Unit--IV: PRODUCT DESIGN TOOLS & TECHNIQUES

Unit

Product Modeling
Types of Product Models
Product Development Process Tools TRIZ Altshuller‘s Inventive Principles
Modeling of Product Metrics
Design for Reliability
Design for Manufacturability – Machining-Casting and Metal Forming
Design for Assembly and Disassembly
Design for Environment
 Modeling of Product Metrics
Product metrics − Describes the characteristics of the product such as
size, complexity, design features, performance, and quality level.
KPIs –Key Performance Indicators
Product –Functional Performance; Efficiency
Process- Throughput time; Output quality; ting Cycle Time (production
rate), Capacity Utilization Rate, Process Downtime Level
Business – Revenue; Profit; Capital; Income Sources; ROI
Organization- Quarter on Quarter growth; Operating Cash Flow; Debt
equity Ratio; Turnover; Working Capital; Profitability over time; Income
sources; Expenses vs. Budget; Accounts Receivable Turnover; High
liquid assets
Types of KPIs include
include::
1. Quantitative indicators that can be presented with a number.
2. Qualitative indicators that can't be presented as a number.
3. Leading indicators that can predict the outcome of a process.
4. Lagging indicators that present the success or failure post hoc.
Steps when writing a KPI:
1. Write a clear objective for your KPI.
2. Share your KPI with stakeholders.
3. Review the KPI on a weekly or monthly basis.
4. Make sure the KPI is actionable.
5. Evolve your KPI to fit the changing needs of the business.
6. Check to see that the KPI is attainable.
7. Update your KPI objectives as needed
Design for Reliability-
Reliability-DFR
Reliability – Batch tub Curve for Product Life Cycle Assessment
 DFR Key Activities

DRBTR-Design Review based on Test Reports;

HALT-Highly Accelerated Life Testing (Test Physical Limitations)
DFR Objectives
1. Durability
2. Robustness
3. Useful Life

Too high Reliability – Cost of product will be high / expensive

Too low Reliability – Repair and warranty cost

Terms (Average time the item is expected to function before failure)

1. MTBF-Mean Time Between Failures for Repairable Systems
2. MTTF-Mean Time to Failure for Non-repairable items
3. AFR – Annual Failure Rate

Types:
1. Serial Reliability
2. Parallel Reliability
Serial Reliability

Parallel Reliability
Steps in Designing for Reliability
1. Develop Reliability Plan
2. Problem Statement: Useful product life; accelerated testing used
3. Major points of failures and root cause analysis
4. Reliability must be close to product useful life
Tools for Testing
1. Stress Analysis
2. MTBF and MTTF
3. FMEA
4. Fault Tree Analysis
5. Reliability Block Diagrams
Failure Effects
1. Noise
2. Inoperability
3. Instability
4. Intermittent Operation
5. Roughness
6. Excessive effort
7. Poor Appearance
8. Environmental Damage
9. Customer Service
 Design Against FAILURE
Design against FATIQUE Failure
Design against CREEP Failure
Design against BRITTLE Fracture
Design against PLASTIC Deformation
Design against CHEMICAL Induced Failures
Design against CORROSION Induced Failure
Design for Manufacturing (USA) and Production Engineering (Europe)
Functions of Manufacturing Engineering Casting
Process Engineering Molding
Tool Engineering Deformation Processing
Work Standards Powder Processing
Plant Engineering Material Removal or Cutting
Administrative Control Joining
Heat Treatment
Classification Surface Treatment
Primary Processes Assembly Process
Secondary Processes
Other Factors
Tertiary Processes
Spatial Complexity –Shape and Size
Influence of Materials
Dimensional Accuracy and Tolerance
Cost to Manufacture
Availability; Lead Time and Delivery
Quality
 DFM Guidelines
1. Minimize Total number of Parts
2. Standardize components
3. Standardize Design Features
4. Use common parts across product lines
5. Design Parts to be Multifunctional
6. Design Parts for ease of fabrication
7. Avoid Stringent Tolerances
8. Minimize Secondary and Tertiary Processes
9. Utilize the Special Characteristics of Processes
 Design Consideration for Machining
Design parts that require little machining, and if possible, no machining
(Near net shape or net shape processes)
Tighter tolerance and better surface finish if required can be specified
Avoid machining sharp corners
Avoid deep holes that must be bored
Design parts that can use standard or commercially available tools
Design with materials that have good Machinability
Avoid non-standard hole, thread dimensions
Design parts to have few machining setups
Avoid thin and narrow parts
Avoid undercuts as they require additional setups and special tooling
Holes with large L/D ratio should be avoided
 More number of Machining Setups

Avoid undercuts
 Design for Casting - Guidelines
The flow of the molten metal in the mold cavities, the gating systems, the
rate of cooling, and the gases evolved all influence the quality of a casting.
1. Design the part so that the shape is cast easily.
2. Select a casting process and material suitable for the part, size, mechanical properties,
etc.
3. Locate the parting line of the mold in the part.
4. Locate and design the gates to allow uniform feeding of the mold cavity with molten
metal.
5. Select an appropriate runner geometry for the system.
6. Locate mold features such as sprue, screens and risers, as appropriate.
7. Make sure proper controls and good practices are in place.
8. Corners, angles and section thickness as per casting requirements
9. Drafts generally range from 5 to 15 mm/m
10. Tolerances are usually in the range of ± 0.8 mm for small castings. For large castings,
tolerances may be as much as ± 6 mm
11. In general, the parting line should be along a flat plane rather than be contoured.
12. Multiple gates often are preferable and are necessary for large parts
13. The minimum gate length should be three to five times the gate diameter, depending on
the metal being cast
Examples of designs showing the importance of maintaining uniform cross-
cross-sections
in castings to avoid hot spots and shrinkage cavities.
 Examples of design
Modifications to avoid
shrinkage cavities in castings

Redesign of a casting by
making the parting line
straight to avoid defects
Schematic of Sand Casting Core Making with Runner Riser Sprue Core
Vent and Parting Line
Examples of design details in castings that minimize
the area of the machined surface.
Design for Assembly (DFA)
 Objectives
Ease of assembly
No:of:parts
Handling of parts
Minimize number of assembly operations
Reduce assembly costs
Avoid separate fasteners
Minimize assembly directions (vertical direction is always preferable)
Better orientation for insertion and parts with self locking designs
Standardize parts to reduce variety
Differentiate parts with respect to color, coding, shape
Design parts to prevent nesting
Design the mating parts for easy insertion
Never design the assembly to be turn over
Joining parts can be done with fasteners, welds, snap fits or adhesives
Should be ease for service and Maintenance
Reuse / Recycle / Refurbish / Remanufacture
 Design for Disassembly
A product and its parts can be easily
1. Reused (Recognizable Components)
2. Remanufactured
3. Refurbished and
4. Recycled
Objectives: Green Design Initiatives
Ease of disassembly
Avoid permanent joining methods. Use snap fits or threaded fasteners
Simultaneous Parts replacement strategy instead replacing one part at a time
Minimize effort for handling assembly or product
Modular design to allow components to be removed, replaced or upgraded
Bonding and fastening methods with ease of disassembly
(Cohesion/Adhesion/Friction Fitting/ Mechanical Fastening)
Tools required for disassembly-Simple / Manual / Avoid Special Tools
Level of difficulty – Skilled / Semi-skilled or Unskilled Labour
 A part which is easy to assemble is usually
easier to disassemble and reassemble
1. Reduce or eliminate reorientations
2. Redesign to reduce hardware
3. Design for lightweight materials
4. The Design For Disassembly adds to the green environment
5. Avoid toxic or harmful materials and chemicals

Design for disassembly (DfD

(DfD)) offers flexibility, convertibility, addition,
and subtraction of whole-
whole-buildings
 Designing for Disassembly
•The fewer parts you use, the fewer parts there are to take apart.
•As with parts, the fewer fasteners (e.g. glue, screws, etc.) used, the
better.
•Common and similar fasteners that require only a few standard tools
will help to simplify and speed disassembly.
•Screws are faster to unfasten than nuts and bolts.
•Glues should be avoided.
•Building disassembly instructions into the product will help users
understand how to take it apart.
Design for Environment Process Guidelines
DFE focuses on efforts by
Producers and
Manufacturers to REDUCE
Product or
Process Impact on
Environment
DFE Priorities DFE : To Reduce
1. Energy Efficiency 1. Energy
Sustainable
2. Materials Innovation 2. Materials Development
3. Design for Recyclability 3. Wastes
 TRIZ Methodology

Generate a better and useable IDEA

 TRIZ is empirically based Methodology
It is designed to overcome PSYCHOLOGICAL INERTIA (based upon habits,
education, past successes and failures)
Enhances confidentiality and credibility
Saves time, money and reduces risks
Problems are coded, classified and solved methodologically
TRIZ uses BOK (Body of Knowledge) thru patents search, journals etc,.
IFR-Ideal Final Result (Ideality)

Improvement is to increase ideality by increasing benefits; decreasing cost

and decreasing harm
 Principles of Invention (Altshuller’s 40 Inventive Principles)
Separation Principle
I want a big umbrella to protect me from rain but small in size to carry
(Physical Contradiction)
TRIZ Contradiction Matrix
I make something stronger, it gets heavier
Contradiction Matrix-
Matrix- 39 (Engineering Parameters)
 Example : AIR Bag
Problem Statement (Purpose to solve) –Inflate the air bag faster while
decreasing adverse effect.
Generate a better and useable IDEA
TRIZ Principles of Invention
Principle 16-Partial or excessive action
Use small air bag with higher power (faster inflation)
Principle 21-Rushing through
Inflate the air bag faster than usual practice
Principle-40-Composite Materials
Airbag’s material that can not grab skin as it is deployed
Types of Product Models
Fig. Classification of Simulation Models
Design for Metal Forming
Reference: Engineering Design-by George_E_Dieter

Other topics:
Product Design: Techniques in Reverse Engineering and New Product Development
by Kevin N. Otto
 Unit--IV: PRODUCT DESIGN TOOLS & TECHNIQUES
Unit

Product Modeling
Types of Product Models
Product Development Process Tools TRIZ Altshuller‘s Inventive Principles
Modeling of Product Metrics
Design for Reliability
Design for Manufacturability – Machining-Casting and Metal Forming
Design for Assembly and Disassembly
Design for Environment