Course Handout - Product Design PDF

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Description

BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE, PILANI WORK INTEGRATED LEARNING PROGRAMMES Digital Learning Part A: Content Development Plan

Course Title

PRODUCT DESIGN

Course No(s)

DE ZG541/ MM ZG541

Credit Units

5

Document Version No

3.0

Date

July 21st, 2017

Content Development Team Name Lead Developer

email

mobile

Dr. Srinivasa Prakash Regalla [email protected] 9010202879 -pilani.ac.in

Co-Developer Nil as of now

Nil

NIl

Text Book(s) The textbook forms a comprehensive study resource for the student of this course. In the conventional classroom teaching model, the course instructor will adapt this teaching around the textbook content. The textbook cannot be changed with a proper approval process. If the textbook for your course available as an ebook from the publisher, please inform the office of Digital Learning T1

Otto, K. and Wood, K., “Product Design: Techniques in Reverse Engineering and New Product Development”, Pearson Edition, 2011, New Delhi.

T2

Ulrich, K. T., Eppinger, S. D. and Goyal, A., “Product Design & Development”, TMH,

4th Edition, 2011, New Delhi.

Reference Book(s) & other resources Any additional reference books or other online resources that important to include as a part of the course. In case of online resources, please assure that there is copyright clearance before including it in this list. R1

David G. Ullman, “The Mechanical Design Process”, McGraw-Hill, 1992

R2

Boothroyd, G., Dewhurst, P. and Knight W., “Product Design for Manufacture and Assembly”, 2nd Edition, CRC Taylor & Francis (distributed by Book World Enterprises), Mumbai, India.

Documentation on Labwork 1. Software(s) or Tool(s) required: Microsoft Excel, Pro/E (CREO) 2. Dependencies/Pre-requistes (OS, SDK, other framework, etc): Any B. Tech. holder 3. System Requirements: Normal desktop computer/laptop of usual specifications 4. Download url 5. Capabilities of tool: 6. Mode of working (GUI based- Stand alone installer/ Client Server / Console based/ Browser based): Standalone 7. Open source/ Freeware/ Proprietary: Excel: MSOffice; 8. If Proprietary, any open source or freeware alternative available If yes, provide details (Limitations): Not applicable 9. Any Other Remarks 10. Objective behind Labwork in this course:

Glossary of Terms Module

M

Module is a standalone quantum of designed content. A typical course is delivered using a string of modules. M2 means module 2.

Recorded Lecture

RL

A recorded lecture will consist of a sequence of topic recordings (typically less 10 minutes each). There will be assessments between topic recordings to allow the learner test his/her understanding of video material previously viewed.

RL2.1 = Recorded Lecture 1 in module 2. RL2.2.3 = Third topic recording in recorded lecture RL2.1 CS Contact session submodule/topi cs

Contact session topics refers to topics in form of concepts, discussions items, problems which will be taken up by the course instructor during the contact hours. A contact hours is built by stringing a bunch of contact session topics. CS3.2 = Contact session sub-module 2 associated with module 3 CS3.2.1 = Contact session topic 1 associated with contact session sub-module 2 within module 1

Lab Exercises

LE

Demo Lab exercises associated with various modules

Self-Study

SS

Specific content assigned for self study

Homework

HW

Specific problems/design/lab exercises assigned as homework

Quiz Questions

QZ

Auto assessed Quiz questions of different types

Case Study

CT

Case studies

Work Integration

WI

Exercises on Work Integration

Modular Structure Module Summary No Title of the Module

RL no. RL1.1

Recorded Lecture Titles Introduction to Product Design – Why product design is an open ended problem?

Preliminary considerations RL1.2 Product Development Process Tools M1 in product development RL1. process Scoping Product Development 3 Eliciting and converting M2 customer needs into technical specifications

RL2. Understanding Customer Needs 1 RL2. Establishing Product Function 2 RL3. Product Teardown and Experimentation 1

Understanding M3 self, and then the competitor

RL3. Benchmarking and Establishing Engineering Specifications 2 RL3. The QFD Process 3

What to offer and M4 What all to offer to the customer?

R4.1 Product Portfolios and portfolio architecture R4.2 Product Architecture RL5. Generating Concepts 1

Conceptual M5 Design

RL5. Concept Selection 2 RL5. Concept Embodiment 3

M6 Final stages of design and

RL6. Modelling of Product Metrics 1

RL6. Design for Manufacturing and Assembly 2 prototyping

RL6. Design for Environment 3 RL6. Physical Prototypes and Models and Experimentation 4

Detailed Structure Video: Introduction to the course.

M1: Introduction to Product Design – Why product design is an open ended problem? Type

Title

Description

RL1.1

Introduction to Product Design – Why product design is an open ended problem?

RL1.1.1 = The Unique Nature of Product Design Process RLCS1.1.1 = Relation between type of design and Scurve RL1.1.2 = Types and Models of Engineering Design RLCS1.1.2 = Which type of design RL1.1.3 = Phases in the Product Development Process RLCS1.1.3 = decisions are made while resolving fuzzy front-end RL1.1.4 = Kolb’s Model of Product Development RLCS1.1.4 = distinctions between stage-gate model and spiral model

RL1.2

Product Development Process Tools

RL1.2.1 = Basics of Product Development Team Formation RLCS1.2.1 = Lead time in concurrent engineering RL1.2.2 = MBTI tagging of members RLCS1.2.2 = concurrent engineering results in quicker products to market RL1.2.3 = Sequential and Concurrent Engineering RLCS1.2.3= In what way tangram can serve to fulfill the objectives of a product development team RL1.2.4 = Team Building Activity and Product Development Planning RLCS1.2.4= The “over-the-wall” approach and the concurrent engineering

RL1.3

Scoping Product Development

RL1.3.1 = The S curve of improvement RLCS1.3.1 = uses of mission statement RL1.3.2 = Developing Mission Statement RL1.3.3 = Advanced Method of Device Drivers

CS1.1

Why product design is an open ended problem?

Base Presentation in modular form (should include concept statements followed by problem solving)

CS1.2

Product

Base Presentation in modular form (should include

Development Process Tools CS1.3

concept statements followed by problem solving

Scoping

LE1.1

Lab exercises (Create a tutorial video and a set of lab sheets; a lab sheet will consist of a set of problems to be solved using the tool set)

SS1.1

Self Study (quote appropriate sections numbers from text or ref books or external url)

HW1.1

Assign problems as Homework (quote problem no from text or ref books)

QZ1.1

Collection of basic quiz type questions which are supported on the platform and could be used for video embedded assessments as well as standalone assessments.

M2: Eliciting and converting customer needs into technical specifications Type

Title

Description/Plan/Reference

Understanding Customer Needs

RL2.1.1 = Fundamentals of customer needs RLCS2.1.1 = Extracting customer needs RL2.1.2 = Customer need modeling-basic RLCS2.1.2 = Estimation of the importance weight of the customer needs RL2.1.3 = Advanced Customer need modeling RLCS2.1.3 = Technique of “focus groups” used for extracting customer needs RL2.1.4 = Determining need importance RLCS2.1.4= Estimate the need importance weight

RL2.1

RL2.2

CS2. 1

RL2.2.1 = Establishing Product Function Establishing Product RLCS2.2.1 = FAST and SOP methods of developing product function Function RLLE2.1.1 = Estimate the importance weight of customer needs Base Presentation in modular form (should include concept statements followed by problem solving)

CS2. 2

Base Presentation in modular form (should include concept statements followed by problem solving)

LE2.1

Lab exercises (Create a tutorial video and a set of lab sheets; a lab sheet will consist of a set of problems to be solved using the tool set)

SS2.1

Self Study (quote appropriate sections numbers from text or ref books)

HW2. 1

Assign problems as Homework (quote problem no from text or ref books)

QZ2. 1

Collection of basic quiz type questions which are supported on the platform and could be used for video embedded assessments as well as standalone assessments.

M3: Understanding self, and then the competitor Type

Title

Description/Plan/Reference

RL3.1

RL3.1.1 = An example of product teardown RLCS3.1.1 = How product teardown is different from Product Teardown and Experimentation simple casual disassembly of a product RL3.1.2 = Product Teardown Steps

RL3.2 Benchmarking and Establishing Engineering Specifications

RL-3-2-1-Basic Methods of Benchmarking RLCS3.2.1 = Know your enemy before to know yourself RL-3-2-2-Documenting Benchmarking Analysis

RL3.3

RL-3-3-1-The basic QFD process RL-3-3-2-The House of Quality RL-3-3-3-Examples of House of Quality

The QFD Process

CS3. 1

Product Teardown

Base Presentation in modular form (should include concept statements followed by problem solving)

RL CS3.1.2 = Description RL CS3.1.3 = Description CS3. 2

Benchmarking

Base Presentation in modular form (should include concept statements followed by problem solving) CS3.2.2 = Description CS3.2.3 = Description

LE3.1

Lab exercises (Create a tutorial video and a set of lab sheets; a lab sheet will consist of a set of problems to be solved using the tool set)

SS3.1

Self Study (quote appropriate sections numbers from text or ref books)

HW3. 1

Assign problems as Homework (quote problem no from text or ref books)

QZ3. 1

Collection of basic quiz type questions which are supported on the platform and could be used for video embedded assessments as well as standalone assessments.

M4: What to offer and What all to offer to the customer? Type

Title

RL4.1 Product Portfolios and portfolio architecture

Description/Plan/Reference RL4.1.1 = Product Portfolios and Portfolio Architecture RLCS4.1.1 = Product portfolio architectures

RL4.2 Product Architecture RL4.2.1 = Product Architecture Types RL4.2.2 = Methods of achieving product modularity CS4. 1

Base Presentation in modular form (should include concept statements followed by problem solving) CS4.1.2 = Description CS4.1.3 = Description

CS4. 2

Base Presentation in modular form (should include concept statements followed by problem solving) CS4.2.1 = Description CS4.2.2 = Description CS4.2.3 = Description

LE4.1

Lab exercises (Create a tutorial video and a set of lab sheets; a lab sheet will consist of a set of problems to

be solved using the tool set) SS4.1

Self Study (quote appropriate sections numbers from text or ref books)

HW4. 1

Assign problems as Homework (quote problem no from text or ref books)

QZ4. 1

Collection of basic quiz type questions which are supported on the platform and could be used for video embedded assessments as well as standalone assessments.

M5: Conceptual Design Type

Title

RL5.1

RL5.1.1 = Generating concepts-basic methods Generating Concepts RLCS5.1.1 = memory map technique of generating conceptual RL5.1.2 = Generating concepts-advanced methods

RL5.2 Concept Selection

Description/Plan/Reference

RL5.2.1 = Estimating Technical feasibility in concept selection RLCS5.2.1 = Pugh selection chart RL5.2.2 = The concept selection process and techniques

RL5.3 Concept Embodiment

RL5.3.1 = Basics methods of concept embodiment RL5.3.2 = Advanced methods of concept embodiment

CS5. 1

Base Presentation in modular form (should include concept statements followed by problem solving) designs CS5.1.2 = Description CS5.1.3 = Description

CS5. 2

Selecting best out of the conceptual designs

Base Presentation in modular form (should include concept statements followed by problem solving) CS5.2.2 = Description CS5.2.3 = Description

LE5.1

Lab exercises (Create a tutorial video and a set of lab sheets; a lab sheet will consist of a set of problems to be solved using the tool set)

SS5.1

Self Study (quote appropriate sections numbers from text or ref books)

HW5.

Assign problems as Homework (quote problem no

1

from text or ref books)

QZ5. 1

Collection of basic quiz type questions which are supported on the platform and could be used for video embedded assessments as well as standalone assessments.

M6: Final stages of design and prototyping Type

Title

Description/Plan/Reference

RL6.1 Modelling of Product Metrics

RL6.1.1 = Basics of product modeling RL6.1.2 = Advanced product models

RL6.2 Design for Manufacturing and Assembly

RL6.2.1 = Basic concepts of design for manufacturing and assembly RL6.2.2 = Advanced methods using manufacturing cost analysis

RL6.3

RL6.3.1 =How product manufacturing can cause environmental pollution? RL6.3.2 =Basic DFE methods RL6.3.3=Life cycle assessment methods

Design for Environment

RL6.4 Physical Prototypes, RL6.4.1 =Basics of prototyping RL6.4.2 =Fundamentals of modern rapid prototyping Models and processes Experimentation RL6.4.3 =Most popular rapid prototyping processes CS6. 1

Base Presentation in modular form (should include concept statements followed by problem solving) CS2.1.1 = Description CS2.1.2 = Description CS2.1.3 = Description

CS6. 2

Base Presentation in modular form (should include concept statements followed by problem solving) CS6.2.1 = explain the DFA principle involved CS6.2.2 = Description CS6.2.3 = Description

CS6. 3

DFE

CS6.3.1 = Computer the RERPA rating

CS6. 4

RP

CS6.4.1 = compare the four most prominent rapid prototyping processes

LE6.1

Lab exercises (Create a tutorial video and a set of lab sheets; a lab sheet will consist of a set of problems to be solved using the tool set)

SS6.1

Self Study (quote appropriate sections numbers from text or ref books)

HW6. 1

Assign problems as Homework (quote problem no from text or ref books)

QZ6. 1

Collection of basic quiz type questions which are supported on the platform and could be used for video embedded assessments as well as standalone assessments.

Part B: Course Handout

Birla Institute of Technology & Science, Pilani Work-Integrated Learning Programmes Division First Semester 2018-2019

Course Handout Course No.

: DE ZG541/ MM ZG541

Course Title

: Product Design

Instructor –In-Charge : Srinivas Prakash Regalla

Course Description

Introduction to creative design; user research and requirements analysis, product specification, Computer Aided Design; standardization, variety reduction, preferred numbers and other techniques; modular design; design economics, cost analysis, cost reduction and value analysis techniques, design for production; human factors in design: anthropometric, ergonomic, psycho giccl, physiological considerations in design decision making; legal factors, engineering ethics and society. Scope and Objective This course is designed to impart the knowledge required to develop a new product – understand the opportunity, develop and implement a concept. After the successful completion of this course, students shall be able to understand and implement the various processes, tools and techniques required for a product design like product specification development; product architecture; concept

generation, concept selection, concept testing and embodiment; industrial design; design for X; analytical and numerical models; physical prototypes, models and experimentation; human, legal economic and social issues in product development; patents and intellectual properties. Prescribed Textbook

T1. Otto, Kevin and Kristin Wood, “Product Design: Techniques in Reverse Engineering and New Product Development”, Pearson Education, 2001. Reference Books

R1.Karl T. Ulrich and Steven D. Eppinger, “Product Design and Development”, Tata McGraw-Hill, 2003 R2.David G. Ullman, “The Mechanical Design Process”, McGraw-Hill, 1992 R3.N. J. M. Roozenburg, J. Eekels, Roozenburg N. F. M., “Product Design: Fundamentals and Methods”, John Wiley and Sons, 1995

Plan of Self Study N Title of o the Module

RL no.

RL1. Preliminary 1 considerati RL1. M ons in product 2 1 developme nt process RL1 .3 Eliciting and converting customer M needs into 2 technical specification s

Recorded Lecture Titles

Reference

Introduction to Product Design – Why product design is Chap-1; T1 an open ended problem? Product Development Process Tools

Scoping Product Development

RL2 Understanding Customer Needs .1

Chap-2: T1

Chap-3; T1

Chap-4; T1

Chap-5; T1 RL2 Establishing Product Function .2

RL3 Product Teardown and Experimentation .1 Understandin RL3 Benchmarking and Establishing Engineering M g self, and .2 Specifications 3 then the competitor RL3 The QFD Process .3

Chap-6; T1

Chap-7; T1

Chap-7; T1

Syllabus for Mid Semester Test (Closed Book): Topics in Module M1 to Module M3 What to offer R4.1 Product Portfolios and portfolio architecture and What all M to offer to 4 the R4.2 Product Architecture customer?

Chap-8: T1

M Conceptual 5 Design

RL5 Generating Concepts .1

Chap-10; T1

RL5 Concept Selection .2

Chap-11; T1

Chap-9; T1

RL5 .3

Concept Embodiment

Chap-12; T1

RL6 Modelling of Product Metrics .1

Chap-13; T1

RL6 Design for Manufacturing and Assembly .2

Chap-14; T1

Final stages M of design and 6 prototyping RL6 Design for Environment .3

RL6 Physical Prototypes and Models and Experimentation .4

Chap-15; T1

Chap-17; T1

Syllabus for Comprehensive Exam.(Open Book): All Topics given i...