Engineering 11 Detail Design Bruce Mayer, PE Licensed Electrical & Mechanical Engineer BMayer@ChabotCollege.edu Engineering-11: Engineering Design 1 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt OutLine Detail Design Flow of design information Responsibility for “details” Graphic communication Written communication Oral presentations Engineering-11: Engineering Design 2 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Product Development Pick a product, any product • Most require more than one Engineering discipline to develop. • Some need many disciplines, including (but not limited to): – Design Engineering – Quality Engineering Mechanical Engineering Electrical Engineering Software Engineering Packaging Engineering Industrial Design Research & Development Product Assurance Engineering Software Quality Engineering Supplier Quality Engineering Reliability Engineering – Manufacturing Engineering Industrial Engineering Engineering-11: Engineering Design 3 Tooling Engineering Process/Manufacturing Engineering Test Engineering Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Product Development But wait, there’s more! • Also need NON-ENGINEERING groups to make a product – – – – – – – – – Financial Analysts Product Managers Marketing Managers Marketing Communications Sales, Order Entry, Account Managers Customer Service / Field Service Production Control Purchasing & Commodity Management And many more, depending on the industry . . . Engineering-11: Engineering Design 4 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Information Flow Parametric Design Design variable values e.g. Sizes, dimensions Materials Mfg. processes Performance predictions Overall satisfaction Prototype test results Engineering-11: Engineering Design 5 Special Purpose Parts: Features Arrangements Relative dimensions Variable list Standard Parts: Type Variable list Detail Design Product specifications Production drawings Performance Tests Bills of materials Mfg. specifications Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Design Info Flow & Decision-Making • Product Marketing – Subproject Leader • • • • • Finance – Subproject Leader • Information Technology Finance Channel Marketing Sales PR Advertising Marketing • Product Management – Subproject Leader • • • • Production Quality Supplier Quality Engineering Software Quality Assurance Technical Assistance Team Leader • Systems Engineering – Subproject Leader Electrical Engineering Mechanical Engineering Software Engineering Acoustic Engineering Engineering Services Engineering-11: Engineering Design 6 Product Management Quality Engineering • • • • • • Industrial Design Project Manager • Product Assurance – Subproject Leader Operations • New Product Introduction Manager – Subproject Leader • • • • • Manufacturing Engineering NPD Procurement Tooling Test Engineering Packaging Engineering Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Sales & Marketing Duties Product Warranty Shipping & Installation Plans Warehousing for Spare Parts Advertising campaign Product literature Owner’s manual (layout, printing) • Often Done by a Technical Writing Group Product launch Engineering-11: Engineering Design 7 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Industrial Design Duties Overall Product Appearance/Impression • Color(s) & Paneling • Product trim details • Finish details Ergonomic Refinements Product Packaging Engineering-11: Engineering Design 8 “Curb Appeal” Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Design Engineering Duties Detail design performance analyses Detail drawings Assembly drawings Preproduction prototype performance tests Manufacturing process specifications Bills of materials Engineering change notices/orders Intellectual Property Owner manual(s) (technical: operation & maintenance) Layout drawings Engineering-11: Engineering Design 9 • Patents • Trademarks • Copyrights Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Industrial Engineering Duties Materials & Product flow Facility layout/remodeling Material handling equipment Inventory warehousing Assembly planning (machines & workers) Materials Lead-Time Planning Engineering-11: Engineering Design 10 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Manufacturing Engineering Duties Fixture design & fabrication Tool design & fabrication Process equipment refurbishment/adaptation Process equipment acquisition & installation Process planning & development Supplier Selection & Qualification Worker Training Engineering-11: Engineering Design 11 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Purchasing Dept. Duties Supplier Contract Negotiations Second Source Identification Issuing Requests for Quotation (RFQs) Materials planning Purchased-Part Cost Control Purchased-Part Delivery Schedule Control Engineering-11: Engineering Design 12 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Production Tooling changeover (assist ManufE) Receiving Inspection (Physical) Received-Part Acceptance Testing Worker Training Material Movement Workforce Scheduling Engineering-11: Engineering Design 13 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Communicate Design Information Written and Oral Communications • • • • • eMail Memoranda & Letters Phone calls & Voice mails Reports Meetings Communicate to ALL the stakeholders: • often • thoroughly & clearly Engineering-11: Engineering Design 14 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Graphic Comm Drawings Detail drawings (a.k.a.”BluePrints”) • Fabricated “Piece-Parts” Assembly and SubAssembly Drawings Bills of Materials • sometimes on Assembly • Sometime in a form of a SpreadSheet Layouts • Scaled & Accurate, but not “finished” Engineering-11: Engineering Design 15 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Detail Drawings Show all necessary dimensioned views needed to make the part. Indicate material and tolerances. Indicate any finish treatments (plating, etc.) and requirements for surface-finish roughness. Detail drawings are not necessary for purchased parts, only for parts that will be manufactured to the Engineer’s design. It is often preferred to show just one part per sheet so the same part drawing can be included in multiple assemblies without confusion. Engineering-11: Engineering Design 16 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Fabrication Drawing (ENGR22) TWO Parts on this Sheet Poor form Engineering-11: Engineering Design 17 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Fabrication Drawing Engineering-11: Engineering Design 18 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Assembly Drawings Can be exploded-isometric, sections, single views, exterior views, or assembled isometric drawings. Not usually dimensioned unless there are dimensions that are critical to maintain during assembly. Hidden lines not usually needed. Engineering-11: Engineering Design 19 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Assembly Drawing Engineering-11: Engineering Design 20 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Parts Lists (Bill of Materials) Parts list (a.k.a. “BoM”) on assembly drawings or combined assembly and detail drawings indicates part name, item number, material, and quantity required. • Parts List May be on a Separate Document – Reference in NOTES Section of the Dwg Often a company stock number is also included Part ID on Dwg • Balltags on drawing indicate which part is being called out (next slide) • Part No. may be Placed Directly on Drawing Engineering-11: Engineering Design 21 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Ball-Tag BoM Assy Dwg BallTag Ref. to Parts List Engineering-11: Engineering Design 22 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Direct P/N Callout; No BallTags Engineering-11: Engineering Design 23 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Anatomy of a Working Dwg Rev. Block Zone No. Zone Ltr. Note Block Note Indicator BoM BallTag On-Dwg BoM FOIA Disclaimer Engineering-11: Engineering Design 24 Title Block Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Anatomy of a Working Dwg Zone Block Section/View Line Separate-Sheet Parts List Detail Bubble Engineering-11: Engineering Design 25 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Anatomy of a “BluePrint” Title Block Drawing Title SubBlock Drawing Number Release SubBlock Revision Level Tolerance SubBlock Dwg Sheet Size Matl-Spec SubBlock Dwg Scale BoM Table SubHeadings Company ID SubBlock Dwg Sheet: No. & Cnt Co. Division ID Engineering-11: Engineering Design 26 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Graphic Comm – Illustrations CHARTS - portray relationship(s) among numerical data, for example sales versus time. DIAGRAMS - explain how something works or the relationship between the parts; e.g., free body diagrams to analyze how forces and moments interact with rigid bodies SCHEMATICS - uses abstract symbols; e.g., fluid Plumbing schematic, or electrical-wiring schematic. FIGURES - illustrates textual material SKETCHES - hand-drawn preliminary, or rough “drawings”, drawn without the use of drawing instruments. Engineering-11: Engineering Design 27 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Analytical XY Graph (ENGR25) Temperature Field Self-Iteration Convergence Plot 2.0 1.8 1.3 1.0 I = (Ti-To)/(Tf-To) 1.5 0.8 PARAMETERS • Inj/Ceiling Temp, T1 = 65C • Chuck Temp, T2 = 550C • k[T(z)) for N2 by Reid, Prausnitz, Poling • To = 483.5 °C • Tf = 519.47 °C 0.5 0.3 0.0 0 3 file = Chuck Heat_Xfer_Oct99.xls 6 Engineering-11: Engineering Design 28 9 12 15 18 21 24 27 Iteration Number, i Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt 30 Technical Column Chart Wafer Processing Time Budget for 8k-USG and 5k-BPSG • Apr00 20 18 t0 = Dep-On Time Tcln Thc Processing Time (min/wafer) 16 14 12 10 8 6 file = ThruPut_Calc.xls 4 2 0 USG: mill sys3 USG: 2@3X/1 Engineering-11: Engineering Design 29 USG:2@3X/2 BPSG: mill sys3 BPSG: 2@3X/1 BPSG:2@3X/2 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt FreeBody Diagram (ENGR36) Shows How Forces & Moments InterAct with Physical Objects Example FBD for DrawBridge Plank Engineering-11: Engineering Design 30 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Plumbing Schematic Engineering-11: Engineering Design 31 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Technical Illustrations Cross Belt N2 Dist ribut ion t ube (8 Pl) Cross Belt N2 Dist ribut ion t ube Header/Plenum WJ-1500 Muffle Figure 1. Top/Plan view showing how the cross-belt N2 distribution tubes integrate into the M2 WJ-1500 muffle Engineering-11: Engineering Design 32 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Design Sketch Engineering-11: Engineering Design 33 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Gantt Chart (MileStone Sched) Engineering-11: Engineering Design 34 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Written Design Communication Letters & eMail • Brief communications, often <1 page in length • Sent to a few selected individuals • On a specific, usually familiar, topic • HardCopy Letters are FORMAL – Use Company LetterHead Paper • eMail “letters” are INformal in format and typically very brief Engineering-11: Engineering Design 35 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Written Design Communication Memoranda • Longer than letter, from 3 to 9 pages, • Sent to a broader, usually Internal audience • Can cover more topics in greater depth than a letter. • Memoranda often emailed as attachments Engineering-11: Engineering Design 36 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Written Design Communication Test Reports • Technical reports detailing engineering and/or scientific tests (on materials, prototypes and or products). • Can vary in length from few pages to hundreds of pages. • Contents include sections on: test objectives, test procedures, • data/results, summary and recommendations Engineering-11: Engineering Design 37 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Written Design Communication Research reports • Similar to test reports • But longer in length and broader in coverage • Include additional sections such as: an abstract, background, literature review, laboratory/test program description and bibliography. Engineering-11: Engineering Design 38 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Owner’s Manuals Often Written by the Design Engineer Spare 80 Card • SetUp/Installation of the product • Operating the product • Maintaining (i.e. clean, lubricate and adjust) P37 Optical Sensor Board 35 Card 83 Card P38 81 Card P39 Thermocouple Terminal Block 1 (TCBlk #1) Thermocouple Terminal Block 2 (TCBlk #2) Thermocouple Terminal Block 3 (TCBlk #3) • Repair, if necessary. Can vary in length from 1 page to hundreds of pages Illustrations usually very important 39 Thermocouple Interface Boards (33 Card, 34 Card, 35 Card) B Source P Source Si Source Include sections on: Engineering-11: Engineering Design High Resolution Temperature Interface Boards (80 Card, 81 Card) 1, 4, 7 (for Injector 1) 2, 5, 8 (for Injector 2) 3, 6, 9 (for Injector 3) LED Indicators for Level Sensors in Bubbler Tanks Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt 34 Card 33 Card Engineering Change Orders Brief descriptions of changes made to a product (i.e.; what, why, how) Detailed on a company-approved form Authorized (signed) and distributed to all the critical depts. Engineering-11: Engineering Design 40 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Project Progress/Status Reports Sent to Management, Customers, Clients and other stakeholders, Covers project status re: workscope, schedule and budget. Can vary in length from one to hundreds of pages Prepared weekly, monthly, quarterly, and annually Engineering-11: Engineering Design 41 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Design PostMortem Report Major Sections of an “AfterAction” Report 1. 2. 3. 4. 5. 6. 7. 8. 9. Introduction Design Problem Formulation Project Engineering Concept Design Configuration Design Parametric Design Prototype Tests Final Design Conclusions and Recommendations Engineering-11: Engineering Design 42 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt PowerPoint Presentations Preparation Strategy 1. Plan (time, topics, temperament, audience) 2. Outline 3. Compose 4. Rehearse 5. Refine An excellent presentation requires excellent preparation • See also ENGR10 Engineering-11: Engineering Design 43 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Presentation BOTTOM LINE Tell them what you WILL tell them • Start with an OUTLINE Tell them • The BODY of the Presentation – Make it Inter – esting & Relevant Tell them what you just TOLD them • End with a SUMMARY that emphasizes the important points/conclusions Engineering-11: Engineering Design 44 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt PowerPoint Presentation Plan Decide on: • who the audience will be – Know the Audience and their Interest • what we wish to communicate – Know the Subject – be Ready for Questions • why we are giving the presentation – Know the Point, and Don’t Obscure • how long it should be – Time is Valuable – Emphasize Main Point(s) Engineering-11: Engineering Design 45 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt PowerPoint OutLine Prepare a draft outline of the topics. If a group presentation, the Group needs to agree upon responsibilities. Estimate the time devoted to each topic. Break up longer topics into smaller chunks. Combine or eliminate incidental topics. Discuss the draft outline with your co-workers. Confirm the draft outline with your immediate supervisor. Engineering-11: Engineering Design 46 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Compose Presentation Use the outline to compose Speaker’s Notes on 3x5 note cards (can be imbedded in ppt) • Write clear and concise statements for major ideas and facts. • Number each card in succession. Compose clear & concise PowerPoint slides, Prepare Diagrams using CAD, or Photos with Digital Camera, Movies with videorecorder Bring a MockUp or Working Model if at all Possible for Physical Demonstration Engineering-11: Engineering Design 47 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Rehearse Presentation Important Presentations Should be Rehearsed in front a forgiving audience Practice saying the note card phrases. Give your draft presentation to some friendly coworkers. Rehearse using the intended room and audio/visual aids – always precheck fcn Video tape and critically evaluate presentation delivery & visual-aids. Engineering-11: Engineering Design 48 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Refine Presentation Revise or re-write the note cards Eliminate confusing visual aids. Refine the visual aids. Revise presentation room layout or equipment • Bring Your OWN Equipment if Unsure about the suitability of the actual Venue – Typically LapTop & LiteWeigt PPT Projector Engineering-11: Engineering Design 49 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Execute (Give) Presentation Make your listeners physically comfortable. • Seating, lighting, room temperature, noise level and ventilation. Expect & accept to be somewhat nervous. • Convert nervousness to enthusiasm. Take a deep breath and relax before beginning. Start on time, stick to presentation schedule, and finish on time. • Do not go overtime! Pronounce clearly, sufficient volume, relaxed pace. Engineering-11: Engineering Design 50 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Execute (Give) Presentation Vary the pitch or tone of our voice occasionally Add enthusiasm to our delivery. Use visual aids to judiciously make points Use appropriate gestures and avoid annoying mannerisms – no one wants to be annoyed Make frequent eye contact with our audience. Use a Laser pointer when appropriate. Relax and “enjoy the ride.” Engineering-11: Engineering Design 51 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Summary Detail Design Product “Launched” Only When Detail Design Complete Detail Design Elements • Flow of design information • Responsibility for “details” • Graphic communication • Written communication • Oral presentations Engineering-11: Engineering Design 52 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt All Done for Today More PPT Tips Engineering-11: Engineering Design 53 Tip 1: Put the PPT files on a USB Drive Tip 2: Use Arial or Times New Roman Font Tip 3: Always Carry the Microsoft PowerPoint Viewer Tip 4: Print a PDF of your PowerPoint Presentation Tip 5: Take Care of Margins Tip 6: Some Presentation Rooms Can Be Very Big Tip 7: TurnOFF Screensavers, etc. Tip 8: Power Management Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Engineering 11 Appendix Bruce Mayer, PE Registered Electrical & Mechanical Engineer BMayer@ChabotCollege.edu Engineering-11: Engineering Design 54 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt Tip 1: Put the PPT files on a USB Drive Yes, there’s box.net, slideshare.net and tons of other PowerPoint hosting services where you can upload your PPT files but I still recommend carrying files on a USB drive because there are chances that Internet may be very slow (or unavailable) in the presentation room. With files on the USB stick, you are always in control. Tip 2: Use Arial or Times New Roman Font The default fonts in Office 2007 programs are Calibri, Corbel, Cambria, etc but unfortunately these fonts are not available on computers running older version of Microsoft Office. If you want the presentations to look the same in the conference room as on your laptop, use fonts like Arial or Times New Roman which are universally available. Tip 3: Always Carry the Microsoft PowerPoint Viewer You have designed a great presentation using the latest PowerPoint 2007 but it possible that the computer, where you will run the presentation, is running an ancient copy of PowerPoint 2000. In that case, your presentation will fail to run. not run at all. Download the free Powerpoint 2007 Viewer, transfer it your USB drive and be rest assured that your slide show will be play just perfect on any Windows computer. Tip 4: Print a PDF of your PowerPoint Presentation You can use Acrobat or the Save as PDF plugin of Microsoft Office 2007 to convert your PPT into a read only PDF file. Some members in the audience will always ask you for a copy of the Presentation slides and if you are not too happy in giving away the source file, PDF is a great alternative - it also maintains the layout, transitions and even the fonts. Tip 5: Take Care of Margins If the display properties of your computer do not match that of the projector, chances are that the presentation slides will be cut off at the edges - to avoid this, designate a margin safe area when designing presentations and limit your text or graphics to that area. Tip 6: Some Presentation Rooms Can Be Very Big Do not use small fonts as that will make your slides unreadable especially for back-benchers when the room size is large. The minimum recommended font size in PPT slides is around 24-points (more for headings). Tip 7: Screensavers, IMs, New Email Notifications Turn Off all these distractions before running the slideshow - they can sometimes be very embarrassing. Tip 8: Power Management Some computers (especially laptops) turn off the screen after 5-10 minutes of inactivity. Always turn off this feature using the Power management console. Engineering-11: Engineering Design 55 Bruce Mayer, PE BMayer@ChabotCollege.edu • ENGR-11_Lec-07_Chp13_Detail_Design.ppt