DESIGN PRINCIPLES

Dr.V.Umasanakar
 CUSTOMER VOICE

MANUFACTURING
ASPECTS AND
MANUFACTURE AS PER
DESIGN

FUNCTIONAL VALIDATION OF
DESIGN
Design Perspective
• Product Shall Meet the Expectations Of the Customer.

• First Right Time And Manufacture The Product Shall Satisfy

the Customer
Manufacturer’s perspective
The manufactured product shall be exactly as per design.
The activities and objectives are
Defect Prevention
Defect finding
Defect identification and rectification
Morphology of Design
Design is the progression from abstract to concrete.
The three phases of design are
(a) Feasibility study phase
(b) Preliminary design phase and
(c ) Detailed design phase
Converging Idea into Reality
The idea is a resemblance such of systems and concepts existing
in nature or earlier developed man made systems.
Additional features and requirements as deemed necessary or
fitted into it.
These are further converged into realistic design through rigorous
design and simulation.
PRODUCT
A product is a bundle of satisfaction to the customer. It can be
an assembly, sub assembly or a single part designed for some
useful purpose.
The difficulties encountered in the manufacturing must be
conveyed to design department for carrying out modification in
the design.
Two way communication between Design and Manufacturing
will ensure defect free quality product as issues like achievable
tolerances, process capabilities and practical difficulties can be
resolved.
ADVANCED PRODUCT QUALITY
PLANNING
Understand customer needs: This is done using voice of the
customer techniques to determine customer needs and using
quality function deployment to organize those needs and translate
them into product characteristics/requirements.
Proactive feedback & corrective action: The advance quality
planning process provides feedback from other similar projects
with the objective of developing counter-measures on the current
project. Other mechanisms with verification and validation,
design reviews, analysis of customer feedback and warranty data
also satisfy this objective.
Design within process capabilities: This objective assumes that
the company has brought processes under statistical control, has
determined its process capability and has communicated it
process capability to its development personnel. Once this is
done, development personnel need to formally determine that
critical or special characteristics are within the enterprise's
process capability or initiate action to improve the process or
acquire more capable equipment.
Analyze & mitigate failure modes: This is done using techniques such
as Failure modes and effects analysis or anticipatory failure
determination.
Verification & validation. Design verification is testing to assure that
the design outputs meet design input requirements. Design verification
may include activities such as: design reviews, performing alternate
calculations, understanding tests and demonstrations, and review of
design documents before release. Validation is the process of ensuring
that the product conforms to defined user needs, requirements, and/or
specifications under defined operating conditions. Design validation is
performed on the final product design with parts that meet design
intent. Production validation is performed on the final product design
with parts that meet design intent produced production processes
intended for normal production.
Design reviews: Design reviews are formal reviews conducted
during the development of a product to assure that the
requirements, concept, product or process satisfies the
requirements of that stage of development, the issues are
understood, the risks are being managed, and there is a good
business case for development. Typical design reviews include:
requirements review, concept/preliminary design review, final
design review, and a production readiness/launch review.
Control special/critical characteristics. Special/critical
characteristics are identified through quality function deployment
or other similar structured method. Once these characteristics are
understood, and there is an assessment that the process is capable
of meeting these characteristics (and their tolerances), the process
must be controlled.
A control plan is prepared to indicate how this will be achieved.
Control Plans provide a written description of systems used in
minimizing product and process variation including equipment,
equipment set-up, processing, tooling, fixtures, material,
preventative maintenance and methods.
PRODUCT DEVELOPMENT
Planning
Concept Development
System Level Design
Detailed Design
Testing and Refinement
Production Ramp-up
Product Design = Function + Form
Function = What the Product is supposed to do
Form = How the Product is to do its function
Form = Shape, Geometry, Material, Energy, Operation Sequence,
Information flow etc.
Design is to Map the Form to the Function.
Design may have many solutions but selecting the optimal
solution when there is no clear solution.
Effective Design
Product cost
Product Quality and Performance
Time to Market
Over the Wall approach
Concurrent Engineering
• Cross Functional Team are integrating all functions and stake
holders.
• Stake holders are those who have the concern for the products.
• CE eliminates all the problems faced by over the wall approach.
INPUTS
• Design Goals
• Reliability and Quality Goals
• Preliminary Bill of Material
• Preliminary Process Flow Chart
• Preliminary Listing of Special Product and Process
Characteristics
• Product Assurance Plan
• Management Support
 Design Failure Mode and Effects Analysis (DFMEA)
• Design for Manufacturability and Assembly
• Design Verification
• Design Reviews
• Prototype Build - Control Plan
• Engineering Drawings (Including Math Data)
• Engineering Specifications
Material Specifications
Drawing and Specification Changes
ASIMOV’S MODEL
Design Synthesis
Design Synthesis is the process by which concepts or designs are
developed based on the functional descriptions that are the
products of Functional Analysis and Allocation.
Design synthesis is a creative activity that develops a physical
architecture (a set of product, system, and/or software elements)
capable of performing the required functions within the limits of
the performance parameters prescribed.
Objectives of Design Synthesis
• To combine and restructure hardware and software components
in such a way as to achieve a design solution capable of
satisfying the stated requirements.
• During concept development, synthesis produces system
concepts and establishes basic relationships among the
subsystems.
The physical architecture forms the basis for design definition
documentation, such as, specifications, baselines, and work
breakdown structures (WBS).
Activities in synthesis
Allocate functions and constraints to system elements
– Synthesize system element alternatives
– Assess technology alternatives
– Define physical interfaces
– Define system product WBS
– Develop life cycle techniques and procedures
– Integrate system elements
– Select preferred concept/design
Synthesis tools
Requirements Allocation Sheets (RAS) provide traceability to the
functional and performance requirements.
Simple descriptions like the Concept Decription Sheet (CDS)
help visualize and communicate the system concept.
Logic models, such as the Schematic Block Diagram (SBD),
establish the design and the interrelationships within the system,
Modelling
Modelling techniques allow the physical product to be visualized
and evaluated prior to design decisions.
Models allow optimization of hardware and software parameters,
permit performance predictions to be made, allow operational
sequences to be derived, and permit optimum allocation of
functional and performance requirements among the system
elements.
CDS CONCEPT DESCRIPTION SHEET
The Concept Description Sheet describes (in textual or graphical
form) the technical approach or the design concept, and shows
how the system will be integrated to meet the performance and
functional requirements. It is generally used in early concept
design to show system concepts.
SBD
• The Schematic Block Diagram (SBD) depicts hardware and
software components and their interrelationships.
• They are developed at successively lower
• levels as analysis proceeds to define lower-level functions
within higher-level Requirements
Requirements Analysis and Allocation
The RAS initiated in Functional Analysis and Allocation is
expanded in Design Synthesis to document the connection
between functional requirements and the physical system.
It provides traceability between the Functional Analysis and
Allocation and Synthesis activities. It is a major tool in
maintaining consistency between functional architectures and the
designs that are based on them.