Transcription
Total Design: A Methodology for ProductDesignPart I Introduction to the Concept of TotalDesign Problem Definition-The Brief-The Product DesignSpecification (PDS)Part II Conceptual Design Concept Evaluation-Rating/Weighting-Controlled ConvergenceMethod ConclusionsPrepared by: Miguel A. Torres, Ph. D., P.E. 2001 Miguel A. TorresAssociate ProfessorDepartment of Mechanical EngineeringUniversity of Puerto Rico at Mayaguez
Case Study: IN-LINE SKATESGraphic DesignManufacturingMarket AnalysisIndustrial DesignPackaging EngineeringPlastics EngineeringMechanical DesignErgonomicsTechnical Writing 2001 Miguel A. TorresFluid Design
Case Study II: The PersonalComputerHeat TransferElectromechanical DesignErgonomicsSoftware EngineeringGraphic DesignPlastics EngineeringMechanical DesignManufacturingIndustrial DesignTechnical WritingPackaging Engineering 2001 Miguel A. Torres
Material hologyMachine DesignErgonomicsConclusion:“ A typical product is made up of many technological aswell as non-technological components.”EngineeramoBut, How does this fact comparespliDwith the way we have beeneducated as engineers? 2001 Miguel A. Torres
The engineering degree has been brokendown in manageable packages which we INESPAESPAManageable for the STUDENTSand for the TEACHERINCIINCIUnfortunately, you will see that thisrepresent the professional divisions ofmost universities and indeed INDUSTRY. 2001 Miguel A. Torres
TOTAL DESIGNTotal Design is a systematic methodology to achieveintegration of the technological as well as nontechnological subjects material with the goal ofcreating successful products and processes.CustomerProductTOTAL DESIGN is distinguish from “partial design” in whichTOTAL DESIGN requires the input from people of manydisciplines, both engineering and non-engineering, in a mixthat is almost unique to the product under consideration. 2001 Miguel A. Torres
Product Design CoreMarketSpecificationsConceptual DesignDetail DesignManufacturingSales 2001 Miguel A. Torres
Product Design CoreCoInfCo ostingntrolMarketInformationElectrical StressSpecificationsHydraulicsMechanismsMechanical StressConceptual DesignPower SystemsSurface AmountDetail DesignQuality ControlVibrationsicsnortElectione tipmturecCoafuManTechnology-Dependents ToolsManufacturingSales 2001 Miguel A. Torres
Product Design CoreCoInfCo ostinge si shtnSyntrolalysisnAnoittiCompeMarketConcept SelectionInformationElectrical StressSpecificationsData handlingHydraulicsMechanismsMechanical StressInfo AcquisitionConceptual DesignPower SystemsSurface AmountQuality ControlOptimizationDetail DesignCost nTechnology-Dependents ToolsManufacturingMarket TrendsInfoSalesTechnology-Independent Tools 2001 Miguel A. Torres
MarketMarketAll design starts with a needthat, when satisfied, will fit intoan existing market or create amarket of its own.SpecificationsConceptual DesignThe outcome of this designactivity is a statement of needor a “brief”.Detail DesignManufacturingSales 2001 Miguel A. Torres
MarketMarketAll design starts with a needthat, when satisfied, will fit intoan existing market or create amarket of its own.SpecificationsConceptual DesignThe outcome of this designactivity is a statement of needor a “brief”.Detail DesignExample:ManufacturingDesign a machine for material handlingcapable of maneuvering over rough terrainSales 2001 Miguel A. Torres
MarketMarketAll design starts with a needthat, when satisfied, will fit intoan existing market or create amarket of its own.SpecificationsConceptual DesignThe outcome of this designactivity is a statement of needor a “brief”.Detail DesignExample:ManufacturingDesign a machine for material handlingcapable of maneuvering over rough terrainSales 2001 Miguel A. Torres
WChangesD/WDDWDDDWRequirementsThroughput (mixed Flow) max.10 l/min. @ 2 barsmax. Pressure 10 BarsTemp. of Water standard 60ºCTo fit hose basinLight Operation (Children)No Extra energySmooth, easily cleaned contour,no sharp edgesRequirementsThroughput (mixed Flow) max.10 l/min. @ 2 barsmax. Pressure 10 BarsTemp. of Water standard 60ºCTo fit hose basinLight Operation (Children)No Extra energySmooth, easily cleaned contour,no sharp edgesRequirementsThroughput (mixed Flow) max.10 l/min @ 2 barsmax. Pressure 10 BarsTemp. of Water standard 60ºCTo fit hose basinLight Operation (Children)No Extra energySmooth, easily cleaned contour, 2001no sharp edgesThe outcome of this design activityis the Product Design SpecificationMarketSpecificationsConceptual DesignDetail DesignManufacturingSalesMiguel A. Torres
The General Structure of thePDSTitle:Changes D/WDDWDDDWDATE:RequirementsThroughput (mixed Flow) max.10 l/min. @ 2 barsmax. Pressure 10 BarsTemp. of Water standard 60ºCTo fit hose basinLight Operation (Children)No Extra energySmooth, easily cleaned contour,no sharp edges 2001 Miguel A. TorresResponsible
The Product Design ChangesMarketRequirementsThroughput (mixed Flow) max.10 l/min. @ 2 barsmax. Pressure 10 BarsTemp. of Water standard 60ºCTo fit hose basinLight Operation (Children)No Extra energySmooth, easily cleaned contour,no sharp edgesSpecificationsRequirementsThroughput (mixed Flow) max.10 l/min. @ 2 barsmax. Pressure 10 BarsTemp. of Water standard 60ºCTo fit hose basinLight Operation (Children)No Extra energySmooth, easily cleaned contour,no sharp edgesConceptual DesignDetail Design Controlstherest of the design activities.D/WRequirementsThroughput (mixed Flow) max. ItD is Dynamic.10 l/min @ 2 barsDmax. Pressure 10 BarsTemp. of Water standard 60ºC It WDis legal document.To fit hose basinDDWLight Operation (Children)No Extra energySmooth, easily cleaned contour,no sharp edgesManufacturingSales 2001 Miguel A. Torres
“To be successful, you have to be systematic andthorough, paying meticulous attention to detail fromthe beginning to the end of the design activity.” 2001 Miguel A. Torres
Characteristics of the Product DesignSpecification (PDS): PDSThe PDS is the fundamental control mechanism thatallows this success to manifest itself.The PDS must be comprehensive and unambiguous.At the end of the design process the product must bebalanced with the PDS.Poor PDS leads to poor design that will fail in themarket.Good PDS does not guarantee good design but makethe goal more attainable.PDS set the design in context which are acomprehensive set of constrains. 2001 Miguel A. Torres
The Contents of a PDS: PerformanceWebster’s Dictionaryper per forfor mance mance actionb:b:somethingaccomplished:something faclaim,promise,the fulfillment of a claim, a: the action of representing a character in a eperformance4a:theabilitytoperform:EFFICIENCY4a: the ability to perform: chanismmechanismperformsperforms eactingtostimuli:BEHAVIORthe manner of reacting to stimuli: BEHAVIOR6:6:linguisticlinguisticbehaviorbehavior- -comparecompareCOMPETENCECOMPETENCE 33- -perperforformamatotoryry \-me-,\-me-,totor r-e-e, ,-,-,totor-\r-\adjadj“Performance should be fully defined, e.g., how fast, how slow, how often,continuously vs. discontinuous, energy requirements- electrical, hydraulicvs. pneumatic, tolerances, etc.” 2001 Miguel A. Torres
0 tolerance- “A common failing in specifying performanceis to ask for the ultimate, rather than which isobtainable from economical point of view.” 2001 Miguel A. Torres
The Contents of a PDS: Environment temperature rangepressure range (altitude)humidityshock loading (gravity forces)dirt or dust - how dirty? - howclean?corrosion from fluids - type of fluidor chemicalnoise leversinsectsvibrationtype of labor or person who willuse the equipment - likely degreeof abuse?any unforeseen hazards tocustomer, user or the environment- for example inclusion of CFCs? 2001 Miguel A. Torres
The Contents of a PDS: EnvironmentThese may occur at the following stages: During manufacturing exposure to cutting fluid,solvents, fluxes, acids, etc.During storage - in the plantDuring assembly - assemblyforces, contamination fromsweating hands?During packagingDuring transportationDuring storage - at a wholesale’swarehouseDuring displayDuring use 2001 Miguel A. Torres
PDS: Guide lines PDSThe PDS is a control document.It is a use document.Never write a PDS in an essay format.From the beginning, try to quantifyparameters.Always date the document and to anissue number.Clearly document amendments. 2001 Miguel A. Torres
Conceptual DesignMarket It is the phase of design primarilyconcerned with the generation of solutionsto meet the stated need, i.e., the PDS.SpecificationsConceptual DesignDetail DesignManufacturingConceptual Design is a “Synthesis” 2001 Miguel A. TorresSales
Conceptual DesignMarketConceptual Design has two majorcomponents:1. The generation of solutions to meet thestated need, i.e., the PDS.2. The evaluation of these solutions to selectthe one that is must suited to match the need.SpecificationsConceptual DesignDetail DesignManufacturingSales 2001 Miguel A. Torres
Conceptual Design1. The generation of solutions to meet the PDS.In order to generate solutions or ideas to solve a givendesign problem you must be “creative”Idea!!! 2001 Miguel A. Torres
Conceptual Design1. The generation of solutions to meet the PDS.Yes but how do I become “creative”?Everybody is creative. All we need to do iswatch out for “Mental Blocks” 2001 Miguel A. Torres?
Conceptual DesignRecognizing and dealing with Mental Blocks“The Right Answer” 2001 Miguel A. Torres
Conceptual DesignRecognizing and dealing with Mental Blocks“That is not Logic”Fini 2001 Miguel A. Torressh
Conceptual DesignRecognizing and dealing with Mental Blocks“Follow the Rules” 2001 Miguel A. Torres
Conceptual DesignRecognizing and dealing with Mental Blocks“Be Practical” 2001 Miguel A. Torres
Conceptual DesignRecognizing and dealing with Mental Blocks“Play is Frivolous” 2001 Miguel A. Torres
Conceptual DesignRecognizing and dealing with Mental Blocks“That is not my area” 2001 Miguel A. Torres
Conceptual DesignRecognizing and dealing with Mental Blocks“Avoid Ambiguity”Ambiguous 2001 Miguel A. Torres
Conceptual DesignRecognizing and dealing with Mental Blocks“Don’t be foolish” 2001 Miguel A. Torres
Conceptual DesignRecognizing and dealing with Mental Blocks“To err is wrong” 2001 Miguel A. Torres
Conceptual DesignRecognizing and dealing with Mental Blocks“I’m not Creative” 2001 Miguel A. Torres
Idea Generation: TipsIdea!!! 2001 Miguel A. Torres
Idea Generation: Tips Concepts are best generated byindividuals 2001 Miguel A. Torres
Conceptual DesignIdea Generation: Tips Concepts are best generated byindividualsAvoid at all cost the temptationto “cut and run” and startengineering and developing theideas further. 2001 Miguel A. Torres
Idea Generation: Tips Concepts are best generated byindividualsAvoid at all cost the temptation to“cut and run” and startengineering and developing theideas further.You need as many ideas as youcan. 2001 Miguel A. Torres
Idea Generation: Tips Concepts are best generated byindividualsAvoid at all cost the temptation to“cut and run” and startengineering and developing theideas further.You need as many ideas as youcan.Stay within the laws of physics. 2001 Miguel A. Torres
Idea Generation: TipsPD SConcepts are best generated byindividualsAvoid at all cost the temptation to“cut and run” and startengineering and developing theideas further.You need as many ideas as youcan.Stay within the laws of physics.Always keep the PDS as areference. 2001 Miguel A. Torres
Conceptual DesignIdea Generation: More TipsUse the following techniques:1. Brainstorming2. Analogies3. Combinations 2001 Miguel A. Torres
Conceptual DesignAn idea is not an idea if you cannot communicate it. 3D Sketching Diagrams Circuit Diagrams Block Diagrams World Description Ladder-logic diagrams Mathematical Expressions Analytical DrawingsNote: Concepts or ideas must be titled, numbered andionized so they can be cross referenced later. 2001 Miguel A. Torres
Conceptual DesignConcepts generated at this phase should never bearbitrarily discarded as not been good. Particularlybecause a third party does not like them.“Gut-feeling” design is out of the question. 2001 Miguel A. Torres
To effectively evaluate a concept, an agreedset of criteria is needed.This criteria comes from thePDS. This is carried out in groups(never along) It should be written down. 2001 Miguel A. Torres
The Controlled Convergence MatrixA methodology for sorting out ideas.Example:Brief: “Design a car horn.”PDS: 2001 Miguel A. Torres
Concept EvaluationThe Controlled ConvergenceMatrixD/WPDS for a Car HornDDDDDDDWWWWWDWDWCriteriaAble to Produce 105-125 DbAAble to Produce 2000-5000 HzCorrosion, erosion and water resistant.Resistance to vibration, shock and acceleration.Temperature range -50 F to 200 FTime response: 250 msec.Small number of stages.Power Consumption 35 WLow MaintenanceWeight: 2 lbs.Size: 6x6x6in.Low num. parts.Life in service: 10 yearsManuf. Cost: 3.00Easy installationShelf Life: 20 years 2001 Miguel A. Torres
The Controlled ConvergenceMatrixConcept EvaluationIdeasCriteriaAble to Produce 105-125 DbAAble to Produce 2000-5000 HzCorrosion, erosion and water resistant.Resistance to vibration, shock and acceleration.Temperature range -50 F to 200 FTime response: 250 msec.Small number of stages.Power Consumption 35 WLow MaintenanceWeight: 2 lbs.Size: 6x6x6in.Low num. parts.Life in service: 10 yearsManuf. Cost: 3.00Easy installationShelf Life: 20 years1 2 3 4 5 6 7 8 9 10 11 12 13 14DATUMSum ’sSum Miguel-’s 2001A. TorresSum S’s
The Controlled ConvergenceMatrixConcept EvaluationIdeasCriteriaAble to Produce 105-125 DbAAble to Produce 2000-5000 HzCorrosion, erosion and water resistant.Resistance to vibration, shock and acceleration.Temperature range -50 F to 200 FTime response: 250 msec.Small number of stages.Power Consumption 35 WLow MaintenanceWeight: 2 lbs.Size: 6x6x6in.Low num. parts.Life in service: 10 yearsManuf. Cost: 3.00Easy installationShelf Life: 20 years1 2 3 4 5 6 7 8 9 10 11 12 13 14SSD SSASTSU -SSMSSSum ’sSum -’s 2001A. TorresSum MiguelS’s
The Controlled ConvergenceMatrixConcept EvaluationCriteriaIdeasAble to Produce 105-125 DbAAble to Produce 2000-5000 HzCorrosion, erosion and water resistant.Resistance to vibration, shock and acceleration.Temperature range -50 F to 200 FTime response: 250 msec.Small number of stages.Power Consumption 35 WLow MaintenanceWeight: 2 lbs.Size: 6x6x6in.Low num. parts.Life in service: 10 yearsManuf. Cost: 3.00Easy installationShelf Life: 20 years1 2 3 4 5 6 7 8 9 10 11 12 13 14S - - - - S S S N S S S - - S o S - - S - - - - SDS - T S - S - S- - - S - - S SS - - - S SAS - - - - - S - - - - E S - - - - - -V - - - - - - S TS A - - S S - -L -- - S - - - - -U S - - -- - - - - US S A S S - - - - S S - T - S - - - - - M- S E - - - S - - - S S D S S - S - - S S S- S S S S S SS S0 28 3 5 3 06 91 9 7 12 11Sum -’s 2001MiguelA.Torres1057 4 4 1 5Sum S’sSum ’s28621312131088493
Remember that:The wrong choice of concept in a givendesign situation can rarely, if ever, berecouped by brilliant detail design. 2001 Miguel A. Torres
Total Design is a systematic methodology to achieve integration of the technological as well as non-technological subjects material with the goal of creating successful products and processes. . Webster s Dictionary perŁ for Łmance \pe(r)- fo r-men(t)s\ n (15c) 1a: the execution of an action
