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Engineering Design: Mechanical Engineering Department Andalas University

This document outlines the course content for an Engineering Design course. It includes learning objectives, design process models, design phases, and key concepts. The course aims to teach students to differentiate analytical and design approaches, describe common design process models, explain design phases from concept to detail, and develop effective communication and teamwork skills for engineering design projects.

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100% found this document useful (1 vote)

145 views72 pages

Engineering Design: Mechanical Engineering Department Andalas University

Uploaded by

Hendra Riswan

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PPT, PDF, TXT or read online on Scribd

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Mechanical Engineering Department

Andalas University
TMS 306

ENGINEERING DESIGN
2 cr.
Adjar Pratoto
2010

Quotes

If you fail to plan, you plan to fail. (Varanasi, 2006)

The mere formulation of a problem is far more often essential

than its solution, which may be merely a matter of mathematical
or experimental skill. (Albert Einstein)

If you dont know where youre going, youll probably end up

somewhere else. (Yogi Berra)

Learning Objectives
After completing the course, the students should be able to:

differentiate the analytical approach and the design approach

describe different design process models
explain design phases
communicate effectively
work in team

References:
1.
2.
3.

Cross, N., Engineering Design Methods, 2nd Ed., John Wiley &
Sons, Chichester, 1994
Eggert, R.J., Engineering Design, Pearson Prentice Hall, Upper
Saddle River, N.J., 2005
Dieter, G.E., Engineering Design, 3rd Ed., McGraw-Hill Intl. Ed.,
Singapore, 2000

Engineering Undertaking
New idea

Define need or
opportunity
Specify criteria for
success
Determine probability
of success

Low probability - drop

High probability
Market analysis
Product or system design
and cost estimate

Research and
development

Feasibility study
Refine and revise

Stoecker, 1980

Feasible

Implement construct or
manufacture

Not feasible - drop

Product Realization Process

Realized
product
Product development

Product design
Engineering design
Industrial design
Sales/marketing

Customer
need

Ref.: 2

Service
Distribution
Manufacturing
(Production)

Disposal

A customer need for a new or improved product can

originate from almost anywhere in the firm, but the
majority ideas usually originate from the sales or
marketing group
Industrial design activities focus on how the new or revised
product idea is compatible with the customers anatomical
limitations and/or aesthetic trends in the marketplace
Engineering design activities result in recommended
manufacturing specifications that satisfy the customers
functional performance requirements and manufacturing
constraints
Production design activities involve the design, fabrication,
and installation of production equipment, such as jigs,
fixtures, quality control instrumentation, and material
handling equipment. In some cases, it might involve the
construction of a new factory.
Ref.: 2

Manufacturing activities relate to fabrication, assembly,

and testing. They also include training, scheduling, and
supervising
production
employees.
Significant
coordination between engineering design, production
planning, and manufacturing is necessary during ramp-up
as bugs in the product design and manufacturing
processes are worked out.
Distribution activities involve shipping the product in
wholesale-sized lots to distribution centers located around
the country or world.
Service activities for consumer products usually relate to
repair or replacement at the factory. However, large
appliance manufacturers will train repair persons for home
service.
Disposal activities involve the removal, elimination, and/or
recycling of hazardous chemicals or scarce materials
Ref.: 2

The four stages in the life of a product

Design

Manufacture

Use

Retire

Ref.: 2

Establish function
Determine form

Fabricate
Assemble
Distribute
Set up
Operate
Maintain
Repair
Take down
Disassemble
Recycle
Dispose

To satisfy the consumer

We must consider all the phases in the life of a product

What is engineering design?

A goal directed problem solving activity (Archer)
Decision making in the face of uncertainty with high
penalties for error (Asimow)
The use of scientific principles, technical information and
imagination in the definition of a mechanical structure,
machine or system to perform pre-specified functions
with maximum economy and efficiency (Fielden)
To device, subject to certain problem solving
constraints, a component, system or process to
accomplish a specified task optimally, subject to certain
solution constraints (Dixon)

What is engineering design?

Establishes and defines solutions to and pertinent

structures for problems not solved before, or new solutions
to problems which have previously been solved in a
different way (Blumrich)

Process of devising a system, component, or process to

meet desired needs (ABET, Inc.)
Engineering design integrates mathematics, basic
sciences, engineering sciences and complementary
studies in developing elements, systems and processes
to meet specific needs. It is a creative, iterative and
often open-ended process subject to various
constraints (CAB, Canada)

In the course of performing design work,

evidence of the following should be present:
Iterative re-evaluation re-assessment and redevelopment of work plans, specification and constraints
Ongoing communication with key stakeholders or their
representatives
Co-operative approaches (team work)

The Four Cs of Design

Creativity
Requires creation of something that has not existed before or not
existed in the designers mind before

Complexity
Requires decisions on many variables and parameters

Choice
Requires making choices between many possible solutions at all
levels, from basic concepts to smallest detail of shape

Compromise
Requires balancing multiple and sometimes conflicting
requirements
Ref.: 3

Scientific method vs Design method

Existing
knowledge
Scientific
curiosity

State of the art

Identification of
need
Conceptualization

Hypothesis
Logical analysis

Feasibility
analysis

Proof

Production

Scientific Method

Design Method

Types of design

Ref.: 2

Original design
Variant design
Adaptive design
Selection design
Redesign
Artistic design
Tinkering

Original design : conceiving and embodying an original,

innovative concept for a given task. It develops a new
component, assembly, or process that had not existed before.
Variant design seeks to modify the performance of an
existing product by varying some of its design variable values
or product parameters, such as size, or specific material, or
manufacturing processes.
Note, however, that the fundamental working principle or
concept is usually maintained.
Adaptive design is when we adapt a known solution to
accomplish a new task.
Selection design : matching the desired functional
requirements of a component with the actual performance of
standard components listed in vendors catalogs.

Redesign. Much of our working career will be devoted to the

improvement of existing products. To obtain the
improvements we usually modify parts, or subassemblies, or
combinations thereof, by changing their shapes, sizes,
configurations, materials, and manufacturing processes.
Since design is determining form, whenever we improve an
aspect of form, we are essentially redesigning
Artistic design It deals with an objects appearance
(clothing, furniture, etc.). It is not considered as engineering
design.
Tinkering. Development of products (pots, pans, cutlery,
sofas, etc.) using new material or try different fabrication
method without regard to the underlying sciences. It is not
considered as engineering design.

Formulation
original
design
Concept Design

part
design

selection
design
variant
design

Configuration
Design

Parametric Design

Detail Design

Design projects commonly fall

into one of five types:
Variation of an existing product
Improvement of an existing product
Development of a new product for a lowvolume production run
Development of a new product for mass
production
One-of-a-kind design
Ref.: 3

Design Phases

Anybody can design products!

The design engineer has specific skills:
- He can use analytical tools

Structured Design
Methodologies Get Results!
Notable design cycle time reductions:
Xerox
(design cycle)
70s
1990
1995

3 yr.
< 2 yr.
30 wk.

Caterpillar
1980
1993

50 mo.
20 mo.

Steps in the
Engineering Design Process

Design Phases
Formulation

Concept

Preliminary
Design

Configuration
Embodiment
Design
Parametric

Detail

Need
Analysis of problem
Problem statement
Conceptual design
Selected schemes
Embodiment of schemes
Detailing
Working, drawing, etc
FRENCHS MODEL

PAHL and BEITZ MODEL

Work breakdown structure

W id g e t
D e s ig n

P r o b le m F o r m u la t io n

s it e v is it
Q F D /H o Q
E n g . C h a r a c t e r is t ic s
C o n s t r a in t s
S a is fa c t io n c u r v e s
S e le c t s t r a t e g y
D e v e lo p p la n
D e s ig n r e v ie w m e e t in g

C o n c e p t D e s ig n

G e n e r a t e a lt e r n a t iv e c o n c e p t s
A n a ly z e a lt e r n a t iv e s
E v a lu a t e a lt e r n a t iv e
R e fin e
D e s ig n r e v ie w m e e t in g

C o n fig u r a t io n D e s ig n

P a r a m e t r ic D e s ig n

D e v e lo p a r c h it e c t u r e
G e n e r a t e c o n fig u r a t io n s
A n a ly z e

P a r a m e t r ic p r o b le m fo r m u la t io n
G e n e r a t e a lt e r n a t iv e s
A n a ly z e a lt e r n a t iv e s

DFA
DFM
E v a lu a t e
R e fin e
D e s in r e v ie w m e e t in g

FM EA
F a u lt t r e e s
F is h b o n e d ia g r a m s
E v a lu a t e a lt e r n a t iv e s
O p t im iz a t io n
M u lt i- a t t r ib u t e o p t .
D e s ig n r e v ie w m e e t in g

D e t a il D e s ig n

D e t a il d r a w in g s
A s s e m b ly d r a w in g s
I llu s t r a t io n s
P ro je c t R e p o r t
P ro to ty p e te s t re p o rts
O r a l p r e s e n t a t io n s
D e s ig n r e v ie w m e e t in g

Customer needs
Formulation

Abstract embodiment of
physical principles
Material geometry

Customer requirements
Importance weights
Eng. Charact.
Eng. Design Spec.

Concept Design

Configuration Design
Special-purpose parts.
Standard parts
Design variable values
Sizes, dimensions
Matl./Manufac. processes.
Performance predictions.
Overall satisfaction

Parametric Design

Detail Design

Product specifications
Production drawings
Bills of materials.
Manufact. specifications
Performance tests

Problem Formulation

Need Identification - Clarifying

objectives
When a client, sponsor or company manager first
approaches a designer with a product need, it is unlikely
that the need will be expressed very clearly
The starting point for a design is therefore very often an
ill-defined problem
Customer requirements (Maslow, 1943):

Ref.: 1, 3

Physiological needs
Safety and security needs
Social needs
Psychological needs
Self-fulfillment needs

Stage 1: Clarifying objectives

Gathering Information from customers:

Interviews with customers

Focus group discussion
Customer surveys (external and internal)
Customer complaints
Constructing a survey instrument:

Ref.: 3

Determine the survey purpose

Determine the type of data-collection method
Identify what specific information is needed
Design the questions
Arrange the order of questions
Pretest the survey
Administer the survey

Stage 1: Clarifying objectives

The Objectives Tree Method

Prepare a list of design objectives

Order the list into sets of higher-level and lower-level

objectives

Draw a diagrammatic tree of objectives, showing

hierarchical relationship and interconnections

The branches (or roots) in the tree represent relationship which

suggest means of achieving objectives
Ref.: 1

Ref.: ECE 404 Scott Umbaugh

Establishing functions

The Function Analysis Method

Express the overall function for the design in terms of the conversion
of inputs into outputs
The overall , black box function should be broad widening the system
boundary.

Break down the overall function into a set of essential sub-functions

The sub-functions comprise all the tasks that have to be performed inside
the black box.

Draw a block diagram showing the interactions between sub-functions

The black box is made transparent, so that the sub-functions and their
interconnections are clarified.

Draw the system boundary

The system boundary defines the functional limits for the product or device
to be designed.

Search for appropriate components for performing the sub-functions

and their interactions.
Many alternative components may be capable of performing the identified
functions.
Ref.: 1

Determining characteristics

Quality Function Deployment (QFD)

House of Quality
QFD is a planning and problemsolving tool for translating customer
requirements (CRs) into the
engineering characteristics (ECs)
Listen to the voice of customer

House of Quality

Customer
Requirement
Whats

House of quality

1. Identify the customers (internal and external): consumers,

manufacturing, regulators, distribution, marketing, sales
2. List the customer needs (WHAT is to be done), they can be
list as primary, secondary and tertiary
3. Determine the primary importance or priority of the
customer needs (scale of 1-5 or 1-10) (use if possible
pairwise comparison)
4. Translate customer needs into measurable engineering
requirements (HOW to do it in term of measurements).
Each customer need can correspond to multiple
engineering requirements that can be expressed in
quantifiable terms,
5. Determine relationship of engineering design requirements
to customer needs

House of quality

6. Use customer to benchmark existing products and

evaluate the perceived competitions ability to meet the
needs (1-not satisfied need, 5-fully satisfied need)
7. Rank the technical difficulty for each engineering
requirement (1-5 or 1-10)
8. Define interrelationship between technical requirements,
9. Set target values and ideal values for engineering
requirements,
10.Define the most critical engineering requirements by
analyzing the conjunction between customer needs,
benchmarking, interactions and importance

Part
Requirements

QFD 2

Part
Requirements
Target

Production
Requirements

QFD 3

Manufacturing
Requirements
Target

Manufacturing
Requirements

Design
Requirements
Target

Manufacturing
Requirements
Part
Requirements

QFD 1
Design
Requirements

Customer
Requirements

Design
Requirements

QFD 4

Production
Requirements
Target

Generating alternatives

Alternative concepts
1

Subfunctions

Transmit

Chain

Belt

Brake

Disc

Drum

Steer

Handlebar Control
Stick

3
Gearbox

Fly-bywire

Generating alternatives

Feature

Means

Support

Wheels

Track

Air cushion

Slides

Propulsion

Driven
wheels

Air thrust

Moving
cable

Linear
induction

Power

Electric

Petrol

Diesel

Bottled gas

Steam

Gears and
shaft

Belts

Chains

hydraulic

Flexible cable

Steering

Turning
wheels

Air thrust

Rails

Stopping

Brakes

Reverse
thrust

Ratchet

Lifting

Hydraulic
ram

Rack and
pinion

Screw

Chain or
rope hoist

Operator

Seated at
front

Seated at
rear

Standing

Walking

Transmission

Pedipulators

Remote
control

Evaluating Alternatives
The screening criteria should focus on functionality and
manufacturability:
Will the concept likely function?
Will the concept likely meet the customers minimum
performance requirements?
Will the concept likely survive the operating environment?
Will the concept likely satisfy other critically important
customer requirements?
Will the concept be manufacturable?
Will the concept likely satisfy the financial and/or marketing
requirements?

The evaluation method:

Weighted-rating Method
Pughs Concept Selection Method

The weighted objectives method

List the design objectives

Rank-order the list of objectives
Assign relative weightings to the objectives
Establish performance parameters or utility
scores for each of the objective
Calculate and compare the relative utility values
of the alternative designs