c1 - Introduction of Engineering Design

DJJ 40173
Engineering Design
CHAPTER 1 – INTRODUCTION TO
ENGINEERING DESIGN
1
Learning Outcome
1 Explain the engineering design

Engineering Design
Introduction to
2 Justify the designing process
3 Justify the design consideration
4 Evaluate the ergonomic factors in design
5 Evaluate factors in material selection for designing

process.
2
Definition of engineering:
“The creative application of scientific principles to design or develop

structures, machines, apparatus, or manufacturing processes, or
Engineering Design
works utilizing them singly or in combination; or to construct or

operate the same with full cognizance of their design; or to forecast
their behaviour under specific operating conditions; all as respects an
intended function, economics of operation and safety to life and
property”.
- American Engineers' Council for Professional Development
3
Definition of design:
“Design is
“Design is an
an innovative
innovative and
and highly
highly iterative
iterative process.
process. It
It is
is also
also aa
Engineering Design
decision-making process.”
decision-making process.”
“Design is
“Design is aa communication-intensive
communication-intensive activity
activity in
in which
which both
both words
words
and pictures
and pictures are
are used
used besides
besides written
written and
and oral
oral forms
forms are
are employed.”
employed.”
Richard G.
Richard G. Budynas,
Budynas, J.
J. Keith
Keith Nisbett
Nisbett (2011)
(2011)
4
Definition of engineering design :
Engineering design is the process of devising a system, component, or

process to meet desired needs. It is a decision-making process
(iterative), in which the basic science and mathematics and
Engineering Design
engineering sciences are applied to convert resources optimally to

meet a stated objective.
(ABET) - Accreditation Board for Engineering and Technology
5
Types of design:
“Design can be classified base on their production of their product

or component, which are product design, process design and
industrial design”
Engineering Design
6 6
Types of design:
As in any field of human activity, there are different degrees of

difficulty. In design, these stages are:
Engineering Design
Adaptive design
Development design
New design/Original design
7
Types of design:
Adaptive design
Engineering Design
• In most cases, the designer’s work is concerned with adaptation of

existing designs.
• This type of design needs no special knowledge or skill and can be
attempted by designers of ordinary technical training.
• The designer only makes minor alternation or modification in the
existing designs of the product.
• An example is a washing machine. This has been based on the same
conceptual design for the last several years and varies in only a few
parameters, such as its dimensions, materials, and detailed power
specifications.
8
Types of design:
An example of adaptive design: Washing Machine

Engineering Design
Change of
material for a
drum
9
Types of design:
Development design
Engineering Design
• This type of design needs considerable scientific training and design

ability in order to modify the existing designs into a new idea by
adopting a new material or different method of manufacture.
• In this case, though the designer starts from the existing design,
but the final product may differ markedly from the original product.
quite
• Examples of this development could be from a manual gearbox in a

car to an automatic one and from the traditional tube-based
television to the modern plasma, LCD versions and LED versions.
10
Types of design:
An example of development design

Engineering Design
11
Types of design:
New design
• The most difficult level in that generating a new concept involves

Engineering Design
mastering all the previous skills in addition to creativity and

imagination, insight, and foresight.
• Examples of this are the design of the first automobile, airplane, or
even the wheel (a long time ago).
• Try to think of entirely new designs which have been introduced
over the last decade.
12
Do you know?
Lists the reason for failures in most engineering designs:

Engineering Design
• Incorrect or overextended assumptions

• Poor understanding of the problem to be solved
• Incorrect design specifications
• Faulty manufacturing and assembly
• Error in design calculations
• Incomplete experimentation and inadequate data collection
• Errors in drawings
• Faulty reasoning from good assumptions
13
What is a Design Process?
A design process is a systematic problem-solving strategy, with

criteria and constraints, used to develop many possible solutions to
Designing Process
solve or satisfy human needs or wants and to narrow down the

possible solutions to one final choice.
14
There are several design processes used in the
different technical fields. The phases in design,
acknowledging the many feedbacks and iterations.
Designing Process
Richard, G.B. and Keith, N. J. (2011).

Shigleys Mechanical Engineering
Design. 9th Edition. McGraw-Hill,
New York.
15
Primary Needs
• The primary need can arise from various sources.

Designing Process
• It could be that user of an existing piece of machinery requires to

update the process and therefore modify the mechanism.
• Another reason could be exploitation of new technology. Further, a

product may be in need of advancement over a competitor.
16
Primary & Secondary Needs
Primary need include as below:

Designing Process
•Fulfilment of functions
•Reliability
•Cost
•Serviceability
•Life
•Ease of maintenance
Secondary need include as below:
• Ergonomics
• Aesthetics
• Safety
• Economics 17
Problem Definition
• Receive a problem to solve from the client.

• Gather information.
Designing Process
• Be inspired through media exposure of a current problem and take

action.
• More specific and must include all the specifications for the object
that is to be designed.
• The specifications define the cost, the number to be manufactured,
the expected life, the range, the operating temperature, and the
reliability. Specified characteristics can include the speeds, feeds,
temperature limitations, maximum range, expected variations in the
variables, dimensional and weight limitations, etc.
18
Designing Process Examples
19
Designing Process
20
Synthesis
2 Process
• To combine several different pieces into a whole.

• Connecting possible system elements is sometimes called the
invention of the concept or concept design.
Designing Process
21
Analysis
2 & Optimization Process
• To assess whether the system performance is satisfactory or

better, and if satisfactory, just how well it will perform.
Designing Process
• Break down a concept/ idea into its important parts/ points.
• Both analysis and optimization require that we construct or devise

abstract models of the system that will admit some form of
mathematical analysis.
22
Evaluation
2
• Significant phase of the total design process.
• Evaluation is the final proof of a successful design and usually

Designing Process
involves the testing of a prototype in the laboratory.
• The project designer or design team will need to address a myriad

of engineering and non-engineering questions.
Is it reliable?
Will it compete successfully with similar products?
Is it economical to manufacture and to use?
Is it easily maintained and adjusted? Can a profit be made from its sale or use?
How likely is it to result in product-liability lawsuits?
And is insurance easily and cheaply obtained?
Is it likely that recalls will be needed to replace defective parts or systems?
23
Several detail examples of
detail design process
Designing Process
24
Example Design Process
1. Identifying problems and

opportunities
Designing Process
2. Framing a design brief

3. Investigation and research
4. Generating alternative solutions
5. Choosing a solution
6. Developmental work
7. Modeling and prototyping
8. Testing and evaluating
9. Redesigning and improving
25
1. Identify the need

2. Define the criteria
Designing Process
3. Explore/research/investigate
4. Generate alternate solutions
5. Choose a solution
6. Develop the solution
7. Model/prototype
8. Test and evaluate
9. Redesign and improve
26
1. Define a Problem
2. Brainstorm
3. Research and Generate Ideas
4. Identify Criteria and Specify
Designing Process
Constraints
5. Explore Possibilities
6. Select an Approach
7. Develop a Design Proposal
8. Make a Model or Prototype
9. Test and Evaluate the Design using
Specifications
10. Refine the Design
11. Create or Make Solution
12. Communicate Processes and Results 27
Designing Process Example Design Process
28
Design Consideration
It can be referred as some characteristics that influences the

design of the element or, perhaps, the entire system. Usually quite
a number of such characteristics must be considered and

prioritized in a given design situation.
29
Economic & Production Factor
• Investment Cost – Cost of initiation of activity or project

• Operation & Maintenance Cost – operation and maintaining
entire plat, systems and equipment.

• Fixed & Variable Cost – Fixed Cost (Cost that remain constant
over the operational) and Variable cost (Vary with production
volume)
30
Economic & Production Factor
• Incremental or Marginal Cost – The cost incremental level of
output is covered by the income generated.
• Direct & Indirect Cost – Direct (Material, labour and any
subcontract) and Indirect (Utilities, taxes, maintenances)

• Recurring & Nonrecurring Cost - Cost that continue occurred
over the life such as manufacturing cost.
• Past Cost – Project expenditures that have occurred in the past.
31
Codes & Standard in Design
A standard can be defined as a set of technical definition and guidelines

for designer and manufacturers.
32
Codes & Standard in Design
33
Safety & Product Liability
Products liability is a phrase used to describe our legal responsibility

to our customers under civil action or criminal actions (Blinn, 1989).
The injured party, called the plaintiff, against the manufacturer or

seller, called the defendant, takes civil actions to recover damages
for personal injury or loss to property caused by defect(s) in design
or manufacture.
34
Another definition of product's liability is the area of law in which

manufacturers, distributors, suppliers, retailers, and others who make
products available to the public are held responsible for the injuries
those products cause.
35
Design Defects: Liability arises from a mistake or oversight in the

design of a product, which makes it dangerous when used as intended,

or when used for another reasonably foreseeable purpose.
36
Manufacturing Defects: Liability arises from a defect that results

from the manufacturing process.
37
Marketing Defects: A marketing defect involves such issues as

inadequate warning labels or instructions, which, for example, prevent

a user from recognizing a defect in the product, or from being aware
of how to safely use or apply the product.
38
Ergonomic Factors in Design Ergonomic
 Ergonomics concerned with the understanding of

interactions among human and other elements of a system in
order to optimize human well-being and overall performance
 It takes into the account the users capabilities and limitations
to ensure that tasks functions, information and the environments
suit each user.
39
Ergonomic Definition
References Definition
Ergonomic Factors in Design
Science of fitting workplace conditions and job demands to the

capabilities of the working population
NIOSH 1997c
(1) Effective and successful “fits” assure high productivity
(2) Avoidance of illness and injury risks
(3) Increased satisfaction among the workforce
Ergonomics is the systematic study of people at work with the
ILO 1998 objective of improving the work situation, the working conditions and
the task performed
Study of work. It is the science of designing the job to fit the workers,
OSHA US 2000 rather than physically forcing the worker’s body to fit the job
Science concerned the “fit” between people and their work. If put
HSE UK 2013 people first, taking account of their capabilities and limitation
Ergonomics is an approach or solution to deal with a number of
HUMANTECH 2016 problems—among them are work-related musculoskeletal disorders
40
Ergonomic Factors in Design Benefit of Ergonomic
Improved
Health and
Safety
Improve Higher Morale

Competitiveness Throughout the
Workplace
Reduce Workplace Improved Quality

Injuries (work and
wellbeing)
Decrease
Improve
Absenteeism
Productivity
41
Display Element of Relationship Basic Ergonomic
Between Human & Machine
42
Ergonomic Factors in Design Analyze Ergonomic Factors
Definition of Ergonomics Risk Factors…
 Any attribute, characteristic or exposure that may

cause or contribute to musculoskeletal injury.
 Two or more risk factors may be present at one

time, thereby increasing the risk of injury.
43
Analyze Ergonomic Factors
Ergonomics Risk Factor [ERF]

Environmental Stress Awkward

(thermal environment, Posture
noise and extreme Forceful and Sustained
Exertions
atmospheric pressure
environment)
Contact Stress ERF Repetitive

Motion
Static and
Vibration Sustained Posture
44
Awkward PAIN
Posture
NABN
2018
Positions of the body while performing work activities that

deviate significantly from neutral position.
Bending
Working Working with neck and lack of

with the Elbows ability to
Over- or back bent more
Twisting hands above the vary
reaching above the shoulders than 30 degrees
without support posture
head
45
20
Seating min
Posture
Elbow Position monitor so that

must the top of viewing area is
in 90o at eye level
Contact stress
Back supported and
promotes natural curve
of the lower back
Thighs horizontal with a Feet fully support

90o – 110o angle at the hip on the floor
46
Simple solution …
Poor grip Sharing the load

Overuse muscle with both hands
The wrist tendons at the base of the thumb may affected by awkward and
overuse muscle activity. The disease named de Quervain's. 47
Proper Posture
Maintaining good posture While seating,

is vital in taking care spine sit in comfortable chair
with back support
0o – 35o
While using computer, need to ensure

that neck in neutral position
48
Forceful and Sustained Exertions

Involves the use of high level force while transporting or supporting

load
lifting
Moving load using

hands or through the lowering
application of bodily
force
Forceful and sustained
exertions
carrying pushing Also exist in sustained postures

which place excessive force on
joints and overload the muscles
pulling and tendons
49
Repetitive Motion
Repeated movements of the same groups of joints

and muscle
Too Too Long

frequent quickly duration
Highly repetitive =
if the cycle time is 30 seconds or less
50
Static and Sustained Posture

• Minimal or restricted or no movement where the body held on to

a particular position over a prolonged period.
• Problem? Yes..
Fatigue Pain Injuries
Prolonged standing – standing position for duration more than 2 hours

Prolonged sitting – sitting for duration more that 30 minutes
51
Design machine and equipment

 Machines and equipment's should be design with the human
characteristics in the mind
Good Matching between the machine dimensions and

the human characteristics
Help workers to do their job easily safely and efficiently

52
Malaysian Guideline for Lifting
and Lowering load

Male Female
7kg 3kg
13kg 7kg
16kg 10kg
13kg 7kg
7kg 3kg
53
Material Selection in Design Types of Material
54
Material Selection in Design Material Properties
55
• Physical – specific gravity, particle size distribution, etc.

• Chemical
• Mechanical – strength, elastic modulus
• Thermal – thermal coefficient
• Electrical
• Optical
• Magnetic
56
57
Solution step during material selection:
1. Ask yourself what the design requirements are for the given
application in terms of physical, mechanical, thermal, chemical,
electrical and magnetic properties. Select a few materials that
fulfil all the requirements. Rank them.
2. From the materials selected, ask yourself which materials are easy
to manufacture and which are not. Rank them.
58
3. Look at the cost of purchasing raw materials as well as the

storage, special surface treatment and transportation costs,
etc. Rank them.
4. From the ranking generated in steps 1 to 3, select the most

optimal material for the design application.
59
Material Selection in Design Material Selection
In general, the total cost is the most important factor in selecting a

material. Hence it is natural to use it as one of the key factors in the
initial screening process.
Cost is a good characteristic when it is related to some important

material property that controls the performance of the design.
60
61
62
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DJJ 40173

1 Explain the engineering design

2 Justify the designing process

3 Justify the design consideration

4 Evaluate the ergonomic factors in design

5 Evaluate factors in material selection for designing

“The creative application of scientific principles to design or develop

works utilizing them singly or in combination; or to construct or

Engineering design is the process of devising a system, component, or

engineering sciences are applied to convert resources optimally to

(ABET) - Accreditation Board for Engineering and Technology

“Design can be classified base on their production of their product

As in any field of human activity, there are different degrees of

• In most cases, the designer’s work is concerned with adaptation of

An example of adaptive design: Washing Machine

• This type of design needs considerable scientific training and design

• Examples of this development could be from a manual gearbox in a

An example of development design

• The most difficult level in that generating a new concept involves

mastering all the previous skills in addition to creativity and

Lists the reason for failures in most engineering designs:

• Incorrect or overextended assumptions

A design process is a systematic problem-solving strategy, with

solve or satisfy human needs or wants and to narrow down the

Richard, G.B. and Keith, N. J. (2011).

• The primary need can arise from various sources.

• It could be that user of an existing piece of machinery requires to

• Another reason could be exploitation of new technology. Further, a

Primary need include as below:

• Receive a problem to solve from the client.

• Be inspired through media exposure of a current problem and take

• To combine several different pieces into a whole.

• To assess whether the system performance is satisfactory or

• Break down a concept/ idea into its important parts/ points.

• Both analysis and optimization require that we construct or devise

• Evaluation is the final proof of a successful design and usually

involves the testing of a prototype in the laboratory.

• The project designer or design team will need to address a myriad

1. Identifying problems and

2. Framing a design brief

1. Identify the need

It can be referred as some characteristics that influences the

a number of such characteristics must be considered and

• Investment Cost – Cost of initiation of activity or project

entire plat, systems and equipment.

subcontract) and Indirect (Utilities, taxes, maintenances)

A standard can be defined as a set of technical definition and guidelines

Products liability is a phrase used to describe our legal responsibility

The injured party, called the plaintiff, against the manufacturer or

Another definition of product's liability is the area of law in which

Design Defects: Liability arises from a mistake or oversight in the

design of a product, which makes it dangerous when used as intended,

Manufacturing Defects: Liability arises from a defect that results

from the manufacturing process.

Marketing Defects: A marketing defect involves such issues as

inadequate warning labels or instructions, which, for example, prevent

 Ergonomics concerned with the understanding of

Improve Higher Morale

Reduce Workplace Improved Quality

Definition of Ergonomics Risk Factors…

 Any attribute, characteristic or exposure that may

 Two or more risk factors may be present at one

Ergonomics Risk Factor [ERF]

Environmental Stress Awkward