MORPHOLOGY MORPHOLOGY OF DESIGNOF DESIGN

Phase VI PLANNING FOR USEPhase VI PLANNING FOR USE

Consumer Oriented Process must be Consumer Oriented Process must be incorporated in the design processincorporated in the design process

User Oriented Process User Oriented Process Ease of maintenanceEase of maintenance ReliabibilityReliabibility Product SafetyProduct Safety Convience in Use ( Human Factor Convience in Use ( Human Factor

Engineering)Engineering) Aesthetic AppealAesthetic Appeal Economy of OperationEconomy of Operation Duration of ServiviceDuration of Servivice

Planning Planning for the for the

Retirement of productRetirement of product The final step in the design process is the disposal The final step in the design process is the disposal

of product when it has reached end of useful lifeof product when it has reached end of useful life Useful life is determined by point where design can Useful life is determined by point where design can

no longer function no longer function Technological obsolescence in which competitive Technological obsolescence in which competitive

design cheaper performs the function better or design cheaper performs the function better or cheapercheaper

In Consumer product, it may come through changes In Consumer product, it may come through changes in fashion and tastein fashion and taste

Computer aided design --- CADComputer aided design --- CAD Computer Controlled Machine ToolsComputer Controlled Machine Tools CAD and CCM link is called design database in CAD and CCM link is called design database in

digital format digital format

Design of New Product Design of New Product StepsSteps

Product Specification

Develop Design Concept

Analyse Critical Design Features

Create Detail Design

Analyze Detail Design

Generate Detail Drawing

Build Prototype

Test Prototype

Program N/C Machine Tools and Automated Mfg. Equipment

Manufacture Product

Test Finished Product

Ship the Product

Monitor Field Performance

Historical and Current Test Data

Further consideration in Further consideration in Design Design

The design process has followed time The design process has followed time sequence of events in the usual projectsequence of events in the usual project

To look design at another aspect, Design To look design at another aspect, Design factor are grouped into three categoriesfactor are grouped into three categories Functional RequirementsFunctional Requirements Total Life CycleTotal Life Cycle Further Major factorsFurther Major factors

Functional RequirementsFunctional Requirements

Design must meet performance Design must meet performance specificationspecification

Performance specification in problem Performance specification in problem defination defination

Overemphasis the specification of property Overemphasis the specification of property values and performance parameters values and performance parameters

Computer Aided Design (CAD) tool for Computer Aided Design (CAD) tool for analytical analysis with interactive analytical analysis with interactive computer graphicscomputer graphics

Product LiabilityProduct Liability

Due to competitive nature business Due to competitive nature business emphasized has been given on emphasized has been given on reliabilityreliability ReliabilityReliability

MaintainabilityMaintainability AvailabilityAvailability RepairabilityRepairability

ReliabilityReliability

Reliability is defined as probability Reliability is defined as probability that device will be perform that device will be perform adequately in service for the period adequately in service for the period of time intended under specified of time intended under specified operating conditionoperating condition

MaintainabilityMaintainability

Ease Ease EconomyEconomy Safety of performing functionSafety of performing function Minimize maintainace timeMinimize maintainace time Maximize time in productive serviceMaximize time in productive service

ANTICIPATION FAILURE ANTICIPATION FAILURE MODE OF PRODUCTMODE OF PRODUCT

Fault Tree AnalysisFault Tree Analysis Failure Modes and Effect AnalysisFailure Modes and Effect Analysis Hazard AnalysisHazard Analysis

Design ReviewDesign Review

The design review is vital aspect of The design review is vital aspect of the design processthe design process

Design Review provides a systemic Design Review provides a systemic method for identifying the problems method for identifying the problems with the design, aids in determing the with the design, aids in determing the possible course of actionpossible course of action

Initiate action to correct problem Initiate action to correct problem areas areas

Design Review TeamDesign Review Team Team Leader Project Manager: Team Leader Project Manager:

(technical knowledge and know how (technical knowledge and know how for product)for product)

DesignDesign ManufacturingManufacturing MarketingMarketing PurchasingPurchasing Quality ControlQuality Control Reliability EngineeringReliability Engineering Field ServiceField Service

Design Review ChecklistDesign Review Checklist

Design requirementsDesign requirements Functional requirementsFunctional requirements Environmental requirementsEnvironmental requirements Manufacturing requirementsManufacturing requirements Operational requirementsOperational requirements Reliability requirementsReliability requirements

Chapter 2Chapter 2DESIGN IN A DESIGN IN A

BROADERCONTEXTBROADERCONTEXT

2.1 Spectrum of 2.1 Spectrum of Engineering ActivitiesEngineering Activities

It is defined as application of science to It is defined as application of science to the solution of problem of society at a the solution of problem of society at a profit costprofit cost

According to the ABET According to the ABET Engineering is the profession in which a Engineering is the profession in which a

knowledge of the mathematical and natural knowledge of the mathematical and natural sciences gained by study, experience and sciences gained by study, experience and practice is applied with judgment to develop practice is applied with judgment to develop the ways to utilize , economically, the the ways to utilize , economically, the materials and forces of nature for the benefit materials and forces of nature for the benefit of mankind of mankind

AIM OF ENINEERINGAIM OF ENINEERING

Solution of specific society problem using Solution of specific society problem using mathematics and science mathematics and science

Limitation/ ConstraintsLimitation/ Constraints LegalLegal EnvironmentalEnvironmental EconomicEconomic

Engineering FunctionsEngineering Functions Refer Fig 2.1 Engineering function starts with Refer Fig 2.1 Engineering function starts with

research, closest to academic experienceresearch, closest to academic experience More emphasis is on financial and More emphasis is on financial and

administrative matters towards downwards of administrative matters towards downwards of hierarchy hierarchy

ResearchResearch DevelopmentDevelopment DesignDesign Production and ConstructionProduction and Construction Operation and MaintenanceOperation and Maintenance SalesSales ManagementManagement

ResearchResearch R & D are the glamour end of R & D are the glamour end of

engineeringengineering Research limited to scientist working Research limited to scientist working

in Lab to explore the naturein Lab to explore the nature R & D ActivitiesR & D Activities

ResearchResearch Exploratory DevelopmentExploratory Development Advance DevelopmentAdvance Development Engineering DevelopmentEngineering Development Management and SupportManagement and Support

BASIC and Applied BASIC and Applied ResearchResearch

DESIGNDESIGN The design is the function of creating a The design is the function of creating a

technical plan to solve a problemtechnical plan to solve a problem It involves both analysis and synthesesIt involves both analysis and syntheses Needs not only calculation on Needs not only calculation on

computer and lines on drawing but computer and lines on drawing but much computermuch computer

It involves planning of “how the thing It involves planning of “how the thing designed will be manufactured and designed will be manufactured and how it will be maintainedhow it will be maintained

Production and Production and ConstructionConstruction

This activity translates the design into This activity translates the design into manufacturing process , process plant or civil manufacturing process , process plant or civil structure engineering structurestructure engineering structure

Engineers are responsible toEngineers are responsible to Taking the design through initial production to prove that Taking the design through initial production to prove that

product can be manufactured in planned costproduct can be manufactured in planned cost General list of employee to work with expert and General list of employee to work with expert and

organize the schedule and complete task in allocated organize the schedule and complete task in allocated costcost

To supervise the plants workforce, material's flow and To supervise the plants workforce, material's flow and machinemachine

Meeting the production schedule while maintaing the Meeting the production schedule while maintaing the product qualityproduct quality

Provide plant engineering function of providing plant Provide plant engineering function of providing plant utility services, maintenance and modificationutility services, maintenance and modification

Sales Engineering: liaison between customers and Sales Engineering: liaison between customers and production facilitiesproduction facilities

2.2 ORGANIZATION OF 2.2 ORGANIZATION OF ENGINEERING FUNCTIONENGINEERING FUNCTION

There are three types of organization There are three types of organization structurestructure Functional OrganizationFunctional Organization Project OrganizationProject Organization Project Functional Staff OrganizationProject Functional Staff Organization

Functional OrganizationFunctional Organization

Organization is grouped into separate Organization is grouped into separate identifiable units based on functional identifiable units based on functional specialtiesspecialties

Similar work is performed in same Similar work is performed in same organizational unitorganizational unit

All R & D and design work reports to a All R & D and design work reports to a single vice president and manufacturing single vice president and manufacturing activity is the responsibility of other vice activity is the responsibility of other vice president president

Many functions are under a single vice Many functions are under a single vice president president

Functional OrganizationFunctional Organization Chart Chart

Board of Directors

Stack Holders

President

Vice President Vice President Vice President Vice President Vice President

Project OrganizationProject Organization

The functions are organized around a The functions are organized around a single product or major systemsingle product or major system

Functions are redistributed based on Functions are redistributed based on need among a number of project need among a number of project managersmanagers

It is dynamic and time-limited since its It is dynamic and time-limited since its life is based on completion of project life is based on completion of project objective and then people are objective and then people are reassignedreassigned

Project Organization Project Organization ChartChart

President

Manager Project X

Vice President

Manager Project Y

Manager Project Z

Line OrganizationLine Organization Line organization represents a chain of Line organization represents a chain of

command relationship in which command relationship in which supervisor reports to the managersupervisor reports to the manager

Line functions are concerned with Line functions are concerned with achieving the prime objective of the achieving the prime objective of the projectproject

Staff functions support the one or more Staff functions support the one or more line organization line organization

SF provide special expertise and SF provide special expertise and information to achieve the objectives of information to achieve the objectives of organizationorganization

SF are not the part of chain command. SF are not the part of chain command.

Project Functional Staff Project Functional Staff OrganizationOrganization

It is formed by merging of functional It is formed by merging of functional organization and project teamorganization and project team

An organization consist of project team An organization consist of project team superimposed on existing vertical superimposed on existing vertical functional structure of organizationfunctional structure of organization

An Engineer can switch one department An Engineer can switch one department to another by providing technical to another by providing technical assistance assistance

Matrix Organization Matrix Organization

President

Mechanical Design

Vice President of Researach and Engineering

Electrical Design

System Engineering

Other Vice President

Project Management

Project X

Project Y

Project Z

Chapter 3Chapter 3DESIGN METHODSDESIGN METHODS

3.1 INTRODUCTION3.1 INTRODUCTION

Successful design calls for skills in problem solving and Successful design calls for skills in problem solving and descision makingdescision making

Conceptualization step is the most important since it Conceptualization step is the most important since it constitute engineering and scientific principles that constitute engineering and scientific principles that constitute design constitute design

Design methods are needed to assist complex processDesign methods are needed to assist complex process Computer based “design tools” are being developed using Computer based “design tools” are being developed using

expert system, mathematical modeling and advanced expert system, mathematical modeling and advanced optimization technique but scope of this chapter is simpler optimization technique but scope of this chapter is simpler design methodsdesign methods

Sketching or Drawing to help visulize design conceptSketching or Drawing to help visulize design concept Systemizing the decision process in World War II Systemizing the decision process in World War II

developments in operation researchdevelopments in operation research Management science and operation techniqueManagement science and operation technique

INTRODUCTION (Cont…)INTRODUCTION (Cont…)

Of the design methods one tries to formalize Of the design methods one tries to formalize the design procedures and externalize the the design procedures and externalize the design thinkingdesign thinking

Aim of formalization is to prevent Aim of formalization is to prevent overlooked factors in design process or the overlooked factors in design process or the occurrence of errors occurrence of errors

In externalization thoughts and thinking out In externalization thoughts and thinking out of designer’s head and put them in charts of designer’s head and put them in charts and diagramand diagram

3.2 Creativity and Problem 3.2 Creativity and Problem SolvingSolving

Creativity is the ability to synthesize new Creativity is the ability to synthesize new combinations of ideas and concepts into meaningful combinations of ideas and concepts into meaningful and useful formand useful form

There is myth ‘ Creative ideas arrive with flash flash There is myth ‘ Creative ideas arrive with flash flash like spontaneity – the flash of lighting and clap of like spontaneity – the flash of lighting and clap of thunder routinethunder routine

Ideas occur slow and can be enhanced with study Ideas occur slow and can be enhanced with study and practice and practice

Creative process can be viewed as moving from Creative process can be viewed as moving from amorphous/shapeless idea to a well structured idea, amorphous/shapeless idea to a well structured idea, from implicit to explicitfrom implicit to explicit

Creative ideas can not be turned on upon commandCreative ideas can not be turned on upon command

Steps for Enhancement in Steps for Enhancement in Creative Thinking Creative Thinking

Develop a creative attitudeDevelop a creative attitude Develop self confidence to tackle the problemDevelop self confidence to tackle the problem Build confidence with small success Build confidence with small success

Unlock your imaginationUnlock your imagination Come out of imagination Come out of imagination Question ask again “why” and “what if”Question ask again “why” and “what if” Thought games are designed to provide practice Thought games are designed to provide practice

in unlocking imaginationin unlocking imagination Be persistent Be persistent

Creativity occurs with lighting strike Creativity occurs with lighting strike It requires hard work and consistency since It requires hard work and consistency since

problems are not solved in first attemptproblems are not solved in first attempt

Steps for Enhancement in Steps for Enhancement in Creative Thinking Creative Thinking

Develop an open mindDevelop an open mind Receptive to ideas from any and all sourcesReceptive to ideas from any and all sources Solutions are not the property of a Solutions are not the property of a

particular disciplineparticular discipline Suspend your judgmentSuspend your judgment

Critical attitude of EngineersCritical attitude of Engineers Avoid judgment at early stageAvoid judgment at early stage

Set Problem BoundariesSet Problem Boundaries Establish the boundaries of problem Establish the boundaries of problem

definationdefination

Chapter 4Chapter 4Modeling and SimulationModeling and Simulation

MODELINGMODELING

A model is an idealization of a real world situation A model is an idealization of a real world situation that aids in analysis of problemthat aids in analysis of problem Free body diagram, electric circuit diagram, Free body diagram, electric circuit diagram,

sphere by earth sphere by earth A model may be classified asA model may be classified as

Descriptive : real world system or phenomenon e-Descriptive : real world system or phenomenon e-g model of an aircraft gas turbine. It does not g model of an aircraft gas turbine. It does not predict the behavior of systempredict the behavior of system

Predictive : used in engineering design in order to Predictive : used in engineering design in order to understand and predict the behavior of systemunderstand and predict the behavior of system

MATHEMATICAL MATHEMATICAL MODELINGMODELING

In MM the component of system are idealized In MM the component of system are idealized by elements having the same characteristics by elements having the same characteristics and behavior can be described by and behavior can be described by mathematical equationmathematical equation

A generalized picture of model for a system A generalized picture of model for a system or component is shown in Fig 4.3or component is shown in Fig 4.3

Engineering System is complex and can be Engineering System is complex and can be easily understood by breaking into smaller easily understood by breaking into smaller components and modeling each of themcomponents and modeling each of them

Interaction of these components is to be Interaction of these components is to be defineddefined

Block DiagramBlock Diagram

Power Plant

Coal

Electricity

Steam Boiler Combustion Chamber

Steam Turbine Generator Electricity

Coal

Fig 4.1 . Overall Block Diagram of Power Plant

Fig 4.2 . Block Diagram of major components of Power Plant

Block DiagramBlock Diagram Coal

GeneratorFeeder

Fig 4.5 . Detailed system for a coal fired Power Plant

Combustion Chamber

Stock

Turbine

Heater

Cooling Pond

CondenserBoiler Tube

Coal

Gases

Water Gases

Ash Heat

Steam

Water

Water

Pump

Pump

Water

Water

Electricity

Spray Water

Chapter 6Chapter 6Material Selection ProcessMaterial Selection Process

Material Selection Material Selection ProcessProcess

A Problem of material selection A Problem of material selection involves one of two different involves one of two different situationssituations Selection of the materials for a new Selection of the materials for a new

product or new designproduct or new design Reevaluation of an existing product or Reevaluation of an existing product or

design to reduce cost, increase design to reduce cost, increase reliability, improve performancereliability, improve performance

Steps in the Manufacturing Steps in the Manufacturing ProcessProcess

Material selection is problem solving Material selection is problem solving processprocess

The steps in the process can be The steps in the process can be defined asdefined as Analysis of the materials requirementsAnalysis of the materials requirements Screening of candidate materialsScreening of candidate materials Selection of candidate materialSelection of candidate material Development of Design data Development of Design data

Analysis of material Analysis of material requirementsrequirements

Determine the conditions of service Determine the conditions of service and environment that the product and environment that the product must standmust stand

Translate then in critical material Translate then in critical material propertiesproperties

Screening of Candidate Screening of Candidate materialmaterial

Compare the needed properties Compare the needed properties ( responses) with large material ( responses) with large material property data base to select a few property data base to select a few material that look promising for the material that look promising for the application application

Selection of candidate Selection of candidate materialmaterial

Analyze candidate material in terms Analyze candidate material in terms of product performance, cost , of product performance, cost , fabricability and availability to select fabricability and availability to select the best material for the applicationthe best material for the application

Development of Design Development of Design DataData

Determine experimentally the key Determine experimentally the key material properties for the selected material properties for the selected material to obtain statistically material to obtain statistically reliable measures of the material reliable measures of the material performance under the specific performance under the specific conditions expected to be conditions expected to be encountered in service encountered in service

7.2 Classification of 7.2 Classification of Manufacturing ProcessManufacturing Process

Critical Path MethodCritical Path Method

CPM is a a technique used CPM is a a technique used