chapter 3.5 3.9-quality and innovation in product and process design

BNN20303Quality Assurance and Quality Control in Biotechnology

By: Dr. Nadirul Hasraf Mat Nayan

CHAPTER 3QUALITY AND

INNOVATION IN PRODUCT AND PROCESS DESIGN

Chapter OverviewCHAPTER 3: QUALITY AND INNOVATION IN PRODUCT AND

PROCESS DESIGNCHAPTER 3.1: Introduction to Quality and Innovation in Product and Process Design

CHAPTER 3.2: Quality by Design (QBD)

CHAPTER 3.3: The Design Process

CHAPTER 3.4: Quality Function Deployment (QFD)

CHAPTER 3.5: Technology in Design

Chapter OverviewCHAPTER 3: QUALITY AND INNOVATION IN PRODUCT AND

PROCESS DESIGN

CHAPTER 3.6: Prototyping Methodologies

CHAPTER 3.7: Designing for Reliability

CHAPTER 3.8: Environmental Considerations in Design

CHAPTER 3.9: Summary

Chapter 3.5

Technology in Design

3.5: Technology in Design Introduction:Nowadays, a square, a pencil, and a drafting table, are no longer the tools of the

designer.

Today, a designer is much more likely to use a computer-aided design (CAD) system.

These system are used in designing anything from an ultralight airplane, to a hamburger, to a home, or to a new intersection that can handle higher volume of traffic.

Computer aided tools greatly improved the ability of the designers to generate new a varied designs.

3.5: Technology in Design Introduction:

In addition, they simplify the design process.

CAD systems can also help to develop more reliable and robust designs.

For example, auto designers once had to place mock-ups of automobiles into wind tunnels to test the aerodynamics of a design.However, now the wind resistance coefficients for automobiles can be simulated on computers, cutting costs and design times and allowing for quick adjustments to the design.

3.5: Technology in Design Advance in CAD Systems:An important advance in CAD systems has been the advent of multiuser CAD

systems.

Using a common database in a network, multiple designers in locations world-wide can work on a design simultaneously around the clock.

For example, consider a multinational corporation developing a new products. When the U.S. designers sleep, Asian and European designers work. When the U.S. designers return to work, they can see the progress that has been made overnight.

When developing the Boeing 777, Boeing used hundreds of designers on the project simultaneously. These designers used their CAD systems to ensure there were no inconsistencies in design that would render the airplane unusable.

3.5: Technology in Design CAD Systems Application:

CAD systems are used in:

i. Geometric modellingii. Engineering analysisiii.Design review and automationiv. Automated drafting


i. Geometric Modelling Geometric modelling is used to develop a computer-compatible

mathematical of a part.

The image developed is typically a wire-frame drawing of a component.

This part may appear in two dimensions as a two-dimensional drawing of a three-dimensional object, or in full three dimensional view with complex geometry.


ii. Engineering Analysis Engineering analysis may involve many different engineering tests

such as heat transfer calculations, stress calculations, or differential equations to determine the dynamic behaviours of the system being designed.

Analysis-of-mass-properties features in CAD systems automatically identify properties of a designed object such as weight, area, volume, center of gravity, and moment of inertia.

CAD systems allow for the automatic calculation of these properties.


iii. Design Review and Automation Designs are checked for accuracy during design review.

Using CAD, the designer can zoom in on any part od design detail for close inspection of a part.

Layering also is performed during design review by overlaying the geometric images of the final shape of a part over an image of a rough casting.


iii. Design Review and Automation This validates the design by ensuring that enough material is available

on the casting to accomplish the final machined dimensions of the part.

Examining a design to see if different components in a product occupy the same space is called interference checking.

Interference checking was of major importance in the design of the Boeing 777. Hundreds of pipes and thousands of wires occupy the walls of the aircraft. Interference checking in design review ensured that design were feasible. This was especially important for Boeing because so many engineers were participating in the design.


iv. Automated drafting Automated drafting results in the creation of a final drawing of the

designed product and its components.

Some of the features of an engineered drawing include automated dimensioning, generation of cross-hatched areas, scaling of the drawing, development of sectional views, and enlarged views of particular part areas.

3.5: Technology in Design CAD Systems Component:

i. Group Technology Group technology component of the CAD system

allows for the cataloging and standardization of parts and components for complex products.

Standard parts can result in fewer suppliers, simpler inventory, and less variability in processes.

3.5: Technology in Design CAD Systems Component:ii. Computer-aided Inspection (CAI) and Computer-aided

Testing (CAT) CAI and CAT allow for 100% inspection of products at a

relatively low cost.

Inspection is performed by infrared and noncontact sensors that allow for parts to be inspected without handling, thereby reducing the chance of damage to products.

Chapter 3.6

Prototyping Methodologies

3.6: Prototyping Methodologies

Introduction:

With the increase of CAD systems, the approaches to prototyping products have expanded.

Prototyping is a iterative approach to design in which series of product mock-ups is developed until the customer and the designer agree on the final design.

In some cases, the customer might not be an external user but upper management that approves the final designs of products.


Types of Prototypes:

To get better idea of how prototypes can be used, we will defines types of prototypes:

i. Basic Prototypeii. Paper Prototypeiii.Working Prototype



i. Basic Prototype

The basic prototype is a nonworking mock-up of the product that can be reviewed by customers prior to acceptance.

Sometimes simple prototypes are developed prior to trade shows.

For auto companies, these are called concept cars that might not hit the market for several years, if ever.



ii. Paper PrototypePaper prototypes consist of a series of drawings developed by the designer on

CAD systems and reviewed by decision makers prior to acceptance.

Again, this can be an iterative process.

In Windows- and Apple-based computer applications, graphical-user interface (GUI) prototypes are developed using sticky note pads and flip-chart paper to allow user to view mock-ups of the program’s proposed computer screens.



iii. Working Prototype

These are fully working models of the final product.

However, depending on the product, working prototypes can be cost prohibitive because the complete design cycle must be completed to create them.


Prototypes Design Cycle:

i. Organizing the Design Teamii. The Product Life Cycleiii. Product Families and the Product Life Cycleiv. Complementary Productsv. Designing Products That Work

3.6: Prototyping Methodologies Prototypes Design Cycle:

i. Organizing the Design Team

If the design process steps discussed previously are performed sequentially, the design process will be vey time-consuming.

Therefore, the steps are performed simultaneously as often as possible.

This approach is called concurrent engineering and has been very helpful in speeding up the design life cycle.

Products such as Caterpillar tractors and all new automobiles have been designed using this strategy.


i. Organizing the Design Team

Teams are a primary component of concurrent engineering and include program management teams, technical teams, and design-build teams.

The benefits of concurrent engineering primarily include communication among group members and speed.

By working on a products and processes simultaneously, the group make fewer mistakes, and the time to get the concept to market is reduced drastically.

The team concept joins people from various discipline, which enhances communication and the cross-fertilization of ideas.


ii. The Product Life Cycle

Once new products are developed, work may already be underway to introduce the next generation of products.

The product life-cycle concepts demonstrates the need for developing new products by showing products design, redesign, and complementary product development on a continuum.


iii. Product Families and the Product Life CycleTwo imperatives have come to the forefront in the study

of product life cycles.

The first is that product life cycles are becoming shorter. This means that obsolescence is a greater problem for designers and the speed at which new product concepts are delivered to market is becoming much more important for companies around the world.


iii. Product Families and the Product Life CycleThe second imperative is that as product life cycles shorten, product variety

and change become much more important to the successful competitor because complementary products are needed to consume productive capacity.

Complementary products are needed for two reasons:

i. First, as discussed, product obsolescence requires that products be updated.

ii. Second, some products have seasonal demand necessitating counterseasonal products.


iii. Product Families and the Product Life Cycle Variety

Change

Variety refers to the differences in products that are produced and marketed by a single firm at any given time.

Change is the magnitude of the differences in a product when measured at two different times.

Change can occur as a result of evolutionary small changes to a product or drastic big changes to a product.


iv. Complementary ProductsThere isn’t a lot that a company can do to control the rate a which the life

cycle occurs.

However, company can plan to introduce new and complementary products.

Complementary products are new products using similar technologies that can coexist in a family of products.

These products extend the life of the product line by offering new features or improvements to prior versions


iv. Complementary ProductsAt times, these improvements are cosmetics, and at times, they are

substantive.

One example of a complementary product is a product that has a counterseasonal demand when compared with a base products such as motorcycles and snowmobiles.

A company produces ATVs for summer use and snowmobiles for winter use.

This allows for level production rates throughout the year.


v. Designing Products That Work There are many things to consider when designing products, and one of the biggest

considerations is design for manufacture (DFM).

Loosely speaking, design for manufacture means to design products so that they are cost-effective and simple to build.

However, there are many other considerations in a design.

One consideration is how we design the product so that it is easy to maintain.

After all, maintenance, if required can be very expensive.


v. Designing Products That Work

Another aspect is designing for reliability.

It makes little sense to design a product that is capable and stable, but not reliable.

Another issue relating to design is speed.

Speed refers to the time it takes for a concept to reach the market.

If it takes a long time for products to reach the market, competitiveness may be hampered.


v. Designing Products That Work

Product designs must be simple.

Designing for simplicity means standardizing parts, modularizing, and using a few parts as possible in a design.

Environmental issues also have become key considerations for companies designing products.

With changes in regulations around the world, products must be designed for reuse, disassembly, and remanufacture.

GROUP PRESENTATION MARKING SCHEME

•Presentation – 60 %Did the students cover all the required reading for the assignment?Is the presentation clearly an integrated group effort as opposed to

individual contributions cobbled together?Is there evidence that the group have discussed their work prior to

the presentation and are aware of the contribution of each member?Have they independently found relevant material using their own

research skills?Have they come to a well-argued conclusion?How well have they co-ordinated their activity and planned their

presentation?


•Group Dynamic– 30 %Is the presentation lively and interesting?Have the group shown initiative and creativity in the design

of the presentation?How well do the presenters present themselves? Is there

good voice projection, eye contact, confident delivery and interaction between the presenters? What use is made of cue cards/ bullet points as opposed to reading from a script?


•Communication– 10 %How well prepared are the group to answer or pose

questions that are relevant to the subject?

Has the group answered the question/s?

chapter 3.5 3.9-quality and innovation in product and process design

Documents

process design chapter

design process chapter

design qbd chapter

design introduction

design advance

design review

design times

design cad systems application