1. Detail Design
Chapter 9
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2. Detail Design in PDP
Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies

3. 9.1 Introduction What is Detail Design?
Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies

4. Detail Design
Detail design is the phase where all of the details are brought together, all decisions are finalized, and a decision is made by management to release the design for production.
Detail design is the lowest level in the hierarchy of design abstraction.
Detail design is a very specific and concrete activity.
Poor detail design can ruin a brilliant design concept and lead to manufacturing defects, high costs, and poor reliability in service.
THE REVERSE IS NOT TRUE!
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5. 9.2 Activities and Decisions in Detail Design
What are the tasks needed to be accomplished in Detail Design?
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6. Chief Activities of Detail Design
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7. Make/Buy Decision
This type of decision will be made chiefly on the basis of cost and manufacturing capacity, with due consideration given to issues of quality and reliability of delivery of components.
The decision to manufacture a critical component in- house is based solely on the need to protect trade secrets concerned with a critical manufacturing process.
An important reason for making this decision early is so you can bring the supplier into the design effort as an extended team member.
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8. Complete the Selection and Sizing of Components
It is necessary to complete these activities before the design can be complete.
If the product design is at all complex, it most likely will be necessary to impose a design freeze at some point prior to completion.
Design Freeze: Beyond a certain point in time no changes to the design will be permitted unless they go through a formal review by a design control board.
With a design freeze, only those last-minute changes that truly affect performance, safety, or cost are approved.
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9. Complete Engineering Drawings
A major task in the detail design phase is to complete the engineering drawings.
Drawings of individual parts are usually called detail drawings.
Detail drawings show the geometric features, dimensions, and tolerances of the parts.
Assembly drawings show how the parts are put together to create the product or system.
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10. Complete the Bill of Materials
The bill of materials (BOM) or parts list is a list of each individual component in the product.
BOM is used in planning for manufacture and in determining the best estimate product cost.
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11. Revise the Product Design Specification
In detail design the PDS should be updated to include all current requirements that the design must meet.
There is difference between the part specification and the product design specification.
For individual parts the drawing and the specification are often the same document.
When a part specification is issued it contains information on:
Technical performance part
Reliability requirement
Dimensions
Design life
Test requirements
Packaging requirement
Materials requirements
Marking for shipment
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12. Complete Verification Prototype Testing
Once the design is finalized, a beta-prototype is built and verification tested to ensure that the design meets the PDS and that it is safe and reliable.
Beta-Prototype: It is made with the same materials and manufacturing processes as the product but not necessarily from the actual production line.
Depending on the complexity of the product, the verification testing may simply be to run the product during an expected duty cycle and under overload conditions, or it may be a series of statistically planned tests.
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13. Final Cost Estimate
The detail drawings allow the determination of final cost estimates, since knowledge of the material, the dimensions, tolerances, and finish of each part are needed to determine manufacturing cost.
Cost analysis also needs specific information about the particular machines and process steps that will be used to make each part.
Note: Cost estimates will have been made at each step of the product design process with successively smaller margins for error.
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14. Prepare Design Project Report
A design project report usually is written at the conclusion of a project to describe the tasks undertaken and to discuss the design in detail.
A design project report is a vital document for passing on design know-how to a subsequent design team engages in a product redesign project.
A design project report may be an important document if the product becomes involved in either product liability or patent litigation.
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15. Final Design Review
Many formal meetings or reviews will have preceded the final design review.
These meetings include:
An initial product concept meeting to begin the establishment of the PDS,
A review at the end of conceptual design to decide whether to proceed with full-scale product development
A review after embodiment design to decide whether to move into detail design.
The final design review results in a decision by management on whether the product design is ready for production.
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16. Release Design to Manufacturing
The release of the product design to manufacturing ends the main activity of the design personnel on that product.
The release may be done unconditionally, or under pressure to introduce a new product it may be done conditionally.
The increasing use of the concurrent engineering approach to minimize the product development time blurs the boundary between detail design and manufacturing.
It is common to release the design to manufacturing in two or three “waves,” with those designs that have the longest lead time for designing and making tooling being released first.
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17. 9.3 Communicating Design and Manufacturing Information
How can we communicate the design into another party?
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18. Engineering Drawings The information on a detail drawing includes:
Standard view of orthogonal projection
Auxiliary views
Dimensions
Tolerances
Material specification
Manufacturing details
Design layouts show the spatial relationships of all components in the assembled product (the system).
Assembly drawings are created in detail design as tools for passing design intent to the production department.
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19. Detail Drawing of a Lever
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20. Exploded Assembly Drawing: Gear Reducer
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21. Bill of Material (BOM)
ASM Handbook, vol. 20, p. 228, ASM International.
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22. Written Documents
Design engineers prepare both informal and formal documents as part of their daily routines:
Informal:
-messages
Brief memoranda and daily entries in a design journal
Formal:
Letters
Technical reports
Technical Papers
Proposals
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23. Electronic Mail
No form of communication has grown so rapidly as electronic mail ( ).
Well over eight trillion messages are sent each year!
Guidelines for professional writing:
Use proper capitalization, spelling and sentence structure.
Use information and brief subject lines in all your messages.
Keep your messages short.
Compress any attachments that are large.
Do NOT use emoticons or other informal visuals.
In addition to an informal signature use a formal signature block
Delete unnecessary or repetitive information in a response to a sender
Include relevant detail when you are responding to a sender
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24. Memorandum Reports
The memorandum report usually is written to a specific person or group of persons concerning a specific topic with which both the writer and recipient are familiar.
A memorandum is a letter written to a colleague or group of colleagues within the same organization.
A memorandum report is an effective way to communicate the same information to an entire business unit or all members of the same group.
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25. Design Notebook
The place where the decisions made during design are found is the design notebook.
The design notebook should be an 8 by 11 inch bound notebook (not spiral bound), preferably with a hard cover.
Good rules for keeping notebook:
Keep an index
Entries should be made in ink and must be legible
Make your entries at the time you do the work
All data must be in their original primary form
Rough graphs should be drawn directly in the notebook
Give complete references to book, journal, reports, patents and any other source of information
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26. Formal Technical Reports
A formal technical report, usually written at the end of a project, is a completely and stand-alone document aimed at persons having widely diverse backgrounds.
The outline of a typical professional report:
Cover letter
Title page
Executive summary
Table of contents
Introduction
Technical issue sections
Conclusion
References
Appendixes
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27. Common Challenges in Technical Writing
Tense:
The choice of the tense of verbs is often confusion:
Past Tense
Present Tense
Future Tense
References
References are usually placed at the end of the written text:
Technical Journal Article
Book
A private communication
Internal reports
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28. Meetings
The business world is full of meetings that are held to exchange information and plan activities.
At the lowest level of this hierarchy is the design team meeting.
The purpose of the meeting is to share the progress that has been made, identify problem, and find help and support in solving the problems.
Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies

29. Oral Presentation
Impressions and reputations are made most quickly by audience reaction to an oral presentation.
Oral communication has several special characteristics:
Quick feedback by questions and dialogue
Impact of personal enthusiasm
Impact of visual aids
Important influence of tone
Emphasis
Gesture
Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies

30. Design Briefing
You should know the purpose of your talk and have a good idea of who will be attending your presentation.
The most appropriate type of delivery for most business- oriented talks is an extemporaneous-prepared talk.
Develop the material in your talk in terms of the interest of the audience.
Organize it on a thought-by-thought rather than a word- by-word basis.
Write your conclusions first!
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31. What is final design review?
Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies

32. Input Documents
The input for the review consists of documents such as:
PDS
QFD analysis
Key technical analyses like FEA, CFD
FMEAs
Quality Plan
Testing plan and results of the verification tests
Detail and assembly drawings
Product specifications
Cost projections
Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies

33. Review Meeting Process & Output from Review
The design review meeting should be formally structured with a well-planned agenda.
The final design review is more of an audit in contrast to the earlier reviews which are more multifunctional problem-solving sessions.
The output from the design review is a decision as the whether the product is ready to release to the manufacturing department.
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34. 9.5 Design and Business Activities Beyond Detail Design
What are the design and business activities required?
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35. Items on a Final Design Review Checklist
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36. Technical Activities Process planning Develop production control plan
Designing for tooling and fixtures
Develop quality assurance plan
Develop maintenance plan
Develop plan for retirement from service
Manufacturing production acceptance test
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37. Business Activities Negotiate with suppliers Develop distribution plan
Write the user manual
Decide on warranty
Develop a plan for customer service
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38. 9.6 Facilitating Design & Manufacturing with Computer-Based Methods
How can computer-based methods help design and manufacturing?
Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies

39. CAE and CAD
Computer-aided engineering (CAE) has had an important and growing influence on:
reducing the product design cycle time
improving the quality of the product
decreasing manufacturing cost
Computer-aided design (CAD) has saved countless hours of redrawing details.
The ability to store standard details in a CAD system for retrieval when needed saves much drafting labor.
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40. Product Lifecycle Management (PLM)
Product lifecycle management (PLM) refers to a set of computer-based tools that has been developed to assist a company to more effectively perform the product design and manufacturing functions from conceptual design to product retirement.
Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies

41. Three Subsystems to PLM
Product data management (PDM):
Provides a link between product design and manufacturing
Manufacturing process management (MPM):
Bridges the gap between product design and production control
Customer relationship management (CRM):
Provides integrated support to marketing, sales, and the customer service functions.
Dieter/Schmidt, Engineering Design 5e. ©2013. The McGraw-Hill Companies