CHAPTER 23 & 24

PRODUCT DESIGN AND

DEVELOPMENT
AND
PROCESS PLANNING

Dr. Mousumi Roy, P.E.

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 Welcome Back… hope you had a great break!
• Homework 2 is due today – I will post the
solution tomorrow
• Exam 2 is postponed until Tuesday,
March 28th .
• It will include chapters 10,11, 23&24, 25,
and Structural Dynamics & Industrial
Control Systems
• I have posted the review questions for
those chapters
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Learning Objectives:
• Type of Products
• Typical Product Development Process
• Sustainability in Product Design (Design for Environment)

• Concurrent Engineering
• Automation in Design and Manufacturing

• Advanced Manufacturing Planning

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 Technology or User Driven?

(a)

iClicker: which one is

technology driven? (c)
a. b. c. (b)

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Product Design: Types of Products

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 Typical Product Development Process

Iclicker Q: Is it easy to
Innovate? No, it is not. For example: Dupont
a. Yes estimates that it takes 250 ideas to yield
b. No one marketable products
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What are the Design Challenges for a New Product?

People Business
“desirable” “viable”

Technical
“feasible” New
Product

Source: IDEO 8
 The Ability to Design is both a Science and an Art

Your next car may be a living room on wheels

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 Environmental Impact of Product Design
Iclicker Q: Write two of the several environmental impact from the Manufacturing
Industry that are harmful to people & our planet.

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What are the Design Challenges for a New Sustainable
Product?

Add
Sustainability
People Business
to this
“desirable” “viable”
diagram

Technical
“feasible” New
Product

Source: IDEO 12
 L in
Life ear
Cyc vs. C
leà ircu
Sus lar
tain
abl
e

What are Triple Bottom Lines or 3P?

(People, Planet, Profit): 3P by John Elkington – the Green Business “Guru”
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Let’s look at a product life from design to disposal
iClicker Q: What are the sustainable goals with resect to 3P?

Figure S5.1 14
 Design for Environment (DFE)

ØDFE provides a practical

method to minimize
environmental impacts.

ØLife Cycle thinking is the basis

for the DFE.

ØHelps to expand traditional

manufacturing to a closed loop
system relating the product
life cycle to the natural life
cycle.

Two Life Cycles: 15

 Four Simple Rules for Design for Environment
Design Products and Processes…

q with industrial materials that can be recycled continually with no loss in

performance, thereby creating new industrial materials.

q with natural materials that can be fully returned to the earth’ s natural cycles,
thereby creating new natural materials.

q that do not produce unnatural, toxic materials that cannot be safely

processed by either natural or industrial cycles.

q with clean, renewable sources of energy, rather than fossil fuels.

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Concurrent Engineering

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Traditional Approach to Product Development

A Linear Progress from Planning stage to Production Stage

(although many rounds of going back and forth may exist)
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 Traditional vs.
Concurrent Engineering
Traditional approach to
product design tends to
separate design and
manufacturing
engineering.

There is little interaction

between design engineers
and manufacturing
engineers who might
provide advice on
producibility

https://www.youtube.com/watch?v=Yex_Ol1quxw 19
 Concurrent Engineering
Concurrent engineering is a method of designing and developing products, in which
the different stages run simultaneously, rather than consecutively.

• Manufacturing engineering becomes involved early in the product development

cycle.

• Other functions are also involved, such as field service, quality engineering,
vendors, and in some cases customers

• Through early involvement of all interested parties, the total product

development cycle time is reduced

• How does it help productivity?

Ø It decreases the product development time, and the time to bring the product
to the market
Ø leading to improved productivity and reduced costs. 20
 Four Elements of Concurrent Engineering
Concurrent
Engineering

Design for
Design for Design for Life
Manufacturing Design for Cost
Quality Cycle
and Assembly

DFM/A requires a cross- It provides principles and Efforts made to Gives consideration
functional team to facilitate procedures to ensure that identify and to various aspects of
the integration and sharing the highest possible quality develop ways to product life cycle
views required for DFM. is designed into the reduce cost such as reliability,
product. Uses QFD & House through design maintainability, etc.,
of Quality. 21
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 1. Recognition of need
Someone recognizes the need that can be satisfied by a new design

6. Presentation
Documenting the design (e.g., 2. Problem definition
drawings) Specification of the item
The Design
Process
An Iterative Process
5. Evaluation 3. Synthesis
Compare design against Creation and
original specification conceptualization

4. Analysis and optimization

Concept is analyzed and redesigned 23
Computer- Aided-Design ( CAD) can be used to
augment the design process

Geometric modeling

Engineering analysis

Design evaluation & review

Automated drafting
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 Computer-Aided-Manufacturing (CAM)
Most closely associated with functions in manufacturing engineering

Two Broad
Applications

Manufacturing Manufacturing
Planning Control
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 Automation in Automation In
Manufacturing Planning Manufacturing Control
q Computer-aided process planning (CAPP) v Process monitoring and
q CAD/CAM assisted NC part programming control
q Computerized machinability data systems:
v Quality control
Computer programs which recommend the v Shop floor control
appropriate cutting conditions v Inventory control
q Computerized work standards v Just-in-time production
q Computer-aided assembly line balancing systems
q Cost estimating: Key steps are
computerized.
q Production and inventory planning
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 Computer-Aided Process
Manual Process Planning Planning (CAPP)
iClicker Q: Name one limitation for
Manual Process Planning.
Limitations:
• Tied to personal experience.
Ø CAPP has been introduced to automate the
- Depends on the knowledge of planner
of the production facilities, equipment,
process planning function by using
their capabilities, process and tooling.
computer systems
.
• It is time consuming and slow process.
Ø Two Types :
1. Retrieval systems
• Also, slow in responding to changes in
2. Generative systems
product design and production.

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 Retrieval (Variant) systems Generative systems
• Based on group technology, parts • The process plan is created using systematic
classification and coding: procedures that might be applied by a
human planner
Ø A standard process plan is stored in
computer files for each part code
number • In a fully generative CAPP system, the
Ø The standard plans are based on process sequence is planned to work without
current part routings in use in the human assistance and without predefined
factory, or on an ideal plan prepared standard plans
for each family
§ For each new part, the standard plan is • Computer programs capable of solving
edited if modifications are needed complex problems that normally require a
human with years of education and
experience

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 Benefits of Computer –Aided Process Planning (CAPP):

• Leads to more logical and consistent process plans than

traditional process planning

• Process rationalization and standardization

• Increased productivity of process planners

• Reduced lead time to prepare process plans

• Improved legibility over manually written route sheets

• Incorporation of other application programs 29

 CAD, CAM and CIM
u What is the Goal for CAD/CAM?

ØAutomate different phases of design and manufacturing

ØAutomate the transition from design to manufacturing

u What is Computer - Integrated - Manufacturing (CIM)?

Ideal CIM system uses computer and communication technology to
all of the operational functions and information processing
functions in manufacturing as follows:
From order receipt,
Through design and production,
To product shipment
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 The Scope of CAD/CAM and CIM

ERP supports automation for CIM

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 Advanced Manufacturing Planning
• Emphasizes planning for the future
Ø Distinct from process planning because
it is concerned with products being
contemplated in the company's long-
term plans rather than products
currently being designed and released
Advanced manufacturing planning
attempts to __________
• determine what production resources will
be needed to make those future products
• forecast the new products that will be
introduced in next 2 to 10 years future
 Activities in Advanced Manufacturing Planning

1. New technology evaluation

• Decisions required whether to develop new processes for future products
in-house or purchase from vendors
2. Investment project management
• Investments required for new process technologies must be planned and
managed
3. Facilities planning
• New plants may be needed to produce new products
4. Manufacturing research and development
• To develop the new process technologies
End

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