Perancangan Produk

Lesson 02:
A.Product analysis and design
B.Reverse Engineering
C.Design Process
 Introduction
Designing is the process of making many decisions
that converts a need into a product reality.
Starting point for product development:
Idea development: all products begin with an idea
whether from:
customers, competitors or suppliers
Engineering process:
Forward engineering
Reverse engineering: buying a competitors product

Need Product

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Introduction
Engineering is the profession involved in:
Designing,
manufacturing,
constructing, and
maintaining of products, systems, and
structures.
At a higher level, there are two types of
engineering:
forward engineering and
reverse engineering.

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A. Product analysis and design
Successful product design depends on
asking the right questions about the
proposed product.
It is influenced by external factors such as
what consumers want or need and features
made possible by new materials or
technologies.
Roles in product design:
The client
The designer
The manufacturer
The user

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Roles in product design
The client
The client employs the designer and sets the
brief for the designer to work to.
The client decides whether the product can
go into production.
The designer
The designer plans the design of the
product, and presents product ideas and
prototypes to the client.
The designer needs to understand the
market into which the product is to be sold.

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Roles in product design
The manufacturer
The manufacturer advises on the planning of
manufacture, choosing the most effective
method of production and the best organization
of equipment and people.
The manufacturer also decides the best way to
quality control the production process.
The user
The user is the person who the product is
designed for.
The product should meet their needs.
Users want good quality products at a price they
can afford.

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Product analysis
Product design analysis means studying how
well a product does its job.
This involves answering the following
questions:
What is the function and purpose of the product?
What are the different parts of the product and
how do they work together?
How does the product use shape, form, colour,
texture and decoration?
What materials and components are used to
make the product?

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Product analysis
Which processes were used to make the
product?
Who would buy this product?
How well does the product do its job
compared with other similar products?
What is unique about the product?

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Example: shape, form, color, texture
and decoration
Property Example Description

Shape Shape can be 2D or 3D.

Form Form is 3D - it is a solid

object made up of shapes
joined together.

Color Color is used to make a

product more interesting and
attractive.

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 Property Example Description

Texture Texture is used to make an

object more interesting.
Surfaces are made 3D by the
use of grooves, patterns and
applying other materials such
as fabrics.
Decoration Decoration may be achieved
by the use of different
colours, shapes or materials.
A decoration may be pasted
onto a product, or be part of
the material itself.

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Typical skills used in new product
development

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B. Forward and Reverse Engineering
Forward engineering is the traditional
process of moving from high-level
abstractions and logical designs to the
physical implementation of a system.
The process of duplicating an existing
component, subassembly, or product,
without the aid of drawings,
documentation, or computer model is
known as reverse engineering.

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What is Reverse Engineering?
The systematic methodology for analyzing
the technological principles of an existing
products through analysis of its structure,
function and operation.
That involves taking apart and analyzing its
workings in detail, usually with the intention
to construct a new device or program that
does the same thing without actually copying
anything from the original.

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Reverse engineering can be viewed as
the process of analyzing a system to:
Identify the system's components and their
interrelationships
Create representations of the system in
another form or a higher level of
abstraction
Create the physical representation of that
system

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Is reverse engineering legal?
Is reverse engineering illegal?
Does reverse engineering infringe an owners
copyright?
There is no universal definitive or straightforward
answer to this question and, as the relevant law is
constantly changing in many countries.
Copyright does not prohibit reverse-engineering,
except where the thing being reverse-engineered is a
copy-prevention mechanism.
This is because copyright law is all about the making
and distributing of copies.
Under regular property law, once you have bought
something, you're perfectly within your rights to take
it apart and see how it works.

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 However, the actual legality of reverse engineering
depends on:
the laws of the country where the reverse engineering is
conducted;
the type of product reverse engineered (e.g.
hardware/software);
any restrictive purchase or licence conditions of the
product;
how the product was obtained;
how the reverse engineering is carried out;
who carries out the reverse engineering;
why the reverse engineering was done; and
what use the results of the reverse engineering are put to.

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Intellectual Property: Copyrights,
Trademarks, Patents
Copyrights
Ownership of an original work created by an
author
A form of intellectual property protection
covers the look & feel and content of
printed media
Gives author the right to exclude others
from using the finished work
Good for life of its author + 70 years
Issue:
Copyrights infringement

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Trademark / Trade Name
A word / symbol distinguishing one good
from other goods in the market
Trademark infringement

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Patent
It is a property right for an invention
granted by a government to the inventor.
It empowers the owner of an invention to
prevent others from manufacturing, using,
importing or selling the patented invention.
The Patent Right protects patent products
for a maximum duration of 20 years.

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How to protect products being reversed
engineered?
Basically, it is nearly difficult to protect
products being reversed engineered.
What we can do is to make product is hard
for being reversed engineered.
Use software protection for software to be
disassemblers and decompilers
Design the product that difficult to be
dissected

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Reverse Engineering Methodology
Investigation, Prediction and Hypothesis
Reverse
Concrete Experience: Function & Form Engineering

Design Models
Modeling &
Analysis
Design Analysis

Parametric Adaptive Original Redesign

Redesign Redesign Redesign
Reverse Engineering Methodology
1. Investigation, Prediction and Hypothesis
Develop black box model
Use / Experience product
List assumed working principles
Perform economic feasibility of redesign
State process description or activity diagram
 Reverse Engineering Methodology
2. Concrete Experience: Function and Form
Plan and execute product disassembly
Group defined systems and components
together
Experiment with product components
Develop free body diagrams
Identify function sharing and compatibility
Transform to engineering specs. and metrics
Reverse Engineering Methodology
3. Design Models
Identify actual physical principles
Constantly consider the customer
Create engineering models and metric
ranges
Alternatively or concurrently build prototype
to test parameters
Reverse Engineering Methodology
4. Design Analysis
Calibrate model
Create engineering analysis, simulation or
optimization
Create experiment and testing procedures
Reverse Engineering Methodology
5. Parametric Redesign
Optimize design parameters
Perform sensitivity analysis and tolerance
design
Build and test prototype
Reverse Engineering Methodology
6. Adaptive Redesign
Recommend new subsystems
Search for inventive solutions
Analyze force flows and component
combinations
Build and test prototype
Reverse Engineering Methodology

7. Original Redesign
Develop new functional structure
Choose alternatives
Verify design concepts
Build and test prototype
Example of Reverse Engineering
Step 1: A cloud of points taken from scanned
data using a digitizer such as a laser scanner,
computed tomography, or faro arms.
Step 2: Convert the point cloud to a polygonal
model. The resultant mesh is cleaned up,
smoothed, and sculpted to the required shape
and accuracy.

Step 1 Step 2

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 Step 3: Draw or create curves on the mesh
using automated tools such as feature
detection tools or dynamic templates.
Step 4: Create a restructured spring mesh
using semiautomatic tools.
Step 5: Fit NURBS surfaces using surface
fitting and editing tools.

Step 3 Step 4 Step 5

Non-uniform rational basis spline (NURBS) is a mathematical model commonly used

in computer graphics for generating and representing curves and surfaces which
offers great flexibility and precision for handling both analytic (surfaces defined by
common mathematical formulae) and modeled
30 shapes.
 Step 6: Export the resulting final NURBS
surface that satisfies accuracy and smoothness
requirements to a CAD package for generating
tool paths for machining.
Step 7: Manufacture and analyze the part for
physical, thermal, and electrical properties.

Step 6 Step 7

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C. Design Process
A simple four-stage
model of the
design process

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Design Process
French's model of the
design process

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 Design Process
Arrange the design process below?
a. Build Model or Prototype
b. Select Best Design
c. Problem Identification and Needs
d. Communicate Results
e. Test, Evaluate and Redesign
f. Research Phase
g. Product Design Specification (PDS)
h. Brainstorming and Conceptual Designs

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Design Process
Elements of Design the Process:
1. Problem Identification and Needs
2. Research Phase
3. Product Design Specification (PDS)
4. Brainstorming and Conceptual Design
5. Select Best Design
6. Build Model or Prototype
7. Test, Evaluate and Redesign
8. Communicate Results

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Design vs. Cost
Costs of manufacture become a great
concern to the profitability of a product

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1. Problem Identification and Needs
A situation, problem or need may lead to the decision
to create a design.
Design can be stimulated from a variety of
starting points, for example:
market-based demands (real world influence/s)
client-based demands (responding to a problem,
need, request, or identified opportunity)
personal expression (focusing on ones own
feelings, interests or personal necessity).
Examples:
Design a vehicle that can communicate with other
vehicles to prevent accidents.

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Problem Identification and Requirements
Specification

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2. Research Phase
Stay consistent with working criteria while
researching
Research activity:
Market research
Competition analysis
Literature searching
Patent extracting etc.
Examples:
Research may require going to the library, using
computer databases, writing letters, performing
experiments, and asking questions.
Read books and magazines, view films or videos,
search the internet, ask questions of the experts,
create and analyze a survey

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3. Product Design Specification (PDS)
PDS is a document that contains all of the facts
relating to the product outcome.
It defines the elements, factors and boundaries
of the product to be designed.
The contents of PDS:
Performance
Size & weight
Product cost
Safety
Materials
Ergonomics & aesthetic
Life in service etc.

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Requirement for PDS
Identifies requirements design must satisfy
for success:
1. Marketing requirements (Customer needs)
2. Engineering requirements:
Applies to technical aspects
Performance requirements
Customers:
People who define the PDS
People who influence product success
People you cannot ignore

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Customers
The design team and its members are not
customers
Every PDS statement must be associated with at
least one customer
Internal customers are within the organization
Internal Customers: management, manufacturing
& procurements, marketing, legal
External customers are outside the organization
External Customers: end users, company buyers,
retailer, maintenance, society (marketing),
government and standards

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Constraints
Economic
Environmental
Ethical and Legal
Health and Safety
Manufacturability
Political and Social
Sustainability

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 4. Brainstorming and Conceptual Design
Develop multiple ideas and conceptual design
that will solve the problems and meet the
requirements in PDS:
Generate many ideas
Evaluate against PDS
Brainstorm and generate creative ideas
including possible problems
Analyze potential solutions (DFM, DFA etc)
Examples:
What should the product look like so that
people will buy it?
How will the solution actually work?
What materials should I use?

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Concept Generation
Substitute new elements
Combine existing elements
Adapt different operation
Modify size, shape, function
Put to other use other app domains
Eliminate parts or whole
Rearrange or reverse work better

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5. Select Best Design
Decide on one idea and design that best meets
the criteria, fits within the constraints, and has
the least amount of negative characteristics.
Choose the best solution and develop detailed
design specifications
List the strengths and weaknesses of each
alternative idea or design.
Optimization Making improvements to the
design idea for better performance or increased
safety
Trade-off Giving up one desirable trait for
another (i.e., giving up on using a certain
material so that the object is more affordable)

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6. Build Model or Prototype
Develop models for the selected solutions
Model building is used to gather additional
information and test design ideas.
Types of models: descriptive, functional,
mathematical, computer, and scale.
Examples:
Realistic drawings or renderings help you visualize what the
solution will look like in real life.
Scale models or mock-ups are small, accurate representations
of the final product.
3D CAD (computer aided designs) can show objects in action.
A prototype is a working model; it looks and functions just like
the finished product.

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7. Test, Evaluate and Redesign
Models of design solutions must be tested and
important questions must be answered during
the evaluation.
Test the model against working criteria and goals
Test for functionality and performance
Evaluate the results of testing to determine the
solution to use
If none of the solutions are ideal, return to stage 4
Once a solution is selected, continue to stage 8

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8. Communicate Results
Document the designs specifications and
measurements and communicate to all groups.
Communication between groups is especially
important in this stage
Meetings
Presentations
Reports
Drawings
Final design revisions
All groups should agree on the proposed project,
including: management, technical, business, and
legal support representatives

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