Sar SU Eee elite g Incept ribai Phule Pune University Semester VII (Mechanical and Automobile Engineering) Product Design and Development (Code : 402045A) What are the techy Explain any one, ues used for Idea generation ? ‘Ans. : Following are the tools and techniques used for Idea generation(Idea Generation Approaches} 1. Triz Method, 2. Benchmarking, 3. Brainstorming 4. Alternate thinking, 5. Reverse Engineering Triz Method * TRIZ is the Russian acronym for the “Theory of Inventive Problem Solving,” an international system of creativity developed in the USSR. between 1946 and 1985, by engineer and scientist Genrich $, Altshuller and his colleagues. According to TRIZ, universal principles of creativity form the basis of innovation, TRIZ identifies and codifies these principles, and uses them to make the creative process more predictable. ‘* In other words, whatever problem you're facing, somebody, somewhere, has already solved it (or one very lke it). Creative problem solving involves finding that solution and adapting it to your problem. © TRIZ is most useful in roles such as product development, engineering and process ‘management. design + For example - Six Sigma quality improvement processes often make use of TRIZ The Key TRIZ Tools Let's look at two a the central concepts behind TRIZ: 1. Generalizing Problems and Solutions ‘The primary findings of TRIZ research areas follows ‘+ Problems and solutions are repeated across industries and sciences. By representing a problem as a “contradiction” (we explore this later in this article), ‘you can predict creative solutions to that problem, Patterns of technical evolution tend to repeat themselves across industries and sciences, Creative innovations often use scientific effects outside the field where they were developed. Using TRIZ consists of fearning these repeating patterns of problem and solution, understanding the contradictions present in a situation, and developing new methods of using scientific effects. ‘You then apply the general TRIZ patterns to the specific situation that confronts you, and discover a generalized version of the problem, Fig 3.1 illustrates this process. Fig. 3.1: The TRIZ Problem-Solving Method Here, you take the specific problem that you face and generalize it to one of the TRIZ. general problems. From the TRIZ general problems, you identify the general ‘TRIZ solution you need, and then consider how you can apply itto your specific problem. ‘The TRIZ databases are actually a collection of “open source" resources compiled by users and aficonados of the system (such as the 40 Principles and 76 Standard Solutions, which we look at, below) Eliminating Contradictions Another fundamental TRIZ concept is that there are fundamental contradictions at the root of most problems. In many cases, a reliable way 10 solvea problem isto eliminat hese contradictionsProduct Design and Development (SPPU) 3 TRIZ recognizes two categories of contradictions > Technical contradictions. These are classical engineering “trade-offs where you can't reach the desired state because something else in the system, prevents it In other words, when something gets better, something else automatically gets worse For example: © The product gets stronger (good), but the weight increases (bad). ‘© Service is customized to each customer (good), but the service delivery system gets complicated (bad) © Training is comprehensive (good), but it ‘employees away from their assignments (bad), keeps © The key technical contradictions are summarized in the TRIZ Contradiction Matrix. As with all TRIZ resources, it takes time and study to become familiar with the Contradiction Matrix © Physical or inherent contradictions. These are situations in which an object or system suffers contradictory, opposite requirements, Everyday examples include ‘© Sofware should be complex (to have many features), but simple (to be easy to learn. ‘© Coffee should be hot (to be enjoyed), but cool (to avoid burning the drinker) ‘+ An umbrella should be large (to keep the rain off), but ‘small (to be maneuverable in a crowd) © You can solve physical contradictions with the TRIZ Separation Principles. These separate your requirements according to basic categories of Space, ‘Time and Scale Five Top TRIZ Concepts and Techniques : ‘TRIZ. comes with 2 range of ideas and techniques beyond the basic principles outlined above. Some a conceptual and analytical, such as ‘¢ The Law of Ideality. This states that any system tends to become more reliable throughout its life, through regular improvement, ‘¢ Functional Modeling, Analysis and Trimming. TRIZ uses these methods to define problems. ‘+ Locating the Zones of Conflict. (This is known to Six Sigma problem-solvers as "Root Cause Analysis”) «The Laws of Technical Evolution and Technology Forecasting, These categorize technical evolution by demand, function and system Quickread + The 76 Standard Solutions. These are specific solutions devised to a range of common problems in design and innovation. You can use one such tool or many to solve a problem, depending on its nature. Cocapldesn | Reciremens anaiys Conve 99 Engreerag paremeters| ae! TAZ anal “O vertve pce —— [spect souton 1 oo convening { ‘ocess | Separating cervaditon Salisiyag contradiction = Bypassing contadton ee | Fig. 3.2 @.2 Discuss the stepwise procedure for Benchmarking COR Define benchnating. Explain stopwie procedure for boncnmarking ‘Ans. : Benchmarking ‘+ In simple words we can state that benchmarking is a process of comparing out product with competitors. In ‘our own language basic of which is "know your enemy to know yoursell” ‘+ Development team must realize not only their products but also importantly how other competitors provide similar product. ‘© To realize this competition development team must teardown and analyze competitive products.Product Dy ign and Development (SPPU) 3 Quickread a es ES © Benchmarking provides a standard or point of reference and range that can be used to judge quality value or performance. Benchmarking approach involves following steps Step 1: Prepare list of Design issues «For comparative benchmarking it is essential to develop list of various design issues. This list must be continuously updated and revised, While taking the efforts for benchmarking an excellent exploration path must be followed. Outcome of this step is it will reduce wastage of time and resources. : Formation of list’ of competitive or similar (Related) Product © After considering the design issues and product function as a part of product development team we should examine scope for sales or retail stores. While Step2 considering a product we must list all competitors along with their different product models. «Ifthe competitors are having family of product under a common platform, we must collect detail information because It will help us to know competitor's preferred market segment. ‘© This step should be detection of competitor's in terms ‘of company names and product names along with complete set of different products, supplier names and vendors. This list must be screened by highlighting particular competitors which are assumed to be most critical for design team to fully realize, ‘Step 3 : Conduct an information search ‘© For benchmarking itis essential that design team must gather as much as information about product. It involves collection of useful information Ike any printed article that mentions the product, material of produc, it's features, the name of company, customers, ‘market share. Corporate libraries are the best choice to begin the search for useful information. Before starting any activity a design team must realize the market demand for product features and what the ‘competitor is doing to meet it. ‘A design team should gather information on: 1. The product and similar product. 2. Their function wise performance. 3. The different targeted market segments. ‘© Written sources of information: Libraries, company’s ‘market share report, various industrial review reports. * Other sources : www, internet, social media like Facebook, What's App, industry associations, friends in industry ‘Step 4: Teardown multiple products in class ‘¢ After collection of useful information search, we should prepare a list of successful products in the market and related design issues for teardown. Then perform complete teardown of these products using different methods of teardown process, ©The outcome of this step is very important as it includes BOM(bill of materialsjioe. each product, Functional model for each product, an exploded view of each product, and Function-to-Form mappings of the functions to assemblies. Step 5: Functional Benchmarking ‘© Benchmarking performed by comparison of product form is having certain limitation as in this approach any component in one product may not be functionally equivalent with same component in other product. To remove this limitation we will adopt functional equivalency approach in benchmarking. ‘© Here we will find same function in the other product's function models. For this function we will list the various physical forms found among the competition to solve this problem. ‘Step 6 : Establish Best-in-class competitors by function ‘¢ After preparing list of various solutions used for every function, comparative analysis can be completed. For each function the highest performing solution can be called as “Best-in-Class”. We will finalize the solution which is less expensive Step 7: Plotting the industry trends ‘+ After collection of information next step is to arrange ‘and transform information clear explanation of implication for design task: 77 1. Market categorization (Market segmentation) 2. Benchmarking of technical solutions. according to process include 3. Benchmarking of competitors. 1. Market categorization Here we should identify socio-economic market segment at which different products are almed. We should categorize product solutions by socioeconomic status of customer of individual product and also by percentage of product i-rjeasy-solutions|W Product Desi Development (SPPU) 2. Benchmarking of technical solutions 1s an approach of comparison of How products perform. The most effective approach is the development of technology timeline using “s-curves” = ———— Capra ee — nays ad comparison of rents )— ee 5. improvement plan to overcome ‘the best in class Teplementtin and menstaing~) ‘of the action plans Cen Inprovomen 4 Quickread 3. Benchmarking of Competitors It As similar to benchmarking of technical solutions. It considers the performance over time of the entire portfolio ‘of company. Benchmarking should be carried out by considering points such as market share, price, inventory costs labor costs ete _ 1 Ask customers about thew requrements tor produ 2 Sel assessment on tho crea! factors denied ty te customer Partcular and wey stops ‘n benchmarking, 7 Communicaton ol benchmarking resus 2 Jasieation ofthe recommendations I terme of resources 8, Determine how much the organization could prove |. Devetoament o action plans a 1. The action plans shoule be clearly expressed n terms ol time and resources 2. The implementaion shoul be guided by text 1. Gorstant upeate and folow up of the resus tem the analyse Especial mporant roo forgot he possivo| improvements ached by compet Fig. 3.3 : Benchmarking Approach 3 Explain the concept of brainstorming with suitable © Iti intuitive method of generating the concepts, it concentrates on architecture and product function. This method uses really new ideas also often mix several ideas to produce something exciting which is non obvious. ‘* Group discussions are held to generate as many as new Ideas. The group generally consist of 6 to 10 People. ‘The group members are encouraged to be open and as wild as they want in suggesting solutions. It concentrates on functional needs of product than that ‘of product specifications ©The main objective of brainstorming is to achieve several concepts or solutions. + These mentioned solutions are accepted initially irrespective it may be practical or not. No ideas are held back or criticized, so within a short period of time hundreds of ideas can be obtained on the table. Only after creation of ideas freely the group looks ahead to critically evaluate them for the purpose of its practical implementation. @ OOoProduct Design and Development (SPPU) 3 ‘eae (at ronan) EY Fig. 3.4 : Brainstorming Process ‘+ Typical procedure to be followed in brainstorming. © Assign a group or Team Leader. ‘0 He should direct or record. He should encourage all participants. ‘© Form a group of 6 to 10 People. ‘© Brainstorm for 30 to 45 minutes. In that first 10 ‘minutes are for orientation of problem, next 20 to 25 ‘minutes are for increasing the ideas coming from team members and final ten minutes are for trickling the Ideas. © We need to obtain new ideas so we should put only expert group in the brainstorm group. Individual team members are allowed to enter with set of ideas depending upon goal of brainstorming, Bosses, managers and supervisors should not be included in session. ‘Advantages of Brainstorming 1. It facilitates mixing of several ideas to generate new ideas, 2. Itconcentrates on functional needs of product than that of product specifications, 3. It generates several concepts or solutions, 4. allows team members to express their ideas without any mental burden of bosses, managers. Disadvantages of Brainstorming 1, The "Right Idea” may not come at “Right time” 2. Possibility of domination of certain team member in discussion, 3. Team may be distracted from original idea 4. Team may not be open for new ideas. Guickread QA Explain the concept of laters! twrking example Alternate Thinking © tis solving the problems through indirect and creative approach Here we consider that it \s not immediately obvious and involving ideas may not be obtainable by using only step by step logical approach. Lateral thinking distinguishes iself from standard perception of creativity. with stable An © It differentiates “Vertical Logic” from “Horaontal imagination” where vertical logic is classical method for problem solving working out soluuons step by step from given data and ‘horizontal imagination means having many ideas but is unconcerned with deta {implementation of them. ‘© Critical thinking is concerned with judging true value of statements and finding the errors. Whereas lateral thinking is concerned with “Movement Value” of statements and ideas. Person who uses lateral thinking the moves from one known idea to creating new ideas. ‘*Fourtypes of thinking tools in lateral thinking 1. Specific idea creating tools to break current thinking patterns, routine patterns 2. Focus tools to broaden search for new ideas. 3. Harvest tools to ensure more value is received from idea generation output 4, Treatment tools those promote considerations of real world constraints, resources and suppor 5 What is reverse engineering 7 Discuss the necessity and procedure of product teardown. ‘Ans. : Reverse Engineering Reverse engineering it gives snapshot of the product how other designers have combined parts to meet the ‘customer needs Steps of Reverse Engineering 1. Discover operational requirements 2, Examine function of product 3. Determine relationships between component parts of product 4. Determine manufacturing and assembly process used to produce product |! Suyand | Frapenct [3 Dsaserdy(Ossecen Sano pats Fig. 3.5 : Reverse Engineering Approach tycasy-solutions3 and Development W Product Des Reverse Engineering can show a design team that what ‘4 competitor has done, Example, Ford Engineers have disassembled the engines of cars such as BMW, Audi, Toyota and picked up best features to form popular model Le Tauras model of Ford 6 How can you interpret the results of your product ‘SWOT analysis and use it proactively to change ? Ans. ‘* To understand in detail your product strengths, so you can better position your product in your ‘communication initiatives and in any point-of-sale ‘marketing campaigns ‘* Work on your product weaknesses, so that they could ‘become strengths inthe future ‘# Assess whether it is worth to pursue some of the opportunities you identified, by serving latent demand ‘with product extensions or completely new products Once this vision is clarified and approved, you will quickly need to move from theory to action # Define a clear product roadmap and 2 product plan, splitting it into “phases” and “waves”. For each phase of this roadmap, define specific project activities, deliverables and timeline Be realistic in your timeline and effort assumptions! Getting things done always takes longer than anticipated. ‘© Focus on the “quick wins’: are there any actions that you can implement quickly and that will bring you tangible economic results? If so, prioritize them in the ‘execution plan and, in parallel, work on implementing the product roadmap ‘© Conduct a periodic progress review, both atthe product level and at the Company level: perform a new product ‘SWOT analysis at least every year, as competition can move fast and may force you to revisit your product priorities and roadmap ‘¢ This is not easy, and will require a lot of time and effort, ‘but you need to remain focused on the target: iplementing successfully your product strategy. 7 What is concept selection ? OR Discuss various factors that affect concept selection, TEE Ans. : Concept Selection Process ‘© Concepts selection process is 2 team based decision making attempt, There Is no any clear solution concept Quickread that should be accepted, various members of the team have strong opinions on various solutions and incorrect decision can be expensive. ‘The concept selection process Is an attempt to handle this uncertainty. Here a design team evaluates alternatives and come to a conclusion by taking acceptable decision among team about most effective concept that Is tobe finalized, A. design team will have agreement regarding finalization of the concept. Every team member in the team will realize why they changed their mind and finally every member will support their change in position. The concept selection process should be completed in a room with at least three walls that can be written on paper attached. One will have definitions of criteria with alternatives. Another wall will have evaluation interaction and final wall will be used to keep notes and rejected information, The selection process isa five step process with iterations, Concepts selection process 1. Taking acceptable decision among team “regarding cr Taking accepable decision among ea] regarding alteratves | 3 Ranking the alternatives. 4 Evaluating the alternatives ] ‘tacking the negatives Fig. 3.6 : Concepts selection process jon among team regarding ‘Taking acceptable di criteria ‘The first step is to establish evaluation criteria on which the concept selection process is based. Generally there are three evaluation criteria, That is cost, technical difficulty and customer satisfaction. Initial task is to resolve differences among criteria’s into definitions that are common to the team. To prepare definitions of criteria should start with proposed list of evaluation criteria. This list should be developed from customer needs and engineering specifications ofthe product. The team must determine what the scope of criteria does and does not include. as CEIproduct Design and Development (SPPU) 3 ‘eg: Acost criteria can include unit manufacturing cost alone or could also include retailer, warranty costs. ‘While taking the decisions regarding high quality information each criteria might have understood with ‘numerical scale, Such as endurance stress in MPA to represent strength. This numerical scale may not be appropriate due to low quality information then it should not be used. Concept selection is sometimes kept on hold until extensive analysis and completed and ‘so information quality is high and numerical scale will work wel. 2. Taking acceptable decision among team regarding alternatives Taking acceptable decision ‘among team regarding criteria J “Taking acceptable decision ‘among team regarding alternatives ] Ranking the allematves. J Evaluating the alternatives q Attacking the negatives Fig. 3.7 : Concept Selection Process ‘© After finalizing evaluation criteria various alternatives should be realized on common basis. Procedure of establishing the alternatives is same as that of evaluating the criteria. These alternatives are evaluated from concept generation. ‘These alternatives must be well defined so that all team members may realize them without any confusion. ‘Sketches facilitate clear realization about concept. each, alternative is given a commonly understandable definition, and important fact is to realize what should bbe engineered with concept to result in final product. ‘+ Every person should contribute his understanding with his specialty to give fnished touch to alternative in terms of evaluation criteria, Z Quickread 3. Ranking ©The next step is to clearly ranking the alternatives. It uses well defined criteria ranking scheme which is based on the quality of information. The ranking is finished using a decision matrix chart. Ranking of all alternatives should be done on the basis of each criteria. A team should not rank each alternative across all criteria before considering another alternative. © Specific scale is used to rank the alternatives scale isin terms of(-){+),{s) Meaning of the scale is that a (+) is Worse than an (s),which is worse than (+). We can use miore refined scale if quality of information permits us to do the same. 4. Assessment ‘Aer completing the ranking procedure for each criteria, the final evaluation should be collected in to overall ranking summary of on each alternative Ordering of alternatives should be from best to worst ranking that can be easly understood. This ranking is simple as mathematical exercise to see how the alternatives rate over al 5. Attacking the Negatives ‘After finishing the assessment, alternatives those are poorly ranked should be taken out from the list The alternatives those rate favorably must be closely examined. Alternatives that rank high overall but have few score should be carefully and closely scrutinized. We should eliminate negatives. 18 Explain pugh’s concept selection chart with suitable example, Dt Ee ‘Ans. : Pugh’s Concept Selection Process ‘The process of concept selection can be applied with the help of decision making tool as developed by Pugh. It is ‘most effective tool for primary concept selection with low quality of information. They are also effective as quality of information increases with refined selection scale. The selection process is five step processes with iterations. 1 Establishing the all criteria and alternatives 2. Selectthe Datum 3. (@) Ranking and assessment (6) Alternative rank ordering 4. Attacking the negatives leration and solution Zjeas'_ WE Product Nesign anc Development (SPU) a8 Quickread er Estatanng te a Ste | eaten and altemaves | ‘steo 2 ‘Select the datum | \ step 3 | {py aneratiwe rank raoing| / conceot Fig. 3.8 : Steps in Pugh’s Concept Selection Process 1. Establishing the criteria and alternatives Concept Alternatives and criteria are established with Pugh’s selection chart as discussed in the concept selection process. The alternatives and criteria are displayed on the main wall and labelled as Pugh’s selection chart. Table 3.1 : Template of Pugh’s Selection Chart [ | CONCEPTS ‘Sketch of Datum ‘Sketch ofL | Sketch ofM ‘Sketch ofN Sketch of P criteria i 0 | i . | z w 0 g wv a | ’ o vi 0 | a 0 | Z(o)Posiuve a» | z * | (Negative : | 7 l 2. Select the Datum 3(a)Ranking and Assessment : The next step isto establish the evaluation scale. For | After selecting datum all alternatives are assessed and preliminary concepts Pugh suggested minimal scale of evaluated for each criteria, one criteria at a time with (© 5.2)For more refined scale numerical ranking scale | jegpect to datum Ifthe team suggest that alternative tuay be ved Team should alec one alternative that | "tet worse performance than datum hen It should ranked as (3) or (0) on every criteria and called a5 | ye assigned as) rank: if team suggests that alternative Datum. The datum is an alternative with which every performs better performance than datum then it should other concept will be compared. Other concepts can be be assigned as (+) rank and if team suggests alternative Tae by wang sae as eer worse ihe ame (| pears sume perfomance 2s datum ten shoul be or beter (+) on each criteria, Pugh suggest using the | assigned a(s) rank These rankings are documented in alternative that the team votes as best that will be . us) mat . es Pugh’s chart on the front wall of the room during decision making process, i a esl selected as datum,W Product Design and Development (SPPU) 4-9 31) ‘Alternative Rank Ordering ‘After ranking the alternatives on every criterion the given rating should be combined into overall core, that will be used to arrange the alternatives from best to worst. It is not as simply asa (-) cancels a (+),only this is not sufficient. There should be average summation of ranks. (-) on one alternative may really be (~~), and in another way a (+) may be 0.5(+) while compared with teach other or datum. So its essential to determine the average overall summation score. [Attacking the negatives : ‘Thus low average rated alternatives should be removed cout from further consideration. Then highly average Quickread ‘ated alternatives with (-) score should be critically examined to create options for new akernatives Mostly eliminate the(-) scared alternatives, Iteration and solution : Eventually team united takes acceptable decision ‘among team on a winning or preferred akernative. At this stage team realizes refined choice of alternative but team could not make final decision as specific data is lacking, Ukimately by neglecting negative Iterations only consider rank alternative try to solve them and find the solution. 2.9 Explain construct Pugh’s selection chart for mobile Handset. Assume four vanants and any fve factors for selection ‘Ans. : Consider four (4) variants in mobile as 1 2 3 4 Samsung Mobile Galaxy Samsung Mobile Galaxy S8 Samsung Mobile Galaxy $8 plus Samsung Mobile Galaxy Advanced $8 plus Five factors of selection 1 2 3, 4 s. 6 ‘@.10 Explain the concept of Product Characteristics used in ‘Ans. : Product Characteristics product development and Design. Product characteristics is fone of those factor. The following four aspects are considered under product characteristic 1 3 4. Long Battery Life Memory Storage Screen resolution Weight of Phone (Mobile) Quality of Camera (Pixels) Now prepare Pugh’s Matrix and select most suitable phone. Price can also be considerable criteria. product development and Design Many factors are to be analyzed in connection with the Functional Aspect 2. Operational Aspect Durability and Dependability Aspects ‘Aesthetic Aspects 5. Ergonomic Aspects Functional Aspect: : When the marketing possiblities of a product have been explored, the functional Scope of the product has to be carefully analyzed and properly defined. The definition of the objective of a product does speak about the complete functional scope of the Product. EG Let these be four varars of Samsung ‘ala motile Let nese be fve slacon crea’ by Consizerng you have to select he prone (Mobi ‘A mixer, grinder, for example, has a clearly defined objective to grind and mix or Shake the various items. Basically the mixer consists of a motor and a speed control Unit but it has to be designed so as to serve with all attachments. Now the customer has to decide and define the functional aspect ofthe food mixer Unit compatible with his requirements, taste and paying capaciy Similarly in other products, the functional scope ofthe Producunit may be in the form of detachable accessories attachments and the usage canbe left to the customer decision. So the functional aspect is concerned with the ease and efficiency of the product, performance tyeasy-solutionsPS pment (SPU) Product Design and De 2. Operational Aspect : [After knowing the functional aspect of a prod relevant to consider the Operational aspect. iat the product should vt, Ht is tis not important only th function properly 4s _ But is should also be easy to understand and simple to operate Sometimes the product has to be suitable ‘and very often itis subjected to for various ‘operational conditions carying degrees of expertise of workers oF operators «sith this trend for increased versatihty of products, the products should be designed in such a way that by using basic attachments it should be possible to build a suitable combination for specific purposes. “Thus the versatility of products/machines should also be analyzed in the light of above discussion Especially if some operations are tobe carried out with the aid of different accessories or attachments, the esigner should always bear in mind the time required for an operator to perform the changeover operation. ‘The tendency should be short get ready and short put away period 3. Durability and Dependability # Theeconomic analysis ofthe cost of product is essential in view of the fact that durability and dependability are dosely related with the selection of materials and workmanship. Since quality Is the degree of perfection so it is not easy to define this characteristic, but durability and dependability are the factors that often determine quality of a product and thus have to be carefully considered by the designer. Durability may be defined as length of active life or continuance of the product under given working conditions. © Durability may not always be connected with selection ‘of good materials. © An additional criterion regarding quality dependability, which maybe defined as the capability of ‘a product to function to satisfaction when called uponto dots ob, © Another aspect of durability is that of maintainability which may be defined as the ease with which 2 productequipment can be maintained ‘© This is of particular importance in case the machine is ‘supposed to work continuously and also when any repair and maintenance involves loss of running time Quickread ‘Aesthetic Aspect ‘esthetic aspect is concerned with the appearance and ook of the product. Where the dependability durability, finctional scope and operational aspects of the product have already been defined aesthetic aspect is mainly concerned with final shape of the Product Depending upon the man's aesthetic taste gradual changes in appearance or the product are taking place. in some cases, however, moulding of final shape of the product may have financial implications for instance the product may require the addition of some special materials and processes in addition to those basically required from the operational and functional point of view. «In such cases careful cost analysis of the aesthetic aspects will be required. In case of consumer products aesthetics may be the governing factor in design eg, appearance of automobiles and other household utlities/equipment cr fashion goods. When styling isa dominant factor in product design itis utilized for creating demand And sometimes ‘monopolies the market. 5. Ergonomic Aspects It is the process of designing or arranging workplaces, products and systems so that they fit the people who use them. Most people have heard of ergonomics and think it is ‘something to do with seating or with the design of car ‘controls and instruments ~ and it s.. but itis so much ‘more, Ergonomics applies tothe design of anything that involves people - workspaces, sports and leisure, health and safety. © Ergonomics (or ‘human factors’ as North America) isa branch of science that aims to learn about human abilities and limitations, and then apply this learning to improve people's interaction with it is referred to in products, systems and environments © Ergonomics aims to improve workspaces and environments to minimise risk of injury or harm. So as technologies change, so too does the need to ensure that the tools we access for work, rest and play are designed for our body's requirements. The following are some of the main benefits of ergonomic product design ‘© Safety - Product safety is imperative in today's health and safety-driven world, Businesses put an emphasis SE 10.05)-solutions]Product Design and Development (SPPU) 3 oon safety, and it is an exceptionally high priority in ‘manufacturing industries. Ergonomic design can help improve safety. For example, a power drill often has hand guards to help prevent accidents. Or a set of drawers may have a safety mechanism to prevent the individual drawers falling out. If you design a product with ergonomics in ‘mind, you can ensure that it is entirely safe for your customers to use. ‘+ Comfort Products that you interact with physically ‘must be comfortable. If you are using a product for a prolonged period of time, it must not cause any physical pain or potential ailments. The best example of ‘ergonomic design to improve comfort is an office chair. I you work in an office, you will sit in your chair for many hours in a working day. With that in mind, the chair has to be comfortable. It should support your back, promote good posture, and also support your ‘arms and legs. An ergonomically designed product will offer unparalleled levels of comfort. + Ease of Use - What good is a product or service if tis difficult to use? What would you think as an end customer if you spent hours trying to figure out how to use a product? Ergonomie product design can help Improve ease of use. When you take time to look at how the product is used and perceived, you can draw on the data you collect to tailor the design of your product for ease of use, @.11 What is necessity of economic analysis of product 7 Elaborate Ans. :conomic Analysis as per Production Aspect ‘© To achieve a definite objective under the given set of limitations and assumptions we need to choose a systematic approach. That systematic approach of deciding Includes This systematic approach is called Economic Analysis of Product. optimum use of comparison of two or more alternatives. ‘© Employed opportunity cost of recourses is considered by Economics analysis of product which tries to ‘measure in monetary terms the private and social costs and benefits of project to the community or economy. ‘+ The process of analyzing total costs consist of all Parameters of Inputfor any type of a Product. It consists ‘of two basic types of costs, fixed cost and variable cost Quickread Different costs associated with economic analysis are Total costs, total fixed casts, total variable cost, average total costs, average fized cost Different methods of economic analysis 1) Breakeven analysis ii) Return on investment iin) iv) NPV (Net Present Value) caleulatons. Investment risk ‘This process of analyzing total costs should be known to Managers. They should realize i This process includes all the parameters of input for any product Which isto be sold. Total costs are made up of two basic types of eosts, fixed cost and variable cost © Variable cost : When Costs are variable, they can be changed by managers during any production period, usually because of fluctuations in quantities bought or produced is called 2s variable cost Examples Social Security, Workers’ Compensation, Ingredients, Packing Materials. Equipment Repairs, Utilities, Interest on Loans. © Fixed costs : When costs are fixed and these costs cannot be changed by managers during any production period is called as fixed cost. The most ‘common time period used for dividing fixed and variable costs is one year. Fixed cost consider two types of parameters Depreciable Depreciable. Examples are Land, Building Repairs, Property Taxes, Insurance, equipment cost, Storage Costs. and non: A cost analysis should be performed which is based upon the type of management decisions needed for control before the start of actual Production, Consistent, accurate cost information will provide accurate analysis for decisions those are required to be made to price products and manage costs to maximize profits Using the formulas listed below, an estimate can be calculated for an average annual cost that can be compared to the average annual price received for the product. These costs are based: on the. actual or estimated volume or capacity of production. Fundamental formulae for a specific time period, usually one year, are listed here NP = TR-TCa Product Design and Development (SPPU) ‘Total Revenues - Total Costs for one year TR = QP ‘Total Revenues = Total numberof items sold + Price ofeach item sold throughout the year. ‘Net Profit = Te = TRC+TVC TC = Total Fixed Costs ¢ Total Variable Costs, ‘TEC = Annual costs that do not vary during the year. TVC = Costs that will vary with production levels AVC = TVC/Q ‘Total Variable Costs Number of items sold TRC/Q Total Fixed Costs Average Variable Costs. = aR AFC R Quickread Product function is simplest representatih of product and tis combination oust a Noun and ative verb eg In case of grinder or mixer which we are Using for cutting the groundnuts the overall produc function wi be, ut the groundnuts on) ae Average Fixed Costs = umber of items sold ATC = TC/Q Total Cost ‘Average Total Cost’ = “Number of items sold Also called average break-even price or average per unit cost of production. Total Cost (TC) incurred in producing a certain number of goods. ‘+ Total Fixed Cost (TFC) : Fixed costs are the costs that are independent of the number of goods you produce, ‘or more simply the costs you incur when you do not produce any goods, ‘+ Total Variable Costs (TVC) : These are just the ‘opposite of fixed costs; these are the costs that do change when we produce more + Average Total Costs (ATC) : Our average total cost is ur fixed costs over the number of units we produce. ‘+ Average Fixed Costs (AFC) : Our average fixed cost is ‘our fixed costs over the number of units. he total cost is simply all the costs ‘Average Fixed Cost = Fixed Costs / Number of Units Average Variable Costs (AVC) “ota Variable Co pvergeVarable Con = T3aiVaie tens oe {0:12 plan tunctonal madeing Ans: Functional Modeling +A function of a product is a dear statement of relationship between) avallable input and desired utput-Wf a product, independent of any particular form. ‘+ Product Function is mainly intended function of @ ‘Chea tuneton vee ] fea] “Sieawcn | | | Fig, 3.9: Process of Functional Modeling In case of Xerox machine-"Make Copies’, then based on these overall functions, we need to further decompose Into sub functional statements. When all are completed it satisfies the overall function (Basic Function).this process is called as functional decomposition. ‘+ Subfunction : It is component of product function. An Coverall function can be divided into simple identified subfunctions corresponding to subtasks. The relationship between some subfunctions and overall function is controlled by input-output relationship. ‘+ Abstraction : It is the process of ignoring the less important stuffs related to function and paying attention towards essential stuffs. t is nothing but segregation of general, essential and less important. Customer needs are refined to criteria for evaluating the concepts. In recent development of methods of ‘engineering design has focused on mapping the customer needs into functional descriptions. These @s CEIProduct Design and De pment (SPPU) 3 descriptions are used to create, select set of technologies that satisfy the functional requirements. Here we are concentrating on “what” has to be done by a new concept and not “how” Isto be achieved. © Functional modeling prepares a base for organizing the design team, tasks and process, Functions are directly derived from customer needs. These functions clearly define the boundaries to associate subassemblies or assemblies of the final design solution. It explores concurrent engineering approach and _ provides ‘opportunity to seek modular concept. + Functional modeling provides a platform for abstracting a design task More solutions may be generated for system to solve design problem by mapping or combining different customer need to function, Functional Modeling Process ‘There are five phases in the functional modeling process as shown in the figure. Different activities under different phase are as: Phase - 1 Creation of process description : It describes the process which is derived from problem definition and customer needs and basic product function. It defines the basic process, Phase - 2 Itmainly consist of two activities : a) Distinguishing and defining the constraints. b) Creating function tree or Preparation of Task listing Distingui Constraint: 3 and define the constraint IIs a statement of clear criteria that must be satisfied by a product and it requires consideration of entire product to decide the cri eg. : Customer needs which are not satisfied by considering “what the product does?", but are mainly depend on “how the product has it's FORM?" Airlines purchase airplanes from the companies and their essential requirement is that plane must be less in dry Weight, means they need the plane with very less weight which depends on exterior form of a product and it has nothing to do with what the airplane does?(performs function) so here “requirement of less ria value. Quickread dry weight airplane” is constraint After defining these constraints we have to prepare a list for different tasks or we should create a functional tree diagram which enlists basic functions, sub functions, ete Phase - 3 It involves combining the sub functions so as to get more refined function structure in this phase itis also essential to check how the energy flow takes place through the process. Phase - 4 It is the activity of comparing function structure with customer requirements, whether the customer needs are satisfied by the function structure or not. In this stage there is simultaneous consideration of different tasks listed in phase two. Phase -5 Its final phase of function modeling process which Involves two activities it gives us option for function structure that means here we can generate alternative function structures by considering previous phase input. Ultimate outcome through this phase of functional modeling process is to detect the product architecture and different assemblies. At this stage we are having feedback facility and it is an iterative process so that depending upon feedback we can restart the process again with phase - 1, ‘Apply functional analysis system technique for paper ‘punching machine for punching as basic function and explain with basic diagram. SOND OF Esplen product funtion analysis with FAST method. Elaborate wth sutable product example FAST (Functional Analysis System Technique) This technique is used to define analyze and Fealize product functions and how the functions are linked to i sagas: Sk whch Gerla arm oneal Hare require attention to increase the product value. It is used to exhibit functions in a logical sequence, arrange them as per the priority and check their inter dependency. [cryeasy-solutions}34 W_ Product Design and Development (SPPU) # The first step is to consider all the functions that product will perform in the view of customer here Important thing is to ask “what the product does’, and what the product is" isnot comparatively important. Then while defining the function of a product simple verb and noun structure should be used oF we can arrange ita verb followed by noun is used eg. generate torque, rind material It is clear that these functions have different level of importance, among all these functions one of the basic function should be selected. In the view of customer the product exists, main reason behind itis “Function of Product’. For example basic function of chair is to support the person firmly who is sitting on it Under different set of conditions a product may have more than one basic function. Quickread So there exists complexity while handling the functions, ‘This complexity requires separate analysis for separate condition FAST handles this complexity smoothly by considering separate analysis fr separate condition, Consider an example of establishing a function tree diagram for Domestic food grinder (Mixer -Grinder) used for grinding groundnuts. The basic function of grinder while grinding the groundnuts is to “cut the groundnuts in small pieces’. Once the basic function is detected all the other function that grinder perform, either as 2 whole or ‘within any ofits subsystem are subordinate to the basic functions, They support the basic function and help the product to work and sell. These are categorized as secondary functions which are important for the performance of basic function, further they become direct reason of basi function. How? — — wy? Purposes Functions Functions ot which appears] | which appears project one ie ‘allbme ( Base any secondary uncon Unoesired funetons Read Critical path secondary of uncon function (Functions causes due to crcl path ‘unctons) (atthe same time happening functions) ‘Domain of project study Fig. 3.10: The FAST Diagram