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1. Product Design and
Development
OMF551 PRODUCT DESIGN AND DEVELOPMENT
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2. To be learnt
• OBJECTIVE: The course aims at providing the basic concepts of
product design, product features and its architecture so that student
can have a basic knowledge in the common features a product has
and how to incorporate them suitably in product.
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3. UNIT I INTRODUCTION 9
• Need for IPPD – Strategic importance of Product development –
integration of customer, designer, material supplier and process
planner, Competitor and customer – Behaviour analysis.
Understanding customer – prompting customer understanding –
involve customer in development and managing requirements –
Organization – process management and improvement – Plan and
establish product specifications.
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4. UNIT II CONCEPT GENERATION AND
SELECTION 9
• Task – Structured approaches – clarification – search – externally and
internally – explore systematically – reflect on the solutions and
processes – concept selection – methodology – benefits.
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5. UNIT III PRODUCT ARCHITECTURE 9
• Implications – Product change – variety – component standardization
– product performance – manufacturability – product development
management – establishing the architecture – creation – clustering –
geometric layout development – fundamental and incidental
interactions – related system level design issues – secondary systems
– architecture of the chunks – creating detailed interface
specifications.
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6. UNIT IV INDUSTRIAL DESIGN 9
• Integrate process design – Managing costs – Robust design –
Integrating CAE, CAD, CAM tools – Simulating product performance
and manufacturing processes electronically – Need for industrial
design – impact – design process – investigation of for industrial
design – impact – design process – investigation of customer needs –
conceptualization – refinement – management of the industrial
design process – technology driven products – user – driven products
– assessing the quality of industrial design.
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7. UNIT V DESIGN FOR MANUFACTURING AND
PRODUCT DEVELOPMENT 9
• Definition – Estimation of Manufacturing cost – reducing the
component costs and assembly costs – Minimize system complexity –
Prototype basics – principles of prototyping – planning for prototypes
– Economic Analysis – Understanding and representing tasks –
baseline project planning – accelerating the project – project
execution.
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8. • OUTCOME:
• To design some products for the given set of applications
• The knowledge gained through prototyping technology will help the
student to make a prototype of a problem and hence product design
and development can be achieved.
• TEXT BOOK:
• 1. Kari T.Ulrich and Steven D.Eppinger, ”Product Design and
Development”, McGraw-Hill International Edns
• 2. Stephen Rosenthal, “Effective Product Design and Development”,
Business One Orwin, Homewood, 1992, ISBN 1-55623-603-4. 3.
Staurt Pugh, “Tool Design –Integrated Methods for Successful
Product Engineering”, Addison Wesley Publishing, New york, NY
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9. Assessment through a project
• Students should produce a physical prototype of their products by
the end of the course.
• There should be a demonstrable market for the product.
• The product should be a material good and not a service
• The product should have a high likelihood of containing fewer than
10 parts
• The product should require no basic technological breakthroughs
• Most products are really not very well designed
• Ask business people you know what products they would really like
to have
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10. • Teams seem to work best when they contain from three to five
students (should include students from IT and Mechanical)
• Building a Team Based on Random Selection:
• Building a Team Based on Self-Selection:
• Project budget limited to ₹ 1,000/-
• Use of labs in LICET is permitted
• prototype would be both a "looks like" and a "works like" prototype
• Prototype should be photographed in a detailed manner
• Finally presentation in prescence of faculty , experts
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11. Development Processes and
Product Planning
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Phase 1
Concept
Development
Phase 2 Phase 5
Phase 4
Phase 3
System-Level
Design
Detail
Design
Testing and
Refinement
Production
Ramp-up

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Every project must make two important
decisions about the way they will carry
out their product development.
1. What is the Product Development Process
and
2. What is the Product Development
Organization
The process is the method the team will use to
go from idea to product.
The organization is the team structure that will
be employed to accomplish the
development process.

15. • The scholars and the lion - knowledge without wisdom
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• What is a Structured approach to Design?
• It is a set of methodologies and tools that provide the
communications infrastructure between the marketing, engineering,
and manufacturing functions of a company.
• It breaks down the design process into sub-processes that have a
natural progression from idea to product.
• These tools and methods also provide the communication network
for the design team. They organize the project activities and
encourage the use of design tools at the appropriate stages of the
product development.

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•What are some of the problems that could
occur if the team did not have a plan or method
of completing their project?
•What role do “milestones” play in organizing a
project?
•How does the Development Process affect the
Organizational structure?

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Development Phase
Introduction to a Phase/Gate development process
Activities
A
B
C
D
E
Checkpoint
Meeting
Proceed to
next phase
1
Cancel
Project
3
Redirect
Project
2

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Tested, piloted
and introduced
Plans
Designs
Development
Prototypes
The pattern of Product
Development
Product Development Process

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Generic Phase/Gate Process
Phase 1
Concept
Development
Phase 2 Phase 5
Phase 4
Phase 3
System-Level
Design
Detail
Design
Testing and
Refinement
Production
Ramp-up
Concept Development:
Develop a “body of facts” about the proposed
product concept.
Identify target market, establish customer needs,
determine technology requirements and
availability.
Generated alternative product concepts, and select
a single concept for further development.
Propose initial product specifications.

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Assumptions can make or break a development project
Body of Facts - BOFs
Strategy or Solution
Critical Assumptions
The BOF is a collection of all the critical
information that you know about your project.

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What happens when Assumptions prove to be invalid?
Body of Facts - BOFs
Assumptions Changed!!
Unstable
Strategy!!

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Generic Phase/Gate Process
Phase 1
Concept
Development
Phase 2 Phase 5
Phase 4
Phase 3
System-Level
Design
Detail
Design
Testing and
Refinement
Production
Ramp-up
System-Level Design:
Define the proposed product architecture,
break into subsystems and components,
complete initial feasibility evaluations of key
subsystems,
complete staffing requirements and assignments,
and refine the functional specifications.

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Generic Phase/Gate Process
Phase 1
Concept
Development
Phase 2 Phase 5
Phase 4
Phase 3
System-Level
Design
Detail
Design
Testing and
Refinement
Production
Ramp-up
Detail Design:
Start full scale development of the product,
begin initial prototyping of entire product,
choose materials,
develop detailed specifications for all
components,
develop test plans and quality objectives.

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Generic Phase/Gate Process
Phase 1
Concept
Development
Phase 2 Phase 5
Phase 4
Phase 3
System-Level
Design
Detail
Design
Testing and
Refinement
Production
Ramp-up
Testing and Refinement:
Do performance and reliability testing,
build-test-fix-document cycles until product
meets functional specifications.

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Generic Phase/Gate Process
Phase 1
Concept
Development
Phase 2 Phase 5
Phase 4
Phase 3
System-Level
Design
Detail
Design
Testing and
Refinement
Production
Ramp-up
Production Ramp-up: complete documentation,
complete final qualification testing,
all parts and components available for production
volumes,
production tooling complete,
build first production runs,
and release documentation to production.

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Integrated Product Design and
Development

30. Why IPPD
• Objective of any organization is to provide customer satisfaction by
building product and services, which not only satisfy needs and want
but also create value for them.
• Focus on specialization and customization is ever increasing.
• combines the product design processes along with the process
design process to create a new standard for producing competitive
and high-quality products.
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31. TATA NEXON EV
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32. • TATA Micro Internships
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Introduction to PLC Revision 6.0
Product Development Process
Opportunity
Proposal
Concept
Phase Review
Feasibility
Phase Review
Development
Phase Review
Qualification
Phase Review
Ramp-up
Phase Review
Concept
Phase
Feasibility
Phase
Development
Phase
Qualification
Phase
Ramp-Up
Phase
2.1 Prelim. Integrated
Program Plan
3.1 Integrated Program
Plan
3.2 Product Requirement
3.3 System
Design
5.2 Beta
Test
• IPP Updates
• Phase Review Presentations
6.1 Introduction
Implementation
4.1 Introduction Planning
4.10
Engineering
Verification
Test
5.1 Alpha
Test
4.3 Software Development
4.2 Hardware Development
4.5 Test Planning and
Development
4.6 Manufacturing Development 5.4 Pilot
Production
6.2 Production Ramp-
Up
4.9 Customer Satisfaction Development
4.8 Technical
Publications
6.3 Customer Satisfaction
Implementation
4.7 Supply Chain and Logistics Development
5.3 Design
Verification Test
4.4 Subsystem Development
Product Launch
Production &
EOL Phases
8.1 End Of
Life
EO
L
7.1 Product
Improveme
nt

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Early phases of Product Development
Market analysis
and Strategy
Technology
development

Concept Development

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Phase 1
Concept
Development
Phase 2 Phase 5
Phase 4
Phase 3
System-Level
Design
Detail
Design
Testing and
Refinement
Production
Ramp-up
Concept Development Phase
Mission
Statement
Identify
Customer
Needs
Establish
Target
Specs
Analyze
competitive
Products
Generate
Product
Concepts
Select a
Product
Concept
Refine
Specs
Perform
Economic
Analysis
Plan
Remaining
Development
Project
Development
Plan
Concept Development

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Control Documents
It is important to maintain complete and accurate documentation on a
design project to insure that the key plans,decisions, and results
are captured and made available to everyone who will impact or be
impacted by the project.
What are some problems that can occur without adequate
documentation?
• Duplicated efforts by team members
• Problems being solved more than once because previous results were
not available.
• Management becoming alarmed because of mis-information or
rumors.
• Unclear project requirements and unclear customer needs
• Delayed projects because critical path activities were not completed
on time.
• Wrong parts being ordered
• etc.
• etc.

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ECEn 490 Control Documents
Identify
Customer
Needs
Establish
Target
Specs
Analyze
competitive
Products
Generate
Product
Concepts
Select a
Product
Concept
Refine
Specs
Perform
Economic
Analysis
Plan
Remaining
Development
Project
• Preliminary & Final “Functional Specifications Document” - (FSD)
• “Concept Evaluation and Selection Document”- (CESD)
• “Project Schedule” with Staffing Assignments – (Schedule)
• “Final Project Report”
(Most of the control documents are initiated during the 1st phase, and only updated in later
phases.)
FSD CES FSD Schedule

39. Relationship between the key factors of
product development
• There are three factors that control product development:
• Cost of development
• Time to complete the process
• The definition of the product features
• You get to pick two of the three, but the third is always a dependent
variable.
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Development
time-T
Development
cost-C
Product
Features-F
C=F/T
The key parameters of Development
Trade offs between the key product development
factors.

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Development
time-T
Development
cost-C
Product
Features-F
C=F/T
The key parameters of Development
If you want to reduce
development time...
You will need to increase
development costs
…and, keep product
features….
“Marketing says that if we don’t get the product out sooner we will not
be the market leader, and by-the-way, ‘you can’t cut features!’”

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Development
time-T
Development
cost-C
Product
Features-F
C=F/T
The key parameters of Development
If you want to maintain
time-to-market... ..and your budget
just got cut...
…you will need to
cut product features
Or….
“You know how important Project X is to the company, we still need it
on time, but I am having to cut your expenses to make the quarter!!”

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Development
time-T
Development
cost-C
Product
Features-F
C=F/T
The key parameters of Development
…and, it is going to take
longer to develop!!
Your budget is
the same...
…but we need to add
a few features...
“The good news is that we haven’t cut your budget, but we still need to
add auto-sensing to the product!!”

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• Summary
• Companies are in the business to make money
• Successful companies consistently out-engineer their competition.
• The way you implement a design is often as important as the design itself.
• You must make trade-offs between feature, time, and resources. C=F/T.
• If you follow the methodology in the class, you will be more successful with your
senior project design.

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Development
time-T
Development
cost-C
Product
Features-F
C=F/T
Control Documents support key factors
PFSD
FSD
CES
Schedule
Final
Project
Reports