Product Development Project
Fundamentals of Product Design, Development
and Manufacturing
Prof. S.K.Sahoo
1
Mechanical Engineering Department
ME 3274 Product Development Project
• Objectives
A. Understand fundamental concepts in Product design and
development.
B. To know about various common techniques used in Need
analysis, idea generation and morphological analysis.
C. To be acquainted with different design check and modeling
procedures.
D. To be conversant with patent writing procedures with
reference to specific product and/or process.
E. Encourage an atmosphere of Startup.
TOPICS TO COVER
• Need analysis, Need statement, Cause-effect
diagram
• Idea generation, Evaluation, Morphology
analysis
• SWOT Analysis, Objective tree, Functional tree
• Specifications, Modelling
• Patent writing
• Startup strategy
ME 3274 Product Development Project
(Cont…)
• Learning Outcome
1.0 Can explain the fundamental concepts in Product Deign.
2.0 Able to consider the factors influencing the Product
development.
3.0 Able to determine and draw Specifications, cost, production
rate, model of the conceptualized product.
4.0 Capable of relating the concept of Product design to societal
need and consumer satisfaction.
5.0 Enable to write Patent of the product/service designed for a
societal need
6.0 Able to take decision on initiating a startup.
Mapping
Objectives
A
D
Topics
Need analysis, Need statement,
Cause-effect diagram
B
C
Idea generation, Evaluation,
Morphology analysis
2.0
4.0
B
D
SWOT Analysis,
Objective tree,
Functional tree
1.0
2.0
Specifications,
Modelling
3.0
4.0
Patent writing
1.0
3.0
Startup strategy
1.0
4.0
A
E
A
E
A
D
Outcome(s)
1.0
3.0
5.0
6.0
5.0
6.0
REFERENCES
1. P Kumar, Product Design, PHI 2012
2. KT Ulrich and Eppinger, Product Design and
Development, McGraw Hill, 2016
3. Dieter and Schmidt, Engineering Design, McGraw Hill,
2020
4. Manufacturing Technology vol I & II, P. N. Rao, TMH
5. Manufacturing Engineering and Technology, S.
Kalpakjian, Pearson India, 2012
6. https://nptel.ac.in/courses/107103082
7. https://nptel.ac.in/courses/112107217
8. https://nptel.ac.in/courses/112104230
Evaluation
1. Mid Semester Evaluation : 20
Submission of one page (written both side) final product
details with specification and cost table.
2. End Semester Evaluation : 30
Submission of final lab record with product model, patent
writing and startup strategy.
3. Continuous Assessment : 50
a. Each thirteen Class progress to be checked and graded
d. Viva (if required)
Course Teacher: Dr. S.K.Sahoo, Professor ME Dept.
Ph. 0661-2462520 e-mail: sks@nitrkl.ac.in
Room: ME Dept., ME Sciences Building # 105
Product Design
Design is a process concerned with generating ideas and
suggesting ways to turn these ideas into reality to satisfy
some societal needs optimally under the relevant
constraints.
Only idea generation is not sufficient to call it as a
design. It should come as a tangible entity to satisfy
some societal needs.
Engineering Design is the systematic process of
generating ideas and its evaluation of specifications for
a product whose function achieve stated objectives and
satisfy specified constraints.
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The Process of Design
• Designing is the process of making many
decisions that converts an abstract concept into
a hardware reality.
Concept
Product
Product Design Type
• Design by evolution
• Original design (or Inventing)
• Adaptive Design (or Synthesis)
• Variant Design (or Modification)
Product Design Philosophy
• Design by creative Imagination
• Scientific Design and Development process
Reasons for Product Design
• Economic
• Purchasing power, demand fluctuation, Warranty,
Insurance
• Social and demographic
• Changing attitude, aging population, etc.
• Political, liability, or legal
• Safety issues, new regulations, government changes
• Competitive
• New products and services in the market, promotions
• Cost or availability
• Raw materials, components, labor
• Technological
• Components, production processes
Trends in Product Design
Societal need/Customer satisfaction
• Designing products & services that are “user friendly”
– Self driving car/ auto alarming software /home
delivery of petrol
Reducing time to introduce/produce new product or
service
– Customized drone in 1 week/ B.Tech. in 3 years
The organization’s capabilities to produce or deliver the
right item on time
– Enough low cost bikes and laptops are not supplied
by companies during 90’s
 Environmental concerns
• Designing products that satisfy pollution norm/ use less
material, etc
– Changes in engine for passenger cars
An Effective Design
Effective designs provide a competitive edge by:
•
•
•
Bringing new ideas to the market quickly
Doing a better job of satisfying customer needs
Making new products easier to manufacture,
use, and repair than existing products
Objectives of Product and Service Design
• Main focus
– Need/Customer satisfaction
• Secondary focus
– Function of product/service
– Cost/profit
– Quality
– Appearance
– Ease of use
– Ease of production/assembly
– Ease of maintenance/service
Considerations in Product Design
• Product Life Cycles
• Standardization
• Mass Customization
• Modular Design
• Robust Design
• Concurrent Engineering
• Computer-Aided Design
Three Phases of Design Process
• Explorative or Divergence Phase
– Understanding of problems
– Collection of all possible information
– Not biased by existing commercial solutions
• Transformation Phase
– Generation of alternating ideas applying
experience, intuition, geniuses, innovative
capacity
• Convergence Phase
– Eliminate unworkable/infeasible/unrealistic /
alternatives and choose the optimal one
7-Step Design Process
1. Problem definition
2. External Search
3. Internal Search (Brainstorming)
4. Evaluation and Selection
5. Detail Design (Engineering)
6. Prototyping
7. Documentation
Design, Development and Manufacturing
Idea
generation
Feasibility
study
Product Yes Preliminary
feasible?
design
No
Final
design
Prototype
Process
planning
Design & Manufacturing
Specifications
Manufacturing
Tools for Generating Design Concepts
•
•
Idea cultivation
– Brainstorming
– Mind Mapping
– SWOT
Concept formation & Decision
making
– Force Field Analysis
•
Filter modifications
– Six Thinking Hats
– Synetics
– Critical Path Analysis
Product Development Process
PDD Process
Product Design
Idea Generation
Detail Design
Evaluation
Prototyping
Product Design
Manufacturing
Effect of Product Life Cycle
on
Product Design & Development
Sales and
Profits
Sales
Profits
Product
Development
Introduction
Growth
Losses/
Investments
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Maturity
Time
Decline
Product Development Type
Description
Generic
(Need base)
Technology
Push
(Innovation)
Existing
Products
(Imitation)
Process
Intensive
Customization
(Adoption)
The firm begins
with a market
opportunity, then
finds an
appropriate
technology to
meet customer
needs.
The firm begins
with a new
technology, then
finds an
appropriate
market.
The firm assumes
that the new
product will be
built around the
same
technological
subsystem as an
existing product.
Characteristics of
the product are
constrained by the
production
process.
New products are
slight variations of
existing
configurations.
Additional initial
activity of
matching
technology and
market.
Concept
development
assumes a
technology
platform.
Both process and
product must be
developed
together from the
very beginning, or
an existing
production
process must be
specified from the
beginning.
Similarity of
projects allows for
a highly structured
development
process.
Snack foods,
cereal, chemicals,
semiconductors.
Switches, motors,
batteries,
containers.
Distinctions
with respect
to the generic
process
Concept
development
assumes a given
technology.
Examples
Sporting goods,
furniture, tools.
Laser, new plastic,
PLC, resin, LED.
Consumer
electronics,
computers,
printers.
Development is
almost like a
production
process.
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Product development steps/activities
Realization of Need
Statement of need/problem
Need analysis
Generation of alternative design ideas
No
Evaluation
Yes
Design development
No
Realizability, Feasibility
Utility, Economic, Safety
Design for function
Design for manufacture
Design for maintenance
Evaluation
Yes
Detail Design
Optimization/
Standardization
Production
Detail process plan
Optimization/
Standardization
Summary
Product Development Process
Step 1. Problem/need Identification
• Systematic Need Analysis
 Keen Observations
 Customers complains
 Primary/secondary Fish-bone diagrams
 Personal experience
 Users feedback
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Product Development Process
Step 2. Idea Generation
• Systematic Search for New Product Ideas
 Internal sources
 External sources (Patents, Journals)
 Brainstorming
 Adaptation, Imitation
 Nature, Biological processes
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Product Development Process
Step 3. Idea Evaluation
Process to spot good ideas and drop poor ones
Criteria
 Market Size
 Product Price
 Development Time & Costs
 Manufacturing Costs
 Rate of Return
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Product Development Process
Step 4. Concept Development & Testing
1. Generate Product Ideas into
Alternative Product Concepts
(Morphological Analysis)
2. Concept Testing - Test the
Product Concepts with Groups
of Target Customers
3. Choose the Best One
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Product Development Process
Step 5. Marketing Strategy Development
Marketing Strategy Statement Formulation
Part One - Overall:
Target Market
Planned Product Positioning
Sales & Profit Goals
Market Share
Part Two - Short-Term:
Product’s Planned Price
Distribution
Marketing Budget
Part Three - Long-Term:
Sales & Profit Goals
Marketing Mix Strategy
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Product Development Process
Step 6. Business Analysis
Step 7. Manufacturing
Business Analysis
Review of Product Sales, Costs,
and Profits Projections to See if
They Meet Company Objectives
If No, Eliminate
Product Concept
If Yes, LAUNCH!!
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Product Development Process
Step 8. Test Marketing
Standard
Test Market
Controlled
Test Market
Full marketing campaign
in a small number of
representative cities.
A few stores that have
agreed to carry new
products for a fee.
Simulated
Test Market
Test in a simulated
shopping environment
to a sample of
consumers.
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Product Development Project
Prof. S.K.Sahoo
1
Mechanical Engineering Department
Product Development Project
Standing Instruction
Maintain a hard bound project record.
Individual members of the group will collect/search/find
their own finding and evaluation. These are to be recorded
on one’s own lab record.
When group meets and assemble together, all these
individual finding will be summarized and recorded. This
summarized one may be copied by all or on one of the
member record book.
When making search, find the concept/idea/technology
used by others. Not the device, it can fall under
plagiarism.
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Need Identification & Analysis
Most Important and difficult part
Methods to follow:
-
Focus on problem, not on the
solution or existing product
Keen Observations
 Do not biased by commercially
User/Customers complains
available product exists in market.
Users feedback
Personal experience
Present need of a particular group
users or place, etc
Analyze the problem, different direct and indirect
factors responsible
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Fish-bone or Cause-effect Diagram
Express the problem/need to logical language form
Convert the language to numerical form giving required limits,
requirements of different parameters.
From these numerical data find the appropriate domain of solution,
limitations and idea/method
Multiple of fish-bone diagram should be drawn to pin-point the
problem and its causes w.r.t. its engineering side.
2 Mobile sources
4
Fire
3
Deforestation
fire
Paddy field
Smoking
Personal vehicles
6 Urbanization
Train
By human Plane
Volcano
Air
pollution
Power plant
5 Natural causes 1 Industry
Primary Fish-bone diagram
4
Mechanical Engineering Department
Fish-bone or Cause-effect Diagram
It will explore and graphically represents the different factors
responsible for the problem for which one is trying to develop a
product.
5 Ineffective 4 Poor chimney
filters
Bad
Poor design
Large in numbers
1 Use of fossil fuel
Less tax
construction No restriction
Wrong design
Govt fault No checking
6 Industrialization 3 Slack in law
2 Not using
filters
Secondary Fish-bone Diagram
Industrial
Air
pollution
Fish-bone or Cause-effect Diagram
Pin pointing the exact problem with engineering feature as per the
development prospect
4 Ineffective
5 Poor design
Old concept
More frequency
6 Complex
maintenance
materials
1 Non controlable
Poor choice Less friendly
No feedback
Wrong selection
More maintenance
More defects
3 More cost
2 Quick
failure
Tertiary Fish-bone Diagram
Ineffective
filters
used by
Industry
Need statement
Clearly define the problem with its domain of solution you want.
It should contain:
• Problem
• Standard of performance (quality/usability level)
• Constraints (limitations)
It should be of one or two sentence(s)
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Idea/Concept Generation Process
Idea generation: Search for alternative
Methods to follow: ideas/Process
• Patents (Google search for US patent, individual site of other
countries, ie, Indian, European, Japanese etc)
• Journals (Institute is subscribed to almost journals, go to
library site of nitrkl)
Each member should collect own
• Observing the nature around
information and to mention the
source in his record.
• Biological process
• Adaptation of an existing solution
• Imitation of other solutions, etc Idea/process can be manual, mechanical,
electromechanical, biological, etc.
• Brainstorming
Here also, focus on ideas/processes that can be taken to solve the
problem, not on a particular product
 List all possible or impossible, feasible or infeasible, real or imaginary,
cheap or costly ideas for evaluation
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Evaluation of ideas or processes
With respect to some parameters these can be evaluated. Parameter
can be taken as: •It is subjective in nature
•Give relative marks in a reasonable way
•Cost
•Time to develop •One can give different weightage to different parameters
and accordingly find the total mark
•Feasibility
•One get the HIGHEST MARK will be selected
•Usability, etc
•There are a lot of other good mathematical evaluation
process are available. Follow a good book.
Cost
0.4
Time to develop
0.2
Maintenance
0.1
8
8x.4=3.2
2
2x.2=.4
10
10x.1=1
-- -- -
Parameter-(n-1)
0.05
Parameter-m
0.15
Total
0
0x0.05=0
6
6x.15=0.9
Max
mark
Idea-1
Idea-2
Idea-3
-Idea-n
10: Excellent, 8: Good, 6: Satis., 4: Av., 2: Unacceptable, 0: Failure
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Decomposition of the Problem (Functional Tree)
Final Problem/
Functional
requirement
Sub Problem/
Function
Sub-Sub
Problem/
Function
Sub-Sub
Problem/
Function
Sub Problem/
Function
Sub-Sub
Problem/
Function
Morphological Analysis to find
Possible Products to implement the chosen idea
A) Find the different functions /sub-systems required to implement the chosen
idea to a product.
B) Find the different alternatives to obtain the each function or sub-system
For example:
Rotation function : Alternative will, gear, rope, belt drive, etc
Transport of mass function : Alternative will, by gravity, by screws, by
conveyor, etc
Supply control function : Alternative will, pneumatic, position sensors,
etc.
Power supply : Solar, Electrical, Gasoline
Motion control: ----------------Signal generator: --------
Make a Matrix
Mechanical Engineering Department
Morphological matrix
Alternative
Alternative-1
Alternative-2
Alternative -3
gear drive
Rope drive
Chain drive
------
Alternative –(n-1)
Alternative -n
Function
Rotation
Transport of
mass
Supply
control
---
Electric motor
Body/frame
Combining alt-1 of function-1, alt-3 of function-2, alt-4 of function-3 , we can
make a device. It indicates, If
L=no. of alternatives for function 1
M=no. of alternatives for function 2
N=no. of alternatives for function 3
..
Total Possible Products (PP) = L × M × N × P……
Out of which some may be infeasible, very costly, non-compatible etc., will be
rejected.
Still, a good number of devices left out of which one will be selected.
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Mechanical Engineering Department
Evaluation of Possible products for development
Parameters to be taken for evaluation (It depend on device), ie,
-
Cost
Response time (quick to act)
safety
life period, etc
It can subjective or objective in nature
Give relative marks in a reasonable way
One can give different weightage to different functions
and accordingly find the total mark
PP-1=P1A3+P2A1+P3A2+P4A1------PP-2=P1A1+P2A4+P3A3+P4A2------PP-3=P1A1+P2A1+P3A2+P4A2------PP-n=P1A2+P2A1+P3A5+P4Am------PP-1
PP-2
PP-3
Cost
0.4
Time to develop
0.2
Maintenance
0.1
8
8x.4=3.2
2
2x.2=.4
10
10x.1=1
-- -- -
One get the HIGHEST MARK will be selected
There are a lot of other good mathematical evaluation
process are available. Follow a good book.
Parameter-(n-1)
0.05
Parameter-m
0.15
Total
0
0x0.05=0
6
6x.15=0.9
Max
mark
Final Product
-PP-n
Now this device is selected for further development (fixing specification,
simplification, standardization, drawing, modeling and fabrication, patenting, etc.)
Each student will maintain his own lab record for verification, checking and evaluation in each class.
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Checking the Suitability of the idea/product for
development
1. Objective Tree:
It provides a checking, whether, the final product
address all the objectives or not.
It is a graphical representation of the prime and subsidiary objectives of
the final product one want to develop. It will affect the decision on
choosing the mechanisms and components to be used for the final
product. The objective tree depends on the product. As an illustration, it
may looks like:
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SWOT Analysis
• It will give an overall commercial opportunity of the
developed product. It list out Strength, Weakness,
Opportunities and Threats about the product if goes for a
production.
• For instance in product analysis
• identify strength and weaknesses of the product
• search through possibilities and threats (for instance for
product launch)
inside
outside
Strength
---------
Weakness
-------
Opportunity
-------
Threats
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Detail Functional Design Tree:
(Design got function)
It will give a diagrammatical representation of each
function/components requirements and their relationship among
themselves. As an illustration, it may looks like:
At each level, asked critical questions specific to the product, ie,
What is its rigidity?
Its weight to volume ratio?
Can it take load?
How to construct?
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Drawings and detail specifications
Each part/component should have
Part number
Drawing with 2 projections (use a software Auto
CAD, solid works, Catia, etc)
Dimension
Tolerance
Finish
Materials
 Assembly drawing
 Make modification to decrease size and volume
 Take care of ergonomics, aesthetic look, safety, etc.
 (use a software Auto CAD, solid works, Catia, etc)
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Detail Specifications
Any service required also has a
part number and its full
description and cost should be
indicated.
Sl. Part Part Parameter Value/ Material Finish/ Tolerance Make or
No. no. name / metric dimensi
quality
buy
on
If make, cost
method
Total
Mechanical Engineering Department
Other considerations in the Design and Development Process
• Planning for manufacture
• Make or buy decission, Design of tooling and fixtures,
designing the process sheet and the production line, planning
the work schedules, the quality assurance system, and the
system of information flow.
• Planning for distribution
• Planning for packaging, shipping, warehousing, and
distribution of the product to the customer.
• Planning for use
• The decisions made in phases I through III will determine such
important factors as ease of use, ease of maintenance,
reliability, product safety, aesthetic appeal, economy of
operation, and product durability.
• Planning for product retirement
• Again, decisions made in phases I through III must provide for
safe disposal of the product when it reaches its useful life, or
recycling of its materials or reuse or remanufacture.
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Patent Writing (Indian Patent)
Mechanical Engineering Department
Startup Business Strategy
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Important Domain Areas
Innovation has been successfully applied and can be applied to the following areas.
I.
Renewable Energy
- Solar Energy Application for Lighting, Water Pumping in remote areas.
- Mini Grid / Individual Home Grid can be developed specially in remote areas.
- Hybrid Solar and Wind System
- Trigeneration (utilizing gas for heating, cooling and electricity generation)
-
II.
III.
IV.
V.
VI.
VII.
Agriculture
- Sensor-based pest, water, fertilizer management
- Biotechnology Application for high yield and disease resistant varieties
ICT application for disease and growth monitoring
- New/smart/ tools for food processing /cultivation , etc
Health
ICT-based Diagnostic Kits
- Targeted Delivery
Waste management
- Collection, segregation, storage, use, alert, system, etc
- Municipal Solid Waste Management
- Weeds and Algae Management at ponds
Pollution Control and Environment Management: Industrial Waste Treatment
RFID / Embedded system
Management of goods,
Management of household appliances (like fans, refrigerators)
Sensors for security, leakage of gas
Smart Cities
Application of Renewable Energy, Smart grid
Waste Management and converting it into electricity / heat
ICT application for service management and integration of various systems.
- good drainage, drain blockage removal
Water management
Treatment of waterborne diseases
Removal of Iron, Fluoride, Arsenic and Chromium from the Water
- Reducing the use of water for about 10 liters per person
-
VIII.
Solar DC system in rural areas (without invertors and battery)
Solar DC system without minimum battery backup
Improving battery life 1000 cycles to 3000 to 5000 life cycles with almost same cost.
Drinking water for all at all places
Passengers’ safety and comfort devices
Railways
Road
- ladder for upper/middle berth
- re-design of seat for easy in-out
IX.
Devices for Old age/PH peoples /House keeping
- Application of ICT
Mechanization of manual processes
- Helping aids
X. Products/small mechanized M/c for rural/Tribal employments
- Machines for use of Lack, Shal leafs, other natural byproducts
Devices operating without electricity
XI. Low cost Products
- Water filter
Refrigerator
- Reduces the cost small wind mill to Rs.1 lakh per KW
-
DC system for small power especially in rural areas and slums
XII.
New conceptual products
- spoke less umbrella
Alarm clock for deaf people
XIII. Products for Medicals / Veterinary
for critically ill patients movements/care
for doctors aids
for nurse and attendants
XIV. Scaling/Miniaturization of products
- Water purifier
Chapati making machine
Having decentralized sewerage treatment plant for 5000 households with cost less than
Rs.5000 per households
XV.
Energy/mass conservation
- Waste heat/energy utilization
Energy harvesting
Water wastage and conservation
XVI. Accessories to increase the efficiency/effective ness of existing products
- Juice maker
- Industrial filter
- Braking system
XVII. Accident prevention
- child trap in bore well
slippery floor
XVIII. Products of convenient
- descaling of fish
- cotton wool treading
- de-husking coconut
XIX.
New Materials
Rare earth materials for battery, fuel cells, space application, for wind
turbines, etc.
- Wood and Bamboo based construction materials
XX.
Biomass
-
XXI.
XXII
-
Improving yield of Biomass
Enhancing efficiency of Gasification, Combustion Technology
Biomass power system increasing efficiency from average 18% to 27% and for gasification
technology increasing efficiency from average 22% to 35%
Biomass electricity supply chain management to organize, collection and storage (like
cotton, sugar cane etc)
Sea Resources
Extracting molecules/proteins from sea animal for drugs
Energy from sea weeds
Environmental Pollution management
Air
Soil
water etc
23.Agriculture:
23.1 Technology to increase shelf life and minimize post-harvest losses.
23.2 Technologies for plant pest and disease detection, monitoring and mitigation. Target Crops: Tomato,
Pomegranate, Cotton & Coffee
23.3 Technology for on-site drying and grading of cash crops.
24. Animal Husbandry/Allied:
24.1 Novel artificial insemination techniques for cattle (for enhanced fertilization rates)
24.2 Cost-effective on-farm pregnancy detection kits for cattle to detect PAB/AGA/other hormones
24.3 Affordable farmer-level mastitis detection
24.4 Fast and accurate method for detection of contaminants in milk
Schedule of Progress Date wise
Product development Project
Class-1 (8.1.2024)
Introduction and Instruction
Class-2 (22.1.2024)
Need Identification, cause effect diagram (May be three or more) showing engineering side
of the problem with engineering difficulties which cause this societal/industrial problem. Need
statement.
Class-3 (29.1.2024)
Clearly analyze the problem and make it very specific.
Class-4 (5.2.2024)
Concept/Idea/Method/Technology generation and evaluation (comparison) of these ideas.
Class-5 (12.2.2024)
Division of chosen idea to different function or mechanism and Morphological Analysis.
Class-6 (19.2.2024)
Evaluation of alternative devices using suitable parameters & finalization of product.
Class-7 (4.3.2024)
Checking the suitability of the product for development (Functional tree, Objective tree, SWOT analysis).
Detail specification table. Submission of a One page (written on both side) Abstract (It contains:
Statement of the problem, Principle of mechanism used, Figure, Working principle, Cost table indicating
all components, services, final cost, etc.).
Class-8 (11.3.2024)
Rough drawing of components, Assemble product, dimension, materials of each component.
Class-9 (18.3.2024) 3D modeling of product using AutoCad, Catia, development, continue…
Class-10 (25.3.2024) 3D modeling of product using AutoCad, Catia, development, continue…
Class-11 (1.4.2024) Introduction on Patent writing and Startup strategy.
Class-12 (8.3.2024) Patent writing.
Class-13 (15.4.2024)
Startup strategy.
Submission of Patent application & Startup strategy of the proposed product and
record for evaluation.