Dr. Mohammed Al-dujaili

Department of Non-Metallic Materials Engineering

Faculty of Materials Engineering

University of Babylon

2016-2017

Lecture 3

Stage: Third

Subject: Industrial Engineering

Chapter 3

Detailed Steps for Product Design, Translate Specification Product, Raw Material Tests

Overview

Detailed design is such a fundamental necessity to manufacturers that it exists at the intersection of many product development processes, and given this broad influence. As well as, the impact of prevailing industry dynamics such as distributed product development, shortening product development lifecycles and increased product complexity, companies are feeling immense pressure to improve their detailed design process.

Definition of Detailed Design

As a core engineering process, detailed design transforms concept alternatives, preliminary physical architectures, design specifications, and technical requirements into final, cross-disciplinary design definitions. These designs are further refined and all accompanying documentation required for manufacturing is completed in order for timely delivery to the customer of a fully defined, complete product.

Or

Developing a completely defined product design that is fully documented for manufacturing in managing global design, the top priority action to standardize processes. Global design extends the challenges of control, communication and collaboration. Best-in-class companies were four times more likely to employ centralized product data and automated processes. the diagram explains process of fully defining product design that meets requirements and is sufficiently documented for manufacturing.

Figure: Detailed Design

Understanding the Need for Detailed Design

Detailed design provides the link for the integrating all cross-disciplinary conceptual and preliminary data into a complete, finished digital product definition. Accordingly, today’s detailed design process is characterized by highly sophisticated designs and an ever-increasing demand for the data sharing. Since many companies operate in a distributed environment, among partners, design teams, across time-zones, language barriers, fast, and secure information access is essential. It’s an absolute necessity to ensure that everyone is working on the correct version of the data. While, tracking team decisions and having real-time visibility into the team’s progress.

Along the way, engineers must continually manage change and design complexity. They need to rapidly delivering high quality designs that work reliably and offer users value. The aim, to improve collaboration between all different design disciplines (electrical, mechanical, software). Changes to requirements are frequent, and incorporating those changes into the design process in a managed and controlled way is vital.

Benefits of an Optimized Process for Detailed Design

An optimized, formalized, and flexible detailed design process enables companies to rapidly high quality designs that offer users real value. Typical benefits of the improving the detailed design process may include:

· Improve Design Productivity

• Centrally control and manage all design data (mechanical, electrical, software, documents)

• Enable concurrent design of interrelated components

• Easily and effectively drive design to meet key requirements

•Further automate and streamline the generation of deliverables

· Increase Design Process Efficiency

• Enable a formalized, automated, and repeatable design processes

• Ensure everyone is working on the correct version of the product data

• Enable “what if” design investigations, either with or without formal data management

• Improve project execution and visibility into team progress optimize design reuse

• Reduce design cost by supporting part reuse and eliminating component duplication

• Improve ability to quickly and easily find appropriately classified designs

. Improve Design Collaboration

• Manage global product development which is involving external suppliers and users

• Provide for a secure distributed team and user design collaboration

• Safely share cross-discipline product data across a globally dispersed enterprise product development team

• Encourage early and frequent cross-discipline communication; visualize heterogeneous design data.

Figure: Benefits of an Optimized Process for Detailed Design

Detailed steps for the product design

Product design can be broken into 7 steps, and as follows;

1. Problem Assessment

It is a good idea to write down what the problem is the first. Don't write down the solution to the problem at this point, even if the company know how to do so. The company simply need to state what the problem is and nothing more.

2. Design Specification

This is the step in which a solution to the previously defined problem begins to form. At this point a list of requirements of the everything the company can think of should be written down. The company is not coming up with a solution just yet only setting the requirements necessary to create the product.

3. Idea Generation

Now the company is getting somewhere, the problem was defined and requirements have been set. At this point the company should brainstorm and sketch out company ideas. Many design companies have no problem meeting with the company to discuss and sketch a few ideas before company will be under any obligation to sign a contract or pay anything.

4. Concept Design

Once at least one good idea for the new product has been sketched the company will want to has the design worked out in a little more detail. The designer will come up with a basic 3d design on a computer that is detailed enough to be sure the idea will work but not so detailed that it takes more than just a few hours to complete.

5. Detailed Design

Now that a solid concept design has been created its time to get down to the details. In this phase the designer will create full detail 3d virtual models of all parts, work out design problems, create assembly and part drawings for every part, find suppliers for all purchased components and create 3d physical prototypes if necessary.

6. Testing

Testing is a very important part of product design and should not be overlooked. This step can be as simple as having a few people use the product for feedback or as complicated as sending it to a testing laboratory for a thorough testing by professionals.

7. Manufacturing

The final step in the design process is manufacturing, in this step the company or the designer will find suitable manufacturing facilities to create the product. The company will need to come up with an agreement with the manufacturer on the terms of what they will be providing, the cost and when it will be delivered.

Figure: Detailed steps for product design

So what factors might a designer have to consider in order to eliminate iteration?

Manufacture - Can the product be made with our facilities?

Sales - Are we producing a product that the users wants?

Purchasing- Are the parts specified in stock, or do why have to order them?

Cost - Is the design going to cost too much to make?

Transport-Is the product the right size for the method of the transporting?

Disposal - How will the product be disposed at the end of its life?

The Detail Design Process

Translate Specification Product

To design a product well, a design teams needs to know what it is they are designing, and what the end-users will expect from it. Quality Function Deployment is a systematic approach to design based on a close awareness of customer desires, coupled with the integration of corporate functional groups. It consists in translating customer desires (for example, the ease of writing for a pen) into design characteristics (pen ink viscosity, pressure on ball-point) for each stage of the product development.

Figure: Stages of the product development

Ultimately, the goal of QFD is to translate often subjective quality criteria into objective ones that can be quantified and measured and which can then be used to design and manufacture the product.

Figure: Design and manufacture the product

It is a complimentary method for the determining how and where priorities are to be assigned in product development.

Three main goals in implementing QFD are:

1. Prioritize spoken and unspoken customer wants and needs.

2. Translate these needs into technical characteristics and specifications.

3. Build and deliver a quality product or service by focusing everybody toward customer satisfaction.

Since its introduction:

• Plan new products

• Design product requirements

• Determine process characteristics

• Control the manufacturing process

• Document already existing product specifications.

Raw material testing and quality control.

Our raw material testing laboratory provides purity, contamination, and material testing services, for a variety of raw materials. Raw material quality control is important to prevent product failure and ensure a consistent level of quality, as well as safety in consumer and industrial products. Occasional testing of this type will help keep up the company reputation for fine products and save costs by helping to prevent product recalls.

From polymers, plastics, rubbers, metals, powders, gels, dyes, and other commonly used raw materials, whenever a manufacturer switches suppliers they should have an independent testing laboratory test the quality of the ingredients. This will verify the materials are at the level of quality the manufacturer is paying their supplier for, and that no contaminates are finding their way into the materials.

Figure: Raw material testing and quality control

Raw materials testing:

A. Quality Control Laboratory

B. Materials Analysis and Testing

C. Cargo Inspection Services

D. Crude oil and petroleum Feedstock's Tests

E. Polymer and Plastics Analysis

F. Biofuels Testing and Inspection

G. Petro-chemicals Testing

H. Elemental Analysis and Trace Metals

Accordingly, scientists provide a variety of raw material quality control testing services including;

1) Material Analysis:

Materials testing laboratory analyzes samples of all classes for identification, purity, properties, impurities, and more. The objective of material characterization is often to understand the chemistry of the major and minor components in a substance.

1. Manufacturing Product Failure cases, an unknown contaminant is usually the main cause of the failure.

2. Chemical Product Development cases, identify components of a competing product or discontinued raw material testing.

2) Product Failure Analysis;

Failure analysis laboratory can help identify the cause, develop a solution, and prevent future product failure which can be extremely costly for works in terms of production costs, time delays.

3) Quality Control Testing

Quality control laboratory will helps ensure products are safe and effective throughout the manufacturing process to the finished product. The method development and method validation developments programs for early or late-stage product.

4) Material Purity Testing

Need to test for impurities? Purity testing laboratory which specializes in material analysis of contaminants, testing impurities, determine residuals that may be left behind, and test for degradation over time.

Material Behavior Assumptions

There is a very wide range of materials used for the structures, with drastically different behavior. The following behavioral assumptions.

1. Macroscopic Model. The material is mathematically modeled as a continuum body. Features at the meso, micro and nano levels: crystal grains, molecules, and atoms, are ignored.

2. Elasticity. This means the stress-strain response is reversible and consequently the material has a preferred natural state. This state is assumed to be taken in the absence of loads at a reference temperature.

3. Linearity. The relationship between strains and stresses is linear. Doubling stresses doubles strains, and vice versa.

4. Isotropy. The properties of the material are independent of direction. This is a good assumption for the materials such as; metals, concrete, plastics, etc. It is not adequate for the heterogeneous mixtures such as composites or reinforced concrete, which are anisotropic by nature.

5. Small Strains. Deformations are considered so small that changes of the geometry are neglected as the loads are applied. The violation of this assumption requires the introduction of the nonlinear relations between displacements and strains. This is necessary for the highly deformable materials such as rubber (more generally, polymers).

Figure: Material Behavior Assumptions

Figure: The relations between displacements and strains ε: epsilon-delta

Typical tension test behavior of mild steel, which displays a well-defined yield point and extensive yield region.

Figure: Three material response “flavors” as displayed in a tension test

Figure: Different steel grades have approximately the same elastic modulus, but very different post-elastic behavior