1 Product Design and Development Final exam review Fall 2011.

1

Product Design and DevelopmentProduct Design and Development

Final exam review Fall 2011Final exam review Fall 2011

3

MULTIPLE CHOICE QUESTIONS

AND SHORT ANSWERS

Multiple choice questions cover all material including detailed design. Make sure you

know good CAD modeling practices, views, dimensioning rules (over dimensioning,

under dimensioning), weld types, differences between part and assembly drawings etc.

Review guest lectures.

4Clearance fit Transition fit Interference fit

ec001.SLDASM

Sample question:

Identify fits A, B, C

hole shaft hole shaft hole shaft

5

Line fit

Transition fit

Interference fit

Sample question:

Identify fits A, B, C

6

Identify some commonly used features:

Have many sketches they need?

Which one may or may not be the first feature in Feature Manager Design Tree?

7

USE SI UNITS ON EXAM

DO NOT CONFUSE UNITS OF MASS AND FORCE

PRICE/COST IS NOT A DESIGN SPECIFICATION

8

PRODUCT DESIGN TECHNIQUES - KNOW WHAT ARE THEY

AND WHEN THEY ARE USED

CUSTOMER SURVEY

QUALITY FUNCTION DEPLOYMENT

GANTT’S CHARTS

CRITICAL PATH METHOD

FUNCTIONAL DECOMPOSITION

BRAINSTORMINGMORPHOLOGICAL ANALYSIS

FEASIBILITY JUDGMENT

TECHNOLOGY READINESS ASSESSMENT

GO/NO-GO SCREENING

DECISION MATRIX METHOD

CAD

MATERIAL SELECTION

ENGINEERING MODELS

SIMULATION

DFR

DFM

DFA

RISK ENGINEERING

PRELIMINARY HAZARD ANALYSIS

FAULT TREE ANALYSIS

FAILURE MODES AND EFFECT ANALYSIS

PRODUCT LIFE CYCLE

DESIGN FOR HUMAN FACTORS

DFE

DESING FOR DISASSEMBLY

DESIGN FOR RECYCLING

PATENT SEARCH

FEA

9

CUSTOMER SURVEY

QUALITY FUNCTION DEPLOYMENT

GANTT’S CHARTS

CRITICAL PATH METHOD

Specification Development

PRODUCT DESIGN TECHNIQUES - SPECIFICATION DESIGN

Planning Phase

10

FEASIBILITY JUDGMENT

TECHNOLOGY READINESS ASSESSMENT

GO/NO-GO SCREENING

DECISION MATRIX METHOD

Concept Selection

PRODUCT DESIGN TECHNIQUES - CONCEPTUAL DESIGN

Concept generation

FUNCTIONAL DECOMPOSITION

BRAINSTORMING

MORPHOLOGICAL ANALYSIS

11

CAD

Best Modeling Practices

Part Modeling

Assembly Modeling

Drawings

MATERIAL SELECTION

ENGINEERING MODELS (form, shape, function)

SIMULATION

PRODUCT DESIGN TECHNIQUES - DETAILED DESIGN

12

DFM

DFA

DFR

Preliminary Hazard Analysis

Fault Tree Analysis

Failure Modes and Effect Analysis

Risk Management (Risk engineering)

DESIGN FOR HUMAN FACTORS

DFE

Design for Disassembly

Design for recycling

Product life cycle

PRODUCT DESIGN TECHNIQUES - DETAILED DESIGN

13

KNOW WHAT QFD IS AND WHAT IT IS USED FOR

Quality Function Deployment is a Quality Function Deployment is a technique developed in Japan during the technique developed in Japan during the mid-1970's for better understanding the mid-1970's for better understanding the design problem, in particular of customer design problem, in particular of customer needs.needs.

Deployment: The distribution of forces in Deployment: The distribution of forces in preparation for battle or work.preparation for battle or work.

14

General Comments:

- No matter how well the design team thinks it understands a problem, it should employ the QFD technique for all mechanical design projects, because in the process the team will learn what it doesn't know about the problem.

– The customer's requirements must be translated into measurable design targets before a large amount of time and resources are invested in the design effort.

– It is important to first consider what needs to be designed and, only after that is fully understood, to worry about how the design will look and work.

Quality Function Deployment (QFD)

15

1. Identify the customers: Who are they? 2. Determine the customers' requirements: What do the customers want? 3. Determine relative importance of the requirements: Who versus what 4. Generate engineering specifications: How will the customers' requirements be met? 5. Relate customers , requirements to engineering specifications: Hows measure whats? 6. Identify relationships between engineering requirements: How are the "hows" dependent

on each other?

7. Identify and evaluate the competition: How satisfied is the customer now? 8. Set engineering targets: How much is good enough?

The eight basic steps in the Quality Function Deployment technique are:


16

Easy to inflate

Small size defl.

Easy to maneuver

Comfortable paddle

Bounces off rocks

Self bailing

Stable

Fast

Lightweight

Affordable

Cargo space

Wei

gh

t

Len

gth

Wid

th

Mu

lti

cham

ber

Ch

amb

er v

ol

Str

eng

th m

at.

Can

adia

n C

oas

t

Customer importance

3

4

3

3

31

2

2

24

1

4

9 4

9

9

19

9

9

9

9

4

units kg m %1 m3 N/m

85 27 27 43 1 18 18Absolute importance

relative importance

219

% 39 12 12 20 0 8 8

9

4

19

5

2

2

2

42

3

1

5

32

3

2

1

5

32

5

1

3

32

4

2

1

2

33

5

2

5

32

A B C

COMPETITION


17

Functional Decomposition Technique

Functional decomposition

Morphological matrix shows alternative means of achieving given functionality

UNDERSTAND WHAT IS

FUNCTIONAL

DECOMPOSITION AND

MORPHOLOGICAL

ANALYSIS AND HOW

THEY WORK TOGETHER

TO GENERATE

CONCEPTS

18

Morphological analysis is used to identify the necessary product

functionality and explore alternative means and combinations of

achieving that functionality. For each element of product function, there

may be a number of possible solutions. The morphological chart is

prepared and used to develop alternative combinations of means to

perform functions and each feasible combination represents a potential

solution.

Morphological * Analysis

* Morphology: The science of the form and structure

19

CONCEPT EVALUATION TECHNIQUES

Feasibility Judgment

Technology Readiness Assessment

Go/no-go Screening

Decision Matrix Method

NumerousConcepts

Gut Feeling

State of Art

Customer Requirements

Absolute

Relative

Type of Comparison Technique Basis of Comparison

Best Concept(s)

KNOW CONCEPT SELECTION

TECHNIQUES

20

PROJECT PLANNING TECHNIQUES

CPM

GANTT CHARTS

21

PRELIMINARY HAZARD ANALYSIS

FAULT TREE ANALYSIS


DESIGN FOR RELIABILITY TECHNIQUES (DFR)

22

The output fault occurrence probabilities for AND gate is:

1AND

mF Fii

FAULT TREE ANALYSIS

F1 F2

FAND

Example:

F1 = 0.1

F2 = 0.05

FAND = 0.1 * 0.05 = 0.005INPUT EVENTS

OUTPUT EVENT

where

FAND is the probability of occurrence of the AND gate output fault event

m is the number of independent input fault events

Fi is the probability of occurrence of input fault event i, for i=1, 2, …m

AND

Be able to calculate probabilities in Fault Tree

23

m

iiFFO

1R

The output fault occurrence probabilities for OR gate:

where

FOR is the probability of occurrence of the OR gate output fault event

m is the number of independent input fault events

Fi is the probability of occurrence of input fault event i, for i=1, 2, …m

Note: For small (i.e. less than 10 percent) occurrence probabilities of

input fault events of the OR gate, the above equation reduces to:

1 (1 )1

OR

mF Fii

FAULT TREE ANALYSIS

F1 F2

FOR

Example:

F1 = 0.1

F2 = 0.05

FOR = 1 – (1 - 0.1)*(1- 0.05) = 0.145INPUT EVENTS

OUTPUT EVENT

OR

Be able to calculate probabilities in Fault Tree

24

RANKING PROCEDURE FOR FMEA

Risk Priority Number

RPN = R occurrence x R severity x R detection

RPN = 1 failure is highly unlikely and

unimportant

RPN = 30 it is OK

RPN = 100 failure will occur

RPN = 1000 hazardous and harmful failure

will occur

Be able to calculate RPN and discuss/justify all numbers

25

The improvement potential I.P.

A T

A

N - NI.P. = × 100

N

Where:

NA is the actual number of components

NT is the theoretical minimum number of components

Rate the product on the worksheet:

If I.P. 10%, then current design is

outstanding

If 10% < I.P. 20%, then current design is

very good

If 20% < I.P. 40%, then current design is

good

If 40% < I.P. 60%, then current design is fair

If I.P. > 60%, then current design is poor

Be able to calculate I.P.

27

EXAM PROBLEM

Imagine a photo of some common household object is given.

You may be asked to:

Perform DFA (13 rules) and DFM on it.

Identify failure modes and perform FMEA

Next you’ll propose a redesign to make it suitable for people with arthritis* by identifying customer needs and linking them to design specifications (QFD)

You’ll then develop two concepts complete with sketches, evaluate them and perform DFA on the winning concept and DFM on selected components..

The above is not “all inclusive”. You don’t have to memorize the 13 DFA rule but you must know how to use them in the table format to calculate scores.

* Definition of Arthritis

Arthritis is a disease that causes pain and loss of movement of the joints. The word arthritis literally means joint inflammation, and refers to more than 100 different diseases.

Description of Arthritis

Arthritis affects the movements you rely on for everyday activities. Arthritis is usually chronic. This means that it can last on and off for a lifetime.

28

EXAMPLE:

A FLOUR SIFTER NEEDS TO BE REDESIGNED TO MAKE IT SUITABLE FOR

USE BY PEOPLE WITH ARTHRITIS IN HANDS

29

DFA?

EXISTING FLOUR SIFTER

30


EXISTING FLOUR SIFTER

31

CUSTOMER REQUIREMENTS FOR PEOPLE WITH ARTHRITIS

1

2

3

4

5

6

7

8

DESIGN OF A NEW FLOUR SIFTER

32

HOW TO TRANSLATE CUSTOMER REQUIREMENTS INTO ENGINEERING TARGETS?


33

?CREATE TWO CONCEPTS: CONCEPT 1, CONCEPT 2

WHAT TECHNIQUES CAN WE USE FOR CONCEPT CREATION?

BE PREPARED TO SKETCH YOUR CONCEPTS


34

WHAT TECHNIQUES CAN WE USE FOR CONCEPT EVALUATION?

?Decision-Matrix Form

Concepts for Comparison

Scores

Totals

Wei

gh

tsCustomer Requirements

The relative importance of requirements found using pair-wise comparison technique

Concepts to be compared

1 2

3

4

5


35Evaluation Based on Decision Matrix

The winnerRelative importance of requirements


36

We have selected our concept, is it better or worse as compared to the existing sifter?

DFM?

DFA?


37

Performance requirements of the material in our proposed flour sifter?

Material properties associated with the above performance requirements?

Any design recommendations inspired by DFE?

?


38

PAST EXAMS

39

PAST EXAMS

40

GOOD LUCK ON YOUR EXAMS!GOOD LUCK ON YOUR EXAMS!

1 Product Design and Development Final exam review Fall 2011.

Documents

Transcript of 1 Product Design and Development Final exam review Fall 2011.