Design Engineering Processes

• After completing this unit, you will know about:

– The role of engineering in the manufacturing company

– The six stages of the design engineering process

– The use of Design Criteria

• There are three assignments that are part of this unit:– The first two are to be completed

individually

– The third is to be completed as part of a team effort

Engineering in Manufacturing

• Engineers are the problem-solvers in manufacturing companies.

• They design products & plan the most efficient manufacturing system to produce the product.

Introducing Design Engineering

• Design Engineers create ideas for products.– They develop these ideas into plans.– They decide if a profit can be made by

producing the product.– They make designs, models, and

engineering drawings to help develop and test the ideas.

Design Engineering Processes

• Design Engineering begins with the research and development of new product ideas.

• Research and Development is also called “R&D”.– Identifies & develops new ideas for

products, materials, and processes.

Research

• The Research part of R&D is the step-by-step search for new information, facts, and principles about a topic.

• Research is very methodical (meaning it uses a method or process).– Two types:

• Pure Research (also called Basic Research)– Search for new information without thinking about

the use of that information

• Applied Research– Search for practical applications for the new

knowledge found through Pre Research

Development

• The Development part of R&D is a type of applied research that tries to:– Create new products– Create new applications for existing

products

• Development takes new materials or product ideas discovered by researchers and creates new products.

Research & Development Questions

• Before engineers decide to manufacture a product, they ask three basic questions:

• Can the product be made with our equipment?• Will customers buy it?• Can it be sold at a profit?

ASSIGNMENT # 1 (complete individually)• Write a complete paragraph for each of the three

questions listed above and explain why these questions are important and how an engineer might find the answers.

• Write a complete paragraph to explain why engineers would try to find new applications for existing products?

Stages in the Design Engineering Process

• Six Stages of the Design Engineering Process:

1. Desire

2. Preparation

3. Ideation

4. Incubation

5. Illumination

6. Verification

Stage 1: Desire

• Desire– The engineer must have the desire to

create a new design– The engineer must be interested in the

product– Also called motivation– Desire provides the energy, interest, and

motivation for the engineer to complete the job

Stage 2: Preparation

• Preparation– Stage of the engineer learning,

exploring, and gathering information– “doing your homework” time– Engineers study existing products– Talk to experts– Talk to potential customers– Study tools, processes, and materials– Must develop the Design Criteria

Stage 2 continued:The Design Criteria

• Preparation: The Design Criteria• Function

– What is the product is designed to do?• Form

– What is the size, shape, and structure of the product?• Ergonomics

– Is it designed for comfortable human use?• Aesthetics

– Is it considered visually appealing?• Ease of Manufacture

– Can the company make the product?• Standardization

– Does it use standard tools, parts, and sizes?• Durability

– What is the expected life of product?• Costs

– Can it be sold at a profit?

Stage 3: Ideation

• Ideation– Brainstorming for ideas

• Provides ideas for possible products

– Sketching ideas• Thumbnail sketches (rough sketches)

– Renderings• Shows all details of the finished product

– Mock-ups• Scale model of actual product

– Made from easy-to-use materials

– No real working parts

Stage 4: Incubation

• Incubation– Take a break

– Ponder

– Reflect

– Think

Stage 5: Illumination

• Illumination– New ideas generate subconsciously

– “Ah ha!” stage

– The “light bulb” goes on!

Stage 6: Verification

• Verification– Prove the idea

– Make sure the product actual works!

– Build a Prototype• Actual materials

• Working components

– Testing• Does it meet the Design Criteria?

Engineering in Manufacturing

• ASSIGNMENT # 2 (complete individually)– Write a complete paragraph for each of the

Design Criteria.– Explain why each of the eight factors are

important in the manufacturing process.• The Design Criteria questions:

– What is the product is designed to do?– What is the size, shape, and structure of the product?– Is it designed for comfortable human use?– Is it considered visually appealing?– Can the company make the product?– Does it use standard tools, parts, and sizes?– What is the expected life of product?– Can it be sold at a profit?

Engineering in Manufacturing

• ASSIGNMENT # 3 (complete as Team)– Your team is to design a package that can

securely hold and ship 4 golf balls.• Develop a written set of Design Criteria• Prepare a Thumbnail sketch of the package• You will be given 5 sheets of paper and 50 centimeters

of tape as your materials.• Points awarded for:

– Completeness of Design Criteria– Completeness of the Thumbnail Sketch– Creativity of solution– Least amount of paper and tape used– Durability of package