chapter 1

1. DEPARTMENT OF
MANUFACTURING AND
MATERIALS ENGINEERING
MME 4116
PRODUCT DESIGN AND
DEVELOPMENT
BY:
DR MOHD RADZI BIN HAJI CHE DAUD

2. CHAPTER 1
ENGINEERING DESIGN

3. 1.1 Introduction
What is design?
Dieter/Schmidt, Engineering Design 5e.
©2013. The McGraw-Hill Companies
3

4. What is design?
4
• “To fashion after a plan!”
• To design is:
To synthesize new or to arrange existing things in a new way
to satisfy a recognized need of society.
“Design establishes and defines solutions to and pertinent
structures for problems not solved before, or new solutions to
problems which have previously been solved in a different way.”
Dieter/Schmidt, Engineering Design 5e.
©2013. The McGraw-Hill Companies

5. The Four C’s of Design
5
• Creativity
Requires creation of something that has not existed before or
has not existed in the designer’s mind before.
• Complexity
Requires decisions on many variables and parameters.
• Choice
Requires making choices between many possible solutions
at all levels, from basic concepts to the smallest detail of shape.
• Compromise
Requires balancing multiple and sometimes conflicting
requirements.
Dieter/Schmidt, Engineering Design 5e.
©2013. The McGraw-Hill Companies

6. 1.2 Engineering Design Process
Why is engineering design process
needed?
Dieter/Schmidt, Engineering Design 5e.
©2013. The McGraw-Hill Companies
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7. Importance of the Engineering Design
Process
7
• Decisions made in the design process cost very little
in terms of the overall product cost but have a
major effect on the cost of the product.
• You cannot compensate in manufacturing for
defects introduced in the design phase.
• The design process should be conducted so as to
develop quality, cost-competitive products in the
shortest time possible.
Dieter/Schmidt, Engineering Design 5e.
©2013. The McGraw-Hill Companies

8. Product Cost Commitment during
Phases of the Design Process
8
Dieter/Schmidt, Engineering Design 5e.
©2013. The McGraw-Hill Companies
Adapted from D. Ullman, The Mechanical Design Process, 4th ed., McGraw-Hill, New York,2010.

9. Types of Designs
9
• Original Design: Innovative design
• Adaptive Design
• Redesign: Variant design
• Selection design
Dieter/Schmidt, Engineering Design 5e.
©2013. The McGraw-Hill Companies

10. 1.3 Ways To Think About The
Engineering Design Process
What do we mean by “designing a
system”?
Dieter/Schmidt, Engineering Design 5e.
©2013. The McGraw-Hill Companies
10

11. Simplified Iteration Model
11
Dieter/Schmidt, Engineering Design 5e.
©2013. The McGraw-Hill Companies
Adapted from M. Asimow, Introduction to Design, Prentice-Hall, Englewood Cliffs, NJ, 1962.

12. Design Method Versus Scientific
Method
12
Dieter/Schmidt, Engineering Design 5e.
©2013. The McGraw-Hill Companies
Adapted from P. H. Hill, The Science of Engineering Design, Holt, Rinehart and Winston, New York 1970.

13. A Problem-Solving Methodology
13
• Definition of the problem
• Gathering of information
• Generation of alternative solutions
• Evaluation of alternatives and decision making
• Communication of the results
Dieter/Schmidt, Engineering Design 5e.
©2013. The McGraw-Hill Companies

14. How The Design Depends On How The
Problem Is Defined
14
Dieter/Schmidt, Engineering Design 5e.
©2013. The McGraw-Hill Companies

15. Design Paradox Between Design
Knowledge and Design Freedom
15
Dieter/Schmidt, Engineering Design 5e.
©2013. The McGraw-Hill Companies

16. 1.4 Description of Design Process
What are the steps of Design
Process?
Dieter/Schmidt, Engineering Design 5e.
©2013. The McGraw-Hill Companies
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17. Design Process Phases
17
• Phase I:
Conceptual Design
• Phase III:
Detail Design
• Phase II:
Embodiment Design
Dieter/Schmidt, Engineering Design 5e.
©2013. The McGraw-Hill Companies

18. Phase I. Conceptual Design
18
Dieter/Schmidt, Engineering Design 5e.
©2013. The McGraw-Hill Companies

19. Phase II. Embodiment Design
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Dieter/Schmidt, Engineering Design 5e.
©2013. The McGraw-Hill Companies

20. Phase III. Detail Design
20
Dieter/Schmidt, Engineering Design 5e.
©2013. The McGraw-Hill Companies

21. Engineering Design Process
21
Dieter/Schmidt, Engineering Design 5e.
©2013. The McGraw-Hill Companies

22. 1.5 Consideration Of A Good
Design
What are the various considerations
of a good design?
Dieter/Schmidt, Engineering Design 5e.
©2013. The McGraw-Hill Companies
22

23. Considerations of Good Design
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1) Achievement of Performance Requirements
2) Life-Cycle Issues
3) Social and Regulatory Issues
Dieter/Schmidt, Engineering Design 5e.
©2013. The McGraw-Hill Companies

24. Achievement of Performance
Requirements
24
• A major characteristic of a design is its function.
• Performance Requirements:
Primary Performance Requirements
Complementary Performance Requirements
Part (Component): A single piece requiring no assembly
Assembly: When two or more parts are joined.
Subassemblies: Smaller assemblies which compose larger
assemblies.
Dieter/Schmidt, Engineering Design 5e.
©2013. The McGraw-Hill Companies

25. Total Materials Life Cycle
25
Dieter/Schmidt, Engineering Design 5e.
©2013. The McGraw-Hill Companies
Reproduced from “Materials and Man’s Needs,” National Academy of Sciences, Washington, D.C., 1974.

26. Regulatory and Social Issues
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 The code of ethics of all professional engineering societies
require the engineer to protect public health and safety.
Example of Standards and Codes:
ASME: American Society of Mechanical Engineers
ASTM: American Society for Testing and Materials
OSHA: Occupational Safety and Health Administration
CPSC: Consumer Product Safety Commission
EPA: Environmental Protection Agency
DHS: Department of Homeland Security
Dieter/Schmidt, Engineering Design 5e.
©2013. The McGraw-Hill Companies

27. 1.6 Computer-Aided Engineering
What are the changes that plentiful
computing has produced?
Dieter/Schmidt, Engineering Design 5e.
©2013. The McGraw-Hill Companies
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28. Computer-Aided Engineering (CAE)
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 The advent of plentiful computing has produced a major
change in the way engineering design is practiced.
Advantages of Computer-Aided Engineering:
Automated engineering drawing in two dimensions
Three dimensional modeling
Finite Element Modeling (FEM)
Rapid prototyping
Design optimization
Computer-Aided Design (CAD)
Computer-Aided Manufacturing (CAM)
Dieter/Schmidt, Engineering Design 5e.
©2013. The McGraw-Hill Companies

29. 1.7 Designing To Codes And
Standards
What are the codes and standards?
Dieter/Schmidt, Engineering Design 5e.
©2013. The McGraw-Hill Companies
29

30. Designing To Codes And Standards
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• A code is a collection of laws and rules that assists a
government agency in meeting its obligation to protect
the general welfare by preventing damage to property
or injury or loss of life to persons.
• A standard is a generally agreed-upon set of
procedures, criteria, dimensions, materials, or parts.
• Efficiency
• Safety
• Interchangeability
• Compatibility
Chief Aspects of Designing To Codes and Standards:
I
n
c
r
e
a
s
e
Dieter/Schmidt, Engineering Design 5e.
©2013. The McGraw-Hill Companies

31. Two Broad Forms of Codes
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• Performance Codes are stated in terms of the
specific requirement that is expected to be
achieved.
• Prescriptive(specification) Codes state the
requirements in terms of specific details and
leave no discretion to the designer.
Performance Codes Prescriptive Codes
Dieter/Schmidt, Engineering Design 5e.
©2013. The McGraw-Hill Companies

32. 1.8 Design Review
What is design review?
Dieter/Schmidt, Engineering Design 5e.
©2013. The McGraw-Hill Companies
32

33. Design Review
33
• A design review is a retrospective study of the design up to that point in
time.
• The essence of the technical review of the design is to compare the
findings against the detailed Product Design Specification (PDS).
• The PDS is a detailed document that describes what the design
must be in terms of:
– Performance requirements
– Environment in which it must operate
– Product life
– Quality
– Reliability
– Cost
– Host of other design requirements
Dieter/Schmidt, Engineering Design 5e.
©2013. The McGraw-Hill Companies

34. Redesign
34
• Two categories of redesigns:
– Fixes
– Updates
• A fix is a design modification that is required due to
less than acceptable performance once the product
has been introduced into the marketplace.
• Updates are usually planned as part of the product’s
life cycle before the product is introduced to the
market.
Dieter/Schmidt, Engineering Design 5e.
©2013. The McGraw-Hill Companies

35. An Examples of Design Update
35
Dieter/Schmidt, Engineering Design 5e.
©2013. The McGraw-Hill Companies

36. 1.8 Societal Considerations in
Engineering Design
What are the effects of engineering
design on society?
Dieter/Schmidt, Engineering Design 5e.
©2013. The McGraw-Hill Companies
36

37. Societal Considerations in Engineering
Design
37
• ABET Code of Ethics:
“Engineers shall hold paramount the safety,
health, and welfare of the public in the
performance of their profession.”
• Some influences on the practice of engineering
design due to increased societal awareness of
technology:
– Greater influence of lawyers on engineering decisions
– More time spent in planning and predicting
– Emphasis on “defensive research and development”
– More effort expended in research, development, and
engineering in environmental control and safety.Dieter/Schmidt, Engineering Design 5e.
©2013. The McGraw-Hill Companies

38. Characteristics of an Environmentally
Responsible Design
38
• Easy to disassemble
• Able to be recycled
• Contains recycled materials
• Uses identifiable and recyclable plastics
• Reduces use of energy and natural materials
in its manufacture
• Manufactured without producing hazardous
waste
• Avoids use of hazardous materials
• Reduces product chemical emissions
Dieter/Schmidt, Engineering Design 5e.
©2013. The McGraw-Hill Companies

39. Keys Roles of Government in
Interacting with Technology
39
• As a stimulus to free enterprise through
changes in the tax system
• By influencing interest rates and the supply of
venture capital through changes in fiscal
policy to control the growth of the economy
• As a major customer for high technology,
chiefly in military, space, andS energy systems
• As a funding source (patron) for research and
development
• As a regulator of technologyDieter/Schmidt, Engineering Design 5e.
©2013. The McGraw-Hill Companies

40. THANK YOU