be made and be represented
in front of the management.

6. What are the focus issues in generation-1?

There are two focus issues in generation 1. These are:
a) Short term action issue: These issues require less time to be solved and only a little of
rework needs to be done to resolve the issue.
b) Long term action issue: These issues require comparatively long time where the designer
has to correct the design /drawing by a schedule date which is well documented.
7. What is an aggregate in a product? Give a portfolio detail for parts in
an aggregate.
An aggregate can be a subsystem or component in a product which is necessary for the complete
assembly and functioning of the product. The portfolio detail for parts in an aggregate contains
the drawings and models for the part, production method of the part and their material which is
used to make them up.

8. What is G-1 prototype? How it is important at G-1 stage?

The G-1 prototype is the initial and the first working product which is made by the product
development team in the R&D department. It is important as it is used as a model to demonstrate
the product in front of the management. It also shows the procedure by which the product will be
made and the costing and profit expected by the product.

9. What are the important events during G-1 aggregate building?

The important events during G-1 aggregate building are as follows:
1) Planning for the design of the product by dividing into the aggregates and further into
components.
2) Preparing the CAD models for the different components and carrying the classification
into different categories as exclusive tooled up components etcetera.
3) Preparing the make or buy decision for the different components of an aggregates.
4) Creating the portfolio for the different components.
5) Acquiring the materials and outsourced components.
6) Preparing and conducting the test and validation of the components.
7) Assembling and producing the components.
8) Finally finishing the product.
 10.How G-1 aggregate is created?
The G-1 aggregates are created in the proto shop of the R&D department. The project exclusive
component is confirmed for quantities required by component development team in meeting. The
protocol of 100% inspection is followed and each component is inspected in the quality area. The
component which are conforming and compliant to quality as per drawing released by project
team are accepted and shipped to store. Generally, the tooled up exclusive component is to the
extent of 20% of the total component which are created in house. The plan for the aggregate
production is made and the aggregate is built according to the plan.

11.How the issue in G-1 prototype are resolved?

As the issues are divided in short term action and long-term action issues, they are delt with
according to the procedure. The issues can be like mismatch in assembly which can be corrected
with a bit of reworking, and can be like imperfection in design which is corrected by the designer
and is done by the given scheduled date which fall in long-term category.

12.Why creating 3-D model is beneficial at the G-1 stage?

The 3-D model creation is beneficial because of the following reasons:
a) Once 3-D models are ready, 3D assembly simulations are possible to detect and correct
any possible assembly tools interference.
b) The Simulation created by the 3-D model can help in the process planning and time
determination of the assembly and the latter can be smoothened by using these
simulations.
c) The product can be easily validated using CAE once its 3-D model is obtained.
13.Explain concept of exclusive tooled up components in G-1. Why it is
needed?
The exclusive tooled up components are those which are created by using general purpose tools,
machines, mostly through hand/manual interventions and in small numbers. It is needed as the
tools are not precisely available and this is always a crude approach to create the first version of
the aggregate. As there is a lot of rework, revisions and corrections in upbringing the aggregate
to level of portfolio details the exclusive tooled up components help in this process.

14.How G-1 prototypes are validated through CAE route?

The validation through the CAE route is done using the following:
a) The product features are tested in virtual environment.
b) The features are validated in the simulation.
c) The operating conditions and constraints are applied on the component to make the
simulation as close to the real scenario as possible.
d) The virtual calibration is done and data is collected on the product in simulation.
 e) The data obtained is used as the proof of validation.

15.How validation through laboratory route is carried out?

The validation through laboratory route is carried out as following:
a) The 3D model of the project exclusive components are submitted to the CAE department.
b) The limiting condition, such as loads, under which they are to be virtually simulated and
tested is signed on with them.
c) The virtual test is conducted by the CAE engineer and the manager which is then shared
to the designer.
d) If there is no problem in the design then the design is certified to have passed the CAE
test.
e) In case of encountering and problems the designer iterates the model and sent it to the
laboratory for testing again.