Product

Deign & Rapid

Prototyping
(PDRP)
(Idea to Reality)
(Problem to solution)
 Product Design & Rapid Prototyping

Subject code: UME537N Exam hours: 03

No of Lecture Hours/week: 03 Exam marks:100

Total no of Lecture Hours:40

Books
1.Product design & development by Karl T Ulrich and Steven D Eppinger
2.Rapid Prototyping principles and applications by C K Chua, K F Leong
and C S Lim

Shivanand C Yali 9448408057

 Problem Solving
Product design is the process of imagining, creating, and
iterating products that solve users’ problems or address
specific needs in a given market

Idea to Reality

Technology for Solving

Rapid Prototyping is the best technique used in every phase
of product design
 Why PRODUCT DESIGN ?
Earlier we call our self as a agriculture based
economy. But with the government programs
like
i)Make in india
ii)Stand up india
iii)Start up india

.....there are so many issues in which we can

contribute and now India focus is more on
manufacturing
Idea to Reality…… start with idea- many iteration-best solution
Our major focus till now are on
i) Manufacturing the product
ii) Assembling the products

But we are lacking in designing the product

So design approach must change in our

engineers to become self sufficient, self reliant in
designing the best possible products
 Many multinational companies were manufacturing their
products in our country

But we are not the best designer

The design of the car or automobile is done by some other

country and India is used as manufacturing hub to
produce that product or to assemble that product
Our focus should be to become a designer, to train our
designers to best designers in the world
So now many of technical institute have focus and teach on
the course of product design
What is product design?

Any Problem - solving that problem ie Product

What is design?
Design is a plan
is a specification Many
is a drawing
is a process of imagining
is a fundamental human activity and capability
is the realisation of a concept
is to make something .......... etc
So

Design is a ...
way of thinking
Lets see a example
Which shape is different?
Answer may be
The only one with straight lines( made with
only straight lines)
The only one with no points
The only one that is asymmetric

So which is correct.....
All answers are correct ?

So Design is a way of thinking

(Thinking Divergently (differently) , iterative
(Refining) )
Earlier to today (way of thinking changed-change in product-
better product –because of way of thinking- design)
What is product ?
Product is developing something, which is useful
for the customer ( understand customer needs,
economics)
If no customer no point in developing a product
A product is any item or service you sell to serve a
customer’s need or want.
A product can be physical or virtual.
Physical products include durable goods (such as cars,
furniture, and computers) and nondurable goods (such
as food and beverages).
Virtual products are offerings of services or experiences
(such as education and software).
A product may be a hybrid and include both physical and
virtual elements.
Product design is therefore is about answering
problems

So product design is Thinking divergently, making

iteratively
ie
Something produced by human or mechanical
effort, or by a natural process to solve problem
Definitions .......

•
PRODUCT DESIGN IS ABOUT ANSWERING PROBLEMS
•
Is to create a new product to be sold by a business to its customers
•
Efficient and effective generation and development of ideas through
a process that leads to new products
•
Process of creating or improving a product by learning what
consumers wants and examining similar products that are already
available
Product design describes the process of imagining, creating,
and iterating products that solve users' problems or address
specific needs in a given market
 Rapid Prototyping (Additive & Subtractive )

3D printing has become the fastest and most

accurate way of bringing your design to life and
seeing a physical representation of it.

Since the 1980’s, technology in additive

manufacturing has advanced and has become an
essential part of the product design phase in
almost every industry
Letsknow what is manufacturing(RP is also Manu...)
Product is developing something, which is useful for the customer
•

Design is a way of thinking

•

So product design is Thinking divergently, making iteratively-right at first

•

time
Rapid Prototyping (Manufacturing) is the tool used in product design
•

The product design process has experienced huge evolution over the last few
•

years with the rise and adoption of 3D printing

Rapid prototyping takes your idea out of the computer and into the real
•

world

Many geometry
Iteration Many material Final Product
Many colour

So PD + RP =PDRP
 Traditional Methods (Earlier, old)

Manufacturing Input Processes Out Put

Raw material Useful Product
Conversion of raw materials in to useful product
● Manufacturing process can be additive, subtractive, or formative

● Casting
● Machining
● Forming Traditional Methods
● Joining

Very less scope for rethinking in traditional methods

 NonTraditional Methods (Latest. new)

Rapid Prototyping
SUBTRACTIVE ADDITIVE
 Create parts by removing  Build objects by adding
material
material
Layer by layer material is
 Layer by layer material is
gradually removed from a solid
block to fabricate 3-D product. added one over another to
More waste develop desired solid 3-D product

CNC Minimum waste

3D Printing
 Subtractive Manufacturing (RP) (CNC)
You want to make a sphere...

The really old way: Take a block of material and carve it

out

The more modern way:

• Generate 3D model
• Generate CNC program
• Machine away unwanted
material
 Additive Manufacturing (RP)(3D Printing)
●
Generate a 3D model
●
Software slices the 3D model
into thin slices
Machine builds it layer by layer
●

Both can be rapid prototyping

 Why PD & RP =PDRP

The product design process has experienced huge evolution

over the last few years with the rise and adoption of 3D printing

Rapid prototyping takes your designs out of the computer

and into the real world

So Product design and Rapid Prototyping go together

 What is RAPID PROTYPING?

Group of techniques used quickly fabricate a

scale or working model of a physical part using
three-dimensional computer aided design data

Magic printer
Converting 2D to 3D
Direct scale or working model
•
Defined as process that automatically create physical prototype
from 3D CAD model in a short period of time
•
Suppose if u design a CAD model, the same part comes out of
printer
•
Magic printer
•
If u design a cylindrical bearing –gives the print command – the
part comes out of printer
•
Here parts are built by adding layer by layer
•
The concept used is if u give a CAD model . Which is sliced into
different layers
 Benefits(PDRP)
Increase sales of your products or service

Improve market position

Boost customer loyalty (Repeatedly purchase)

Reduce customer complaints

Create new products and services and open up new markets

(Add on )

Reduce time to market for new products and services (idea

to finished product)
 UME639N : PRODUCT DESIGN & RAPID PROTOTYPING

Unit –I
Introduction : Definition , importance of PD, Objectives of PD,essential requirements of PD, who
designs product, Project team, steps in new PD, Characteristics of successful product
development, duration and cost of product development , challenges of product development,
Design for manufacture, remanufacturing , sequential and concurrent engineering .

7 Hours

Design for manufacture & assembly: Design for Manufacture and Assembly, History ,
Implementation of Design for Assembly , Design for Manufacture , How Does DFMA Work,
Advantages of Applying DFMA during Product Design design for Maintainability, Design for
Environment Design for safety, Vision and Illumination design 7 Hours

Unit-II
Development processes and organizations :A generic development process, Usefulness of a well-
defined Development Process, task & responsibilities for marketing, design and manufacturing ,
concept development: the front end process, adopting the generic product development process,
process flow diagram for variant of products, product development organizations (functional,
project & matrix) 6 Hours
 Unit-III
Introduction: Prototype fundamentals,definition of Prototypes, types of prototypes, need for
the compression in product development, RP fundamentals , RP wheel, history of RP
systems, applications of RP, growth of RP industry, basic principle of rapid prototyping
processes, classification of RP systems . advantages and disadvantages of rapid
prototyping

Stereolithogrphy systems: principle, process details , advantages and disadvantages,

applications 10 Hours
Unit-IV
Selective Laser sintering: principle, process details , advantages and disadvantages,
applications. Fused deposition modeling: principle, , process details , advantages and
disadvantages, applications. Laminated object manufacturing : principle, process
details, LOM materials advantages and disadvantages, applications. Solid Ground
curing: principle of operation , machine details, advantages and disadvantages,
applications

10 Hours
•
TEXT BOOKS:
•
1.Product design & development by Karl T Ulrich and Steven D Eppinger
•
2.Rapid Prototyping principles and applications by C K Chua, K F Leong and C
S Lim
•

REFERENCE BOOKS:
•

•
1.Product Design and Manufacturing - A C Chitale and R C Gupta, PH1, - 3rd
Edition, 2003.
•
2. New Product Development - Timjones. Butterworth Heinmann -Oxford. UCI -
1997
 HOW ?(PD benefited from RP)
•
Realizing the design concepts

•
Incorporating the changes instantly

•
Saving cost and time

•
Customizing designs

•
Minimizing design flaws
Realizing the design concepts
•Rapid prototyping allows designers to realize their concepts
beyond virtual visualization

•This enables to understand the look and feel of the

design ,rather than simply assuming through the CAD model

•Helps designers to carry forward their ideas and implement

them in their design prior to finalization

•It also provides a proof of concepts for investor

Incorporating the changes instantly

•Having a physical model in hand, it is possible to

incorporate the changes instantly by asking the feedback
from the customer

•Prior to finalizing the design , there are several

iterations required

•With each iterative process, the design improves

further , building confidence for both designer as well as
the end consumer
 Design is always an iterative process requiring multiple rounds
of testing, evaluation, and refinement before getting to a final
product.
Rapid prototyping with 3D printing provides the flexibility to
create more realistic prototypes faster and implement changes
instantly, elevating this crucial trial and error process.
Saving cost and time

•With additive manufacturing, the cost and time

required to develop moulds , patterns and special tools
can be eliminated

•The same CAD software and the printing equipment

can be utilized to produce different geometries

•Waste is less as compared to conventional (subtractive)

Customizing designs

•Is the ability to develop customized products as per the

individual requirements

•It requires no special tool or process to implement

design changes in the product (Car with storage space)

•A small change in the CAD model and the entire

process remains the same
Minimizing design flaws

•The additive manufacturing offers the ability to

identify flaws in the design prior to mass production
•The risks of faults and usability issues can be identified
earlier to avoid problems that might occur later during
manufacturing process
•The use of RP in product design is indeed a profitable
decision and must be encouraged in the manufacturing
organization
Dress organizer
LEDoorHandle
Chair with Book shelve
Load Carrier for Labourer

Indian Wins Best Product Design

 Folding bicycle
•
It’s a sports device which can easily be carried uphill
Rocking wheel chair
 Food Packaging
Packaging designs need to make the product
emerge out of a shell and boost its brand
image
 Finger Reader
Finger Reader is a fine example of how visually impaired can be more independent in
places like a grocery store or shops.

The reader is a combination of a finger device and Bluetooth Headset, where the
finger-pointer scans products for barcodes and relays the product information to
earpiece as audio instructions.

Info like product description, price, ingredients, nutrition etc. is easily accessible
Sony Bracelet Computer

Although this is a concept and we

can only dream of, it will have to
wait a few months to be
implemented.
 Importance of product design
Product design is one of the most important and sensitive factor for an organization

Product design is important to an organization or a brand as it differentiates the



brands from others

We will always differentiate a

Levi’s jeans from a Killer jeans



Arrow shirts are different from Van heusen



Sony tv with other



Iphone with other



This is because their product de sign is different


 Contn….
•
If you actually compare laptops and desktops, they
are just two types of product design of the same
product
•
In the last several years, we have seen that the
market share of desktops has rapidly dropped
•
This is all because of a simple change in product
design
•
Success or failure of the product decides
company's business, market share and reputation
•
So during design stage various factors related to
the product need to be addressed
 Objectives of the product design
•
To ensure growth of the organization

•
To make the product more effective and create more utility

Understand what the customer wants and design with that in

•

mind

•
To reduce the cost of the product (end use)

•
To achieve the desired product quality

•
To meet new requirement of the customers

•
To increase company's market share and to target new market
•Product is developing something, which is useful for the customer
•Design is a way of thinking
•So product design is Thinking divergently, making iteratively-
right at first time (physical or virtual)
•Rapid Prototyping (Manufacturing) is the tool used in product
design
•Types of Manufacturing (Traditional and Non traditional)
•Benefits

Many geometry Final Product

•Iteration Many material
Many colour
 Benefits(PDRP)
Increase sales of your products or service

Improve market position

Boost customer loyalty (Repeatedly purchase)

Reduce customer complaints

Create new products and services and open up new markets

(Add on )

Reduce time to market for new products and services (idea

to finished product)
 Benefits (RP in PD)

Realizing the design concepts

Incorporating the changes instantly
Saving cost and time
Customizing designs
Minimizing design flaws

66
 Results of product design
•
Designers come up with new and interesting things that
makes us dream nicely about our future
•
From simple items to complicated ones
•
They are designing new products that fascinate us and
are meant to help us and make our life easier and more
practical in the future

A few of these new products ideas are

Simple to complex(Innovative)
Essential requirements or features of
good product design
 1. Function
The product must be designed in such a way that it
optimally performs the main task or function for
which it is purchased by a buyer.
In other words, the product must satisfy the needs and
wants of the consumer.
• For e.g. The main function of an Air Conditioner (AC) is
to provide quick cooling of a room. So, AC must be
designed in such a way that it can cool a room as fast as
technologically possible. If it doesn't meet basic
expectations, the consumers won't buy it.
• For example, a customer expects a gas lighter to be
convenient (i.e., to instantly light the gas stove). If the gas
lighter cannot achieve that, then the purpose is lost as the
basic function is not met

• Taking data and instructions from a user, processing the

data as per instructions, and displaying or storing the
processed data, are the functions of a computer
2. Repairability
Repairable products make good sense

Repair is good for manufacturers , good for economy , and

good for environment
The product must be designed in such a way that it can be
easily repaired whenever necessary during a malfunction.
The product repairs must be done quickly that too at a low
repair cost.
Consumers usually don't buy those costly products, which
are either very expensive to repair / maintain or those who
take a longer time and more money for repairing.
1. An example of a repair is a repairing brake system,
clutch, lighting etc in a car.
2. Repairing of compressor in fridge
3. Repairing of Bearing in a fan
 3.Reliability
• Consumers prefer to purchase and use often those products which
perform their main function or task optimally for a longer period
without any annoying malfunctions, breakdowns or failures.
• In short, a product must perform quite well and give trouble-free
service for a decent amount of time.
• It must not need constant repairs and/or frequent maintenances. It
is so, since repairs often turn costly and are very time consuming.
• A reliable product gains consumers' trust, loyalty and this creates
its goodwill in the competitive market.
• Therefore, reliability is an important factor to be kept in mind
while designing a product.
• Godrej steel almirah, sony tv’s, apple iphone’s etc
 4. Aesthetics

• Engineering involvement with aesthetics is vital for the creation of

innovative and successful products in today’s fast changing world
• If something is aesthetically pleasing to you, it is pleasurable and
you like it
• If it is aesthetically displeasing to you, it is displeasurable and you
don’t like it
• Aesthetic involves all of your senses – vision , hearing, touch, taste
and smell
• Aesthetics must be kept in mind while designing a product.
• It refers to, how the product looks, feels, sounds, tastes or smells.
Aesthetics is the most crucial factor that needs to be considered in
product design
• That is, the product must look, feel, sound, taste or smell very
good.
• It must be attractive, compact and convenient to use.
• Its packaging must also be made graphically appealing and
colorful.
• If this aspect is not considered, product will fail in the market.

EX:
• A flowery colorful clock might be chosen for aesthetic reasons
• Attractive shape of the vacuum cleaner
• Pleasing shape of car
 5. Durability
• Reliability is ability of a product to "not fail" in a given time-
frame. Durability is length of time a product is functional. Now,
this may seem the same on surface, but it is not. Reliability is
mean time to first failure, but durability is when the product can
no longer work.
• Durability refers to the life of a product.
• A durable product performs flawlessly for a longer period.
• It is a sign of a good-quality product. Consumers want their
products to have a longer life.
• This factor is very crucial for durable and costly products like
televisions, refrigerators, cars, so on.
• Therefore, durability is another important requirement that must be
kept in mind while designing a product.
• Maruthi cars are known for durability-2 years warranty-minimum
5 years nothing will happen
 6. Producibility (able to produce)

• The product must be designed in such a way that it can

be produced in large quantities with ease at a minimum
production cost.
• The production department must be able to produce the
product easily, quickly, in ample quantities and at a low
production cost.
• Organization should be capable
• The production process must not be very complex, and it
must not require costly machines to produce the product.
 7. Simplicity

• The design of the product must be very simple.

• The simpler a design, the easier, it is to produce and use

(handle).

• Simple products are also economical and reliable.

• The product must have the least number of operations

without affecting its functionality.
 8. Compact
• The product must be small; it must occupy less space,
and must have lower weight.
• In other words, it must be very compact.
• The company must try to make its products as small
as possible.
• Today, everything is turning smaller. Big sized cell
phones are now out of fashion.
• In the 1950s, computers were as huge as spacious
rooms.
• However, today we have laptops and palmtop
computers.
• Most products can be made compact. Still, this cannot be done
for all products. In some case, it is just the opposite

• Today people want bigger televisions. Similarly, there is a limit

on small size. We cannot have a phone which is so tiny that it
requires a microscope to see its keypad.
 Essential requirements or features of good
product design

Ac, Gas stove Lighter ,Computer

Do for what it was designed

small,occupy less space, and lower weight Compressor in fridge, Bearing in a fan
depends on product repair make good sense
economy , environment

Godrej fridge, sony tv’s, apple iphone’s

Trouble free service for decent
Wireless charger period
Easy to use

Organization limitation • Attractive shape of the vacuum cleaner

Able to produce Pleasing shape of car
vision , hearing, touch, taste and smell
Maruthi cars, Samsung fridge
Longer period life
Who designs products?
• It is an interdisciplinary activity requiring
contributions from nearly all the functions of a
firm
• However, three functions are almost always central
to a product development project
• Marketing
• Design
• Manufacturing
Marketing (bridge)
• The marketing function mediates the interaction between the
firm and its customers
• Marketing often facilitates the identification of product
opportunities (demand), the definition of market segments (who
is your customer), and the identification of customer needs
(wants)
• Marketing also typically arranges for communication between
the firm and its customers, sets target prices (best price ) and
oversees the launch and promotion of the product
Design (idea that meet need)
• The design function plays the lead role in defining the
physical form of the product to best meet customer needs
• In this context, the design function includes engineering
design( Mechanical, electrical, software, etc) and industrial
design (aesthetics, ergonomics(designed to work smoothly with
human body)) Key board
• Need (customers wants) to Product (how need is to achieve)
Manufacturing (physical)
• The manufacturing function is primarily responsible for
designing and operating the production system in order to
produce the product
• Broadly defined the manufacturing function also often
includes purchasing, distribution and installation
Project Team (structure)

Project Team members can be divided into two groups,
Core and Extended.


Core Team Members often have a full time roles whilst
Extended Team Members may be involved on a part
time or as-needed basis


Project team usually has a single team leader, who could
be drawn from any of the functions of the firm
The team can be thought of as consisting of a core (key
persons) team and an extended (support) team

In order to work together effectively, the core team usually

remains small enough to meet in a conference room, while
the extended team may consists of dozens, hundreds or even
thousands of other members
Core Team
A core team or a core group is a group of people who do the main
part of a job or piece of work. Other people may also help, but only
for limited periods of time
Different individuals within these functions often have specific
disciplinary training in such as market research, mechanical
engineering, electrical engineering, material science, or
manufacturing operations- Key Persons

Extended Team
But Several other functions including finance and sales are
frequently involved on a part time basis in the design of
new product- Support
The collection of Core and Extended team is the project team
What is a Core Team?
•
A Core Team (CT) is composed of several subject matter
experts who are led by the team leader to work on a
particular project (small enough- decision makers)
Common responsibilities of the Core team

1.Carrying out project-related decisions based on their

field of expertise

2.Leading and directing the extended team

3. Administrating the project budget

What is an Extended Team?
The extended team is a group of experts from outside
brought in to project to help core team
An extended team is an extra pair of hands for your core team.
The extended team model is a form of outsourcing (any number)
Common responsibilities of the Extended team

1. Delivering subject-matter expertise

2. Carrying out tasks based on the company’s project

plan

3.Working with the core team

 Steps in new product design (General)
In today’s competitive market, the
ability to offer product that meet customer’s
needs and expectations has never been more
important .
Rather
They need to be innovative (Different)

•
1. Idea Generation (Internal, external and Competitor)
•
2. Screening Ideas (Filtering, promising ideas taken further)
•
3. Feasibility Study (market, economic and technical analysis)
•
4. Preliminary Design (form and function)
•
5. Pilot Runs and Testing (prototypes)
•
6. New Product Launch (ramp up production)
Idea Generation
•
The design process begins with understanding the
customers and their needs.
•
Ideas for new products can come from a variety of
sources both within and outside the firm.

Sources of idea generation are the people and places from where
you get your ideas.

It may be Internal or External

Several internal and external sources help to
generate ideas.
Employees and the research & development
department of the company are great internal
sources.

Whereas, external sources are customers,

environment, suppliers, competitors, distribution
channels, government, educational institutions, and
focus groups.
Competitors are also the source of ideas for new
products or services.
Screening Ideas
Idea screening refers to reviewing
new-product ideas in order to drop
poor ones as soon as possible

•
The purpose of screening ideas is to eliminate those ideas that do
not appear to have high potential and so avoid the costs incurred
at subsequent stages
•
To have a better evaluation of ideas, each of the dimensions of
the ideas is scored on a 0-10 scale
•
The resulting aggregate score helps in deciding which idea to
progress and which idea should be dropped

Initial screening of the ideas is designed to stop the ideas,

which are unsuitable for further considerations
The screener must ask at least three questions

Will the customer in the target market benefit from the

•

product?

•
Is it technically feasible to manufacture the product? Yes

Will the product be profitable when manufactured and

•

delivered to the customer at the target price?

Feasibility Study Market
analysis
•
A feasibility study is an assessment of the practicality
•
Feasibility study consists of a
1 Market analysis Economic Technical
analysis analysis
2 Economic analysis
3 Technical analysis
•
The market analysis through customer analysis and market
survey assesses whether there is an enough demand for the
proposed product to invest in developing further.
•
If the sufficient demand exists, then there is an economic
analysis that aims at establishing the production and
development costs and compares them with estimated sales
volume.
•
Finally, technical analysis is concerned with technical viability
of the product with respect to technology, process of
 Design is not just how it looks but also how it works.

Preliminary Design
•
Design engineers take general performance specifications and
translate them in to technical specifications
•
The process of preliminary design involves building a prototype,
testing the prototype, revising the design, retesting and so on
until a viable design is determined
•
Preliminary Design incorporates both function and form.
Preliminary design starts with the functional baseline
Functional design can refer to a focus on function for what it was
designed
Form design refers to the physical appearance of a product, its
shape, size, color, styling etc.
Aesthetics aspects such as image, market appeal, special
identification, finish etc. will also form a part of the form design
Function and form are always interconnected. In every good design,
there's a balance between both
Pilot Runs and Testing
•
In the preliminary design stage, prototypes are built and tested
after several iterations, pilot run of the manufacturing process is
conducted (Small no produced and released )
•
Adjustments are made as needed before finalizing the design.
•
Apart from continuously testing the product for performance,
market testing is also carried out to check the acceptability of the
product in the defined market and customer group
•
This helps to know in advance, whether customer will accept and
buy this product on launching in the market
•
Thus, test marketing is a powerful tool
 New Product Launch
A product launch is a planned effort to bring a new product to market..

If you don’t do the product launch effectively, you may not hit your revenue and
profitability goals.
•
Launching a new product or service involves ramp up
production.
•
The process has been refined and debugged, but it has yet to
operate at a sustained level of production.
•
In ramp up, production starts at a relatively low level of volume,
as the organization develops confidence in its abilities to execute
production consistently and marketing’s abilities to sell the
product, the volume increases.
•
Launching the new product or service involves co-coordinating
the supply chain and rolling out marketing plans.
•
Marketing and production will work in a co-coordinated way
 1. Idea Generation (Internal, external and Competitor) S
•

2. Screening Ideas (Filtering, promising ideas taken further) (Funnel)

T
•

•
3. Feasibility Study (market, economic and technical analysis)
•
4. Preliminary Design (form and function) E In PD

•
5. Pilot Runs and Testing (prototypes) (detailed Design) P
•
6. New Product Launch (ramp up production) S
Market
analysis

Economic Technical
analysis analysis
Characteristics of Successful Product
Development
•
Successful product development results in products that can be
produced and sold profitably
•
Five specific dimensions are commonly used to assess the
performance of a product development effort

•
Product quality
Key things once achieving
•
Product cost
•
Development time needs to be regularly monitored and
•
Development cost Additional things be improved based on market and
customer feedback.
•
Development capability
Product Quality (Essential Requirements)
Product Quality is the collection of all the features and characteristics
of a product that contribute to its ability to meet the customer needs
and requirements
It’s the ability of the product to fulfill what the end user wants
•
How good is the product resulting from the
development effort ? Essential Requirements

•
Does it satisfy customer needs?
•
Is it robust and reliable?

So quality refers to the ability of a product to consistently meet or

•

exceed customer requirements or expectations i.e essential

requirements

So Product quality is ultimately reflected in market share and

•
A quality product has a good price for value.
•
Sony- High quality picture
•
Apple- High quality Mobiles
•
The mercedes –High quality car
•
People know that when they pay the price, they are getting an
product that is top of the line
•
So mercedes apple & sony are able to charge more for high
quality
Product Cost
Refers to the costs used to create a product. (optimum)
Product costs include direct material (DM), direct labor (DL), and
manufacturing overhead (MOH).

1. Direct material
Direct material costs are the costs of raw materials or parts that go directly
into producing products.
2. Direct labor
Direct labor costs are the wages, benefits, and insurance that are paid to
employees who are directly involved in manufacturing and producing the
goods
3. Manufacturing overhead
Manufacturing overhead costs include direct factory-related costs that are
incurred when producing a product, such as the cost of machinery and the
cost to operate the machinery (glue, oil, tape, cleaning supplies, security
guards, supervisors)
Product cost determines how much profit accrues to the firm for a
•

particular sales volume and a particular sales price

Example of Product Costs
Company A is a manufacturer of tables. Its product costs may
include:
O
P Direct material: The cost of wood used to create the tables.
T
I
Direct labor: The cost of wages and benefits for the carpenters
M to create the tables.
U Manufacturing overhead
m

i)indirect material: The cost of nails used to hold the tables

together.
ii)indirect labor: The cost of wages and benefits for the security
guards to overlook the manufacturing facility

So cost should be optimum

Development Time
A firm will be most successful if its development times are shorter

•
How quickly did the team complete the product development effort ?
•
Development time determines how responsive the firm
•
How quickly the firm receives the economic returns from the team’s
efforts
•
Refining the design process to maximize speed whilst protecting the
user experience is a delicate balancing act

The new product process must respond to the three unique inputs
the right quality product, at the right time , and at the right cost

Key things once achieving

Development cost
•
How much did the firm have to spend to develop the product?
( addition to product cost)

•
Development cost is usually a significant fraction of the
investment required to achieve the profits
•
This is the cost that cannot be assigned to the product, but
charged as an expenses for further
•
Fixed one
•
Non manufacturing cost
•
i.e office & administration , selling & distribution
•
Salary , rent, audit fees, depreciation on office assets etc
So when organization able to arrange expenses of development
cost- successfull
Development Capability

•
Are the team and the firm better able to develop future product
as a result of their experience with a product development team?
•
Development capability is an asset the firm can use to develop
products more effectively and economically in the future

High performance along these five dimensions should

ultimately lead to success of Product
 The challenges of product development
Developing a product from scratch can present several unknown challenges

Product designers face various challenges during the development cycle, however,
not all of them are technical. Some of the challenges are due to external factors
also
Developing great product is hard

Turning an idea into a marketable product is complex and

multifaceted, it is full of challenges
1. Trade offs
2. Dynamics
3. Time Pressure
4. Economics
5. Creation
6. Team diversity
7. Team spirit
Trade off
It is a situation that involves losing one quality or aspect of
something in return for gaining another quality or aspect .

Ex :Large cars can carry many people, but they also tend to be
heavy and hence have relatively poor fuel economy
Trade-off means that a balance achieved between two desirable
features. This is the most difficult part of product development.

An airplane can be made lighter, but this action will probably

increase manufacturing cost
One of the most difficult aspects of product development is
recognizing, understanding, and managing such trade-offs in a
way that maximizes the success of the product
Dynamics

Being successful in the market is not only the end but sustaining the
competition in the market is also even more challenging

As the technologies improve, customer preferences changes/evolve

and the introduction of the new products in the markets. The
decision making in this kind of environment is a challenging task

So, decision making is an environment of constant change is a

formidable (very difficult) task

Team should be Dynamic

Time Pressure
Most product design companies compete to launch the product
first in the market
Increasingly product development teams are experiencing greater
time pressure due to intense competition
But product development decisions must usually be made quickly
and without complete information
Due to global competition, the entire new product development
from concept to market launch is often carried out to a very tight
delivery schedule.
Economics
Product economics is all about profitably developing and
selling an engineering product to solve a customer’s
problem
To earn a reasonable return on this investment, the
resulting product must be both appealing to customer and
relatively inexpensive to produce
Thus, the challenge is to make the correct decisions during the product design
stage so that subsequent costs (material, labour & overheads) can be kept to a
minimum.

The product should be a reasonable price so that the customers are willing to pay and
inexpensive to produce.
Creation – The product development process begins with an idea
and ends with the production
Understanding creativity in the context of a product
development team is of paramount (more important)
importance, especially in the high-technology industry where
creativity is a key resource
So the product development process is intensely creative

Team diversity – Successful development requires many

different skills and talents
As a result, development teams involve people with a
wide range of different training, experience, perspective
and personalities
Team spirit- Product development teams are often highly
motivated, cooperative groups
The team members may be set side by side so they can focus
their collective energy on creating the product
Characteristics of Successful Product Development Five specific dimensions are commonly
used to assess the performance of a
•
Product quality product development effort

•
Product cost Key things once achieving
•
Development time
•
Development cost needs to be regularly monitored
Additional things and
•
Development capability be improved based on market and
customer feedback.

The challenges
Product designers face various challenges during the development cycle

1. Trade offs (losing one quality for gaining another quality)

2. Dynamics (Team should be Dynamic) (sustaining competition)
3. Time Pressure (First to market) (short development time) (global)
4. Economics (Optimum cost) (Reasonable)
5. Creation (creativity gains importance)
6. Team diversity (Skill and Talents)
7. Team spirit (Cooperative) (team work)
IMPORTANT ASPECTS IN PRODUCT
DESIGN
Some additional factors those need to be considered during the
product design stage
Concurrent and Sequential Design
Remanufacturing
Design for Manufacture
Design for Assembly
Design For Manufacture and Assembly
Design for Environment
Design for Maintenance
Design for Safety
 Sequential and Concurrent Design

Sequential engineering is the term used to explain the

method of production in a linear system.
The various steps are done one after another, with all
attention and resources focused on that single task.
Traditionally, products were designed and manufactured
following the sequential engineering methods
Where people from different departments work one after
the other on successive phases of development
 Sequential and Concurrent Design
•
There are two approaches to product development process
•
Those are sequential and concurrent design

•
When a company undertakes to design a new product, there are many
stages it has to go through before the product reaches the marketplace
•
Traditionally, products were designed and manufactured following
sequential methods
 Sequential Design
•
Early Many companies organise this in an orderly sequence, with
each stage having to be completed before the product is released
onto the next stage. This is referred to as sequential engineering
or consecutive engineering.
•
No department ever has an overview of the whole process, this
can be compared to passing the information over a brick wall to
the next department and not being able to see it again

QUALITY DISTRIBUTION SALES

RESEARCH DESIGN MANUFACTURE
CONTROL

OVER THE WALL ENGINEERING

In sequential engineering, each step is worked on in a
certain order.
All attention is put toward completing the first step of the
project until it is complete. Once the first step is complete,
the engineering team will then move on to the second step of
the project.
Sequential engineering is sometimes referred to as "throw-
it-over-the-wall" engineering, because of the linear order in
which a project is completed
•
As a result, there is little communication between departments
and often a lack of interest and concern amongst employees on
issues such as quality control and product management
•
The product is first completely defined by the design
department , and then manufacturing department take over and
define the manufacturing process, etc
•
This was a lengthy process
•
This orderly step-by-step process will bring control to complex
projects but is very slow.
•
In today’s highly competitive marketplace this can lead to
product failures and lost sales.
 Advantages and disadvantages
Advantages
•
It is a simple, well-defined method and easy to understand
•
It is easy to manage due to the rigidity of the model
•
In this phases are processed and completed one at a time i.e do
not overlap
Disadvantages
•
Once an application is in the testing stage, it is very difficult to
go back and change something
•
Customer does not see a working product until the end, and if
any changes need to be made at that point it can be costly and
time-consuming.
•
This is therefore a slow and costly approach, often leading to a
low quality and less competitive product
 Concurrent Design
•
Concurrent engineering is a different approach to product
development within engineering and is the preferred approach.
•
During a concurrent design, several teams work on different phases
of the design at the same time.
•
Is a strategy where all the tasks involved in product development
are done in parallel.
•
Collaboration between all individuals, groups and departments
within a company.
Concurrent Engineering = Team collaboration
•
Concurrent is a work methodology based on the parallelization
of tasks
•
It is a well defined systems approach towards optimizing design
cycles
•
Because of this, concurrent has been implemented in a number
of companies, organizations
•
In this several teams within an organization work simultaneously
to develop new product and this allows a more streamlined
approach
•
Here different tasks are tackled at the same time and not
necessarily in the usual order
•
Information found out later in the process can be added to earlier
parts, improving them, and also saving lot of time
•
Ex the design team for an auto manufacturer can work on the
shape of a new car while technicians test its aerodynamics in the
wind tunnel
•
Team knows the design goals/objectives
Team is aware of the interrelationships between all aspects of the
•

design process
•
Superior communication between all sections of the company
As the cost of petrol rises, car manufacturers are taking more and more care in
designing their cars to be fuel efficient.
making sure a car meets as little resistance as possible from the air it travels
through. The more aerodynamically efficient it is, the less fuel it will use to
travel along at any given speed. The faster the car moves, the more important
it is to keep the air resistance - drag - to a minimum.

The aerodynamic efficiency of a car's shape is measured by its co-efficient of

drag (generally known as its Cd figure). For example, a flat plate held at right
angles to the airflow has a Cd of 1.25, whereas the most efficient production
car shapes at the moment have a Cd of about 0.28.
•
Is a long term business strategy, with long term benefits to
business
•
Though initial implementation can be challenging (Technology made easy)
•
It removes the need to have multiple design reworks, by creating
an environment for designing a product right the first time
 Advantages
Enhanced quality : Enable workers and managers to discover
any production issues earlier in the process, which leads to a
higher quality product
•
Companies will keep look with changing markets
•
Decisions made sooner rather than later
•
Reduces/eliminates repetition of tasks
•
Reduces waste and reworking of design
•
Product quicker to market
•
Maximises company profit
•
Company operates more efficiently
 Disadvantages
•
It increases the time spent in preliminary design

Additionally, this requires excellent and current communication

•

between all teams, which is sometimes not easily feasible.

(Technology made easy)
IMPORTANT ASPECTS IN PRODUCT
DESIGN
Some additional factors those need to be considered during the
product design stage are
Concurrent and Sequential Design
Remanufacturing
Design for Manufacture
Design for Assembly
Design For Manufacture and Assembly
Design for Environment
Design for Maintenance
Design for Safety
Remanufacturing
Remanufactured product will be a combination of new and reused parts

Remanufacturing is a concept that has been gaining increasing

importance, as our society becomes more environmentally
conscious

Remanufacturing uses components of old products in the

production of new ones.

In addition to the environmental benefits, there are significant cost

benefits because remanufactured products can be half the price of
their new one.

Remanufacturing has been quite popular in the production of

mobiles, computers, televisions, and automobiles.
Remanufacturing is a process by which a previously used, worn, or
non-functional product or part is returned to a like-new or better-
than-new condition, from both a quality and performance
perspective.

It gives products a new life cycle and keeps material out of landfills.
 Not only is remanufacturing an environmentally friendly process,
it allows products to be reused, rather than go to waste, and
therefore supports a circular economy

Remanufacturing requires fewer raw

materials, consumes less energy, and
produces less waste than a product
B
from scratch.
E
N
Remanufacturing
E
F
The savings in each of these areas are
I
significant, and most often result in a
T
product of comparable quality that
S
costs less for both the remanufacturer
and the consumer.

The traditional linear economy pattern

follows the take-make-dispose scheme
The key difference is that the linear economy focuses on
profitability, irrespective of the product life cycle, whereas the
circular economy targets sustainability.

In a circular economy, waste does

not exist and products and raw
materials are (designed to be)
reused as long and intensive as
possible over and over again.
Waste is the new raw material.

This saves raw materials, the environment and reduces CO2 emissions.
Xerox is a key example of successful remanufacture because
its copiers typically undergo seven life cycles

Remanufacturing make
sense nowadays Such aspect has to be considered
during product design

This means that seven revenue streams are generated from the
manufacture of a single product, and materials are diverted from landfill
or recycling at least six times
 Design for Manufacture
•
When we think of product design, we generally first think of
how to please the customer.
•
However, we also need to consider how easy or difficult it is to
manufacture the product.
•
Otherwise, we might have a great idea that is difficult or too
costly to manufacture.
•
So Design for Manufacturing (DFM) is the process of designing parts,
components or products for ease of manufacturing with an end goal of
making a better product at a lower cost.
•
This is done by simplifying, optimizing and refining the product design.

•
“Optimization of the manufacturing process”
Design for manufacturing (DFM) is emphasizing on manufacturing
issues throughout the product development process.

More specifically, how to design a product that will make a smooth

transition between final prototype and mass manufacturing.

Successful DFM results in lower production cost without sacrificing

product quality.

The heart of any design for manufacturing system is a group of

design guidelines that are structured to help the designer to reduce
cost and difficulty of manufacturing an item.
Design guidelines (DFM)

Reduce the total number of parts

Use of standard components
Develop Modular design
Design parts to be multi-functional
Avoid separate fasteners
Use interchangeable parts
Reduce the total number of parts
The reduction of the number of parts in a product is probably the best
opportunity for reducing manufacturing costs.
Less parts implies less purchase, handling, development time,
equipment, assembly difficulty , etc
In general, it reduces the level of intensity of all activities related to the product during
its entire life
Use of standard components
Standard components are less expensive than custom-made items.
•
The high availability of these components reduces product lead
time (Time to Get parts)
•
A standard component is usually an individual part manufactured
in thousands or millions to the same specification(weight,
material , size)
•
Steel bolt, bearings, switches etc
Develop Modular design

A modular design is an approach for product designing which is

used to produce a complete product by integrating or combining
smaller parts that are independent of each other.
With the modular design approach, a complex product (for
example, a car) can be broken down or divided into smaller and
simpler components that are independently designed and
manufactured
A computer is one of the best examples of modular design.
Typical computer modules include a computer chassis, power
supply units, processors, mainboards, graphics cards, hard drives,
and optical drives
Design parts to be multi-functional
•
Multi- functional parts reduce the total number of parts in a design ,
thus, obtaining the benefits
•
Some examples are
•
a part to act as both an electric conductor and as a structural member
•
as a heat dissipating element and structural member
•
Automobile steering wheel, odometer speedometer
Avoid separate fasteners
• The use of fasteners increases the cost of manufacturing a part
due to handling operation
• In general fasteners should be avoided and replaced

• Example integral hinges or snap fits(locking)

• Integral Hinges are used in plastic

Use interchangeable parts
By using interchangeable parts we can make a greater variety of
•

products with less inventory and significantly lower cost and

provide greater flexibility
•
Identical components that can be substituted one for another
•
These parts are made with precision machines so each part can fit
in any product that uses this part

They are made to specifications that ensure that they are so

•

nearly identical that they will fit into any assembly of the same
type.
•
An example of the benefits of applying these rules is seen in
Figure We can see the progression in the design of a toolbox
using the DFM approach.
•
All of the pictures show a toolbox. However, the first design
shown requires 20 parts. Through simplification and use of dfm
guidelines the number of parts required has been reduced to 2. It
would certainly be much easier to make the product with 2 parts
versus 20 parts. This means fewer chances for error, better
quality, and lower costs due to shorter assembly.

2 Vs 20 DFM
DESIGN FOR ASSEMBLY
Design for assembly (DFA) is a process by which products are
designed with ease of assembly in mind.
If a product contains fewer parts it will take less time to assemble,
thereby reducing assembly costs.
In addition, if the parts are provided with features which make it
easier to grasp, move, orient and insert them, this will also reduce
assembly time and assembly costs
The reduction of the number of parts in an assembly
has the added benefit of generally reducing the total
cost of parts in the assembly.

“Optimization of the part/system assembly”

•
“Optimization of the Assembly process”
Guidelines
Simplification of Assembly

Assembly location should be visible and easily accessible

Parts should be symmetrical (for easy orientation during

assembly)

Parts should have self-aligning and self-locating features so that

they cannot be installed incorrectly

One hand assembly

Parts should have self-fastening features

Simplification of Assembly
(Make the parts easier to assemble)

Design the parts so that they can be assembled from only one side.
This one-sided-assembly avoids reorienting the part during the
assembly.
It is recommended to have this assembly side top down, rather than
sideways or upside-down assembly
Gravity is your friend here.
Assembly location visible and easily accessible

If the worker cannot reach the assembly location well,

it will take more time and effort, and also has more risk
of mistakes.
A good example for this is car seats.
They are bulky, and if you design them not so well, the screws
are hard to access underneath the seat and out of view.
Try to put the screws in a location where they are easier to
reach and see
Parts should be symmetrical (for easy orientation during assembly)

Another major factor that simplifies assembly is to have

symmetric parts, especially when one part needs to be
inserted into another one.
The more symmetric a part is, the less time is needed to find
the correct orientation.
An example you are all familiar with is the USB Type A
connector compare to C Type
It fits in only one way.
In our case I often need two or three tries to get it in.
An improvement is the USB Type C connector, which has axial
symmetry and can be inserted in two different orientations.
Even better would be the common headphone jack, which as
radial symmetry and can be inserted in any orientation.
 Parts should have self-aligning and self-locating features
(so that they cannot be installed incorrectly)
When putting the parts together, do they fit together easily or
does the worker need to pay careful attention to make them
fit?
Often, adding a chamfer makes parts easier to join, or having
additional features that make positioning easier.
 One hand assembly

If you can have parts that can be assembled with one hand
only it will be easier than with two hands.
If you need three hands or more, it becomes even more
complex, as by the nature of hands you need more than one
person to do the assembly.
In general, one-person assembly is better than two, and one
hand is better than two. It may not always be possible, but
it may be worth a look.
 Build in Fasteners

Whenever possible, build the assembly features directly into

the parts, instead of using screws.
Snap fits are often just as secure and require no tools to
assemble.
Sometimes screws are necessary, but use sparingly—
fasteners can consume as much as 50% of assembly labor
A snap-fit is an assembly method used to attach flexible
parts, usually plastic, to form the final product by pushing the
parts' interlocking components together
hhhhhhhhh
h
h
hhhhhhhhhhhhhhhhh
 IMPORTANT ASPECTS IN PRODUCT DESIGN
Concurrent and Sequential Design Remanufacturing
Design for Manufacture Design for
Assembly Design For Manufacture and Assembly Design for
Environment Design for Maintenance
Design for Safety
Remanufacturing uses components of old products in the production of new ones.
It gives products a new life cycle and keeps material out of landfills

DFM- “Optimization of the manufacturing process”

Guidelines:
Reduce the total number of parts
Use of standard components
Develop Modular design
Design parts to be multi-functional
Avoid separate fasteners
Use interchangeable parts

DFA-“Optimization of the Assembly process”

Guidelines:
DFMA
•
DFM says about ease of manufacture
•
DFA says about ease of assembly
•
There is a trade off between DFM and DFA
•
Try to design product such a way that individual parts are easy
to manufacture as well as assembly of the parts is taken care
It is therefore appropriate to use a combined Design for
Manufacturing and Assembly (DFMA) approach, which has
become the standard today.

DFMA
So design for Manufacture and assembly is the combination of DFM and DFA as shown

A set of guidelines developed to ensure that a product is

designed so that it can be easily and efficiently manufactured
and assembled with a minimum of effort, time, and cost.
Products designed using DFMA principles should have higher
quality and reliability than others.
DFMA also ensures that the transition from the design phase to
the production phase is as smooth and rapid as possible.
It is a concurrent engineering team approach.
The advantages of applying DFMA

•DFMA not only reduces the manufacturing cost of the

product but it helps to reduce the time to market and
quality of the product.

• DFMA provides a systematic procedure for analyzing a

proposed design from the point of view of assembly
and manufacture.
Guidelines

1. Minimize part count

2. Make Parts Multi-Functional
3. Design parts to be self-aligning and self-locating.
4. Use stack assemblies.
5. Design of parts in order to reduce orientation & handling problems
6. Modularize multiple parts in to single sub assembly
7. Design parts that cannot be installed incorrectly.
8. Use Standard Parts
9. Avoid separate fasteners
1. Minimize part count

One of the feature of 3D printing is part count

reduction.
Public studies by NASA and other researchers
have shown that in rocket engines, for example,
80 parts can be reduced to just three.
General Electric has proclaimed that 12 3D
printed parts now replace what would have
been 80 components on its Catalyst turboprop
engine.
2.Make Parts Multi-Functional

A multifunctional part reduces the total number of parts because instead of using two parts for two functions, only one part is needed.
3.Design parts to be self-aligning and self-locating.

Parts and assembly site can be designed to be self aligning

The champers is most common self aligning feature
Self aligning feature must be considered
Four protruding parts at top plate has to align to four holes means if one
protruding part aligned with one hole then automatically other three
4. Use stack assemblies

Part is inserted from top of the assembly so that gravity helps to stabilize

Top down approach

5. Design of parts in order to reduce orientation & handling problems
Parts should be designed with handling in mind
Components should not get tangled/nested together when mixed
together in a box or bin
6)Modularize multiple parts in to single sub
assembly
7. Design parts that cannot be installed
incorrectly.

A difficult-to-assemble product is more likely to be assembled

incorrectly.
The assembly defects represent a significant proportion of quality
defects in many companies
Designers should look for ways to mistake proof their designs,
making the proper assembly of mating parts instantly recognizable
and impossible to assemble incorrectly.
If part of a product can only be assembled in a single way, the
likeliness to make a mistake during assembly is highly reduced
This can be done by using: notches, asymmetrical holes and stops.
8.Use Standard Parts in Assembly
Standard parts are cheaper, more available and often more reliable
than custom parts.
If you can utilize commercially available and field-tested components
rather than custom designing each piece, you eliminate a number of
potential problems.
Personalization and customization are expensive and time-consuming.
Using quality standardized parts can shorten time to production as
such parts are typically available

For Manufacturing For ASSEMBLY

A standard component is usually an individual part or component,
manufactured in thousands or millions, to the same specification (such
as size, weight, material etc...).
A good example is a steel bolt. Bolts are available in a vast range of
standard sizes.
However, each size is manufactured to an internationally accepted
standard.
Car manufacturers, assemble thousands of cars every week, with most
cars composed of standard components and fastners.
9. Avoid separate fasteners
Decreasing the number of fasteners reduces assembly weight, cost, and
complexity.
The alternative to fasteners is to incorporate self-aligning features into parts
design.
If fasteners are necessary then use a common size and/or self-tapping screws
Design your product to join without using screws, fasteners or adhesives.
Is it possible for your product to interlock or clip together?
Screws add only about 5% to the material cost, but 75% to the assembly labor.
Remember: if fasteners are required, try to keep the size, number and type to
a minimum and use standard fasteners whenever possible.
So, all of us come to know that when we have to design a product
whatwe must take care of what are the steps that we must follow
We are trying to acquaint ourselves with the guidleines that may help us
during the product design process
So three tools we laready acquanted i.e DFM DFA DFMA
BY DFM DFA and DFMA we learned how easily manufactured and
assembled- Product is successful
But still there is a possibility of failure of the product for some other
reasons
Failure may not be because of the DFMA guidelines
Some other aspects may be the reason for failure ?
?
Is design taken care about –Environment
Maintanance
Safety
These are also very important now a days
ie DFX
Where X is variable
Where
X- Manufacture
X- Assembly
X- Enviornment
Designer should follow some guidelines ,
X- Maintainibility rules and regulations

X-Safety
Design for the Environment (DFE)

Every product has environmental impacts.

DFE provides organizations with a practical method to minimize
these impacts in an effort to create a more sustainable society.
•Manufacture without producing hazardous waste
•Clean technology
•Reduce chemical emissions
Consider
•Reduce energy consumption
•Use non-hazardous materials
•Use recyclable materials
Design for the Environment (DfE) is a design approach to reduce
the overall human health and environmental impact of a
product, process or service
Where impacts are considered across its life cycle
Design for evironment is a product design approach for reducing
the impact of products on the environment
which aims to make the manufacturing process more
environmentally-friendly
E's (Reuse, Remanufacturing, Recycle)

Reuse

It means using of the object or material again and again

for the same purpose or for different purpose without
altering the form of the product
Reusing is the act of taking old items that you might consider throwing away
and finding a new use for them.

Get the most mileage out of the materials you encounter. Jars from grocery
store foods can be used to store leftovers or to take lunch to work. Use old
clothing as cleaning cloth.

Sometimes materials can be reused by other people. Working computers and

parts can often be donated to community centers or charitable organizations.
Clothing can often be donated and given a second life.
Remanufacture

Remanufacturing uses components of old products in the

production of new ones.
In addition to the environmental benefits, there are significant
cost benefits because remanufactured products can be half the
price of their new counterparts
Not only is remanufacturing an environmentally friendly process,
it allows products to be reused, rather than go to waste, and
therefore supports a circular economy.
As a result, remanufacturing technology greatly benefits the
development of the economy and is becoming a new point of
economic growth.
Recycling
Recycling is the process of converting waste materials into new
materials and objects.
Recycling is the process of collecting and processing materials
that would otherwise be thrown away as trash and turning them
into new products.
Recycling can benefit your community and the environment.
Design for safety

Design for Safety (DfSa) provides design engineers and engineering

managers with a range of tools and techniques for incorporating safety
into the design process
Designers can make decisions that significantly reduce the risks to safety
and health during the construction stage and during subsequent use and
maintenance
It explains how to design for maximum safe conditions and minimum risk
of accidents
safety design practices, which will result in improved safety, fewer
accidents, and substantial savings in life cycle costs for producers and users
Designing systems for safety has been a high priority for many safety-
critical systems—especially in the aerospace and military industries
The General Principles

•Avoid risks.
•Evaluate unavoidable risks.
•Combat risks at source. (Fight)
•Technical progress.
•Replace dangerous articles, substances, or systems of work by
non-dangerous or less dangerous articles, substances, or systems
•Use collective protective measures over individual measures
•Develop an adequate prevention policy
•Give appropriate training and instruction to employees.
 Design for maintainibility

Design for maintenance is a discipline that has become

increasingly important in recent years
Maintainability is the degree to which a product allows safe,
quick and easy replacement of its component parts
It should be embodied in the design of the product.
A lack of maintainability will be evident as high product
maintenance costs, long out-of service times, and possible
injuries to maintenance engineers

1. Preventative maintenance Two kinds of maintenance activity

2. Corrective maintenance (repair) can be identified for any product
 Preventative maintenance

Preventative maintenance, for example replacing engine sparplugs

every 30,000 km, or changing the oil filter.
Preventative maintenance requires the replacement of parts that are
still working but are expected to fail soon.
It is also undertaken where degradation of a component endangers
components elsewhere in the product.
For example an old oil filter may cause serious engine damage by
starving bearings of oil, or allowing abrasive metal sludge into
clean areas.
Corrective maintenance

Corrective maintenance (repair), for example fitting a new vehicle

starter motor where the existing motor has burned out.
Remedial maintenance is performed after the product has failed.

A further consideration is where the components are to be

maintained
1st line maintenance
This could be at the point of use, at a repair depot,
2nd line maintenance or at the point of manufacture

3rd line maintenance

1st line maintenance

1st line maintenance occurs at the point of use.

It could be at home
It is appropriate to the replacement of small modular items that
require a minimum kit of tools and can be replaced within
minutes
Bike Xerox machine
Checking air in tyres Checking papers
Cleaning Cleaning
Checking wire connections Using correct size papers
2nd line maintenance
2nd line maintenance occurs at a nearby maintenance depot.
This could be a car dealer, or your local domestic appliance service
centre.
It is appropriate
---where an extended toolkit or special skills and processes are
required
---where adjustments must be made
---where special handling is required
---where the time to repair may be lengthy
---where reassembly is complex
3rd line maintenance

3rd line maintenance is undertaken by the manufacturer.

It is rare for volume products to be returned to the manufacturer
for repair, but does happen where the repair process requires
skills and equipment beyond those available at the local service
centre.
Examples would be aircraft rewiring or engine rebuilds, and
specialist equipment servicing and repair.

SO while designing, these aspects also considered, will make

product successful