Understand the Process Constraints and Cost Drivers;Redesign the costly parts with same Feasibility Study;This stage

bility Study;This stage is also called conceptual design. A design project always begins with
performance,avoid high manuf cost. Work closely with the engineers.Redesign Components to Eliminate a feasibility study. The purpose and activities during feasibility study are Step-1 The Need-
Processing Steps; reduce no of steps, eliminate unnecessary steps, use substitute steps.Choose the Establishing economic evidence •To ascertain there really exists a need •Search for a number
Appropriate Economic Scale for the Part Process; economics of sales: as the volume increases the of possible solutions •Evaluate the solutions i.e. is it physically realizable? Is it economically
manuf cost decreases,fixed cost is divided in various units,variable costs are lowStandardize worthwhile? Is it within our financial capacity? Step-2 The Design problem-Identification and
Components and Processess; economics of sales: as the volume increases the unit cost decreases of a formulations Step-3 The Synthesis of possible solutions Step-4 Physical Realizability Step-5
component, standard components are common to more than one product Adhere to "Black Box" Economicworthwhileness Step-6FinancialFeasibilityII.PreliminaryDesign.
Component Procurement. Thisisthestageartwhichtheconceptgeneratedinthefeasibilitystudyiscarefully
SAFETY- The main principles of safe design are: Inherently safe design (ISD): This approach aims to developed.Theimportantactivitiesdoneat thisstageare: i. SelectionofDesignconcept ii.
reduce or eliminate hazards by replacing dangerous materials or reactions. Some methods of ISD include: Formulationofmathematicalmodel iii. Sensitivityanalysis iv. Compatibilityanalysis v.
Minimization: Reducing the amount of hazardous material present at any one time Substitution: Replacing Stabilityanalysis vi. Formaloptimization vii. Projectionsintothefuture viii.
one material with a less hazardous one Moderation: Reducing the strength of an effect Simplification: Predictionofsystembehaviour ix. Testingthedesignconcept x. SimplificationofDesign. Detail
Designing out problems rather than adding additional equipment or features Safety factors: Ensure DesignIts purpose is to furnish the complete engineering description of the tested product. The
constructions can withstand loads exceeding intended levels Negative feedback: In safety systems, arrangement, from, dimensions, tolerances and surface properties of all individual parts are
negative feedback is used as a control mechanism to maintain safe operating conditions by detecting determined. Also, the materials to be used and the manufacturing process to be adopted etc. are
deviations from desired parameters and automatically initiating corrective actions to mitigate risks. This decided. Finally, complete prototype is tested. i. Preparation of design ii. Overall design of
self-regulating process is integral to ensuring stability and preventing accidents. Multiple independent subsystems iii. Overall design of components iv. Detailed design of parts v. Preparation of
safety barriers: This principle involves having multiple “backup” components to remove single assembly drawings vi. Experimental construction vii. Product test program viii.Analysis and
points of failure. The Factor of Safety is a design principle used to ensure that structures or components Prediction ix. Role of allowance , process capability and tolerance in detailed design. IV: Planning
can withstand loads and stresses beyond their expected operating conditions. It is a ratio that provides a for manufacture This phase includes all the production planning and control activities necessary
margin of safety by accounting for uncertainties in material properties, manufacturing tolerances, and for the manufacture of the product. The main tasks at this phase are * Preparation of process
operating conditions. 10 aspects StandardizationDesigning products with standardized parts and sheet, i.e. the document containing a sequential list of manufacturing processes. * Specify the
processes reduces complexity, facilitates mass production, and minimizes inventory requirements, leading condition of raw materials. * Specify tools & machine requirements. * Estimation of production
to lower costs.Foldable, Stackable DesignCreating foldable or stackable products reduces cost. * Specify the requirement in the plant. * Planning QC systems. * Planning for production
transportation and storage costs by optimizing space utilization during shipping and warehousing. control., Planning for information flow system. Planning for Distribution The economic success
Modular DesignDesigning products with modular components simplifies assembly, allows easy of a design depends on the skill exercised in marketing. Hence, this phase aims at planning an
customization, and reduces production and maintenance costs. Complementary Product effective distribution system. Different activities of this phase are * Designing the packing of the
PlanningPlanning products that share components or production processes can achieve economies of product. * Planning effective and economic warehousing systems. * Planning advertisement
scale, reducing overall manufacturing costs.Group TechnologyGrouping similar components or techniques * Designing the product for effective distribution in the prevailing conditions.
processes reduces setup times, improves efficiency, and enables better utilization of resources. Use of Planning for Consumption/use The purpose of this phase is to incorporate in the design all
Available StockLeveraging existing inventory or readily available materials prevents unnecessary necessary user-oriented features. The various steps are * Design for maintenance * Design for
procurement costs and reduces lead times. AutomationImplementing automation for repetitive or labor- reliability * Design for convenience in use * Design for aesthetic features * Design for prolonged
intensive tasks improves consistency, speeds up production, and reduces labor costs over time. life * Design for product improvement on the basis of service data. Planning for Retirement.
Assembly LineUsing assembly line production ensures smooth workflows, increases efficiency, and This is the phase that takes into account when the product has reached the end of useful life. A
minimizes production time and costs. Specifications and TolerancesMaintaining optimal specifications product may retire when * It does not function properly * Another competitive design emerges
and tolerances ensures quality while avoiding overengineering, which can unnecessarily increase * Changes of taste or fashion The various steps in this phase are * Design for several levels of
costs.Compact DesignDesigning compact products reduces material usage and lowers costs associated use * Design to reduce the rate of obsolescence. * Examine service-terminated product to obtain
with production, packaging, and shipping PROFIT INC (a) Increase the sales price (b) Expand the useful information. Original design refers to creating a completely new product or solution from
market(c) Reduce total costs(a) Increase the sales price by increasing the profit per unitL imitations:(i) scratch, based on fresh ideas and innovative concepts. It does not rely on any pre-existing
Competition(ii) Customer's willingness to pay Danger:Shrinkage of market leading to possible dec- line in designs and is typically used to address new problems or markets. This approach involves
total profit(b) Expand the market by reducing the profit per unit, etc., by advertising.Limitations: extensive research, experimentation, and creativity, often resulting in groundbreaking
CompetitionDanger:Too low a margin of profit per unit should be avoided due to possible instabilities in the developments. However, it comes with higher risks, costs, and longer development times, as
market.(c) Reduce total costs and pass some benefits to customers by reducing sales everything is being built from the ground up. An example would be the invention of the first
price.Limitations:(i) Expenditure on new equipment(ii) Basic labour and materials costs(ii) Minimurn airplane or the development of a revolutionary new technology.On the other hand, adaptive design
requirements of quality Product value is the perceived worth of a product or service in the eyes of involves modifying or adapting an existing design to suit new requirements, improve functionality,
customers.It isakeyconceptinproductdevelopmentandpricing. Functionality, Feature ,Usability, Convenience or fit a different context. It builds upon proven concepts, making it a less risky and faster process.
Customization & Control, Reliability ,Availability, Refinement, Sustainability Adaptive design focuses on incremental improvements or optimizations rather than creating
something entirely new. For instance, upgrading an existing car model by adding advanced safety
features or improving its fuel efficiency would be an example of adaptive design.
Cost value, cost value these are the properties which are the sum of labour, material, Quality Function Deployment is a design planning process driven by customer requirements. 1. QFD
overhead and other cost required to produce. Exchangevalue this is the properties that deploys “The Voice of the Customer”throughout the organization. 2. QFD uses planning matrices --
make it possible to procure other items by trading. each called “The House of Quality”. 3. QFD involves, a) Customer b) what the customer wants c) how to
The Value Analysis Job Plan is a five-step approach aimed at improving product value by fulfill the customers want’s. Process Steps in QFD
analyzing functions, costs, and performance. Here’s a brief overview of the Identify Customer Needs:Gather data from customers to define their needs and expectations for the
steps:Information: Gather detailed data about the product or process to understand its product.Define Engineering Characteristics:Translate the customer needs into engineering
functions and identify areas for improvement.Analysis: Break down and assess the cost and specifications and product features.Create the House of Quality Matrix:Develop the matrix to
value of each function, identifying inefficiencies or unnecessary elements.Creativity: establish relationships between customer requirements (whats) and technical solutions
Brainstorm alternative solutions to enhance value or reduce costs, exploring innovative (hows).Prioritize Requirements:Evaluate the importance of each customer need and the feasibility of
ideas and approaches.Preliminary Judgment: Evaluate and prioritize solutions based on addressing it based on technical requirements.Implement and Monitor:After designing the product,
feasibility, cost-effectiveness, and impact.Evaluation: Conduct a detailed analysis of selected monitor the implementation to ensure the specifications meet the original customer needs. Benefits
solutions, assess their cost-benefit, and finalize the best options for implementation. of QFD Customer-Centered Design: Ensures that products are developed based on real customer
Creativity This is most important phase of VA It is development of ideas Discovery of demands, not assumptions.Improved Communication: Fosters collaboration across departments
alternative designs, methods, systems and process. Analytical approach Creative (e.g., marketing, engineering, manufacturing) to ensure alignment in meeting customer
approach. Recommendation and Implementation 1. OrientationThis initial stage involves expectations.Reduced Costs: By addressing customer needs early in the design process, QFD can
understanding the problem or challenge. It includes gathering relevant information, help avoid costly design changes and improve efficiency.Enhanced Product Quality: Aligns product
clarifying goals, and identifying the context in which the creative solution is needed.2. development with customer satisfaction, leading to higher quality and more competitive products
PreparationIn this phase, individuals gather data, explore existing solutions, and immerse  CREAT TECHS Brainstorming: Group technique to generate a large number of ideas without
themselves in the subject matter. It may involve research, learning, and refining the problem judgment, focusing on quantity over quality.Mind Mapping: Visual method for organizing and exploring
statement to better understand the issue at hand.3. IdeationThis is the brainstorming phase ideas around a central theme. SCAMPER: A technique to improve or create products by asking
where individuals or teams generate a wide variety of ideas and potential solutions. questions about Substitution, Combination, Adaptation, Modification, Putting to another use,
Creativity flows freely as different possibilities are explored without initial judgment.4. Elimination, and Reversal. Six Thinking Hats: A method to explore different perspectives (e.g., logical,
IncubationAfter the ideation phase, the ideas are allowed to "incubate," meaning they are emotional, creative) to generate well-rounded solutions. Reverse Brainstorming: Focuses on
left to settle and develop subconsciously. During this time, the mind processes the ideas, identifying ways to worsen a problem, then reversing those ideas to find solutions. Role Storming:
often leading to new insights and connections.5. SynthesisIn this stage, ideas are combined, Participants assume different roles (e.g., customer, competitor) to generate new ideas. 5 Whys:
refined, and synthesized into more comprehensive solutions. The most promising concepts Asking "Why?" five times to identify the root cause of a problem.Random Word Technique: Using
are selected and developed further, taking into account feasibility and alignment with random words to spark connections and inspire new ideas. The statement "Product Designers are
goals.6. VerificationFinally, the ideas are tested, validated, and refined. This stage involves front-line troops who lead and execute the battle" emphasizes the critical role of product
reviewing and evaluating the solutions to ensure they work in practice and meet the initial designers in the product development process. It suggests that product designers are at the
objectives. Adjustments are made as needed before final implementation.Habitual forefront, taking charge of the design process and facing challenges directly to create innovative,
BlocksThese occur when individuals become stuck in old patterns or ways of thinking.“Tried functional, and user-centric products.The metaphor compares product designers to soldiers in battle,
& True”: Relying solely on past methods or solutions without considering new highlighting that they are not only responsible for strategizing (leading) but also for carrying out the
approaches.Rejecting of Alternative Solutions: Dismissing new ideas or solutions that might execution (designing the product) to bring the product to market successfully. This reflects their key
be more effective or innovative.Lack of Positive Outlook: A pessimistic attitude that limits role in overcoming obstacles, making design decisions, and ensuring that the product meets both user
the ability to see opportunities and new possibilities. Perceptual BlocksThese arise when needs and business goals..  Empathy:Understanding the users deeply by considering their
there is a failure to fully observe or understand the situation.Failure to Use All Senses of emotions, experiences, and needs. Empathy helps designers connect with users and understand their
Observation: Not fully engaging all the senses to gather information and insights.Failure to pain points. User Involvement:Involving users throughout the design process, from research to
Investigate the Obvious: Overlooking simple or obvious solutions that may seem too easy or testing. This ensures that the final product aligns with real user needs and expectations.Iterative
straightforward.Inability to Define the Terms: Difficulty in clarifying the problem or the key Process:People-centric design follows an iterative approach, where ideas are prototyped, tested, and
elements of a challenge, which can hinder creative solutions. Cultural BlocksThese blocks refined based on user feedback. This cycle helps improve the product and address issues early in
stem from societal or cultural constraints that limit creative thinking.Cultural Norms: development. Problem Solving:The focus is on solving the specific problems users face, rather than
Adherence to traditional norms or practices that discourage unconventional or innovative just creating a solution. Designers look for opportunities to innovate by understanding the users'
ideas.Fear of Rejection: Fear of stepping outside the cultural or organizational norms and challenges and how they interact with products. Accessibility and Inclusivity:A people-centric
facing judgment or criticism. Emotional BlocksThese occur when emotions cloud judgment design considers diverse user groups, ensuring the product is accessible and usable for people with
and creativity.Fear of Failure: Anxiety about making mistakes can prevent risk-taking and different abilities, backgrounds, and preferences. User Experience (UX) Focus:Prioritizing user
innovation.Low Self-Esteem: Doubts about one's abilities can stifle creative ideas. satisfaction by optimizing ease of use, emotional response, and overall experience with the product or
service. Simplicity andIntuition:The design should be simple and intuitive, making it easy for users to
navigate and interact with, without unnecessary complexity.
he statement "Product design is a set of activities that require more than engineering" highlights that SIDDALS (i) Optimization by evolution. There is a close parallel between technological evolution and
designing a product involves a multidisciplinary approach. While engineering plays a critical role in ensuring biological evolution. Most designs in the past have been optimized by an attempt to improve on an existing
the product is functional, efficient, and technically sound, other aspects are equally important for the similar design. Survival of the resulting variations depends on the natural selection of user acceptance. (ii )
product's overall success. Here's what this means:Aesthetic and User Experience:Product design also Optimization by intuition. The art of engineering is the ability to make good decisions, without being able to
involves creating an appealing and user-friendly experience. Designers focus on making the product visually provide a justification. Intuition is knowing what to do, without knowing why one does it. The gift of intuition
attractive and easy to use, considering the target audience's preferences.Market Research:Understanding seems to be closely related to the unconscious mind. The history of technology is full of examples of
customer needs, preferences, and market trends is essential. This involves analyzing consumer behavior and engineers who made use of intuition to make major advances. Although the knowledge and tools available
ensuring the product meets real-world requirements.Economic ConsiderationDesign decisions are today are so much more powerful, ultimately intuition continues to play an important role in technological
influenced by cost-effectiveness and scalability. A product must be affordable to manufacture, distribute, and development. (iii) Optimization by trial-and-error modelling. This refers to the usual situation in modern
sell while maintaining profitability.Sustainability:Modern product design often incorporates environmentally engineering design, where it is recognized that the first feasible design is not always the best. Therefore, the
friendly practices, such as selecting sustainable materials and minimizing waste.Compliance and design model is exercised for a few iterations, in the hope of finding an improved design. However, this mode
Standards:Products must adhere to safety, regulatory, and quality standards, which requires collaboration of operation is not true optimization. Some refer to satisfying, as opposed to optimizing, to mean a
with experts beyond engineers.Psychology and Sociology:Understanding human behavior and societal technically acceptable job done rapidly and economically. Such a design should not be called an optimal
trends can shape how products are designed to meet cultural or demographic needs.Teamwork and design. (iv) Optimization by numerical algorithm. This is the area of current active development in which
Collaboration:Product design typically involves multiple stakeholders, including industrial designers, mathematically based strategies are used to search for an optimum. Computer is widely used for such an
marketers, business strategists, and engineers, working together to create a balanced product.. The approach. There is no unique technique for optimization, in engineering design. How well a technique works,
statement "Product designers are front-line troops who lead and execute the battle" is a metaphor that depends on the nature of the functions represented in the problem. All optimization methods cannot be
highlights the crucial and dynamic role of product designers in the creation and development process. covered in a brief chapter; an attempt is made here to discuss a number of such methods, as they are
Product designers are at the forefront of innovation, driving the vision, strategy, and execution of a product. applied in engineering design. Differential CALC -The use of the calculus to determine the maximum or
They lead by deeply understanding user needs, market demands, and technological possibilities, ensuring the minimum values of a function has become the modern trend. Figure 9.1 illustrates various types of extrema
product addresses real-world problems effectively.Their role involves hands-on efforts, from conceptualizing that can occur. A characteristic property of an extremum is that U is momentarily stationary at each point.
ideas and creating prototypes to testing and refining the product for perfection. Like front-line troops, they For example, as E is approached, U increases; but it does not increase and soon decreases to the right of E.
directly face challenges, adapt to obstacles, and make quick, impactful decisions under pressure. Their The Lagrange multipliers provide a powerful method for finding optima in multivariable problems involving
leadership unites diverse perspectives across teams, aligns stakeholders, and pushes the product toward functional constraints. We have the objective function U = U1(x, y, z) subject to the functional constraints, F1 =
success in a competitive marketplace. Product designers also act as problem-solvers, ensuring the product F1(x, y, z) and F2 = F2(x, y, z). We establish a new function, the Lagrange expression LE. LE = U1(x, y, z) +
delivers not only functionality but also value, usability, and appeal, making them indispensable in the Q1F1(x, y, z) + Q2(x, y, z) (9.10) where Q1 and Q2 are the Lagrange multipliers. LINEAR PROGRAMMING
development process. Marketing AspectThe marketing aspect of design focuses on the product's appeal and (SIMPLEX METHOD) Before solving any linear programming problem, we reduce the problem in the standard
its ability to attract and satisfy customers. It considers factors such as aesthetics, branding, target audience form. The major characteristic points of standard form are: 1. Objective function is of the maximization or
preferences, pricing strategy, and market positioning. A successful design ensures that the product aligns minimization type. 2. All constraints are expressed as equations. 3. All decision variables are restricted to be
with consumer expectations and stands out in a competitive marketplace. Functional Aspect non-negative. 4. The right-hand side constant of each constraint is non-negative. In general, we find that the
The functional aspect ensures that the product effectively performs its intended purpose. It involves linear programming problems are not in the standard form. GEOMETRIC PROGRAMMING [3] Geometric
addressing usability, efficiency, ergonomics, and compatibility with user needs. A well-designed product programming is a nonlinear optimization method gaining wide acceptance in engineering design. It is
should solve problems or fulfill tasks reliably while providing a seamless and intuitive user experience. particularly useful when the objective function is the sum of a number of polynomial terms. JOHNSON’S
Operational AspectThe operational aspect is concerned with how the product integrates into workflows, METHOD OF OPTIMUM DESIGN A method of optimum design was developed by Johnson [4] in the early
systems, or daily usage. It includes ease of operation, maintenance requirements, energy efficiency, and seventies. This method is unique in the following respects: 1. A number of possible solutions can be
adaptability to different environments. This aspect ensures that the product not only works as intended but generated. 2. Realistic solutions are obtained because constraints are imposed on the objective function. 3.
also remains practical and efficient in its usage.Durability and Dependability Aspect The objective function could be either minimum weight or minimum cost. Constraints such as maximum
This aspect focuses on the product's lifespan, reliability, and resistance to wear and tear. It emphasizes permissible stress, available space for the part, etc. can be imposed . Need : A design must be in response
quality materials, robust construction, and adherence to safety and performance standards. A durable and to individual or social need 2. Physical Realizability :A design should be convertible into material goods or
dependable product builds consumer trust, reduces long-term costs, and reinforces brand reputation. The services. 3. Economic worthwhileness : the goods or services, described by a design, must have a utility to
broad definition is that aesthetics are something of or relating to art or beauty. Theyareconcerned with the consumer which equals or exceeds the sum of the total costs of making it available to him. 4. Financial
how our senses respond to an object. I fsomething isaesthetically pleasing,you like it. If it is aesthetically feasibility: The operations of designing, producing and distributing the goods must be financially supportable.
displeasing,you donot likeit. Designersknowthataestheticscaninvolveyouremotions,aswellasallyour senses. 5. Optimality:The choice of a design concept must be optimal amongst the available alternatives. 6. Design
Analysis of product aesthetics •Unity a product must appear as a finished, complete unit •Order this refers Criterion: optimality must be established relative to a design criterion.7.Morphology 8. Design Process
to repetition of patterns with suitable break of monotony Basic form elements. Psychology The eye is used Design is an iterative problem solving process. 9.Subproblems Designtreeapproachshouldbefollowed
to perceive vertical and horizontal as the main visual directions. Balance isthedistributionof 10.ReductionofUncertainty Design is derived after processing of information that results in a
thevisualweightofobjects,colors, texture, andspace. If the design was a scale,thes eelements should be transitionfromuncertainty,aboutthesuccessorfailure. 11.Economicworthofevidence
balanced to make a design feel stable. Elegance isatermfrequentlyassociatedwithaestheticsindesign. Authenticinformationshouldbegatheredtomakethedesignprojectasuccess 12.Basesfordecision
Ittypically connotes simplicity,beauty,andgrace. Whenitcomestocomplexsystems, italso connotes Confidenceofdesignprojectforcontinuationortermination 13.MinimumCommitments Commitmentswhichwill fix
predictablebehavior, power,andcreativefunctionality Elegance is what separate the merely functional from futuredesigndecisionsmust not bemade beyond what isnecessarytoexecutetheimmediatesolution
the engaging. Rhythm,joints,product message,stability and weight 14.Communication Adesignisdescriptionofanobjectandprescriptionfor itsproduction