Module

DESIGN & ENGINEERING

(Reference)

2 hours lecture and 2 hour practical per week (Cre

Reference Books (T):

1.

Exploring Engineering - An Introduction to Engineering and Design:

Balmer, R. T., Keat W. D., Wise, G., and Kosky P., Third Edition; (ISBN13: 978-0124158917ISBN-10: 0124158919) .

2.

Engineering Design - A Project based introduction:

Dym, C. L., Little, P. and Orwin E. J. Wiley; (ISBN-978-1-118-32458-5).

3.

Design for X Concurrent engineering imperatives:

Eastman C. M., Springer 1996; (ISBN 978-94-011-3985-4).

4.

Engineering Design Process:

Haik, Y. And Shahin M. T., Cengage Learning; (ISBN-13: 978-0-495-66816-9).

DESIGN & ENGINEERING

(Reference)

2 hours lecture and 2 hour practical per week (Cre

Reference Books (T):

4.

Engineering Design: A Systematic Approach:

Pahl, G., Beitz, W., Feldhusen J. and Grote, K. H., 3rd ed. 2007; (ISBN
978-1-84628-319-2).

6.

Engineering by Design:
Voland, G., Pearson India; (ISBN 978-93-325-3505-3).

7.

A Textbook of Design & Engineering:

Subin P George & Arun K Varghese., Pentex.

8.

Engineering by Design:
Dieter & Schmidt, McGraw Hill Education ( India) Edition 2013.

DESIGN & ENGINEERING

(Reference)

2 hours lecture and 2 hour practical per week (Cre

E References (E):
i.

http://opim.wharton.upenn .edu/ ulrich/designbook.html.

E-Book (Free download).

ii.

http://www2.warwick.ac.uk/fac/sci/wmg/ftmsc/modules/modulelist/peu
ss/designforx/design_for_x_notes_s ection_5.pdf.
E-Resources (Free download).

DESIGN & ENGINEERING

02 (Course Plan)
2 hours lecture and 2 hour practical per week (Credits
Module 4 (Detailed) (2+3 hrs. Theory & 4 hrs. Practice); Mark Weightage: 15%

Theory:
Design for "X":
Quality, reliability, safety, covering Manufacturing / construction,
assembly, maintenance, logistics, handling; disassembly; recycling;
re-engineering etc.
List out the design requirements(x) :
for designing a rocket shell of 3-meter diameter and 8-meter length..

Practice:
Design mineral water bottles :
that could be packed compactly for transportation.
5

Introduction to Design for X

Ref:T7, Ch7.1/Pg65

o DFX techniques are part of detail design and are

o ideal approaches to improve life-cycle cost, quality,
o

increased

design

flexibility,

&

increased

efficiency
o

and productivity using the concurrent design

concepts

o DFX focuses on vital business elements of

o concurrent engineering, maximizing
o the use of the limited resources
o

available to the team.

10/24/16 10:14:47 AM

Different DFX techniques

Ref:T7, Ch7.1/Pg65

o Design for:
o Manufacture / Construction

o Assembly
o Quality
o Maintenance
o Safety
o Handling
o Logistics
o Reliability
o Dis-assembly
o Recycling
o Re-engineering
10/24/16 10:14:47 AM

Design for Manufacturing /

Construction (DFM)

Ref:T7, Ch7.2/Pg66

o Represents an awareness of the importance

of design
o as the time for thoughtful consideration
o of all steps of production.

10/24/16 10:14:48 AM

DFM Guidelines
1. (Minimize total number of parts)

Ref:T7, Ch7.2/Pg66

o Eliminating parts results in great savings.

o A part that is eliminated costs nothing to
o make, assemble, move, store, clean,
inspect,
o rework, or service.
o A part is a good candidate for elimination
if there is
o no need for relative motion,
9
o no need for subsequent adjustment between

10/24/16 10:14:48 AM

DFM Guidelines
2. (Standardize components)

o The

life

and

reliability

Ref:T7, Ch7.2/Pg67

of

standard

components
o may have already been established,
o so cost reduction comes through
o quantity discounts,
o elimination of design efort,
o avoidance of equipment and tooling
costs, and
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10

DFM Guidelines
3. (Use common parts across product
o It is good business
lines)sense to

Ref:T7, Ch7.2/Pg67

o use parts in more than one product.

o Specify the same materials, parts, and subassemblies
o in each product as much as possible.

10/24/16 10:14:48 AM

11

DFM Guidelines
4. (Standardize design features)

Ref:T7, Ch7.2/Pg67

o Standardizing on design features like

o drilled hole sizes,
o screw thread types, and
o bend radii
o minimizes the number of tools
o that must be maintained in the tool
room.
o This reduces manufacturing cost.
10/24/16 10:14:48 AM

12

Ref:T7, Ch7.2/Pg68
DFM Guidelines
5. (Aim to keep designs functional and
o Achieving functionality
is paramount, but
simple)

o dont specify more performance than is

needed.

6. (Design parts to be multifunctional)

o. A good way to minimize part count is to
design
o such that parts can fulfil more than
10/24/16 10:14:48 AM

13

DFM Guidelines
7. (Design parts for ease of fabrication)

Ref:T7, Ch7.2/Pg69

o The least costly material that satisfies

o the functional requirements should be
chosen.
o It is often the case that
o materials with higher strength
o have poorer workability.

10/24/16 10:14:48 AM

14

DFM Guidelines
8. (Avoid excessively tight tolerances)
o Tolerances must be set with great care.

Ref:T7, Ch7.2/Pg69

o Specifying tolerances that are tighter than needed

o will increase the cost.

9. (Minimize secondary and finishing operations)

o Use only when there is a functional reason for
doing
o Machine a surface only when the functionality
o.

requires it or if it is needed for aesthetic purposes.

10/24/16 10:14:48 AM

15

Design for Assembly (DFA)

Ref:T7, Ch7.3/Pg69

o Once parts are manufactured, they need to be

o assembled into sub-assemblies and products.

o The

assembly

process

consists

of

two

operations,
o

handling, which involves grasping, orienting,

and

positioning,

followed

by

insertion

and

fastening.
10/24/16 10:14:48 AM

16

Design for Assembly (DFA)

Ref:T7, Ch7.3/Pg70

o There are three types of assembly, classified by the level of

automation
o . In manual assembly a human operator at a workstation reaches and
o

grasps a part from a tray, and then moves, orients, and

o

pre-positions the part for insertion.

o In automatic assembly, handling is accomplished with a parts feeder,

o

like a vibratory bowl, that feeds the correctly oriented parts for
o

insertion to an automatic work-head, which in turn inserts the part .

o In robotic assembly, the handling and insertion of the part is done

o

by a robot arm under computer control.

10/24/16 10:14:48 AM

17

Design for Quality (DFQ)

Ref:T7, Ch7.4/Pg75

o Design for quality (DFQ) is a modern, scientific approach

that

o formalizes product design,

o automates manual testing, and
o streamlines troubleshooting.
o Instead of relying on finished product testing alone,
o

DFQ

provides

insights

upstream

throughout
o the development process.
10/24/16 10:14:49 AM

18

Design for Quality

(Checklist for DFQ)

Ref:T7, Ch7.4/Pg75

I. Correctness of Drawing

II. Drawings complete with Respect to Functional Tolerance

III. Process

Capability

been

incorporated

while

selecting

Tolerances
IV. Assembly Build Criteria been defined
V. Interference Analysis been performed
VI. Identify the Critical dimensions for assembly
VII.Tolerances been maximized for required Assembly
VIII.Tolerances been optimized for least cost
IX. PPM Estimate meeting our Business Profitability Objective
X.

Provide dimensional verification plan

10/24/16 10:14:49 AM

19

Design for Maintenance

Ref:T7, Ch7.5/Pg76

o Design for Maintenance is an approach

to
o

influence

the

maintenance

activities
o

through

the

design

of

the

equipment.

10/24/16 10:14:49 AM

20

Design for Maintenance

(Guidelines to Enhance Maintainability)

Ref:T7, Ch7.5/Pg76

i. Use materials that do not prolong maintenance activities

avoid
o non-

corrosion

resistant

materials

in

moist

environments.
ii.Use standard, universally applicable components they are
o widely understood, what makes it likely that they are
o easy to maintain or that technicians know how to
maintain them.
iii.Use fasteners that accelerate maintenance activities in the
ideal situation,
o

no tools are required to open or remove components.

10/24/16 10:14:49
iv.Ensure
that AM
the operators of installations are also able21 to

Design for Maintenance

(Guidelines to Enhance Maintainability)

v.

Ref:T7, Ch7.5/Pg76

Provide sufficient space around the maintenance points

Maintenance personnel should be able to execute maintenance

with good posture

vi. Design equipment in such a way that it can only be

maintained
o

in the right way an unambiguous design induces that

o

no mistakes can be made when executing maintenance.

vii. Components that are regularly replaced need to be easy to

handle
o

Standard size and weight, no sharp edges and easy

to transport.

viii.Guarantee
safety by the design itself Instead of using
10/24/16 10:14:50 AM

22

Design for Maintenance

(Guidelines to Enhance Maintainability)

Ref:T7, Ch7.5/Pg76

ix. Design modular systems Modular systems enable complete

replacement of a broken module to repair it at a different place.
x.

Use standard interfaces To enable quick connection

o

between modules and sub-systems

xi. Design the weakest link every system has a weakest link,
which should be
o

a relatively cheap and easily replaceable component.

xii. Position components that often need to be maintained

at an
o

easily accessible place Location of components could be

based on
o

the number of times they need to be maintained

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23

Design for Safety

Ref:T7, Ch7.6/Pg77

o Designers can make decisions

o that significantly reduce
o the risks to safety and health
o during the development stage and
o during subsequent use
o and maintenance.

10/24/16 10:14:50 AM

24

Design for Safety

(The General Principles of Prevention)

Ref:T7, Ch7.6/Pg77

o Avoid risks.

o Evaluate unavoidable risks.

o Combat risks at source.
o Adapt work to the individual, especially the design of places of
work
o Adapt the place of work to technical progress.
o Replace dangerous articles, substances, or systems of work by
o non-dangerous or less dangerous articles, substances, or systems

o Use collective protective measures over individual measures

o Develop an adequate prevention policy
o Give appropriate training and instruction to employees.

10/24/16 10:14:50 AM

25

Design for Handling

Ref:T7, Ch7.7/Pg78

o Design for handing is integral to

o the design of most production systems
o since the efficient flow of
o material between the activities
o of a production system
o is heavily dependent on
o the arrangement (or layout)
o of the activities.
10/24/16 10:14:50 AM

26

Design for Handling

(The Unit Load Concept)

Ref:T7, Ch7.7/Pg78

o A unit load is either a single unit of an item,

o or multiple units so arranged or restricted that they can be
o

handled as a single unit and maintain their integrity.

o Advantages of unit loads are that more items can be handled

o at the same time (thereby reducing the number of trips
o

required and, potentially, reducing handling costs,

o

loading and unloading times, and product damage)

o

and that it enables the use of

o

standardized material handling equipment.

10/24/16 10:14:50 AM

27

Design for Logistics

Ref:T7, Ch7.8/Pg80

o Design for logistics is a series of concepts in

the
o field of supply chain management
o involving

product

and

design

approaches
o that help to control logistics costs and
o increase customer service levels.

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28

Ref:T7, Ch7.8/Pg80
Design for Logistics
(Key Concepts - Economic packaging and
o Design products
transportation)
so that they can be

o efficiently packed and stored

o Design packaging so that products can
be
o consolidated at cross docking points
o Design products to efficiently utilize retail
space
10/24/16 10:14:50 AM

29

Ref:T7, Ch7.8/Pg80
Design for Logistics
(Key Concepts - Concurrent/Parallel Processing)

o Objective is to minimize lead times

o Achieved by redesigning products so that

several

manufacturing

steps

can

take

is

key

to

place in parallel
o Modularity/Decoupling
implementation
o Enables diferent inventory levels
o for diferent parts
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30

Ref:T7, Ch7.8/Pg80
Design for Logistics
(Key Concepts - Mass Customization)

oPredictability of Demand

oPredictability of Operations
oInventory levels
oEquipment capacity requirements
oIncrease

in

the

number

of

components and hence in the number

of suppliers
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31

Design for Reliability (DFR) Ref:T7, Ch7.9/Pg81

1. Reliability must be designed into products and
o

processes using the best available

o

science-based methods.

2. Knowing how to calculate reliability is important, but

o

knowing how to achieve reliability is equally,

o

if not more, important.

3. Reliability practices must begin early in

o

the design process and must be well integrated

o

into the overall product development cycle.

10/24/16 10:14:50 AM

32

Design For Dis-assembly and Recycling

(DFD & DFR)

Ref:T7,
Ch7.10/Pg83

o Design for Dis-assembly (DFD) is the process of

designing

products
o

so that they can easily, cost-efectively and rapidly take

apart
o

at the end of the products life so that components

o

can be reused and/or recycled.

o When designing products with dis-assembly in mind, there are

o

three important factors which must be considered by the

designer:

i. The selection and use of materials

ii. The design of components and product architecture
iii. The selection and use of fasteners
10/24/16 10:14:50 AM

33

Ref:T7,
Design For Dis-assembly and Recycling
Ch7.10/Pg83
(Guidelines for Dis-assembling and
i. Un-plated metals
are more recyclable than plated ones.
Recycling)

ii.Low alloy metals are more recyclable than high alloy ones.
iii.Most cast irons are easily recycled.
iv.Aluminium alloys, steel, and magnesium alloys are readily
separated and recycled from automotive shredder output.
v.Contamination of iron or steel with copper, tin, zinc, lead,
or aluminium reduces recyclability.
vi.Contamination of aluminium with iron, steel, chromium,
zinc, lead, copper or magnesium reduces recyclability.
vii.
Contamination of zinc with iron, steel, lead, tin, or
cadmium reduces recyclability.
10/24/16 10:14:50 AM

34

Design for Re-Engineering

Ref:T7,
Ch7.11/Pg87

o Business process re-engineering (BPR) is a

o

business management strategy focusing on the

o

analysis and design of work-flows and

o

business processes within an organization.

o BPR aimed to help organizations fundamentally rethink

o

how they do their work in order to dramatically

improve
o

customer service, cut operational costs, and

o

become world-class competitors .

10/24/16 10:14:51 AM

35

Design for Re-Engineering

Ref:T7,
Ch7.11/Pg87

o BPR seeks to help companies radically restructure

o

their organizations by focusing on the ground-up

o

design of their business processes.

o Re-engineering emphasized a holistic focus on

o

business objectives and how processes related

o

to them, encouraging full-scale recreation of

o

processes rather than iterative

o

optimization of sub processes.

10/24/16 10:14:51 AM

36