Course OverviewPersonal IntroductionIntroduction to Course

Course Objectives Course Outline / Schedule

Lecture 1

Personal IntroductionIntroduction to Course

Course Objectives Course Outline / Schedule

Meeting time: Mon 6:30 – 8:30 PM

Textbook: Product Design, Kevin Otto andKristin Wood, Pearson Publication

Reference Textbook: Introduction to Mechanical Design,David G. Ullman

Meeting time: Mon 6:30 – 8:30 PM

Textbook: Product Design, Kevin Otto andKristin Wood, Pearson Publication

Reference Textbook: Introduction to Mechanical Design,David G. Ullman

Course Objectives(We will review these at the end of the course…)

Product and Process Design Fundamentals will focus on developing adeeper understanding of Design as Separate Discipline comprising vastTheory and Methods . At the end of the course, you should be able tounderstand :- Understand Design as Separate Discipline

Design Theory and Methods What, WHO, When and How of the Structured Design Methods Apply structured design methods to Design problems

Understand Role of Systems Engineering in design of complex products Understand and Apply what Optimization means in mathematical sense

and how is it applied to the Product DesignTerms and concepts in MDD, MDA and MDOChallenges in the Design of Complex productsNeed for bringing higher fidelity design and analysis in early part of

the designGet hands on experience with the MDO tool developed by the

instructor

Product and Process Design Fundamentals will focus on developing adeeper understanding of Design as Separate Discipline comprising vastTheory and Methods . At the end of the course, you should be able tounderstand :- Understand Design as Separate Discipline

Design Theory and Methods What, WHO, When and How of the Structured Design Methods Apply structured design methods to Design problems

Understand Role of Systems Engineering in design of complex products Understand and Apply what Optimization means in mathematical sense

and how is it applied to the Product DesignTerms and concepts in MDD, MDA and MDOChallenges in the Design of Complex productsNeed for bringing higher fidelity design and analysis in early part of

the designGet hands on experience with the MDO tool developed by the

instructor

Course Objectives(We will review these at the end of the course…)

Learn how to Innovate in design to make product more competitiveusing TRIZ method , Patents Search

Apply Product Lifecycle Management (PLM) approach to ensure allaspects of a product are addressed from design to disposal

Apply Design for X (Manufacturability, Assembly, Environment) fromthe very beginning of design to further ensure competitive edge inproduct design

Learn how to Innovate in design to make product more competitiveusing TRIZ method , Patents Search

Apply Product Lifecycle Management (PLM) approach to ensure allaspects of a product are addressed from design to disposal

Apply Design for X (Manufacturability, Assembly, Environment) fromthe very beginning of design to further ensure competitive edge inproduct design

Learning Objectives

• The students in this class will be able to …• Enumerate and describe the most important Systems

Engineering standards and best practices[1]• Summarize the key steps in the systems engineering process

starting with stakeholder analysis and ending with transitioningsystems to operations

• Appreciate the important role of humans as beneficiaries,designers, operators and maintainers of aerospace systems

• Articulate the limitations of the way that current systemsengineering is practiced in terms of dealing with complexity,lifecycle uncertainty and other factors

• Apply some of the fundamental methods and tools of systemsengineering to some basic “toy” examples as a stepping stone tomore complex and real world projects

• The students in this class will be able to …• Enumerate and describe the most important Systems

Engineering standards and best practices[1]• Summarize the key steps in the systems engineering process

starting with stakeholder analysis and ending with transitioningsystems to operations

• Appreciate the important role of humans as beneficiaries,designers, operators and maintainers of aerospace systems

• Articulate the limitations of the way that current systemsengineering is practiced in terms of dealing with complexity,lifecycle uncertainty and other factors

• Apply some of the fundamental methods and tools of systemsengineering to some basic “toy” examples as a stepping stone tomore complex and real world projects

Course Content(Tentative)

• Introduction to Design Theory and Methods• Introduction to Systems Engineering• Customer Needs Identification• Customer Requirements Analysis• Concept Generation / Creativity / Intellectual Property / TRIZ

Method• Product Lifecycle Management• Product Platforms• Modeling of Products• Multidisciplinary Design, Analysis and Optimization• Design for X (Sustainability, Manufacturing and Assembly)• Project Final Presentation

• Introduction to Design Theory and Methods• Introduction to Systems Engineering• Customer Needs Identification• Customer Requirements Analysis• Concept Generation / Creativity / Intellectual Property / TRIZ

Method• Product Lifecycle Management• Product Platforms• Modeling of Products• Multidisciplinary Design, Analysis and Optimization• Design for X (Sustainability, Manufacturing and Assembly)• Project Final Presentation

Grades Distribution

HW Assignments 25%Term Paper 10%MSE 25%ESE (Final Project) 40%

HW Assignments 25%Term Paper 10%MSE 25%ESE (Final Project) 40%

Introduction to DesignWhy Study Design?Design Approaches

Over The WallSimultaneous / Concurrent EngineeringPLM

Design EnvironmentVideo “Deep Dive at IDEO”

Why Study Design?Design Approaches

Over The WallSimultaneous / Concurrent EngineeringPLM

Design EnvironmentVideo “Deep Dive at IDEO”

WHY STUDY DESIGN?

• Exploding Knowledge including Technology• Dissolving Global Boundaries (Nobel Laureate Thomas Friedman,

“World is Flat”) and the acceleration of globalization ascompanies develop globally integrated organizations

• More demanding customers for all goods and services• Changing industry structure, including mergers and acquisitions

and a new order of manufacturer / supplier relationship assuppliers take increased responsibility for the design of parts,modules and systems

• A profound and rapidly growing role for information technologyin all its forms

• Intensifying competition• Time pressure that demands more, better yet faster results

WHY STUDY DESIGN?• Exploding Knowledge including Technology• Dissolving Global Boundaries (Nobel Laureate Thomas Friedman,

“World is Flat”) and the acceleration of globalization ascompanies develop globally integrated organizations

• More demanding customers for all goods and services• Changing industry structure, including mergers and acquisitions

and a new order of manufacturer / supplier relationship assuppliers take increased responsibility for the design of parts,modules and systems

• A profound and rapidly growing role for information technologyin all its forms

• Intensifying competition• Time pressure that demands more, better yet faster results

Kids’ Strollers

Mima's Kobi is an award-winningstroller that converts easily from acarrycot to a toddler seat and canaccommodate two children

The tot-toting Ride On Carry Onchair takes a load off travelingparents

Mima's Kobi is an award-winningstroller that converts easily from acarrycot to a toddler seat and canaccommodate two children

Moms Origami stroller is self-folding, has an in-built generatorand an LCD display

Taga : a bike and a stroller

• When you first see the Taga you wonder why nobody thoughtof this sooner?

• Taga was developed by a team of industrial designers andmechanical engineers over a period of four years. The frameis made from aluminum alloy which is strong enough to carryheavy loads and it has internal Shimano gears and front andrear brakes.

• When you first see the Taga you wonder why nobody thoughtof this sooner?

• Taga was developed by a team of industrial designers andmechanical engineers over a period of four years. The frameis made from aluminum alloy which is strong enough to carryheavy loads and it has internal Shimano gears and front andrear brakes.

Modern Trends in the Design

• Companies are collaboratingglobally in the effort to leveragetechnology, knowledge, humantalent and other resourcesnecessary to innovate andcompete

• “Global collaborative enterprises“- use of "mirror zones" enablingaround-the-clock, 24-hour productdesign and developmentcapabilities

• Companies are collaboratingglobally in the effort to leveragetechnology, knowledge, humantalent and other resourcesnecessary to innovate andcompete

• “Global collaborative enterprises“- use of "mirror zones" enablingaround-the-clock, 24-hour productdesign and developmentcapabilities

This is really interestingconcept for reducingtime to market and

accelerating productdesign and development

Scattered Enterprise : Boeing 787 DreamlinerDesign

17 Companies, Over 9 Countries, 03Continents

Complex aerospace systems are increasinglydesigned (and built) By geographicallydistributed teams, requiring careful definitionof interfaces

Scattered Enterprise : Boeing 787 DreamlinerDesign

17 Companies, Over 9 Countries, 03 Continents

Attributes of Five Products WithAssociated Development Efforts

Stanley ToolsScrew Driver

RollerbladeIn-LineSkates

HP DeskjetPrinter

VW NewBeetle

Automobile

Boeing 777Airplane

Annual ProductionVol (units/year)

100,000 100,000 4 million 100,000 50

Sales Lifetime (yrs) 40 3 2 6 30Sale Price ($) 3 200 300 17000 130 MillionSale Price ($) 3 200 300 17000 130 MillionNo of Unique Parts 3 35 200 10,000 130,000Development Time(yrs)

1 2 1.5 3.5 4.5

DevelopmentTeam (people)

3 10 75 800 10,000

Development Cost($)

150,000 750,000 50 million 400 million 3 billion

Source - Ulrich and Eppinger

Design

• Taylor (1959): Engineering design is the process ofapplying various techniques and scientificprinciples for the purpose of defining a device, aprocess, or a system in sufficient detail to permitits physical realization.

• Asimow (1962): Engineering design is a purposefulactivity directed towards the goal of fulfillinghuman needs, particularly those which can be metby the technology factors of our culture.

• Feilden (1963): Mechanical engineering design isthe use of scientific principles, technicalinformation and imagination in the definition of amechanical structure, machine or system toperform pre-specified functions with themaximum economy and efficiency.

• Kesselring (1964): Designing means to find atechnically perfect, economically favorable andesthetically satisfactory solution for a given task.

Engineering Design is a Process thatrequires application of various

techniques and scientific principles

Goal of Engineering Design is fulfillingHuman Needs

• Taylor (1959): Engineering design is the process ofapplying various techniques and scientificprinciples for the purpose of defining a device, aprocess, or a system in sufficient detail to permitits physical realization.

• Asimow (1962): Engineering design is a purposefulactivity directed towards the goal of fulfillinghuman needs, particularly those which can be metby the technology factors of our culture.

• Feilden (1963): Mechanical engineering design isthe use of scientific principles, technicalinformation and imagination in the definition of amechanical structure, machine or system toperform pre-specified functions with themaximum economy and efficiency.

• Kesselring (1964): Designing means to find atechnically perfect, economically favorable andesthetically satisfactory solution for a given task.

Finding a technically perfect,economically favorable and

esthetically satisfactory solution for agiven task

Performing pre-specified functions withthe maximum economy and efficiency

Design

• Booker (1964): Simulating what we want tomake (or do) before we make (or do) it asmany times as may be necessary to feelconfident in the final result.

• Archer (1964): A goal-directed problem-solving activity.

• Reswick (1965): A creative activity -- itinvolves bringing into being something newand useful that has not existed previously.

• Hansen (1966): Developing a technicalconstruct is determined through prior visualthinking out.

Design is an Iterative Process

Design Process is a Very FocusedActivity

• Booker (1964): Simulating what we want tomake (or do) before we make (or do) it asmany times as may be necessary to feelconfident in the final result.

• Archer (1964): A goal-directed problem-solving activity.

• Reswick (1965): A creative activity -- itinvolves bringing into being something newand useful that has not existed previously.

• Hansen (1966): Developing a technicalconstruct is determined through prior visualthinking out. Designing is Visualizing an

Object

Designing is a Creative Activity

Design Process is a Very FocusedActivity

What is, then, the definition of Design?

Design of a product is an iterative focusedactivity that requires application ofvarious techniques and scientificprinciples in fulfilling human needs withtechnically perfect, economicallyfavorable and esthetically satisfactorysolution

Design of a product is an iterative focusedactivity that requires application ofvarious techniques and scientificprinciples in fulfilling human needs withtechnically perfect, economicallyfavorable and esthetically satisfactorysolution

Spiral Design