1. 1 13-1 McGraw-Hill/Irwin © 2003 The McGraw-Hill Companies, Inc., All Rights Reserved.

2. 2 13-2 DEVELOPMENT P ART F OUR

3. 3 13-3 Development Figure IV.1

4. 4 13-4 CHAPTER THIRTEEN DESIGN

5. 5 13-5 What Is Design? Has been defined as “the synthesis of technology and human needs into manufacturable products.” In practice, design can mean many things, ranging from styling to ergonomics to setting final product specifications. Design has been successfully used in a variety of ways to help achieve new product objectives. One thing it is not: “prettying up” a product that is about to manufactured!

6. 6 13-6 Contributions of Design to the New Products Process Figure 13.1

7. 7 13-7 Range of Leading Design Applications Purpose of Design Aesthetics Ergonomics Function Manufacturability Servicing Disassembly Item Being Designed Goods Services Architecture Graphic arts Offices Packages Figure 13.2

8. 8 13-8 Product Architecture The process by which a customer need is developed into a product design. Solid architecture improves speed to market, and reduces the cost of changing the product once it is in production. Product components are combined into “chunks,” functional elements are assigned to the chunks, and the chunks are interrelated with each other.

9. 9 13-9 Product Architecture Illustration Figure 13.3

10. 10 13-10 Product Architecture and Product Platforms Product architecture development is related to establishing a product platform. If chunks or modules can be replaced easily within the product architecture, “derivative products” can be made from the same basic platform as technology, market tastes, or manufacturing skills change. Examples: 200 versions of the Sony Walkman from four platforms.

11. 11 13-11 Assessment Factors for an Industrial Design Figure 13.4

12. 12 13-12 Prototype Development Comprehensive Prototype: complete, fully- functioning, full-size product ready to be examined by customers. Focused Prototype: not fully functioning or developed, but designed to examine a limited number of performance attributes or features. –Examples: a crude, working prototype of an electric bicycle; a foam or wood bicycle to determine customers’ reactions to the proposed shape and form.

13. 13 13-13 Model of the Product Design Process Figure 13.6

14. 14 13-14 Improving the Interfaces in the Design Process Co-location Digital co-location Global teams Produceability engineer Upstream partnering with vendors

15. 15 13-15 Computer-Aided Design (CAD) Greatly accelerates the design step and allows assessment of multiple possible designs without building expensive prototypes. Design for Manufacturability (DFM): search for ways to minimize manufacturing costs. Design for Assembly (DFA): search for ways to ease assembly and manufacture. Rational for DFM: A seemingly trivial detail in design phase might have huge manufacturing cost consequences later on!

16. 16 13-16 Some of the Uses of CAD in Auto Industry Determining fit of subassemblies: does the radio/CD player protrude too far into the engine area? Facilitating “decking” of cars (attaching the powertrain to the upper body): do all the pieces fit together perfectly? Crashworthiness: can we modify any aspects of the car’s design to improve its ability to protect the passengers in a crash?

17. 17 13-17 New Developments in CAD Stereolithography (rapid prototyping) Mechanical computer-aided engineering (MCAE)