Chapter 27

The Engineering Design Process

Learning Objectives• Describe the various factors that are changing the

design process• Discuss the steps in design analysis• Explain the importance of creativity and

innovation• Explain concurrent engineering• Define design models and processes

Part I

The Changing Face of Engineering Design

Designer vs. Knowledge Worker• Designer

– Design fundamentals– Materials science– Manufacturing

processes

• Knowledge Worker– Design fundamentals– Materials science– Manufacturing processes– Market trends– Safety– Data management– Teaming– Packaging,distribution,

and storage

Impacts on Design• State and federal regulations

• Environment

• Consumer perceptions

• Demographics

• Socio-economic needs

• Cultural trends

Changing Business Model

Part II

Engineering Design Models

Concurrent Engineering• Integrated

• Emphasizes advantages of simultaneous product design– Focus on all aspects of design at once

• Special emphasis on customer and their needs

Life Cycle Engineering• Entire life of product evaluated at beginning

of process• Address up front

– Performance– Costs– Reliability– Maintainability– Disposal– Market trends

Integrated Product Development• Designed and developed to satisfy all

conditions in product’s life

• Contingency planning in design

Knowledge-based Engineering• Use of computer models

• Simulation of processes

• Data used to develop comprehensive plan– CADD– Manufacturing– Tooling– Structural

Total Quality Management• Integration of all organizational activities

• Goal is to “serve customers”– Establishing process standards– Maximizing production efficiency– Implementing quality improvement processes– Employing integrated teams

• Effectively design customer-driven products

Part III

Creativity and Innovation

Creativity• Ability to produce through imaginative skill

• See patterns and relationships through diverse information

• Bring into existence something new

Being Creative• See relationships and patterns

• Believe you are creative

• Look at problem from a different perspective

• Dream and brainstorm

• Work in a flexible, open, autonomous environment

Innovation• Process of transforming a creative idea into

a tangible product

• Improving the quality of a specific thing

• Allowing for more and better choices

Part IV

Engineering Design Process

Phases• Pre-phase 1

– Needs assessment– Business Case

• Phase 1– Concept

• Phase 2– Development

• Phase 3– Execution

Phases

Needs Assessment

Conceptualization

Development

Execution

Needs Assessment• Extensive research

– Advanced research• Are areas of technology currently not being utilized?• Work with specific industry partners to exploit

technology• Create barriers to market entry

– Existing product research– Focus groups

Business Case• Articulates need

• States plan – Concept to implementation

• Allows for termination– Costs rise– Other specific criteria not met

Concept• Industrial design

– Work within engineering, manufacturing, and cost constraints

– Must be creative

Concept• Initial direction

– Problem communicated to team– Alternative sketches produced

• Solution chosen from alternatives or generated as a hybrid from several alternatives

– Engineering communicates production path

Concept• Quality Function Deployment

– Introduces impartiality into design– Helps highlight customer needs– Uses analytical approach to ranking customer

wishes• Surveys• Interviews• Focus groups• Analysis of customer feedback

Concept• Design Specification

– Dimensions– Weight– Materials– General shape– Power requirements– Voltage requirements– Amperage

specifications– Product life and

durability

• Design Specification– Required agency

approvals– Performance

requirements– Included and optional

accessories– General and special

features– Environmental factors

Development• Creation and testing of prototype

• Checking intellectual properties– Patents– Copyrights– Invention disclosure

• Product bill of materials– Establishes final product cost– Organizes manufacturing process

Development• Failure Mode Element Analysis (FMEA)

– Determine possible failures• Potential effects• Probability of occurrence• Potential causes and triggers• Verification of testing and observation

– Eliminate or minimize failures

Development• Finite Element Analysis (FEA)

– Mathematical solutions• Structural and thermal problems

– Computer model generated• Stresses placed on model and analyzed

Execution• Pre-production build of limited run of

product– Validation of manufacturing processes and

conformance to expected performance

• Securing of regulatory approvals– Flame retardant ability– Durability– Ergonomics

Execution• Receipt of UPC

– Universal Product Code

• Completion of technical literature

• Target inventory levels are made

Summary• The traditional engineering design model

does not take into account many factors in the 21st century market

• Cross-functional teams help the design process through greater cooperation and communication

• The multi-phase model of design begins at a needs assessment and cycles through implementation, only to be revisited