Dr. Mohammed Al-dujaili
Department of Non-Metallic Materials Engineering
Faculty of Materials Engineering
University of Babylon
2013-2014
Lecture 3
Stage: forth
Subject: Industrial Engineering
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.
Understanding the Need for Detailed Design
Detailed design provides the link for 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 data
sharing. Since many companies operate in a distributed environment,
among partners and design teams, and across time-zones and language
barriers, fast, 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 assess risks and balance trade-offs while rapidly
delivering high quality designs that work reliably and offer customers
value. Given the prevalence of electrical content in the majority of today’s
products, it is necessary to effectively handle concurrent design of
interrelated components, and 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. Balancing changing
requirements with cost and quality pressures further complicates matters.
And, ever-shrinking product lifecycles place a premium on an
organization’s ability to implement automation and design reuse.
Benefits of an Optimized Process for Detailed Design
An optimized, formalized, and flexible detailed design process enables
companies to rapidly deliver competitive, high quality designs that offer
customers real value. Typical benefits of 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 (e.g.,
assemblies, drawings, manufacturing process plans)
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 involving external suppliers and
customers
• Provide for secure distributed team and customer 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..
Detailed steps for 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 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. I have seen the development of new products become complicated
and time consuming simply because the problem was never written down.
A proper statement of the problem helps keep everyone on the same page
and works to eliminate project creep.
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 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. Some examples of what should be on its list include, a retail
price (how much are people whiling to pay for this), size of the object (does
it need to fit into someone's hand or through a door or in a garage), how
fast should it go, does it need to be water proof, what should it be made of,
does it use batteries or plug into the wall. This list can go on and on but the
important thing is that the company list what is important to company. This
list will help company and its designer in the next step.
3.Idea Generation
Now the company is getting somewhere, the problem has been defined and
requirements have been set. At this point the company should brainstorm
and sketch out company ideas. Don't worry if the drawings are not pretty,
the company is only trying to see if the concepts could work or if there is
an obvious flaw. If the company is not mechanically inclined, the company
may want to find someone who specializes in product or industrial design
to help. 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. The company will want
to come up with one or two good ideas before moving to the next step.
4.Concept Design
Once at least one good idea for the new product has been sketched the
company will want to have 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. This is the last step where an
idea is either given the green light or trashed.
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. This phase is complete when all problems
have been solved and a full set of drawings have been delivered
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 feed back or as complicated as sending it to a testing laboratory
for a thorough testing by professionals. The level of testing will most likely
be determined by requirements of any retail stores that will be selling the
product. It is important that the company has some companies test the
product which have not been involved in the design process. Some
companies who have not been part of the design will give a less biased
opinion plus company can watch for any difficulty they may have using the
product.
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. 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 customer 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 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.
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.
Design and manufacture the product
It is a complimentary method for determining how and where priorities are
to be assigned in product development. The intent is to employ objective
procedures in increasing detail throughout the development of the product.
The 3 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, Quality Function Deployment has helped to
transform the way many companies:
• 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.
Therefore, tests raw materials, feedstocks and other commodities,
ingredients and components used in a wide range of products. Testing raw
materials can include evaluation and screening of feedstocks, unprocessed
materials, semi-processed materials and finished products for quality
specifications, impurities and more, including higher-end analytical testing
and characterization if required.
Raw materials testing:
A.
B.
C.
D.
E.
Quality Control Laboratory
Materials Analysis and Testing
Cargo Inspection Services
Crude Oil and Petroleum Feedstock's Tests
Polymer and Plastics Analysis
F.
G.
H.
Biofuels Testing and Inspection
Petro-chemicals Testing
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 structures, with drastically
different behavior. In addition the same material can go through different
response regimes: elastic, plastic, viscoelastic, cracking and localization,
fracture. As noted above, we will restrict our attention to a very specific
material class and response regime by making 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. By
convention we will say that the material is then unstressed and undeformed.
On applying loads, and possibly temperature changes, the material
develops nonzero stresses and strains, and moves to occupy a deformed
configuration.
3. Linearity. The relationship between strains and stresses is linear.
Doubling stresses doubles strains, and viceversa.
4. Isotropy. The properties of the material are independent of direction.
This is a good assumption for materials such as metals, concrete, plastics,
etc. It is not adequate for heterogenous mixtures such as composites or
reinforced concrete, which are anisotropic by nature. The substantial
complications introduced by anisotropic behavior justifies its exclusion
from an introductory treatment.
5. Small Strains. Deformations are considered so small that changes of
geometry are neglected as the loads are applied. Violation of this
assumption requires the introduction of nonlinear relations between
displacements and strains. This is necessary for highly deformable
materials such as rubber (more generally, polymers). Inclusion of nonlinear
behavior significantly complicates the constitutive equations and is
therefore left for advanced courses.
Typical tension test behavior of mild steel, which displays a well defined
yield point and extensive yield region.
Three material response “flavors” as displayed in a tension test
Different steel grades have approximately the same elastic modulus, but
very different post-elastic behavior