1. Design Process
Design process is a collection of procedures and habits that help teams design better products

2. The Process of Design
Designing is the process of making many decisions that converts an abstract concept into a hardware reality.
Concept
Product

3. 7-Step Design Process Problem definition (PDS)
External Search (Research)
Internal Search (Brainstorming)
Evaluation and Selection
Detail Design (Engineering)
Prototyping
Documentation

4. What Product? ToyTown Top Executives
Water Balloon
Rope Climber
Can Crusher
Better Mouse Trap
Coin Sorter
Nail Driver
Rope Climber

5. Product Design Specifications Customer Needs
Climbs fast
Affordable as a birthday present
Fully assembled
Uses batteries for power
It is safe
Looks good
Plays music as it climbs
Glows in the dark
Last a long time

6. Product Design Specifications Engineering Specs
Climbs at 1 ft/s or faster
Retail cost is to be less than $30
Uses 2 AA batteries (not included)
Has no removable small parts
Music loudness between db
Luminosity is to be more than 5 W
Works for more than 3 hours on 2 AA

7. External Search Level-I Level-II (Team uses friction wheels)
Rope climbing toys / machines
Rope climbers (sports or circus)
Nature (spiders, bats, etc)
Level-II (Team uses friction wheels)
Hoists
Trolleys
Ski Lifts

8. Internal Search & Evaluation
Brainstorming
Generate many ideas
Evaluate against PDS
Select one to engineer

9. Detail Design (Engineering)
More Abstract
Engineering
Less Abstract

10. Design Process
Top-level problem definition is called PDS (Product Design Specifications)
Problem definitions at lower levels derive from PDS:
Sub-system design specifications.
Component design specifications.
Feature design specifications.

11. Product Development Process
Product Planning
Design Brief (Mission Statement)
Market Research
Product Design Specifications & QFD

12. Product Development Process
PDS
Candidate Design
Detail Design
Concept Synthesis
Prototyping
Concept Evaluation
Release for Production
Candidate Design

13. Detail Design Candidate Design System-Level Design Parameter Design
Components
No Numbers
System-Level Design
Parameter Design
Numbers
Prototype Testing
Release for Production

14. Customers People who are affected by the product Team Globe (External)
Company
(Internal)

15. External Customers Buyers Retailer End Users Maintenance EXTERNAL
Government &
Standards
Society

16. Internal Customers Manufacturing & Management Procurement Marketing
Shipping
Legal

17. What Do They Want? End Users Performance & Functionality Affordability
Ease of use including ergonomics
Reliability and Long life
Versatility
Safety
Low maintenance and easy assembly
Esthetics

18. External Customers Buying managers Low Cost/Performance Safety
Ruggedness (abuse resistance)
Ergonomics
Long warrantees
Reliable with Low downtime
Low operating cost

19. External Customers Retailers Maintenance
Small and attractive packaging
Long shelf life
Low cost/performance and Exciting features
Maintenance
Ease of maintenance

20. External Customers Government / Standards / Society
Conformance to laws and regulations
Promotion of public health and safety
Protection of environment
Solution to chronic problems in society
Traffic
Energy
Noise
Drugs, abuse and other crimes
Diversity / Social tolerance / Security

21. Internal Customers Management Make a big profit On time delivery
Low failure risk
Documentation
Process: Conformance to company product development process

22. Internal Customers Marketing Attractive features to target buyers
Low production cost
Esthetics
Attractive packaging
On time delivery
Long Warrantees

23. Internal Customers Manufacturing
Manufacturability using standard methods and schedules.
Conformance to company documentation formats.
Use of products from preferred vendors.

24. Internal Customers Legal No patent infringements Safety
All required safety warnings and labels
Designed protection against reasonable abuse
Codes and regulations

25. Internal Customers Shipping and Packaging Ease of user assembly
Small packaged size
Ability of locking or fixing sensitive components
Resistance against damage due to dropping, vibrations, moisture, heat, and cold.

26. Performance
cost
Ease of use
Reliability
Safety
Users
*****
Buyers
**** **
Retailers
***
Govrnmnt
Mangmnt
Marketng

27. Product Design Specification
Elements of PDS
Performance (User)
Speed,
Capacity,
Power,
Accuracy,
etc.
PDS is important because most product failures (to be successful) can be traced to one of the elements in PDS. A design engineer that understand the importance of PDS and is efficient in developing one is much more successful in his/her career than those who go after “Eureka” type blank-sheet designs. As a starting engineer, you will be much more impressive and valuable to company management if you do a good job on this task. We have many many examples of this being true.
Performance:Beware of “over-specification”. Care must be exercised to set attainable specification requirements to keep the cost down.
Environment: All aspects of the product’s likely environment such as:
Temperature/Pressure/Humidity
Shock loading / Vibration
Dirt / Dust / Corrosive media / insects
Exposure during manufacturing, storage / packaging
Maintenance: Specify ease of access and frequency and kind of maintenance called for for the product. Need or desirability of any special tools or spare parts.

28. Elements of PDS Environment: (User) Life in service: (User)
Temperature range, humidity, dust and dirt, etc.
Life in service: (User)
10 years, 5000 cycles, etc.
Maintenance: (User)
What is the market policy, what customers accept
Target production cost: (User)
Cost of comparable products and company policy.

29. Elements of PDS
Shipping:
Package sizes
Damage resistance

30. Elements of PDS Quantity (Manufacturing)
Determined by market analysis.
Manufacturing facility (Manufacturing)
Is the design constrained by existing facility?
Are parts to be contracted and assembled in-house?
Does the company policy dictate certain facilities?

31. Element of PDS Size and shape (Marketing) Weight (Marketing)
What is the desired weight?
Should handles or lifting points be provided?
Should it be modular for better handling?
Aesthetics (Marketing,User)
Color, shape, form, texture, finish.
Market research.

32. Elements of PDS Materials (Marketing, Codes, Regulations)
Left to designers unless company guidelines or regulations restrict certain materials (asbestos, lead).
Product life span (Marketing, Manufacturing)
Life of a product as a marketable entity. Several months or several years?
Ergonomics
All products interact with human users at least to some degree during use and maintenance. It is important to describe the nature of this interface and record design requirements for ease of use, transportation, and handling.

33. Elements of PDS Laws, Codes, and standards (Government)
Ergonomics (User)

34. Elements of PDS Quality and reliability (Marketing)
Company policy regarding warranties
Competitors warranty policies
Testing (Marketing, QA)
What tests would be performed to verify performance
Standard tests

35. Elements of PDS Shelf life (storage) - Retail
Possibility of rust, decay, deterioration
Processes (company guidelines)
Use of certain standards (GD&T for example)
Use of certain procedures
Time-scales (deadlines) - Management
Whole design project, milestones

36. Elements of PDS Safety (User, Government, Legal)
What safety requirements are mandated by government
Professional society's codes and standards
Need for warning labels
Likely degrees of abuse or misinterpretation of operating procedures.

37. Elements of PDS Company constraints (Management)
Compatibility with other products
Documentation (Management – Legal)
A product design must include a full formal documentation per company guidelines.
Safety, Operation, and Service documents.
Etc.

38. Elements of PDS Legal (Lawyers)
What product liability law suits are associated with similar products and why.
Note the legal terms:
“defect of specification”
“defect of design”
“defect of manufacture”
Relevant patents

39. Element of PDS Installation (Installers) Disposal (Society)
Many products must interface with other products or be assembled with other products.
Disposal (Society)
Should any parts by recyclable?
bio-degradable?

40. Wording of the PDS Document
Format of most statements in PDS:
The device must ……..
The device is to ……
The device is desired to ….
Avoid mixing requirements.
One sentence per requirement.
Cast PDS statements in a positive format

41. PDS is a Dynamic Document
A design statement usually begins as a vague statement
The device is to be easy to use
The device is to be safe
The device is to be inexpensive
The device is to be rugged and reliable
The device is to be portable

42. Wording of the PDS Document
Example: ESCO’s Pin Remover
The pin-remover is to be light.
The pin-remover must work in a wet, cold, and dusty environment.
The Pin-remover must be safe
The Pin-remover must have a 3-year warranty.

43. PDS Example The PR is to be rugged. … must work with air pressure.
… is be easy to use.
… is to pass “HTS” tests.
… is to last 5 years in normal usage.
… is to be easy to carry.

44. PDS Example … is to sell for less than $150.
… is to costless than $50 to make.
… is to have low maintenance needs.
… is to be difficult to use as a hammer.
… must not infringe on patented devices.
… Production volume is to be 300 per year

45. PDS Example … is to be tested by June 2006.
… is to be released by Sep
… is to be used with Dredge Point models.
… is to work faster than the hammer

46. Engineering Specifications
What is
“Fast, accurate, high-performing”?
“Light, Small, portable”?
“Easy to use”?
“Safe”?
“Stylish”?

47. Engineering Specifications
Verifiable PDS statements
Developed for important PDS statements
Have associated target numbers (Yes/No OK)

48. Engineering Specifications Tips
Set up metrics and targets so the designer has maximum options in accomplishing the PDS

49. Engineering Specifications Tips
PDS: The Dog Feeder must not tip over when bumped or pushed by a dog.
Bad: The DF must weigh 50 lbs
Good: The dog feeder must withstand 30 lbs applied to its top from side

50. A Typical PDS Page Requirement: PR is to be easy to maintain
Primary customer: End users
Priority: High
Metrics and Targets
Daily maintenance: None
Weekly maintenance: < 10 minutes – field
Yearly maintenance: < 1 hour – Shop
Cost of weekly maintenance < 10c
Cost of yearly maintenance < $10

51. Engineering Requirements
Competition
IMPORTANCE
Customer Needs
PDS
Statements
Relation Between Engineering and Customer Requirements
Competition
Target