product design and value engineering (pdve) ch 1 introduction

Product Design & Value Engineering

Ch: 1 Introduction P R E PA R E D BY

MR. CHIRAG PATELM.E. (ADVANCED MANUFACTURING SYSTEM)

ASSISTANT PROFESSOR MECHANICAL ENGINEERING DEPARTMENT

PACIFIC SCHOOL OF ENGINEERING

CHIRAG PATEL - PACIFIC SCHOOL OF ENGINEERING 2

Product Design◦ Definition :Product's characteristics, such as its appearance, the materials it is made of its

dimensions and tolerance and performance standards

External Factor s for product design :

1.Customer Requirement2.Quality3.Reduction of manufacturing costs and controls4.The assembly and distribution process5.Environmental effect before and after manufacturing 6.Safety , hygiene , ergonomics factors, etc.


Product Design Characteristics Of Product Development :

1.A product must fully meet design requirements & products specs & standards.

2.A product must be mfg by the most environmentally friendly & economical methods

3.Quality must be built into the product at each stage.

4.Production methods must be flexible enough to respond to changes in market demands, types of products, production rates, Quantities, and on-time delivery req.

5.New developments in materials, production methods, and computer integration of both technological and managerial activities in a mfg org must constantly be evaluated with a view to their appropriate, timely, & economical implementation.

6.Mfg activities must be viewed as a large system, the parts of which are interrelated. Such systems can be modeled, in order to study the effects of factors such as changes in market demands, prod design, and materials.

7.Constantly strive for higher levels of quality and productivity. Output per employee per hour in all phases must be max. Zero-based part rejection are also an integral aspect of mfg


Design And Development Of Product

1. Concurrent Engineering(ce)

2. Quality Function Deployment (QFD)

3. Design For (DFX)

4. Failure Mode And Effects Analysis (FMEA)

5. Computation Techniques And Tools 1. Engineering / Product Based Data Management (E/P BDM)2. Knowledge Based Engineering (KBE)3. Finite Element Analysis (FEA)4. Rapid Prototyping (RP)


Design And Development Of Product

1 Concurrent Engineering(CE)

CE is a systematic approach integrating the design and mfg of products, with a view toward optimizing all elements involved in the life cycle of the product.Life cycle means that all aspects of a product, such as design, development, production, distribution, use, disposal, and recycling, are considered simultaneously.

Basic goals of CE:1.reduce changes in product’s design & engineering.2.reduce time and costs involved in taking the product form its design concept to its production

and its introduction into the marketplace.


1 Concurrent Engineering(CE) A well-designed product is:

1. functional (design)2. well-manufactured (production)3. well-packaged (distribution)4. durable (functions effectively for its intended life) 5. maintainable (use)6. resource-efficient (can be disassembled so that components can be recycled-disposal)

For CE to succeed, it must:1. have the full support of upper management;2. have multifunctional and interactive teamwork, including support groups3. utilize all available technologies.


2.Quality Function Deployment (QFD)

Quality Function Deployment (QFD):

QFD is defined as a method for developing a design quality aiming at satisfying the consumer and then translating the consumer's demand into design targets and major quality assurance points to be used throughout the production phase.

QFD performed onMarketingResearchDevelopment process planningQuality assurance andManufacturing


2.Quality Function Deployment (QFD)

QFD Approach permits a) Listening the voice of customerb) Improving horizontal and vertical communicationc) Setting priorities for product developmentd) Improving product reliabilitye) Defining technical goalsf) Sequencing the individual goalsg) Defining area of cost reduction


Design for X(DfX) DFX (Design for X) is a methodology for the definition and implementation of range of insights and demands which allow the development of an optimal and mature product in the aspects of reliability, manufacturing, assembly, service, transportation, usability, ergonomics, environment and more

These words are made up of two parts1. Life cycle business process (X)2. Performance measures( bility )

X = x + bility

Example :3. Design for total Quality 4. Design for whole life cost5. Design for assembly cost


4 Failure Mode And Effects Analysis (FMEA) Definition: Failure modes and effects analysis (FMEA) is a step-by-step approach for identifying all possible failures in a design, a manufacturing or assembly process, or a product

or service.

There are two type of FMEA1. Process 2. Design

FMEA used for 1. New development of product 2. Security and problem parts3. Product of process modification4. New operation or other condition of existing products


5 Computation Techniques And Tools 5.1 Computer Aided (CAX) Systems

Definition: Computer-aided technologies (CAx) is a broad term that means the use of computer technology to aid in the design, analysis, and manufacture of products.

CAX means computer aided (CA) support of industrial production ,where “X” stands for different activities whiting the product development and manufacturing process.

70 to 80 % product cost are determined in developing phase ,the most important system in this group of tool are CAD(Computer Aided Design).

Characteristic feature of CAD : a. X-D geometric modelling (2-D,3-D)b. Employment of process chains and product models c. Parametric and associative design d. Open architecture of hardware and software systeme. User driver software development f. Distributed product development and life cycle engineering


5 Computation Techniques And Tools 5.1 CAPP(computer Aided Product Planning) :

CAPP(Computer aided product planning ) is the use of computer technology to aid in the process planning of a part or product, in manufacturing.

CAPP is the link between CAD and CAM in that it provides for the planning of the process to be used in producing a designed part.

There are two kind of CAPP system :

1. Variant : A process plan for a new part is created by recalling, identifying and retrieving an existing plan for a similar part and making necessary modifications for the new part.

2. Regenerative : This system create the production process plan with no reference to any existing plan


5 Computation Techniques And Tools 5.2 Engineering /Product Based Data Management (E/P BDM) :

E/P BDM system managed all the information ,data and process –related to product electronically.

It allows two possibilities 1. Creating reports, data transports, images and translation service ,files .NC programmes, documents etc.2. Provide interfaces to other system (CAD,CAM, etc,) or integration with different database.

5.3 Knowledge Based Engineering (KBE) :

KBE is a system can be programmed to reproduce the decision that an engineer has to take decision when producing design with use of database ,a knowledge base and a set of rule called algorithm ,which are able to take decision using the knowledge containing in the knowledge base.

KBE is also known as Expert system


5 Computation Techniques And Tools 5.4 Finite Element Analysis :

Finite element analysis (FEA) is a computerized method for predicting how a product reacts to real-world forces, vibration, heat, fluid flow, and other physical effects.

Finite element analysis shows whether a product will break, wear out, or work the way it was designed

In this system the model obtained is small meshwork of element joined together b common nodes,

These element can be Flat (for surface representation ),volumetric (for solid representation) ,triangular(three nodes ),tetragonal (four nodes ).etc.

The application of FEM permits side stepping the traditional design cycle based on

prototype –testing – modification -prototype

There are no need to physically have the prototype on hand to perform the analyse like stess, displacement ,deformation model visitation etc.


5 Computation Techniques And Tools 5.5 Rapid prototyping (RP) :

Rapid prototyping is a group of techniques used to quickly fabricate a scale model of a physical part or assembly using three-dimensional computer aided design (CAD) data. Construction of the part or assembly is usually done using 3D printing or "additive layer manufacturing" technology

Techniques exist for prototype building are :MIME (Material Increase Manufacturing) Technique SLY ( selective Laser Sintering ) SGC (solid group Curing )FDM (Focused Deposition Modelling)LOM ( Laminated Object Manufacturing )


Characteristics Of Firms And Service Provider

1. Systems Application To Product Design (Objective)a) To replicate the paper system but no provide secure storage and accessb) To manage or control data ,document or drawing recordsc) To manage the process and proceduresd) To maintained a full configuration history of the product

Benefits :e) Do it faster (time saved by system support for a specific task)f) Do it better (lower cost or higher quality through considering more option )g) Not do it all ( the task has been eliminated, automated or combined with another activity, there by saving time )

2. Types of firm/ organization concern a) Qualityb) Prise c) Functionalityd) Development time


Duration And Implementation Cost Of Product Development

Cost will become a more important factor in the acquisition of a product in two situations

1. The technology of a product stabilizes and the competitive playing field level, competition is increasingly based on cost.

2. A customer’s internal economics of financial resources limitation may shift the acquisition decision toward affordability as a more dominant factor


Challenging Of Product Development

New product development has a long history in marketing includes:

Research on customer preferences

Product positioning and segmentation

Product forecasting and test marketing


End of chapter 1

product design and value engineering (pdve) ch 1 introduction

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