Product Design

V N A Naikan
IIT Kharagpur
 Product Design

1. Early Design : Requirement definition and conceptual design

Conceptual Design
2. Trade-off Analysis : Optimization using cost and utility matrices
3. Detailed Design : Analysis and modelling
4. Test and Evaluation : Design reviews, prototyping, simulation, and
testing
5. Manufacturing : Strategies, planning, and methodologies
6. Supply Chain : Logistics, packaging, supply chain, and the
environment
7. Design for People : Ergonomics, reparability, safety, and product
liability
 Early Design
Requirement Definition

• Identify Product
• Define System
Specific needs
• Document Process
• Features
Service

• Feasible
• Realistic Specifications of product requirement
• Complete
Example : A Water Pump
1. Head
2. Flow rate
 Voltage Stabilizer/UPS:
Design Specifications?

1. Output Voltage ?
2. Input Voltage Range ?
3. UPS after power failure-How long ?
4. How much load (KVA) ?
 Conceptual Design

Product
Available Inputs Product
Requirements
• Components
• Sub-systems
• Physical arrangements
• Scientific Principles
• Technology – alternatives
• Functional logic diagram
• Preliminary Reliability Assessment
Concept of Audio Amplifier
 Compare Alternative Design Approaches
1. Complexity
2. Reliability
3. Appearance, space, weight, compactness
4. Availability of components/material
5. Cost
6. Environmental factors
7. Production Technology required
8. Skill required
9. Application/user profiles
10. Competitor products, if any
Outcome:
Select best design approach
Allocate product requirements to lowest level components
Mathematical and simulation models are used
Cost estimates for optimum design
Provides a baseline for detailed design
 Detailed Design
• Finalize the product design
• Mathematical & simulation models are used
• Design simplification
• Detailed Reliability Analysis/Allocations
• Design for Quality
•Parameter design
•Tolerance design
 Detailed Design…..
Stress analysis
Mechanical Stress
- Tension
- Compression
- Torsion/shear
- Combined stress theories
Thermal Stress
- High temperature
- Low temperature
- thermal shock
- thermal cycles
Electrical Stress
- Voltage, current, load
- Magnetic field, interference
Environment
- Emission, Waste management,
- product failure consequence
 Detailed Design…..
• Finite Element Analysis
• Failure Mode Effect Analysis (FMEA)
• Risk and Safety Analysis
• Maintainability Analysis
• Environmental Effects Analysis
• Standardization
• Adopting Technological Developments
• Environmental Impact-Life Cycle-disposal
 Detailed Design…..
• Iterative procedure
• Improve every stage of iteration
• Finalize a design for laboratory assessment
Detailed Design Consists of:
(a) Drawings with dimensions/finish
(b) Component lists and drawings
(c) Component dimensions/finish
(d) Component material and finish, numbers
(e) Functional diagrams/logic diagrams
(f) Important test points in the drawing
Information must be sufficient to construct a laboratory model of the
product
Circuit Design of Power
Amplifier
Circuit Design of Power
Amplifier
Product: Skeleton
Product: Power Amplifier
 Product Prototype
• A prototype is an early sample, model, or release of a
product built to test a concept or process.
• It is a term used in a variety of contexts, including
semantics, design, electronics, and software programming.
• A prototype is generally used to evaluate a new design to
enhance precision by system analysts and users.
• Prototyping serves to provide specifications for a real,
working system rather than a theoretical one
 Test and Evaluation of Prototypes
Goal: Improve design by seeing actual performance &
construct laboratory models
Conduct various Tests
- Functional Requirement Tests
- Tolerance Requirement Tests
- Unwanted O/P tests
- Accelerated/HA Tests/Endurance
- Efficiency and losses
- Components/Parts qualifying Tests
 Test and Evaluation…..
- Environmental Tests
- Heat
- Shock
- Thermal
- Mechanical
- Vibration
- Salt/corrosion
- Low temperature
- Humidity
- Dust
- Saline
• Analysis of Test Results
• Give Feed back
• Improve design based on feed back
• Design Reviews: Reviews (1) (2) (3)……..(n)
• Design Freezing-Final Design of Product
 Manufacturing/Process Design
1. Components/accessories
- Make / Buy
2. Make - Technology - Machine- Speed – Reliability –
Cost -Production Rate - How many machines…
3. Buy -Vendors - Selection - Evaluation – Development
- Agreements - Quality level-JIT
4.Operators- Skill, Experience, How many
5. Maintenance – BdM / PvM / PdM
6. Stores - Spare parts management
- Raw materials management
- Vendor supplied components
- Tools
- Lubricants
- Testing
 Manufacturing/Process Design…
7. Automation/semi-automation/manual
8. Machine layout, balancing, intermediate
material storage (throughput)-capacity
9. Material Handling systems
10. Quality control practices
11. Business Practices, Credit Policy, Market
Advertisement and Sales
12. Packaging
Logistics, supply chain and Environment

1. Delivery/Transportation
2. Installation
3. Service support
4. Environmentally friendly design/disposal
(ISO 14000)
5. Information Management
6. Insurance and legal protection, safety
7. Customer feed back collection
Logistics, supply chain and Environment

Logistics

- Road
Type of Damage
- Rail Cost
/ loss
- Air Packaging Analysis
Analysis
- Ship
Logistics, supply chain and Environment
Supply Chain
S.C. design
- No. of stages-No. of location
- Profile/cost/risk sharing
S.C Operation
- Sales forecasting
- Allocation
- Information/accounts Management
- Transshipment/ Priorities
Environment
ISO 14000
Operation and disposal
Recycling
 Design For People

1. Ergonomics
2. Reparability/Alterability
3. Operability
4. Safety
5. Product Liability
- Poor Quality, Rejection, Economic loss
- Warranty
- Health
- Pollution
- Insurance
- Radiation
 Design For People….
6. Environment
- Noise
- Vibration
- Shock
- Temperature
- Smoke
- Dust
- Radiation
- Chemical reaction
- Pollution
 Design For People….
7. Instruction Manual
8. Essential tools / Spare Parts
9. Electromagnetic Interference-Protection
10. Child Protection
11. Product and Personal Insurance
12. Warnings
13. Warranties/Guarantees
14. Product / Service Support
End