Dyson Product Development

PRODUCT DEVELOPMENT

• 250 Engineers•100 Design Engineers• 80 R+D Engineers• 70 Test Engineers and Technicians

PRODUCT DEVELOPMENT• R+D Engineers include:

• Fluid• Mechanical• Electrical• Electronic• EMC• Thermal• Chemical• Material• Acoustic• Software

PRODUCT DEVELOPMENT

• Design Engineers split into project teams• Typical project team (ie DC05)

• Project Manager• Senior Design Engineers (x2)•Design Engineers (x6)• Quality / Purchasing / Production (x2)

PRODUCT DEVELOPMENT - DC05

• The Brief:• Smaller• Quieter• More Powerful• Lighter


• Initial Concept Phase•Establish building blocks

• Bin capacity• Motor size• Cable reel• Filter size

•Cardboard modelling / sketching• 20+ configurations modelled in first 3 weeks


•Final Concept Phase•Balance rigs / Breadboards - prove machine handling• 2D mechanism models - structure and operation•CAD modelling (to support model building)•All major parts identified

•BOM cost•Tooling Estimates


• First working prototype - prove out theories• Suction power• Noise• Cyclone performance• Blockages


• Cyclone Development• R+D fluid dynamists provide expertise

• Cyclone Geometry• Filter requirements

• Design Engineers• Interpret and package in to product• Testing in product• Iterative development


• Blue foam - visual check• Handles• Actuators• Visual detailing


• Detail design - CAD intensive phase• Part interaction• Fits and assembly• Tooling - design tools

• Rapid prototyping - (in house FDM 2-3 models)• First dimensionally accurate and functioning model• Check machine operation• Performance testing


• Rapid prototyping - SLA Resin cast / SLS (15 machines)

• Accurate performance data• User trials (UK and International)• Mechanical testing

• Abuse testing• Repeat actuation

• Standards and approvals


• Tooling• Capital commitment (1 million pounds)

• First moulded samples - “T1” • Engineering build

• Prove fits and assembly• Machine operation / performance• Testing

• Iterative loop, Tooling modifications and T2


• Production Phase• Pre production build

• Train production team - on line• Prove assembly with production volumes• Test for final product validation

•Start of production - pipe fill• Engineering team into Current support• Trouble shooting production issues• International variants • Cost down

Dyson Product Development

Business

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