1. Product Development process
Product Development process
2 min – představení sebe a témata dnešní přednášky
Ing. Jan Valtera, Ph.D. – Design Metodology

2. The fundamentals for systematic approach are:
Jan Valtera – Design Methodology
Introduction
Systematic product design (Systematic approach) is a complex engineering task that can be roughly classified into two phases:
Conceptual Design phase (looking for the solution principles and the concepts based on the defined requirements list)
Embodiment Design phase (defining of the design layout (or process) to fulfil the concept functions)
The fundamentals for systematic approach are:
Solution Findings Methods (Collecting information: searching the literature, analysing trade publications, assessing catalogues of competitors, exploring patents; Brainstorming, Cross-functional Task Force, Gallery method, etc.)
Selection and Evaluation Methods (Cost-Benefit analysis, VDI Guideline, QFD, FMEA)
2 min

3. Why is it useful for designers to follow the systematic approach?
Jan Valtera – Design Methodology
Motivation
Why is it useful for designers to follow the systematic approach?
methods can be used regardless of designers speciality (comprehensive for general design team)
introducing a working steps – iteration loops (links between objectives, planning and control)
A systematic approach aims to keep the iteration loops as small as possible in order to make design work effective and efficient. This helps to avoid the design team to start again from the beginning if a design failure is found)
1 min

4. General Working Methodology
Jan Valtera – Design Methodology
General Working Methodology
• Define goals by formulating the overall goal, the individual sub goals and their importance. This ensures the motivation to solve the task and supports insight into the problem. • Clarify conditions by defining the initial and boundary constraints. • Dispel prejudice to ensure the most wide-ranging search for solutions possible and to avoid logical errors. • Search for variants to find a number of possible solutions or combinations of solutions from which the best can be selected. • Evaluate based on the goals and conditions. • Make decisions. This is facilitated by objective evaluations. Without decisions and experiencing their consequences there can be no progress.
5 min Dispel Prejudice – e.g. One of our colleague prefer rotational driven movements instead of linear movements. I like magnets and incorporating of magnetic sysems.

5. General Problem Solving Process
Jan Valtera – Design Methodology
General Problem Solving Process
3 min – In oder words …

6. General Problem Solving Process
Jan Valtera – Design Methodology
General Problem Solving Process
Every task involves an initial confrontation of the problem, which involves elucidating what is known or not (yet) known. The intensity of this confrontation depends on the knowledge, ability and experience of the designers, and on the particular field in which they are engaged. In all cases, however, more detailed information about the task itself, about the constraints, about possible solution principles and about known solutions for similar problems is extremely useful since it clarifies the precise nature of the requirements. This information can also reduce confrontation and increase confidence that solutions can be found.
Next comes the definition phase, where the essential problems are defined on a more abstract plane, in order to set the objectives and main constraints. Such solution-neutral definitions open the way to an unconstrained search for solutions because this abstract definition encourages a search for more unconventional solutions.
The next step is creation, where solutions are developed by various means and then varied and combined using methodical guidelines. If the number of variants is large, there must also be an evaluation which is then used to select the best variant through a decision. Because each step of the design process must be evaluated, evaluation serves as a check on progress towards the overall objective.
2 min

7. Product planning – Life cycle of a product
Jan Valtera – Design Methodology
Product planning – Life cycle of a product
5 min – role of engineers (engineers often neglect the work of marketing managers and vice versa) – product sells itself – Apple (white headphones)

8. Development processes of different types of products
Jan Valtera – Design Methodology
Development processes of different types of products
One-off product development (design of a machine/device, where a serial production is not required)
Customer requirements processing
Processing and submitting of the offer (already known design concept)
Design
Manufacturing
Assembling
Testing (system tuning)
Submitting (Design specification, user’s guide, safety information, certificate of conformity)
This process may last for approx. 3 months
5 min

9. Development processes of different types of products
Jan Valtera – Design Methodology
Development processes of different types of products
Mass-produced product development (design of a complex machine (or set of machines/devices), where its serial production is required)
Detailed research of technical (dimension, power, productivity, etc.) and economical parameters
Solution finding (physical principles, state-of-art systems, etc.)
Solution evaluation (e.g. Cost-Benefit analysis)
Functional model design (verification of required functions and weak elements)
Design
Manufacturing
Testing
Design of a prototype (0 – series, design optimization – material, weight, price, etc.)
Testing (in very complex tasks a second prototype may be required)
Serial layout preparation
Production technology (methods and devices used for production of machine components)
Production line testing and parameters tuning
Serial production started
This process may last for approx. 12 months
5 mins

10.
Jan Valtera – Design Methodology
Stepwise development from the one-off produced product to a mass-produced product
3 mins

11. Timing and Scheduling 5 mins 20.11.2018 20.11.2018
Jan Valtera – Design Methodology
Timing and Scheduling
5 mins

12. Systematic Product Design – Conceptual phase
Jan Valtera – Design Methodology
Systematic Product Design – Conceptual phase
Example of the design of Multi-thread tensioner with electronic control:
Problem requirements:
Problem basic requirements:
Tensioner for 10 parallel threads
The tension range 20 – 300 cN
Electronic control of the thread tension
Thread count range ( tex)
3 mins

13. Systematic Product Design – Conceptual phase
Jan Valtera – Design Methodology
Systematic Product Design – Conceptual phase
Example of the design of Multi-thread tensioner with electronic control:
Problem requirements:
a) Requirements processing:
Definition of the requirements importance (on scale 5-highest, 1-lowest)
The tension range 20 – 300 cN 5
Electronic control sensitivity (tension 10 cN) 4
Even force distribution 4
Low cost 3
Parallel yarn guidance 3
Easy thread inserting 3
Small size 2
Thread count range ( tex) 1
3 mins

14. Systematic Product Design – Conceptual phase
Jan Valtera – Design Methodology
Systematic Product Design – Conceptual phase
Example of the design of Multi-thread tensioner with electronic control:
List of sub-functions:
Based on the research of available yarn tension systems and on the requirement list, all the basic working principles and sub-functions have been structured into the classification scheme.
3 mins

15. Systematic Product Design – Conceptual phase
Jan Valtera – Design Methodology
Systematic Product Design – Conceptual phase
Example of the design of Multi-thread tensioner with electronic control
The First principle is based on a disc tensioner, where disc are pressed together by an acting external normal force.
The tension force T is given by the following equation
The additional multi-thread variation can be designed by patterning the disc units over the length. Insertion of yarns into working position
can be achieved by releasing the acting force and opening the inner space between discs.
The second option uses principles based on the gate tensioner, where yarn is wrapped at certain angle α around the non-rotating gate of the tensioner.
The resulted tension is calculated using the Euler´s formula
2 mins

16. Systematic Product Design – Conceptual phase
Jan Valtera – Design Methodology
Systematic Product Design – Conceptual phase
Example of the design of Multi-thread tensioner with electronic control
In order to accommodate more yarns in parallel, the length of gates can be easily extended.
An additional opening mechanism is necessary to enable yarns being inserted into the working position.
Similar principle of friction transmission is used in the third option, where the yarn is wrapped around
the driven cylinder in more twists. These are necessary to stop the yarn sliding over the cylinder.
Hence, the tension is provided by a controlled braking of the cylinder. The multi-thread variation
can be achieved by sufficient extension of the cylinder to accommodate more yarns in parallel.
In order to insert yarns into the proper position, it is however necessary to wrap them around
the cylinder, one by one.
By a combination of component functions, several working solutions have been defined. The multi-thread disc tensioner with electromagnet as the most appropriate design has been then evaluated in the QFD by means of the importance of required parameters
1 min

17. Systematic Product Design – Embodiment phase
Jan Valtera – Design Methodology
Systematic Product Design – Embodiment phase
Example of the design of Multi-thread tensioner with electronic control: QFD
By a combination of component functions, several working solutions have been defined and evaluated in the QFD (quality function deployment).
5 mins

18. Systematic Product Design – Embodiment phase
Jan Valtera – Design Methodology
Systematic Product Design – Embodiment phase
Example of the design of Multi-thread tensioner with electronic control:
Final concept design
1-inner rod with cut grooves
2-ceramic discs
3-distance elements
4-housing
5-sliding rod
6-pushing element
7-electromagnet
8-front and rear set of yarn guides
9-line rails for the yarn guides
3 mins

19. Systematic Product Design – Functional model testing
Jan Valtera – Design Methodology
Systematic Product Design – Functional model testing
Example of the design of Multi-thread tensioner with electronic control:
Functional model testing
2 mins

20. Basic rules of embodiment design
Jan Valtera – Design Methodology
Basic rules of embodiment design
Clarity—that is, clarity of function or lack of ambiguity of a design—facilitates reliable prediction of the performance of the final product and in many cases saves time and costly analyses.
Simplicity generally guarantees economic feasibility. A smaller number of components and simple shapes are produced more quickly and easily.
Safety imposes a consistent approach to the problems of strength, reliability, accident prevention and protection of the environment.
In short, by observing these three basic rules, designers can increase their chances of success because they focus attention on, and help to combine, functional efficiency, economy and safety. Without this combination no satisfactory solution is likely to emerge.

21. Steps of the General Problem Solving Process (from task to solution)
Jan Valtera – Design Methodology
Summary
Systematic Product Design (systematic approach) – conceptual and embodiment phases
Steps of the General Problem Solving Process (from task to solution)
Differences in Product Development Process of one-off and mass produced product
Basic rules of embodiment design
Quality Function Deployment

22. Jan Valtera – Design Methodology
References
Pahl, G.; Beitz, W.; Feldhusen, J.; Grote, K.H: Engineering Design – A systematic approach, Springer, ISBN , Springer-Verlag London Limited, (2007).
Valtera, J.; Zabka, P.; at al.: Výzkum nových struktur textilních a jednoúčelových strojů, Technical University of Liberec, ISRN TUL – KTS/TZ/PZ /01/CZ – CZ +SGS, Liberec, (2011).
Elsner, J.; Zabka, P.; Valtera, J.: Mereni charakteristik brzdicky ovladane elektromagnetem, Technical University of Liberec, ISRN TUL – KTS/VZ/PZ /02/CZ – CZ +SGS, Liberec, (2012).
ELSNER, J., VALTERA, J., ŽABKA, P.: CONCEPTUAL DESIGN OF MULTI-THREAD TENSIONER WITH ELECTRONIC CONTROL, Structure and Structural Mechanics of Textiles, 19th International Conference, TU Liberec, Czech Republic, ISBN

23. Design for Quality - Quality Function Deployment (QFD) – Study Example
Jan Valtera – Design Methodology
Design for Quality - Quality Function Deployment (QFD) – Study Example