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Chapter 27
The Engineering Design Process
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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
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Part I
The Changing Face of Engineering Design
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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
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Impacts on Design• State and federal regulations
• Environment
• Consumer perceptions
• Demographics
• Socio-economic needs
• Cultural trends
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Changing Business Model
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Part II
Engineering Design Models
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Concurrent Engineering• Integrated
• Emphasizes advantages of simultaneous product design– Focus on all aspects of design at once
• Special emphasis on customer and their needs
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Life Cycle Engineering• Entire life of product evaluated at beginning
of process• Address up front
– Performance– Costs– Reliability– Maintainability– Disposal– Market trends
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Integrated Product Development• Designed and developed to satisfy all
conditions in product’s life
• Contingency planning in design
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Knowledge-based Engineering• Use of computer models
• Simulation of processes
• Data used to develop comprehensive plan– CADD– Manufacturing– Tooling– Structural
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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
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Part III
Creativity and Innovation
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Creativity• Ability to produce through imaginative skill
• See patterns and relationships through diverse information
• Bring into existence something new
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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
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Innovation• Process of transforming a creative idea into
a tangible product
• Improving the quality of a specific thing
• Allowing for more and better choices
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Part IV
Engineering Design Process
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Phases• Pre-phase 1
– Needs assessment– Business Case
• Phase 1– Concept
• Phase 2– Development
• Phase 3– Execution
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Phases
Needs Assessment
Conceptualization
Development
Execution
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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
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Business Case• Articulates need
• States plan – Concept to implementation
• Allows for termination– Costs rise– Other specific criteria not met
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Concept• Industrial design
– Work within engineering, manufacturing, and cost constraints
– Must be creative
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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
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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
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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
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Development• Creation and testing of prototype
• Checking intellectual properties– Patents– Copyrights– Invention disclosure
• Product bill of materials– Establishes final product cost– Organizes manufacturing process
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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
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Development• Finite Element Analysis (FEA)
– Mathematical solutions• Structural and thermal problems
– Computer model generated• Stresses placed on model and analyzed
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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
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Execution• Receipt of UPC
– Universal Product Code
• Completion of technical literature
• Target inventory levels are made
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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