PRODUCT DESIGN AND

DEVELOPMENT

1
 (Definitions (1/3
 Product: A term used to describe all
goods, services, and knowledge
sold.
 (Definitions (2/3
 A Product Development Process is the
entire set of activities required to bring a
new product concept to a state of market
readiness.
 PD is the organization and management of
people and the information they develop in
the evolution of a product.
 (Definitions (3/3
 A Design Process is the set of
technical activities within a PD
process that work to meet marketing
and business case vision.
 Six Phases of PD
1. Planning
2. Concept development
3. System-level design
4. Detail design
5. Testing and refinement
6. Production ramp-up
 Product Types
 Market-Pull Products (furniture,
sporting goods, tools)
 Technology-Push Products (Cellular
phones, ABS, Medical equipment)
 The Life of a Product
 Identification of need
 Development of engineering requirements
 Design concept development
 Product design


 Manufacturing
 Assembly
 Distribution
 Installation
 Use
Retirement, disassembly, reuse, and recycle.
 Product Conceptual
Design

Design = Science + Art

 FORM and FUNCTION
 The product FORM should reflect its
FUNCTION
 FUNCTION = What the product is to do
 FORM = How the product is to do its
FUNCTION
 FORM = Shape (geometry), Material,
Connections, Energy and Material
Flow, Operation Procedure
(Information Transfer), etc….
 Design is the process of mapping
function to form.
 Design problems have many
satisfactory solutions and no clear
best solution
 Two Fundamental ”Rules‘ of
Design
I. The Function Rule:
Design requirements should be
satisfied Independently…Hard to
achieve!
II. The Form Rule:
The design must have the least
possible information content.
 Fundamental Rules Updated
I. The Function Rule:
Design requirements must be
satisfied uniformly.
II. The Form Rule:
The design must have the shortest
production path.
 The Golden Triangle
 Effectiveness of the design process is measured
by:
2. Product cost
3. Product quality
4. Time to market (TTM)
 The Design Paradox
 The more you learn the less freedom you
have to use what you know.
 CE relieves this difficulty.
 Design Process Evolution
 Craftsmanship – one person could
design and manufacture an
product
entire
 By the middle of the 20th century:
over-the-wall approach.
 From the late 1980s: concurrent
engineering approach (CE).
The Over-The-Wall Design Method
 Concurrent Engineering (CE)
 CE emphasizes the integration of cross-
functional TEAMS to develop the product.
 The use of teams, including all the
stakeholders, eliminates many of the
problems with the over-the-wall method.
 Stakeholders = people who have a
concern for the product.
Controllable Variables in CE
 The CE Design Team
 A team may be defined as two or more
persons engaged in a common goal, who
are dependent on one another for results,
and who have joint accountability for the
outcomes.
 The PRIDE principle should be followed in
any product development project –
Purpose, Respect, Individuals,
Discussions, and Excellence
 Members of Design Teams
 Product design engineer
 Marketing manager
 Manufacturing engineer
 Drafter
 Technician
 Materials
 specialist
Quality control/quality assurance specialist
 Analyst
 Industrial designer
 Assembly
 manager or supplier’s representative
Vendor’s
Approaches to Design
 Outline
The Design Process The Design Process
Technology in Design Idea Generation
Design Quality Reviews Feasibility Study
Design for Environment Rapid Prototyping
Quality and Concurrent
Function Deployment Design
Design for Final Design and

Learning From The Competitors Robustness Process Plans

1. Perceptual Maps:
It is a visual method of comparing customer perceptions
of different products or services.

Semih Gu¨mu¨¸sba¸s Product Design

 Outline
The Design Process The Design Process
Technology in Design Idea Generation
Design Quality Reviews Feasibility Study
Design for Environment Rapid Prototyping
Quality and Concurrent
Function Deployment Design
Design for Final Design and

Learning From The Competitors

Robustness Process Plans

Semih Gu¨mu¨¸sba¸s Product Design

 Outline
The Design Process The Design Process
Technology in Design Idea Generation
Design Quality Reviews Feasibility Study
Design for Environment Rapid Prototyping
Quality and Concurrent
Function Deployment Design
Design for Final Design and

Learning From The Competitors Robustness Process Plans

2. Benchmarking:
It is comparing a product or process against the best in
class product.
For example:
American Express is well known for its ability to get
customers to pay up quickly
Federal Express, for its
speed McDonald’s, for its
consistency
Disney World, for its
employee commitment...
Semih Gu¨mu¨¸sba¸s Product Design
 Outline
The Design Process The Design Process
Technology in Design Idea Generation
Design Quality Reviews Feasibility Study
Design for Environment Rapid Prototyping
Quality and Concurrent
Function Deployment Design
Design for Final Design and

Learning From The Competitors Robustness Process Plans

3. Reverse Engineering:
It is carefully dismantling a competitor’s product to
improve your own product.
For example:
Ford used this approach successfully in its design of the Taurus
automobile, assessing 400 features of competitors’ products and
copying, adapting, or enhancing more than 300 of them, including
Audi’s accelerator pedal, Toyota’s fuel-gauge accuracy, and
BMW’s tire and jack storage.

Semih Gu¨mu¨¸sba¸s Product Design

 Outline
The Design Process The Design Process
Technology in Design Idea Generation
Design Quality Reviews Feasibility Study
Design for Environment Rapid Prototyping
Quality and Concurrent
Function Deployment Design
Design for Final Design and

Feasibility Study Robustness Process Plans

A feasibility study consists of a market analysis, an

economic analysis, and a technical/strategic analysis.

Market Analysis: The promising concepts undergo a

feasibility study that includes several types of analyses,
beginning with it.

Economic Analysis: It looks at estimates of production and

development costs and compares them to estimated sales volume
if the demand potential exists.

Technical and Strategic Analyses: It answers the technical

and strategical questions.
Semih Gu¨mu¨¸sba¸s Product Design
 Outline
The Design Process The Design Process
Technology in Design Idea Generation
Design Quality Reviews Feasibility Study
Design for Environment Rapid Prototyping
Quality and Concurrent
Function Deployment Design
Design for Final Design and

The Three Types of Concurrent Designs

Robustness Process Plans

1. Form Design:
Form design refers to the physical appearance of a product.
In other words, how the product will look.

2. Functional Design:
It is concerned with how the product performs. Three
performance characteristics considered during this phase of
design are reliability, maintainability, and usability.

Semih Gu¨mu¨¸sba¸s Product Design

 Outline
The Design Process The Design Process
Technology in Design Idea Generation
Design Quality Reviews Feasibility Study
Design for Environment Rapid Prototyping
Quality and Concurrent
Function Deployment Design
Design for Final Design and
Robustness Process Plans

2.1. Reliability
It is the probability that a given part or product will perform
its intended function for a specified length of time under normal
conditions of use.
A product or system’s reliability is a function of the
reliabilities of its component parts and how the parts are
arranged.
Two Components in Series
Rs = R1.R2, where Rs is the reliability of the system.

Semih Gu¨mu¨¸sba¸s Product Design

 Outline
The Design Process The Design Process
Technology in Design Idea Generation
Design Quality Reviews Feasibility Study
Design for Environment Rapid Prototyping
Quality and Concurrent
Function Deployment Design
Design for Final Design and
Robustness Process Plans

2.1. Reliability
It is the probability that a given part or product will perform
its intended function for a specified length of time under normal
conditions of use.
A product or system’s reliability is a function of the
reliabilities of its component parts and how the parts are
arranged.
Two Components in Series
Rs = R1.R2, where Rs is the reliability of the system.

Two Components in Parallel

Rs = R1 + (1 − R1).R2, where Rs is the reliability of the
system.
Semih Gu¨mu¨¸sba¸s Product Design
 Outline
The Design Process The Design Process
Technology in Design Idea Generation
Design Quality Reviews Feasibility Study
Design for Environment Rapid Prototyping
Quality and Concurrent
Function Deployment Design
Design for Final Design and
Robustness Process Plans

MTBF:
Reliability can also be expressed as the length of time a
product or service is in operation before it fails, called the mean
time between failures (MTBF).

(MTBF = 1/failure rate)

For example:
If your laptop battery fails four times in 20 hours of
operation, its failure rate would be 4/20 = 0.20,

Semih Gu¨mu¨¸sba¸s Product Design

 Outline
The Design Process The Design Process
Technology in Design Idea Generation
Design Quality Reviews Feasibility Study
Design for Environment Rapid Prototyping
Quality and Concurrent
Function Deployment Design
Design for Final Design and
Robustness Process Plans

2.2. Maintainability
It (also called serviceability) refers to the ease and/or cost
with which a product or service is maintained or repaired.
MTTR, SA:
One quantitative measure of maintainability is mean time
to repair (MTTR).

System Availability, SA = MTBF

MTBF +MTTR

Semih Gu¨mu¨¸sba¸s Product Design

 Outline
The Design Process The Design Process
Technology in Design Idea Generation
Design Quality Reviews Feasibility Study
Design for Environment Rapid Prototyping
Quality and Concurrent
Function Deployment Design
Design for Final Design and
Robustness Process Plans

2.3. Usability
It is what makes a product or service easy to use and a good
fit for its targeted customer.
Usability comes into play in such examples:
Salt shakers that must be turned upside down to fill
(thereby losing their contents).
Speakers in laptop computers that are covered by your
wrists as you type.
Doors that you can’t tell whether to pull or push.

Semih Gu¨mu¨¸sba¸s Product Design

 Outline
The Design Process The Design Process
Technology in Design Idea Generation
Design Quality Reviews Feasibility Study
Design for Environment Rapid Prototyping
Quality and Concurrent
Function Deployment Design
Design for Final Design and
Robustness Process Plans
Design For Manufacture (DMF)
It is the process of designing a product so that it can
be produced easily and economically.
DFM guidelines promote good design practice, such as:
1 Minimize the number of parts and sub-
assemblies.

Semih Gu¨mu¨¸sba¸s Product Design

 Outline
The Design Process The Design Process
Technology in Design Idea Generation
Design Quality Reviews Feasibility Study
Design for Environment Rapid Prototyping
Quality and Concurrent
Function Deployment Design
Design for Final Design and
Robustness Process Plans
Design For Manufacture (DMF)
It is the process of designing a product so that it can
be produced easily and economically.
DFM guidelines promote good design practice, such as:
1 Minimize the number of parts and sub-
2 assemblies. Avoid tools, separate fasteners, and
adjustments.

Semih Gu¨mu¨¸sba¸s Product Design

 Outline
The Design Process The Design Process
Technology in Design Idea Generation
Design Quality Reviews Feasibility Study
Design for Environment Rapid Prototyping
Quality and Concurrent
Function Deployment Design
Design for Final Design and
Robustness Process Plans
Design For Manufacture (DMF)
It is the process of designing a product so that it can
be produced easily and economically.
DFM guidelines promote good design practice, such as:
1 Minimize the number of parts and sub-
2 assemblies. Avoid tools, separate fasteners, and
3 adjustments.
Use standard parts when possible and
repeatable, well-understood processes.

Semih Gu¨mu¨¸sba¸s Product Design

 Outline
The Design Process The Design Process
Technology in Design Idea Generation
Design Quality Reviews Feasibility Study
Design for Environment Rapid Prototyping
Quality and Concurrent
Function Deployment Design
Design for Final Design and
Robustness Process Plans
Design For Manufacture (DMF)
It is the process of designing a product so that it can
be produced easily and economically.
DFM guidelines promote good design practice, such as:
1 Minimize the number of parts and sub-
2 assemblies. Avoid tools, separate fasteners, and
3 adjustments.
Use standard parts when possible and
4 repeatable, well-understood processes.
Design parts for many uses, and modules.

Semih Gu¨mu¨¸sba¸s Product Design

 Outline
The Design Process The Design Process
Technology in Design Idea Generation
Design Quality Reviews Feasibility Study
Design for Environment Rapid Prototyping
Quality and Concurrent
Function Deployment Design
Design for Final Design and
Robustness Process Plans
Design For Manufacture (DMF)
It is the process of designing a product so that it can
be produced easily and economically.
DFM guidelines promote good design practice, such as:
1 Minimize the number of parts and sub-
2 assemblies. Avoid tools, separate fasteners, and
3 adjustments.
Use standard parts when possible and
4 repeatable, well-understood processes.
5 Design parts for many uses, and modules.
Design for ease of assembly and proper
presentation.
Semih Gu¨mu¨¸sba¸s Product Design
 Outline
The Design Process The Design Process
Technology in Design Idea Generation
Design Quality Reviews Feasibility Study
Design for Environment Rapid Prototyping
Quality and Concurrent
Function Deployment Design
Design for Final Design and
Robustness Process Plans
Design For Manufacture (DMF)
It is the process of designing a product so that it can
be produced easily and economically.
DFM guidelines promote good design practice, such as:
1 Minimize the number of parts and sub-
2 assemblies. Avoid tools, separate fasteners, and
3 adjustments.
Use standard parts when possible and
4 repeatable, well-understood processes.
5 Design parts for many uses, and modules.
6 Design for ease of assembly and proper
presentation.
Allow for efficientSemih
and adequate
Gu¨mu¨¸sba¸s
testing and replacement
Product Design
 Outline
The Design Process The Design Process
Technology in Design Idea Generation
Design Quality Reviews Feasibility Study
Design for Environment Rapid Prototyping
Quality and Concurrent
Function Deployment Design
Design for Final Design and
Robustness Process Plans
Design For Manufacture (DMF)
It is the process of designing a product so that it can
be produced easily and economically.
DFM guidelines promote good design practice, such as:
1 Minimize the number of parts and sub-
2 assemblies. Avoid tools, separate fasteners, and
3 adjustments.
Use standard parts when possible and
4 repeatable, well-understood processes.
5 Design parts for many uses, and modules.
6 Design for ease of assembly and proper
presentation.
Allow for efficientSemih
and adequate
Gu¨mu¨¸sba¸s
testing and replacement
Product Design
 Outline
The Design Process The Design Process
Technology in Design Idea Generation
Design Quality Reviews Feasibility Study
Design for Environment Rapid Prototyping
Quality and Concurrent
Function Deployment Design
Design for Final Design and

Final Design and Process Plans Robustness Process Plans

.
The final design consists of detailed drawings and
specifications for the new product or service.

Semih Gu¨mu¨¸sba¸s Product Design

 Outline
The Design Process The Design Process
Technology in Design Idea Generation
Design Quality Reviews Feasibility Study
Design for Environment Rapid Prototyping
Quality and Concurrent
Function Deployment Design
Design for Final Design and

Final Design and Process Plans Robustness Process Plans

.
The final design consists of detailed drawings and
specifications for the new product or service.
.
We discuss process planning in more detail in Chapter 6.

Semih Gu¨mu¨¸sba¸s Product Design

 Outline
The Design Process
The Design Process
Idea Generation
Technology in Design
Feasibility Study
Design Quality Reviews Rapid Prototyping
Design for Environment and Concurrent
Quality Design
Function Deployment
Final Design and
Design for
Final Design and Process Plans Robustness
Process Plans

.
The final design consists of detailed drawings and
specifications for the new product or service.
.
We discuss process planning in more detail in Chapter 6.

Semih Gu¨mu¨¸sba¸s Product Design

 Outline
The Design Process
Technology in Design Technology in Design
Design Quality Reviews
Collaborate Product Design Systems
Design for Environment
Quality
Function Deployment
Design for

CAD, CAE, CAD/CAM and PLM Robustness

Computer-aided Design (CAD)

It is a software system that uses computer graphics to assist
in the creation, modification, and analysis of a design.

Computer-aided Engineering (CAE)

It is a software system that tests and analyzes designs on
the computer screen.

Semih Gu¨mu¨¸sba¸s Product Design

 Outline
The Design Process
Technology in Design Technology in Design
Design Quality Reviews
Collaborate Product Design Systems
Design for Environment
Quality
Function Deployment
Design for

CAD, CAE, CAD/CAM and PLM Robustness

Computer-aided Design (CAD)

It is a software system that uses computer graphics to assist
in the creation, modification, and analysis of a design.

Computer-aided Engineering (CAE)

It is a software system that tests and analyzes designs on
the computer screen.

Semih Gu¨mu¨¸sba¸s Product Design

 Outline
The Design Process
Technology in Design Technology in Design
Design Quality Reviews
Collaborate Product Design Systems
Design for Environment
Quality
Function Deployment
Design for
Robustness

Computer-aided Design/Manufacturing (CAD/CAM)

It is the ultimate design-to-manufacture
connection.

Product Life Management (PLM)

It is managing the entire lifecycle of a product.

Semih Gu¨mu¨¸sba¸s Product Design

 Outline
The Design Process
Technology in Design Technology in Design
Design Quality Reviews
Collaborate Product Design Systems
Design for Environment
Quality
Function Deployment
Design for
Robustness

Computer-aided Design/Manufacturing (CAD/CAM)

It is the ultimate design-to-manufacture
connection.

Product Life Management (PLM)

It is managing the entire lifecycle of a product.

Semih Gu¨mu¨¸sba¸s Product Design

 Outline
The Design Process
Technology in Design Technology in Design
Design Quality Reviews
Collaborate Product Design Systems
Design for Environment
Quality
Function Deployment
Design for
Robustness

Semih Gu¨mu¨¸sba¸s Product Design

 Outline
The Design Process
Technology in Design Technology in Design
Design Quality Reviews
Collaborate Product Design Systems
Design for Environment
Quality
Function Deployment
Design for

Collborative Product Design (CPD)

Robustness

Collborative Product Design (CPD):

It is a software system for collaborative design and
development among trading partners.

Semih Gu¨mu¨¸sba¸s Product Design

 Outline
The Design Process
Technology in Design
Design Quality Reviews Design Quality Reviews
Design for Environment
Quality
Function Deployment
Design for

FMEA, FTA, and VA Robustness

Failure mode and effects analysis (FMEA):

It is a systematic approach to analyzing the causes and
effects of product failures.

Fault tree analysis (FTA):

It is a visual method for analyzing the interrelationships
among failures.

Semih Gu¨mu¨¸sba¸s Product Design

 Outline
The Design Process
Technology in Design
Design Quality Reviews Design Quality Reviews
Design for Environment
Quality
Function Deployment
Design for

FMEA, FTA, and VA Robustness

Failure mode and effects analysis (FMEA):

It is a systematic approach to analyzing the causes and
effects of product failures.

Fault tree analysis (FTA):

It is a visual method for analyzing the interrelationships
among failures.

Value analysis (VA):

It is a procedure for eliminating unnecessary features
and functions.

Semih Gu¨mu¨¸sba¸s Product Design

 Outline
The Design Process
Technology in Design
Design Quality Reviews Design Quality Reviews
Design for Environment
Quality
Function Deployment
Design for

FMEA, FTA, and VA Robustness

Failure mode and effects analysis (FMEA):

It is a systematic approach to analyzing the causes and
effects of product failures.

Fault tree analysis (FTA):

It is a visual method for analyzing the interrelationships
among failures.

Value analysis (VA):

It is a procedure for eliminating unnecessary features
and functions.

Semih Gu¨mu¨¸sba¸s Product Design

 Outline
The Design Process
Technology in Design
Design Quality Reviews Design Quality Reviews
Design for Environment
Quality
Function Deployment
Design for
Robustness

Failure Mode and Effects Analysis for Potato

Chips

Semih Gu¨mu¨¸sba¸s Product Design

 Outline
The Design Process
Technology in Design
Design Quality Reviews Design Quality Reviews
Design for Environment
Quality
Function Deployment
Design for
Robustness

Fault Tree Analysis for Potato Chips

Semih Gu¨mu¨¸sba¸s Product Design

 Outline
The Design Process
Design for Environment
Technology in Design
Green Sourcing
Design Quality Reviews Green Manufacture
Design for Environment
Green Consumption,
Quality
Function Deployment Recycling And Re-use
Design for

Design for Environment Robustness

Extended producer responsibility (EPR):

It is a concept that holds companies responsible for
their product even after its useful life.

Eco-labeling:
It is a seal of approval for environmentally safe
products.

Semih Gu¨mu¨¸sba¸s Product Design

 Outline
The Design Process
Design for Environment
Technology in Design
Green Sourcing
Design Quality Reviews Green Manufacture
Design for Environment
Green Consumption,
Quality
Function Deployment Recycling And Re-use
Design for

Design for Environment Robustness

Extended producer responsibility (EPR):

It is a concept that holds companies responsible for
their product even after its useful life.

Eco-labeling:
It is a seal of approval for environmentally safe
products.

Semih Gu¨mu¨¸sba¸s Product Design

 Outline
The Design Process
Design for Environment
Technology in Design
Green Sourcing
Design Quality Reviews Green Manufacture
Design for Environment
Green Consumption,
Quality
Function Deployment Recycling And Re-use
Design for
Robustness

International Eco-labels

Semih Gu¨mu¨¸sba¸s Product Design

 Outline
The Design Process
Design for Environment
Technology in Design
Green Sourcing
Design Quality Reviews Green Manufacture
Design for Environment
Green Consumption,
Quality
Function Deployment Recycling And Re-use
Design for

Design for Environment Robustness

Carbon Footprint:
It is a measure of greenhouse gases.

Sustainability:
It is the ability to meet present needs without
compromising those of future generations.

Semih Gu¨mu¨¸sba¸s Product Design

 Outline
The Design Process
Design for Environment
Technology in Design
Green Sourcing
Design Quality Reviews Green Manufacture
Design for Environment
Green Consumption,
Quality
Function Deployment Recycling And Re-use
Design for

Design for Environment Robustness

Carbon Footprint:
It is a measure of greenhouse gases.

Sustainability:
It is the ability to meet present needs without
compromising those of future generations.

Design for environment (DFE):

It involves designing a product from material that can
be recycled or easily repaired rather than discarded.

Semih Gu¨mu¨¸sba¸s Product Design

 Outline
The Design Process
Design for Environment
Technology in Design
Green Sourcing
Design Quality Reviews Green Manufacture
Design for Environment
Green Consumption,
Quality
Function Deployment Recycling And Re-use
Design for

Design for Environment Robustness

Carbon Footprint:
It is a measure of greenhouse gases.

Sustainability:
It is the ability to meet present needs without
compromising those of future generations.

Design for environment (DFE):

It involves designing a product from material that can
be recycled or easily repaired rather than discarded.

Semih Gu¨mu¨¸sba¸s Product Design

 Outline
The Design Process
Design for Environment
Technology in Design
Green Sourcing
Design Quality Reviews Green Manufacture
Design for Environment
Green Consumption,
Quality
Function Deployment Recycling And Re-use
Design for

Green Sourcing Robustness

.
Green sourcing means acquiring goods and services in the most
environmentally friendly way possible. Local producers are greener
sources because they ship their products over shorter distances.
Both businesses and consumers support green sourcing when
they purchase supplies produced locally.

Semih Gu¨mu¨¸sba¸s Product Design

 Outline
The Design Process
Design for Environment
Technology in Design
Green Sourcing
Design Quality Reviews Green Manufacture
Design for Environment
Green Consumption,
Quality
Function Deployment Recycling And Re-use
Design for

Green Manufacture Robustness

.
Green manufacturing is a term used to describe a business
practice that is focused on having as little impact on the
world’s natural environment as possible.

Semih Gu¨mu¨¸sba¸s Product Design

 Outline
The Design Process
Design for Environment
Technology in Design
Green Sourcing
Design Quality Reviews Green Manufacture
Design for Environment
Green Consumption,
Quality
Function Deployment Recycling And Re-use
Design for
Robustness

Design for Environment Lifecycle

Semih Gu¨mu¨¸sba¸s Product Design

 Outline
The Design Process
Design for Environment
Technology in Design
Green Sourcing
Design Quality Reviews Green Manufacture
Design for Environment
Green Consumption,
Quality
Function Deployment Recycling And Re-use
Design for

Green Consumption, Recycling And Re-use

Robustness

Green Consumption:
It is the practice of using environmentally friendly products
that do not cause risk for human health and do not threaten the
function of diversity to natural ecosystems.

Recycling And Re-use:

Recycling is the practice of reusing items that
would otherwise be discarded as waste.

Semih Gu¨mu¨¸sba¸s Product Design

 Outline
The Design Process
Design for Environment
Technology in Design
Green Sourcing
Design Quality Reviews Green Manufacture
Design for Environment
Green Consumption,
Quality
Function Deployment Recycling And Re-use
Design for

Green Consumption, Recycling And Re-use

Robustness

Green Consumption:
It is the practice of using environmentally friendly products
that do not cause risk for human health and do not threaten the
function of diversity to natural ecosystems.

Recycling And Re-use:

Recycling is the practice of reusing items that
would otherwise be discarded as waste.
Re-use is to use again especially in a different way or
after reclaiming or reprocessing.

Semih Gu¨mu¨¸sba¸s Product Design