Engineering Design Process - Answers
Question 1:
With the aid of a standard and well-labelled chart, describe all the steps involved in
systematic design process.
The systematic design process consists of the following key steps, which guide designers
from conceptualization to detailed design. While different representations exist, they
generally follow these stages:
1. Identifying Customer Needs (Requirements): Understanding the customer needs is the
first and most critical step. This includes considering all potential customers (e.g., users,
maintainers, sellers).
2. Market Analysis: Evaluating market demands and competition to ensure that the product
fits within a profitable segment.
3. Defining Goals (Product Concept): Setting clear objectives that meet customer needs,
taking into account the broader market.
4. Establishing Functions: Decomposing the product into its functional components,
focusing on how it will achieve its primary goals.
5. Task Specifications (Product Concept): Detailing what needs to be achieved in
measurable quantities.
6. Conceptualization (Solution Concept): Brainstorming potential solutions for each
function, often utilizing methods like morphological charts to ensure creativity.
7. Evaluating Alternatives (Solution Concept): Screening different concepts, often using
tools like Pugh’s evaluation matrix, to find the best option based on predefined criteria.
8. Embodiment Design: Refining the chosen concept, focusing on details like form, material,
and assembly.
9. Analysis and Optimization: Optimizing the design through calculations and simulations,
ensuring it meets the required performance standards.
10. Experiment: Prototyping and testing the design under real-world conditions to identify
potential improvements.
11. Marketing: Preparing the product for market launch, ensuring it meets customer
expectations and regulatory requirements.
Question 2:
(a) Explain the steps involved in the selection of materials for a design
(b) Write briefly on the following:
(i) Design for Manufacturing, (ii) Design for Assembly, (iii) Design for Environment, (iv)
Cycle time and (v) Bill of Materials.
(a) Steps in Material Selection for a Design:
1. Material Requirements Analysis: Understanding the environmental and service
conditions under which the product will operate.
2. List of Suitable Materials: Narrow down materials that meet the requirements.
3. Choose the Most Suitable Material: Analyze performance, availability, cost, and
manufacturability.
4. Test Data: Test the material under operational conditions.
5. Cost and Availability: Ensure that the material is available at a reasonable cost.
(b) Key Considerations:
1. Design for Manufacturing (DFM): This approach ensures that designs are optimized for
ease of manufacturing, reducing cost and complexity.
2. Design for Assembly (DFA): Focuses on simplifying the assembly process, often by
reducing the number of components.
3. Design for Environment (DFE): This principle focuses on minimizing environmental
impact, considering factors like energy consumption and recyclability throughout the
product lifecycle.
4. Cycle Time: Refers to the total time required to complete a process from start to finish,
crucial for improving efficiency in production.
5. Bill of Materials (BOM): A detailed list of components, raw materials, and subassemblies
needed to manufacture a product, often used in assembly drawings.
Question 3:
(a) Briefly describe the physical and mechanical properties of materials relevant to
engineering design and list five (5) of each property.
(b) Write briefly on the following manufacturing processes as it affects the design of
equipment: (i) Casting, (ii) Forging, (iii) Machining and (iv) Welding.
(a) Physical and Mechanical Properties of Materials Relevant to Engineering Design:
- Physical Properties: Density, thermal conductivity, melting point, electrical conductivity,
and thermal expansion.
- Mechanical Properties: Tensile strength, ductility, hardness, fatigue limit, and toughness.
(b) Manufacturing Processes:
1. Casting: The process of pouring molten material into a mold to achieve a desired shape. It
is the first step in shaping materials.
2. Forging: Involves applying compressive forces to shape metal, typically creating high-
strength parts.
3. Machining: Removing material to create the final product with precision, using methods
like milling and drilling.
4. Welding: The joining of materials through coalescence using heat or pressure.
Question 4:
(a) Briefly explain the use of Morphological Charts in generating design concepts.
(b) Using a morphological chart, present at least two different design concepts for an
automatic can crusher.
(a) Morphological charts help generate design concepts by breaking down functions into
simpler sub-functions. Different combinations of solutions for each sub-function lead to
multiple design concepts.
(b) Design Concepts for an Automatic Can Crusher:
1. Electric-powered crushing mechanism with a simple lever for feeding.
2. Pneumatic system with a sensor-controlled crusher.
Question 5:
(a) Explain three different types of drawings used in Design concepts
(b) Explain the roles of Models in engineering design.
(c) Differentiate between mock-up and Prototype.
(a) Types of Drawings in Design:
1. Sketches (Conceptual Design): Simple representations of design concepts.
2. Assembly Drawings (Embodiment Design): Shows how parts fit together.
3. Detail Drawings (Detailed Design): Specifies all dimensions and tolerances necessary for
manufacturing.
(b) Roles of Models in Engineering Design:
Models, including prototypes and CAD simulations, are used to predict how a design will
behave in real conditions. They help verify functionality, manufacturability, and safety.
(c) Mock-up vs. Prototype:
A mock-up is a non-functional scale or full-size model made for visualization and design
evaluation, while a prototype is a functional version used for testing and validation.
Question 6:
(a) Explain the steps involved in evaluating a given design using Pugh's Evaluation Method.
(b) What are the three cost estimate methods, and what are the differences among them?
(c) Which method is more appropriate for your design project and why?
(a) Steps in Pugh's Evaluation Method:
1. Select Comparison Criteria: The team lists the criteria for comparison from the design
specifications.
2. Choose Datum Concept: A reference concept (datum) is selected, often an industry
standard or a previous generation product.
3. Rate Alternatives: Each design concept is rated as better (+), worse (-), or the same (0)
compared to the datum for each criterion.
4. Total Scores: Calculate the overall score by subtracting the number of negative ratings
from the positive ones.
5. Iteration: The highest-scoring alternative may become the new datum, and the process is
repeated until the optimal design is identified.
(b) Three Cost Estimate Methods:
1. Methods Engineering: A detailed breakdown of each work element, primarily used in
industrial engineering.
2. Analogy: Uses past projects to estimate future costs with adjustments for differences in
size or inflation.
3. Statistical Approach: Uses regression models to predict costs based on key parameters
like weight or power.
(c) The analogy method is often the most appropriate when a similar design exists, as it
allows for quick estimations based on historical data.
Question 7:
(a) What is Design Specification?
(b) Develop a table of specifications for the following objectives.
(i) The design of the crush mechanism is not to exceed 20x20x10cm in the total size.
(ii) The can crusher must have a continuous feed mechanism.
(iii) The can must crushed to 1/5 of its original volume.
(iv) The device must operate safely, children will use it.
(v) The device is fully automatic.
(c) Briefly explain Six Sigma and 5S.
(a) Design Specification:
A design specification is a detailed document listing the performance criteria, constraints,
and design objectives that a product must meet.
(b) Specification Table for the Can Crusher:
| Metric | Value |
| --- | --- |
| Dimensions | 20x20x10 cm |
| Continuous Feed Mechanism | Yes |
| Crushed Volume | 1/5 original size |
| Safety (for children) | High, with accessible controls |
| Automation Level | Fully automatic |
(c) Six Sigma and 5S:
1. Six Sigma: A methodology focused on improving quality by identifying and removing
defects through data-driven decision-making and statistical analysis.
2. 5S: A workplace organization method (Sort, Set in Order, Shine, Standardize, Sustain) that
promotes efficiency, cleanliness, and continuous improvement in production environments.
