1 13-1 McGraw-Hill/Irwin © 2003 The McGraw-Hill Companies, Inc., All Rights Reserved.

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1 1 13-1 McGraw-Hill/Irwin © 2003 The McGraw-Hill Companies, Inc., All Rights Reserved.

2 2 13-2 DEVELOPMENT P ART F OUR

3 3 13-3 Development Figure IV.1

4 4 13-4 CHAPTER THIRTEEN DESIGN

5 5 13-5 What Is Design? Has been defined as “ the synthesis of technology and human needs into manufacturable products. ” In practice, design can mean many things, ranging from styling to ergonomics to setting final product specifications. Design has been successfully used in a variety of ways to help achieve new product objectives. One thing it is not: “ prettying up ” a product that is about to manufactured!

6 6 13-6 Contributions of Design to the New Products Process Figure 13.1

7 7 13-7 Range of Leading Design Applications Purpose of Design Aesthetics Ergonomics Function Manufacturability Servicing Disassembly Item Being Designed Goods Services Architecture Graphic arts Offices Packages Figure 13.2

8 8 13-8 Product Architecture The process by which a customer need is developed into a product design. Solid architecture improves speed to market, and reduces the cost of changing the product once it is in production. Product components are combined into “ chunks, ” functional elements are assigned to the chunks, and the chunks are interrelated with each other.

9 9 13-9 Product Architecture Illustration Figure 13.3

10 10 13-10 Product Architecture and Product Platforms Product architecture development is related to establishing a product platform. If chunks or modules can be replaced easily within the product architecture, “ derivative products ” can be made from the same basic platform as technology, market tastes, or manufacturing skills change. Examples: 200 versions of the Sony Walkman from four platforms.

11 11 13-11 Assessment Factors for an Industrial Design Figure 13.4

12 12 13-12 Prototype Development Comprehensive Prototype: complete, fully- functioning, full-size product ready to be examined by customers. Focused Prototype: not fully functioning or developed, but designed to examine a limited number of performance attributes or features. –Examples: a crude, working prototype of an electric bicycle; a foam or wood bicycle to determine customers ’ reactions to the proposed shape and form.

13 13 13-13 Model of the Product Design Process Figure 13.6

14 14 13-14 Improving the Interfaces in the Design Process Co-location Digital co-location Global teams Produceability engineer Upstream partnering with vendors

15 15 13-15 Computer-Aided Design (CAD) Greatly accelerates the design step and allows assessment of multiple possible designs without building expensive prototypes. Design for Manufacturability (DFM): search for ways to minimize manufacturing costs. Design for Assembly (DFA): search for ways to ease assembly and manufacture. Rational for DFM: A seemingly trivial detail in design phase might have huge manufacturing cost consequences later on!

16 16 13-16 Some of the Uses of CAD in Auto Industry Determining fit of subassemblies: does the radio/CD player protrude too far into the engine area? Facilitating “ decking ” of cars (attaching the powertrain to the upper body): do all the pieces fit together perfectly? Crashworthiness: can we modify any aspects of the car ’ s design to improve its ability to protect the passengers in a crash?

17 17 13-17 New Developments in CAD Stereolithography (rapid prototyping) Mechanical computer-aided engineering (MCAE)