Lesson 01
Manufacturing Guidelines for Product Design
Product Design : Basics
Dr. Inderdeep Singh
Department of Mechanical and Industrial Engineering
1
Product Design Concept
Product design is conceptualization of an idea about a product
and transformation of the idea into a reality.
To transform the idea into reality a specification about the
product is prepared.
This specification is prepared by considering different
constraints such as production process, customer expectation,
etc.
Product Design Concept cont….
In product design stage all aspects of the product are analyzed.
Final decision regarding the product is taken on the basis of the
analysis.
This decision can be any aspect related to the product, e.g.
dimension and tolerances, type of material for each component.
Product Development Process
Concept System-Level Detail Testing and Production
Planning Development Design Design Refinement Ramp-Up
Platform Concept Decomposition
decision decision decision
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Product Design : Steps
1. Synthesis: Try to develop different alternatives.
2. Sketching: Draw sketches in exact scale for different
alternatives
3. Analysis: Analysis different alternatives with respect to
operability, maintainability, inspection, assembling and
dismantling issues, cost parameters, production methods, etc.
4. Selection: Select the best alternative.
Product Design : Steps cont..
5. Basic engineering: Prepare layout in exact scale, calculate
strength of components, select proper cost effective material.
6. Detail design: Prepare detail engineering drawing for each
component.
7. Prototype: If option is there, then prepare prototype and test it.
Product Design :Steps cont..
8. Manufacturing: If prototype is not made, then follow
manufacturing steps and solve manufacturing problems and
assembly problems, if any.
9. Operation: Collect feedback during actual operation of the new
product. If any problem exists, try to provide design based solution.
Also, implement lessons in the future design.
10. Product development: If any modification can be done,
implement the same in the next generation product.
Product Analysis
Many factors have to be analyzed in connection with
development and design.
Factors varying in character and complexity.
Factors affiliated with different fields in production and
industrial engineering.
Some of these factors may be grouped as follows:
1. Marketing aspect
2. Product characteristics
-Functional aspect
-Operational aspect
-Durability and dependability aspect
-Aesthetic aspect
3. Economic analysis
-The profit consideration
-The effect of standardization, simplification and specialization
-The break-even analysis
4. Production aspect
1. Marketing aspect
Once the product is selected, then it is very important to know the
marketability of the product.
All further steps are dependent upon the demand for the proposed
product and customer acceptability of the product.
If there is no potential market, then it is a wasteful exercise to design
and manufacture the product.
It give the answer of following questions:
What will be the expected demand for the product both short-term and
long-term?
Whether the functions that are offered by the product are desirable and
acceptable to the customers?
2. Product characteristics
-Functional aspect
When the marketing possibilities have been explored, the
functional scope of the product has to be carefully analyzed
and properly defined.
The definition of the objective itself rarely tells us much
about the predicted functional scope.
Example : A washing machine
Objective : To wash clothes.
This does not state, however, how the washing should be carried
out, whether the machine should be capable of heating the water
prior to washing, whether rinsing or drying, or both, are to be
done by the machine, and if so by what method, and what
should the proportion be between automatic functioning and
manual supervision.
A functional analysis of this kind obviously affects the design
of the machine, its complexity, its appearance, and its price.
2. Product characteristics
-Operational aspect
The product is not only expected to perform its functions
satisfactorily but it should be easy to handle and operate at the
customers end.
The product is used at different operational conditions and the
customers vary with respect to skill and knowledge and the
designer’s problem becomes complicated with addition of more
functions.
2. Product characteristics
-Durability and Dependability aspect
These two factors define the quality and reliability of the product.
Durability refers to the length of the active life of the product under
given working conditions.
Dependability refers to the reliability with which the product serves its
intended function.
Thus, quality of the product is directly proportional to the quality of
inputs (materials, men, etc.) and the process of manufacture.
Thus, it is a function of cost.
2. Product characteristics
-Aesthetic aspect
It refers to the ‘external look good’ aspect of the product and it is
concerned with molding the final shape around the basic skeleton.
It helps the sales function of the product by attracting the customers
and creating the first impression about the product.
Designers use variety of tools to build aesthetic characteristics into
the products such as:
• Use of special material
• Use of colour
• Texture
• Packaging
http://www.floatproject.org/wp-content/uploads/2011/10/Flower-pot-design-ideas-with-Unique-Design.jpg
3. Economic analysis
An economic analysis is the key to the management decision in
product design policy.
It answer the following questions:
What will be the amount of investment needed to
manufacture the new product?
What are the estimated production costs per piece?
What will be the expected profit margin?
Whether the prices proposed to be offered by the company
are competitive?
Tools in economic analysis
The three S’s (standardization,
simplification and
specialization)
The break-even analysis
http://www.12manage.com/images/picture_break_even_chart.gif
4. Production aspect
The design will be converted in the production shop where it will
be transformed into a physical product to be offered to the
customers
Successful transformation of design into a saleable product is a
challenge to the organization.
Tools in production aspect
DFM
DFA
DFX
