EST 200

Design &
Engineering
Module 5

Vigil J Vijayan​
 DESIGN FOR X (DFX)
• Design for Excellence or DFX: systematic
design approach that entails a wide range of
guidelines and standards focused on optimizing
the product realization lifecycle.

• In reality, the term DFX is better thought of as

Design for "X" where the variable X is
interchangeable with one of many values
depending on the particular
objectives of the venture
• These guideline ensures the issues
related to manufacturing, cost, quality,
assembly and serviceability are
addressed at the design stage.

• If these guidelines are not adhered to

during the design stage, it can lead to
engineering changes occurring at later
stages of the product lifecycle which are
highly expensive and can cause product
delays and cost over-runs
Design for Manufacturing
Design for Assembly
DESIGN FOR SUSTAINABILITY
Environment Life-Cycle Assessments
• Life-cycle assessment (LCA) is a tool that can be used to
evaluate the potential environmental impacts of a product,
material, process, or activity.
• An LCA is a comprehensive method for assessing a range of
environmental impacts across the full life cycle of a product
system, from materials acquisition to manufacturing, use, and
final disposition.
• LCA study results help to promote the responsible design and
redesign of products and processes, leading to reduced
overall environmental impacts and the reduced use and
release of more toxic materials.
• LCA studies identify key materials and processes within the
products' life cycles that are likely to pose the greatest
impacts, including occupational and public toxicity impacts.
• These assessments allow businesses to make product
improvements through environmentally sound process,
material, and design choices.
LCA has three essential steps:
• Inventory analysis lists all inputs (raw materials and energy) and
outputs (products, wastes, and energy), as well as any intermediate
outputs.
• Impact analysis lists all of the effects on the environment of each
item identified in the inventory analysis, and quantifying or
qualitatively describing the consequences (e.g., adverse health effects,
impacts on ecosystems, or resource depletion).
• Improvement analysis lists, measures, and evaluates the needs and
opportunities to address adverse effects found in the first two steps
DESIGN FOR USE
Reliability
• To an engineer, reliability - “the probability that an item will perform its
function under stated conditions of use and maintenance for a stated
measure of a variate”
• we can properly measure the reliability of a component or system only
under the assumption that it has been or will be used under some specified
conditions.
• The appropriate measure of use of the design, called the variate, may be
something other than time
Maintainability
• Maintainability -“probability that a failed component or system will be
restored or repaired to a specific condition within a period of time
when maintenance is performed within prescribed procedures”
• Designing for maintainability requires that the designer take an active
role in setting goals for maintenance, such as times to repair, and in
determining the specifications for maintenance and repair activities in
order to realize these goals.
• This can take a number of forms, including:
• Selecting parts that are easily accessed and repaired;
• Providing redundancy so that systems can be operated while maintenance
continues;
• Specifying preventive or predictive maintenance procedures; and
• Indicating the number and type of spare parts that should be held in inventories in
order to reduce downtime when systems fail
Activity 1
Examine the changes in the design of a foot wear with constraints of 1)
production methods, 2) life span requirement, 3) reliability issues and 4)
environmental factors.
1. Production Methods
Footwear production methods have evolved significantly, from traditional
handmade shoes to modern automated manufacturing processes.

• Traditional Methods: Historically, footwear was crafted by skilled artisans

using manual techniques. This method allowed for customized designs but
was time-consuming and expensive.
• Industrialization and Mass Production: The industrial revolution introduced
mechanization, allowing for mass production of footwear. This shift
dramatically increased output, reducing costs and making shoes more
accessible to the general population.
• Automation and Advanced Manufacturing:
In recent decades, automation and advanced
manufacturing techniques (e.g., 3D printing,
CNC machining, and robotics) have further
increased production efficiency. These methods
enable rapid prototyping and customizable designs,
allowing for more intricate patterns and complex structures.
2. Life Span Requirement
The expected life span of footwear has a direct impact on
design choices, materials, and production methods.

• Durability: Early footwear was often designed to be durable,

with high-quality leather and robust construction techniques.
As manufacturing evolved, there was a shift towards cheaper
materials, sometimes compromising durability.
• Modern Materials: Advances in material science have led to
the development of synthetic materials like polyurethane,
EVA (ethylene-vinyl acetate), and rubber blends. These
materials offer a balance between durability and cost,
allowing manufacturers to design shoes with a longer life
span.
• Repairability: Traditionally, footwear could be repaired,
extending its life. However, modern mass-produced shoes are
often designed for quick replacement, with limited options for
repair. This trend affects the life span of footwear and
contributes to environmental concerns.
3. Reliability Issues
Reliability in footwear design refers to the shoe's performance, comfort,
and safety.

• Comfort and Ergonomics: Modern footwear design has increasingly

focused on ergonomics, using technologies like orthotic insoles and
cushioning to enhance comfort. This focus on reliability ensures that
shoes support various activities, from athletics to daily wear.
• Quality Control: Advances in quality
control techniques and testing have
improved the reliability of footwear.
Automated testing for strength,
flexibility, and wear resistance ensures
consistent product quality.
• Innovation in Design: The introduction
of new design features, such as shock
absorption systems and moisture-wicking
materials, has enhanced the reliability of
footwear, reducing the likelihood of
failure or discomfort.
4. Environmental Factors
The environmental impact of footwear design has become a significant
concern, leading to changes in material selection and production practices.

• Sustainable Materials: There is a growing trend toward using sustainable

materials in footwear design, such as recycled rubber, organic cotton, and
plant-based leather alternatives. This shift helps reduce the environmental
footprint of shoe production.
• Eco-friendly Production Processes: Manufacturers are adopting eco-friendly
production processes, such as reducing waste, minimizing energy
consumption, and using environmentally friendly dyes and adhesives.
• End-of-Life Considerations: With the rise of environmental awareness,
some footwear companies now design shoes that are easier to recycle or
compost at the end of their life span. This approach addresses the issue of
shoe waste in landfills and promotes a circular economy.
Political, Economical, Social, Technological, Environmental & Legal - PESTEL
• Overall, the design of footwear has evolved to meet the
constraints of production methods, life span
requirements, reliability issues, and environmental
factors.
• The trend is moving towards more sustainable, reliable,
and customizable footwear, with a focus on minimizing
environmental impact.
• Through innovations in materials and manufacturing
processes, the footwear industry aims to meet the
diverse needs of consumers while addressing broader
societal and environmental concerns.
 ETHICS IN DESIGN
• ETHICS: UNDERSTANDING OBLIGATIONS
ethics 1: the discipline dealing with what is good and bad and with
moral duty and obligation
ethics 2 a: a set of moral principles or values b: a theory or system of
moral values c: the principles of conduct governing an individual or
group
• CODES OF ETHICS: WHAT ARE OUR PROFESSIONAL OBLIGATIONS?
• OBLIGATIONS MAY START WITH THE CLIENT . . .
• . . . BUT WHAT ABOUT THE PUBLIC AND THE PROFESSION?
• ON ENGINEERING PRACTICE AND THE WELFARE OF THE PUBLIC
e.g., cigarette lighter, nuclear reactor
• ETHICS: ALWAYS A PART OF ENGINEERING PRACTICE
 ENGINEERING ECONOMICS IN DESIGN

• Costs are often broken up into the categories of labor, material, and overhead
costs.
• Labor: costs include payments to the employees who build the designed device,
as well as to support personnel who perform necessary but often invisible tasks
such as taking and filling orders, packaging, and shipping the device.
• Labor costs also include a variety of indirect costs that are less evident because
they are generally not paid directly to employees.
• These indirect costs are sometimes called fringe benefits and include health and
life insurance, retirement benefits, employers’ contributions to Social Security, and
other mandated payroll taxes
• A simple starting point for estimating costs is to keep good records or the activities
needed to build our design’s prototype.
• Materials include those items and inputs directly used in building the device, along with
intermediate materials and inventories that are consumed in the manufacturing process.
• A key tool for estimating the materials cost of an artifact is the bill of materials (BOM),
the list of all of the parts in our design, including the quantities of each part required for
complete assembly
• The BOM is particularly useful since it is usually developed directly from the assembly
drawings, and so it reflects our final design intentions.
• Materials costs can often be reduced significantly by using commercial off-the-shelf
materials rather than making our own.
• This is because outside vendors have the machinery and expertise to make very large
numbers of parts for a lot of customers.
• The costs incurred by a manufacturer that cannot be directly assigned to a single product
are termed overhead.
• Estimating the costs of producing a design requires careful consultation with clients or
their suppliers.
• In practice, each engineering discipline has its own approaches to cost estimating that are
captured by general guidelines
Activity 2
• Describe the how to estimate the cost of a particular design using any
of the following: i) a website, ii) the layout of a plant, iii) the elevation
of a building, iv) an electrical or electronic system or device and v) a
car.
Show how economics will influence the engineering designs. Use
hand sketches to support your arguments.
 Sample Questions
3 Marks
1. Show how designs are varied based on the aspects of production methods, life span, reliability and
environment?
2. Explain how economics influence the engineering designs?
3. How to estimate the cost of a particular design?
4. How do ethics play a decisive role in engineering design?
5. Describe ethics to be followed in engineering design
6. Explain the significance of sustainability in engineering design
7. What are the factors to be considered for a sustainable design?
8. What are design rights, and how can an engineer put it into practice?
9. Explain the cost factor calculation of a particular design?
10. Write the role of economics in engineering design?
11. What are design rights and how can an engineer put it into practice?
12. Describe the role of ethics in the design of any two products.
14 Marks
1. Examine the changes in the design of a foot wear with constraints of 1) production
methods, 2) life span requirement, 3) reliability issues and 4) environmental factors.
Use hand sketches and give proper rationalization for the changes in design.
2. Describe the how to estimate the cost of a particular design using any of the following: i) a
website, ii) the layout of a plant, iii) the elevation of a building, iv) an electrical or
electronic system or device and v) a car.
Show how economics will influence the engineering designs. Use hand sketches to support
your arguments.
3. Design a fan which automatically reduces speed or stops when the temperature reduces
during the night for energy conservation. Use hand sketches to support your design.
4. Describe how to estimate the cost of a pen and list the various parts. Show how the
economics will influence the engineering designs. Use hand sketches to support your
arguments.
5. Illustrate the changes in design of disposable tea cup in terms of production, use and
sustainability.
6. Describe the how to estimate the cost of a table in design stage? Show how economics will
influence the engineering designs.
7. Design a sustainable piping network for reuse of water in a residential building enabling
water conservation. Sketch the design.
8. Design a door handle with a lock which is easy to use. Use hand sketches and give
rationalization for the various features in the design.
9. A table has to be designed as a study table, but it must include a provision to place your
computer. Calculate the cost difference if you want to convert it as a dining table. The cost
calculation must include labor, material and overhead costs.
10. An umbrella has to be designed for daily use. Show how the cost will vary based on material,
design and labor using suitable neat hand sketches?
11. Examine the changes in the design of a footwear in terms of production methods, reliability
issues and environmental factors. Use hand sketches and give proper rationalization for the
changes in design.
12. Describe how to estimate the cost of a residence house in design stage. Show how the economics
will influence its design. Use hand sketches to support your arguments.