Practical Batches: - II

Case studies or product is Chair design

Assignment –I

Q.1 how do you indentify the need for re-development of a product?

Solution: Need for Developing Product
 The product development is multi-Disciplinary activity, which is involving various tool like,
marketing, design and manufacturing. Functional requirement of customer needis implemented for
new product. Marking is very important \play role of developing new product.
 In this phase collect information from customer requirement, which carry out using critical market
survey. During market survey which is collecting information by conducting interview of
customer, telephonic conversion etc.
 After collection of information then get idea about need of customer. According to this need is to
be fulfilling for developing the new product. The next stage of product development is design and
manufacturing the product. When manufacturing is completed then the product the is ready for sele
and marking.

Product development stages :

1] Creating new idea (new product) - concept development
2] Understanding need of customer -System level design
3] Communication-Detail design
4] Testing -Testing and refinement
5] Production -Ramp-up - Deployment of product.

Method of Product Development :

 There are two methods of product development :
a) waterfall (stages -gate) development process ,
b) spiral model
 Water fall model or method: this method is used for straight forward method or this method is
stage by forward direction. Sequential process and used in mechanical industries
 Spiral method: this method is employed for software development company. it is totally time
dependent and complex process.
DMCE PDD lab manual-2

Q2. What is the Engineering design for product?

Solution: Engineering design
Engineering Design is divided into two part 1) product design for strength consideration 2) product
Solution :-

P2=295N
P=100 kg=100x9.81
300 =981N

760 18cm
=
370 460
D=1.22cm

Load Total support

reaction reaction for design
R1

Free body diagram for design the chair with demission

Find support reaction by applying equilibrium principle:

Load reaction R1=981N/4=245.25N (chair contain four ledge so each ledge)
R1=245.25N
Total reaction (R1) =245.25N
Design the chair ledge: Tensile strength (σ) = total reaction of ledge(R)/projected area of ledge(A)

210=245.25/(𝛱/4)d2
d=1.22cm

Q3. What are the changes that you would like to incorporate in any product design?
Solution: Modified the design: The previous design has consider only direct loading condition but now
modify the design ,which consider indirect loading codition so chair ledge has direct and indirect
loading as shown in fig2 regarding buckling of Table ledge, ledge should consider knuckling load have
to be considered,
Solution :-
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Moment reaction

P2=295N
P=100 kg=100x9.81
300 =981N

760 18cm

+ =
370 460
D=2.86cm

Load Total support

reaction reaction for design
R1

Fig.2 Free body diagram for design the chair with demission

Find support reaction by applying equilibrium principle:

Load reaction R1=981N/4=245.25N (chair contain four ledge so each ledge)
Moment reaction can be calculated by taking moment about ledge support position
295x760+981x185=R1x370
R1=1096.445=1100N
Total reaction (R) =load reaction +moment reaction= 245.25+1100=1345.25N
Design the chair ledge:
Tensile strength (σ) = total reaction of ledge(R)/projected area of ledge(A)

210=1345.25/(3.14/4)d2
D=2.863cm
l/d=5; L=2.863x5=14.31=18cm length of ledge

Q4. Explain detail design process for product

Solution: The Design Process - Product design process is mainly focused on following points :
1] Define Engineering design :
Product design have different stages like adaptive design, descriptive design and development and
new design.
1. Adaptive Design: this process is described the adaption of existing of design. The
manufacturing of products and its modification is required. In design phase some dimensions
and geometrical shape and size of parts is to modified. Design activity is involving skills and
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knowledge to solving customer problem. Design should technically and conceptually correct.
Conceptual design is very good knowledge of parametric study like dimension, energy
consumptions involved.
2. Development design: this stage considered scientific training and design ability is needed for
product development. Product design is started initial design and output of results will be
different to exist design. For example, structural analysis is solved in ANSYS for table and char
model. Same table and chair are solved by using mathematical approach. both results are same
but different method or tool are used.
3. New design: new design is very small changes in final design by using imagination and inside
and outside creativity. Some points are noted on as following
o Resion for failure the component
o Incorrect assumption,
o miss understanding problem,
o incorrect design specification
o faulty manufacturing and assembly
o calculation error
o Dimension error/drawing error

2] Importance and challenge of Engineering design

o Throughout history, humans have been successfully designing objects to satisfy the needs of
evolution. Recently, design has been motivated to meet an existing requirement, to reduce a an
inconvenience, or to develop a new approach. The engineers build has become successful;
occasionally, catastrophic failures occur.
o The modified design process flow digram as shown in Fig3
o The Challenger are focuse on following points
• Incorrect or overextended assumptions
• Poor understanding of the problem to be solved
• Incorrect design specifications
• Faulty manufacturing and assembly
• Error in design calculations
• Incomplete experimentation and inadequate data collection
• Errors in drawings
• Faulty reasoning from good assumptions
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1-Making survey

2-Information search

3-systematic techniques ,creative approach and

feasibility calculation Idea

Mechanical 4-selection of optimal mecthod Reject method

Design

5-select material and diamension optimum

method and trail error method

6-Manufacturing method specification &

model construction

7-design analysis and evaluation based on

Therotical and experimental
Reject
design

8.Production distribution and recovery cycle

Fig.3modified design process

3] Concept of systematic design

o Students has large amount of theoretical material and information. They only realize their
weakness of prcatcal knowledge. Design enginer should required to higher level of
understanding exisist product. Then go to new deveoplment of product
o The design process was formalized to enable both students and professional designers to follow
a systematic approach to design and help them guide their creativity and technical problem-
solving skills. There are various forms of the systematic design process, and different people list
as
o few as four steps to as many as nine. Essentially though, they all revolve around the same
following basic principles:
• Requirements
• Product concept
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• Solution concept
• Embodiment design
• Detailed design
o The most important step of the design process is identifying the needs of the customer or the
‗Requirements‘ stage. However, before this is done, it is important to establish who
Design the Passengers should consider following points :
• Crew
• Pilot
• Airport
• Engineers and service crew
• Fueling companies
• Airlines
• Manufacturing and production departments
• Baggage handlers
• Cleaning and catering companies
• Sales and marketing
• Accounts and finance departments
• Military/Courier/Cargo/etc
• Authorities and official bodies
• Companies involved with the items that will be outsourced

4] Stapes for design process:

o To design is to create a new product that goes into profit and benefits society. The design
process is a sequence of events and a set of guidelines that helps define a clear starting point that
takes the designer from visualizing a product. It is real life in a systematic manner—without
delaying their creative process. The ability to design requires both science and art.
o The science can be learned through a systematic process experience, and problem-solving
technique
1. Evolutionary change: A product is allowed to change over a period of time with only slight
improvement. This is done when there is no competition. The creative capabilities of the
designer are limited.
2. Innovation: Rapid scientific growth and technological findings as well as competition
company for market placed. a great deal of importance on new products, which draw heavily
on innovation. The creative skills and analytical ability of the design engineer play an
important role.
o The invention of the electronic equipment was a actually innovative design. Since its invention,
many then tried to chanhing and very little changed until the next innovative and technological
o This created a whole new market along with new competition, and since then, this technology
has been changing once new innovation
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o such as the inclusion of cameras and video-calling and the integration of pda, internet access,
and mp3 facilities into one device.
o Engineers can design for the future but must base results on the past.the detail process is given
by fig.4.

Task

Specification and analysis

of product Envoirment

Specific function Technical requirement

Determination of overall function structure

Determination of special function

Actual function

Comparision of specification and actual function

Design and material selection

Design of production

Actual function and cost

Comparision actual specification function

and specific cost

Production drawing

Actual Production
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Fig. 4. design Process for new product

5] Professions and ethics :

o It is important to understand develop into a professional engineer. This will dictate the deal
with all professional issues. Understanding the concept of professional engineer it may easy, but
adopting and living by more depth and effort.
o Professionalism is a way of life. A professional person is one who engages in an activity that
requires a specialized and comprehensive education and is motivated by a strong desire to serve
humanity.
o The work of engineers generally affects the day-to-day life of all humans. Developing a
professional frame of mind begins with engineering education.
o Being a professional should imply that in addition to providing the specialized work that is
expectedof the professional engineer should provide such services with honesty, integrity, and
morality.
o For additional reading, several online resources deal with ethics, including.
1. The Fundamental Standards: These are the main issues that govern a professional engineer from an
ethical and professional standing.
2. Rules of Practice and Professional Obligations:
 Engineers shall be guided in all their relations by the highest standards of honesty and
integrity.
1. Engineers shall acknowledge their errors and shall not distort or alter the facts.
2. Engineers shall advise their clients or employers when they believe a project will not be
successful.
3. Engineers shall not accept outside employment to the detriment of their regular
4. work or interest. Before accepting any outside engineering employment, they will notify their
employers.
5. Engineers shall not attempt to attract an engineer from another employer by false or misleading
pretenses.
6. Engineers shall not promote their own interest at the expense of the dignity and integrity of the
profession.
 Engineers shall at all times strive to serve the public interest.
1. Engineers shall seek opportunities to participate in public affairs; career guidance for
youths; and work for the advancement of the safety, health, and well-being of their
community.
2. Engineers shall not complete, sign, or seal plans and/or specifications that are not in
conformity with applicable engineering standards.
3. Engineers shall effort to extend public knowledge and appreciation of engineering and its
achievements.
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4. Engineers shall strive to adhere to the principles of sustainable development in order to

protect the environment for future generations.
Ethics: Ethics is a part of all professional careers, but play an extremely important role in engineering.
In this context , we will discuss the importance of engineering ethics using two case studies.
Design and development of Table and chair

Q5. What are the development steps for PDD?

Solution: Generic product development process
Phase- 1-Planning: Planning activity is initial stages of product design which is approval and launches
the actual product development process. In this process is involving assessment of technology
development and market objective. The output of planning phase is special phase is specific target of
product market and business goals, key consumption etc.
Phase- 2: Concept development: this process has been workout market identified, alternative product
concept development and evaluated. Furthermore, one or two concept is selected for product
development and testing. Concept is described, function and feature of product. Analysis of
competitive and economic justification of product is play major role for verification process.

Phase- 3: System level design: This stage includes definatio0n of product architecture and
decomposition of product into system. It is also final assemble of product is generated; the outcome of
this phase is geometric layout of product, functional specification of each product sub-system and
primary process flow chart. System level design is evaluated product architecture and activity of system
level design.
Phase- 4: Detail Design: detail design process, which is consist of complete specification of geometry,
material and design tolerance of part and identification of standards part purchase from supplier. In this
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process has been done production planning and tool design activity. It is performed fabrication of part
of product. Output of this phase is control documentation for design drawing of part product and
assembly of product. Detail design phase are main focused on production cost, design of manufacturing
and robust performance.
Phase- 5: Testing and Refinement: the testing and refinement which is involving construction and
examination of pre-production of product. ―This is also called ( ) alpha-prototype‖. Alpha prototype is
determined whether the product will work and product satisfies customer needs. After that alpha tester
test the assembly of part product prototypes. - Prototype is testing prototype model in present of
costumer at market place. The target of - Prototype testing is to achieve good performance &
reliability of final product.
Phase- 6: product ramp-Up/production deployment:
Product ramp-up does mean that finishing the manufacturing process. It is work out remaining
production process and product is launched.

##---------------------------------------END---------------------------------------------------------##
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Assignment –II
.

Q1. What is planning for re-developing product?

Solution: Various phases of product development planning for product
the various phases of product development planning for product (a Table) as following:

Step-I Identify Opportunity:

These stages have been initiating identification of product development opportunities. The new product
has been including following factor or resources:
-Marketing and sales
-Research and Technology development organization
-new and recent product development team/ staff
-manufacturing and operation organization
-Potential customer
-supplier (Material) inventor and Business partner
-The product life cycle for design and improvement of product.
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New opportunity related some points have described as follows:

-modified the product according to complaint of current customer/user the product
-modification done by conducting interview of lead user for existence of product
-consider the changing the lifestyles, demography and technology of exist product
-systematically collected suggestion from current customer/service This is new
-carefully study of competitors (Competitive Benchmarking) Opportunity
-Search Technology for current situation and use current R&D technology. Of product
- To make data-base of opportunity (sorting and refining opportunity, & Development
it‘s expanded & explore idea)

Design and development of new product like office Table as shown in fig. 5
Product Name-Office Table;
Identify the opportunity:
1] To study the market this type of table is available or not,
2] If available, to find drawback of exists Table in market, and Create document
-Documents: - Bill of material , ,quantity of parts, assembly of parts likewise.
-Find raw material –select according to minimum cost with high strength
Opportunities – new developed design with high quality of Table as per market value.

Document of product: Bill of material

Material Steel, wood
part name Wood plate, ledge and structure of
table
quantity of parts 4-Ledge,1-plywood plate
assembly Total part is assembled to make table

Load of each ledge

=221N

P=90 kg=90x9.81
=883N

20 cm

W=20cm 20cm
D=1.25cm

Load
reaction=221
R1=221 R2=221
N N
N
Fig.5 Engineering design of chair
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Step-II Evaluation and Prioritize project

The first step has been got hundreds of opportunities collected. Now these stages have to select and
evolution of opportunities for new product development (Office table). In this regard four basic
prospects are use full for evaluating and prioritize new product (office table) as follows:

Competitive strategy

Market Segment

Second Phase
Technology Trajectories

Product platform

Competitive strategy: ―the basic approach to markets and product with respect to competitor‖. The
competitor is listed below.
-Technology leadership: - this activity done by R&D of new technology and concept of technology for
product development.
-Cost leadership: -in this process major role of production cost of product, such as low-cost labor, better
management, superior manufacturing method. This strategy is used to deployment of product.
-Customer focus: costumer focus strategy is close with new and existing customer to assess their
changing need. Product design can change according to customer point of view.
Market segment: -
The customer has to large market area. This large market is divided into small group is known as
segment market. Product opportunity = weakness of product for competitor.
Find weakness of competitors product, these are implicated in our product and our product become high
in market place.
STEP-III Allocate Resources and planning Time
Resources allocation: large number of projects is available with development resources. Skilled take
longer to complete product to market. When profit is longer than aggregate planning is to provide the
resources new product development.
-Find-out requirement of resources for each product planning by month or years.
-The critical resources are required for planning such as shop facilities, rapid prototyping equipment,
pilot production line, testing facilities
-Estimate resources are required based on capacity ratio (demand/capacity)
Project Timing: it is also called pipelined management, that are involving various factors
-Timing of product information: - the defected product can be marketed, then product reputation is bad
and market fail.
-technology readiness: high quality of production technology is critical planning process. Product has
better quality and reliably.
Product plan: it is defined as set of project approval by planning process in sequenced time. The plan
may include a mix of new product, platform project, and derivative of project. Project plan is updated
on time basis (Monthly, quarterly, and annually) dependents upon organization.

STEP-III Complete pre-project planning

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This activity is involving small, cress functional team of people. Core team consists of 30-people
presenting technical expertise, marketing, manufacturing and services function. All are describing
product vision and mission statement. Product vision statement = develop network, mid-range, digital
platform for imaging, market and finishing.
Product mission statement: - product mission statement may include some following information
1] Brief description of product= in this activity is identified the basics function of product.
2] Benefit proposition: this is hypothesis of product which is validated during concept development.
3] Business goals: project is function of time, cost and quality. Market target is known as business goal.
4] Primary market: capture 50% product in sale in primary market, market should environmentally
friendly and location of market office is near to network area.
5] Stake holders: - porches and users, manufacturing operation, services operation, distributors,
resellers.
STEP-V reflect on the results and process
This is final stages of planning and policy process
-product opportunity
-Competitive strategy of organization
-Resources allocation
-Partnership and supplier
-Accepting challenges of mission statement
-Develop best possible product
-Product planning should be improved
All above point should cover planning process

Q2. What is concept development and evaluation process for product?

Solution: A)Concept Development

o A product development process is sequence of activity which creativity emloys to consider,

design and commercialize a product. Every organization employs a process at least slightly
different from that of every other organization . developmet of product should focus on, a)
Qulity assurance : this is work on qulity of product. b) Coordination: all developmet taem should
co-ordinate ot each othr , c) planning: this is time management tool and to make schedule of
overall development project. d) improment : the cearful documentation of product development
process and identify improvement opportunity. E) satisfaction: this is out come of effort by all
team members. It is maintain and enhancing enthusiasm and satisfaction of taem member.
The new concept has been developed by employed following steps:
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Design 1 2 3 ------------ m
option

Customer
requirement
option

F1 O11 O12 O13 ------ O1m

F2 O21 O22 O23 ------ O2m

F3 O31 O32 O33 ------- O3m

; ; ; ; ----- ;

Fn On1 On2 On3 ----- On,m

Where, Oij = solution option

Fi = sub-function (function of function).
It is finding main function and sub-function with respect to option solution.
For example, manufacturing office Table, This table shows number of option for official table design.
This table is called morphology chart/matrix.

Step-1 : Develop concept of each function

 This step is selecting /identify concept from many possible solutions. Above matrix select each
concept form sub function. For example, official Table design has no. of option like -plywood, steel
sheet, ss-plate; plastic of function of function is Table plate materials. Above matrix function of
function is, Table plate material, Table ledge shape, Table ledge Cap shape and respective option is
given.
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Step-2 : Sub-function list of all method

 This step represents study the solution of sub-function. Suppose F1 = Table plate material has
multiple solution like plywood, steel sheet, ss-plate; plastic. So, we have to select more appropriate
option of sub-function.

Step-3 : Draws the chart containing all possible sub solution

 Sub-function versus list of solution option is called morphology chart. This chart constructed form
sub-function list. Each row consists of number of possible solutions W.R.T. sub function. This chart
develops according to available option of product.

Step-4 : Identifies feasible combination

 After completion of morphology matrix/chart, the next combine the individual concept into
compensate conceptual design. Method is to be selected one concept for each section /function
For example, selection of option by given symbol

Select option for design the office table function ia as shown below table.
Sub-function Select option

Table plate material Plywood

Table ledge shape Square shape

Table ledge Cap Conical shape

Shape

B) Concept Evaluation
 This activity work on following points/objective of concept evaluation :
1. Use different method to evaluate different concept
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2. Select design alternatives for next development

3. concept evaluation means eliminate the alternative solution of sub function. This is idea
eliminating method and its select for best according to customer requirement
4. Concept is directly measure with respect to customer specification. If not match requirement that
concept are remove.
5. Design team have large amount of experienced on that examine concept eliminated. This method is
totally judgment of product feasibility. Method is select compare which is best/sound on
technological based.
6. Concept are evaluated with respect to each other using criteria –i.e. Pugh concept section

Q3. How do you Develop descript and prescript design model for product?
Solution: Descriptive and Prescriptive Product Models
 The deceptive and prescriptive model is developed for table design. First descriptive model is based
upon model preparation and section. Second prescription is based on actual practice of an Office
Table model.
 The basic product design model approach has been considered following steps/processes for an
office table.

Step-1 : Identify the Functional Requirement

 Identified the functional requirement of development of an official table, this is first stage of design
of table. Find the material, customer specipfication, and correct manufacturing process.
Customer need Actual product specification is implemented

1) Size of an office table Size is proportional to all aspect

2) Color of Table Red/ Brown/ White /black

3) Geometric dimension of table Length ,width, height, thickness of plywood

4) Manufacturing process Metal cutting, welding, grinding, polishing and

painting color.

5) Working strength and weight capacity Actual weight carrying capacity, 10, 20, 50Kg.
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6) Cost Low cost as per market value.

7) Working life 1-year warranty/ free maintenances

Step-2 : Identify the Relationship of Design Parameter

 This stapes has considered the material strength relation and manufacturing process for developing
an official Table. Table frame materials – low carbon steel, plastic, fiber reinforced etc. hammer is
required for maintain run out of frame bar/tube/small pipe. Force required for Lifting or moment of
table is low or lighter, heavy or medium.

Step-3 : Identify the weight balance : as shown in Fig.3 for mass balance of Table
 The weight balance concept is state that, what amount of mass (kg) is carry out? and what direction
of load is applied to table?
 Used equilibrium concept of finding reaction of table is,
F = 0,  Weight =0,
10kg load is applied at center of table to find all support reaction of each ledge as following :
mass = 10kg ,
F = mg = 10  9.81 = 98.1 N;
Applied equilibrium concept for this table
F = 0, R1+R2+R3+R4 – F=0
 R1 = R2 = R3 = R4 = R
F = F = 98.1 = 4R
F 98.1
 R = 4 = 4 = 24.525N

Fig. 6 Mass Balance for

Step-4: Formulate Mathematical Equation for Design of Table

The table consist of top plate and ledge of table as bar element , so required elastic equation for plate
and table ledge as
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Weigth (W)

(h)

Width (b )

Fig7. mathematical model for table

Step-5 : Explore Design Configuration

In this method has focuse on some design modifed product model. The detail process is given by as
following flowchart Fig8.
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1- Identified customer need and Engineering specification

2- desired input and output

Observation 3- Identify physical mechanism Experiment &experance

and literature

4-target of precision M/c element,dynamics,

mechanisam ,
kinematics, solid
mechanics ,modeling
5-constuction of model tool

6-Dimesional analysis ,simulation and group of

variable

FEM,finite
7-implment computationaly (search and discretize ) defference

Cheak model Tune model,procedure

8-Introgate the model calibrate modal
validity and
geometery Data

9-Use the model Design choise ,optimization

Inraction
Process control,
plot,graphics,limit geometry

Fig8. descriptive model for product

The descriptive model has been explained in detailed in following steps:

Step-1 identify the effect (need of customer and specification): this is maping tool to map customer
need to functional design parameter w.r.t. engineering specification.

Step-2 identify flow: in this stages needed identify the material, energy ,and power consumption (I/P)
of product. This is function of product design model, which understand the input and output
transformation,efficiency and qulity of product.
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Step-3 identify physical mechanism : the product has work on actual envoroment and physical
condition. At this stages physical model is function of functional design of product.

Step-4 Target precision: once identify physical mechanism and flow matrix, then requirement of a
creay of product model. This is design decision model ,which is based on effective results. Usuly
target precision is presented in persentages (%) of product model.

Step-5 construct boundary and balance relation : this step which represented governing equation and
boundary of product. This also shows relation between verify of product design and boundary .
the construction boundary and balance is predicted persentag of accuracy based on
simplification and assumption of product model. This step solve mathematical simulation
equation.

Step-6 dimnsional analysis: this is mehematical model which is interduce geometrical properties and
dimension of product. Number of dimensional quantity is arrange from sequencial order . this
also unit conversion process. Large quantity is convert ioto small scale.

Step-7 implement computationaly: this is numerical itration based model, it is work on repitation for
same inerval to specific output. For example , FEM(finite element method), finite different
method ,newton raphason method,forword difference method etc.

Step-8 Interrogated model: this model is studied simplified , verified and tested product model. This is
also find first orderd solution by using mathematical theory. Physical data can be calibrate and
validate the model. During calibration estimate the unknown constant and model order.

Step-9 use the model: after interrogation ,validation and calibration model is ready for use. In this
stage identify design parameter like kinematics motion, limit of geometery and validity. After
final design of product model can be optimize based on primery variable. Select process
contriling parameter for use.

Q4. How do you construct the house of quality for design product?
Solution:
 The house of quality offers several advantages. The first benefit comes from simply creating the
diagram. Employees from different departmentscome together and collaborate on the house of
quality. This inevitably leads to constructive discussions. The input from different departments
ultimately ensures a high-quality, long-lasting, and successful product.There are also advantages
once the house of quality is fully completed. Thanks to visualization, a lot of important information
for planning and development is available at a glance. The detail all HOQ is given fig. 9 for product
development.
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Fig. 9 HOQ for new product development process

Room no 1. : Customer requirement : in this room collect list of customer requirement of product,
understand the need of customer and make list of design specification
Room no 2. :Competitive assessment : this tool show top two to three competitor product ranks with
respect to customer requirement satisfy. Rank or rating of customer is give 1 to 5 number in table.
Room no 3. :Importance rating : this is detail given in example next page.
Room no 4. : Engineering Characteristic (EC) : the list of product feature according to technical
point of view. It is target oriented terms like, force, velocity, density, etc.
Room no 5. :Correlation matrix : it is shows number of independent parameters in the roof of house.
This grading 1 to 9, 1 means low Rating and 9 = high Rating, 3 = medium rating.
Room no 6. : Relationship matrix : it is map EC and CR (customer requirement). This is rating scale 1
to 10. See next example.
Room no 7. : Absolute important : it is calculated some value by using next page.
Similarly,Room no.8 and9 is Relative importance and Set target respectively see in next example.
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Important ratio = (customer important)  (improvement)  (Sales point)

Important ratio for tensile strength = 4  1.3  1.5 = 7.8 ---- similar all customer requirement
Each value important ratio
Relative ratio = Sum of all Important ratio

For example = First raw

7.8 6
= 0.211325 ;
36.91 36.91 = 0.162558;
Absolute importance (row) = relative ration  sum of all cell in relationship matrix
9  0.211325 + 8  0.163 = 3.21
5  0.211325 = 1.06
9  0.176 = 1.584
6  0.107 + 6  0.194 = 1.81
8  0.94 = 7.52
9  0.15 = 1.35
Each cell in Absolute importance
Relative importance = Total sum of Absolute importance

Total sum of Absolute importance = 16.534

DMCE PDD lab manual-2

Calculated Relative importance for all cell as following:

3.21 1.06 1.584 1.81 7.52 1.35
16.534 = 16.534 = 16.534 = 16.534 = 16.534 = 16.534 =
0.194 0.06 0.096 0.11 0.45 0.082
 Selection of engineering characteristic, this is based on value of absolute importance row from total
house quality matrix. Observing matrix, we got absolute important row values is 3.21 and 1.81 so.
Light weight and feel comport is selected for design office Table.

Q5. How do you concept selection matrix for product?

Solution: Concept selection method :

―concept selection is the procrss of evaluating concept with respect to customer need,strengths and
weakness of concept and selecting one concept for develoment ‖. concept selection is one of the
ctivity in concept development phase. Concept selection means to minimise the option or idea
which is based on costomer requirement or specification. Concept selection has two part , concept
screening and concept scoring

Concept selection

concept screening concept scoring

Concept scoring :
1-prepare the section matrix

2-rate the concept

3-rank the concept

4-combine and improve the concept

5-select one or more concept

Step-1 Prepare the section matrix: Develop Decision Matrix

 This is part of evaluation of concept by given customer rating. The decision matrix is minimizing
the idea or selection best idea by using mathematical calculation. The details are given below for
office table design. The customer rating is given during market survey as following:
DMCE PDD lab manual-2

 Customer rating list

Customer speciation % Rating for customer during market survey

Use of standard parts 8%

Safety design 12%

Simplicity and maintenance 10%

Durability 10%

Public acceptance 18%

Reliability 20%

Performance 15%

Cost to development phase 3%

Cost to buyer 40%

The different Design concept of Office Table is given in below

Fig.2.5.2 multiple concept for designing Table

To develop Detail decision (selction) matrix for Office Table according to customer rating during
market survey
DMCE PDD lab manual-2

Table 2.5.1 Selction matrix

development phase
Public acceptance
Design

Total sum W.F.

criteria

Simplicity and
Use standards

Cost to buyer
Safety design

Performance
maintenance
Durability

Reliability

Cost to
Concept
parts

Option

0.08 0.12 0.1 0.1 0.18 0.2 0.15 0.03 0.4

Weight
ratio
Concept -1 Rating 3 5 2 4 9 6 1 1 3 5.64
W.F. 0.24 0.6 0.2 0.4 1.62 1.2 0.15 0.03 1.2
Concept -2 Rating 9 10 10 8 6 7 10 10 8 11.2
W.F. 0.72 1.2 1 0.8 1.08 1.4 1.5 0.3 3.2
Concept -3 Rating 5 6 7 7 8 6 3 4 5 7.73
W.F. 0.4 0.72 0.7 0.7 1.44 1.2 0.45 0.12 2
Concept -4 Rating 8 10 9 8 9 10 10 9 8 12.13
W.F. 0.64 1.2 0.9 0.8 1.62 2 1.5 0.27 3.2 Select

Step-2 Rate the concept: this criteria is based on customer rating on your concept see Table 2.5.1 each
concet has rating out of 10. This is given from coustome in the survy activity. For example ,
cocept1 has rating first raw of selection matrix Table 2.5.4 with respect to design criteria , similarly
concept-2,concept-3 and concept-4.
Step-3 Ranking of concept: this step is focus on calculation of Weight factor or Weight ratio. The all
calculation is given for Table 2.5.1.
Weight factor (W.F) = weight ratio  rating value
The calculation of above matrix weight ratio is,
8
8% = 100 = 0.08

12
12% = = 0.12
100
10
10% = 100 = 0.1

10
10% = 100 = 0.1

18
18% = 100 = 0.18
DMCE PDD lab manual-2

20
20% = 100 = 0.2

15
15% = 100 = 0.15

3
3% = 100 = 0.03

40
40% = 100 = 0.4

W.F. for Concept -1

0.08  3 = 0.4
0.12  5 = 0.6
0.1  2 = 0.2
0.1  4 = 0.4
0.18  9 = 1.62
0.2  6 = 1.2
0.15  1 = 0.15
0.03  1 = 0.03
0.4  3 = 1.2
Sum of W.F. = 0.24 + 0.6 +0.2 + 0.4 + 1.62 + 1.2 + 0.15 + 0.03 + 1.2 = 5.64
Similarly, all concept sum of weighting factor are calculated in given values.

Step-4 combine and improvement the concept: This stages concept has may chance of combine and
inprove the cocept for final section. In this regards concept is some change or modified according to
customer requirement.
Step-5 select one or more concept:
Concept selection Criteria: the final selection of concept which is based on Sum of total weight factor is
maximum. So given design concept-4 is selected for final production. the sum of W.R. maximum value
(i.e.12.13 ) as shown Table 2.5.2. The select concept 4 this is shown fig.2.5.2

##--------------------------------------------END ------------------------------------------------------##
DMCE PDD lab manual-2

Assignment –III (Mini-Project) Modul-4

Q1. Explain Concept generation of product.
Solution: concept generation

The activity of concept generation is description of the technology ,working principles of product. It is
brief decriptioon of product will satisfy the customer need. A cocept is usually experesed as free hand
diagram and 3D model used. A good cocept is used for development process. The concept generation
activity has been involving 5 to 15% weightage for product development process. The concept
generation process is starting of arrangeing customer need and target specification product. Concept
generation is main activity of product development. The datail flow diagram as shown in Fig.10

Fig. 10 concept generation tool

Step-1 clarify the problem: clarify the problem consist of understanding the problem band product
specification. The concept generation which required knowledge of identify customer need and
product reqirment . gathering information to quantify the need and clarify need to customer.

Decompose the complex problem into simple solution: some product has complex situation exsist.
Then required to special technique is employed to get simple solution. Problem decomposition is
defined as the main problem into simpler subproblem is called problem decomposition.
DMCE PDD lab manual-2

For example ,design laptop

D.C.Supply Converter A.C.to

Energy
D.C. voltage
LOTOP Final
Electrolyte Storage bateries
Electric to chemical solution

Optical mouse Mechanical moment

Oprational
to scane
device

Fig. 11 Energy conversion for laptop

Step-2 search external : externally search is essentially an information gathering process. It is dependent
on time and resourceses .thet can be optimize by using expand aand focuse startagy. Five way to
gathering information from sources : 1] use interview 2] expert consultation 3] patant search 4]
literature search and 5] compitative benchmarking .

Step-3: search internally: search internally is totally persolal and individual level concept generation
process. This activity can be open ended and creativity of new product. This process is caaried out
by using some tool as follows :

1. Suspend judgment: such technique is used to daily life or day to-day lives product
development.

2. Generate a lot of idea

3. Welcome idea that may seen infeasible

4. Graphical and physical media

5. Set quantitative goal

6. Use the gallery method

Step-4Explore systematically: this concept is used for sorting collected information or customer
specification. There are two method , clafication tree and concept combination table.

Clasifiaction tree: 1] mimimize the branch 2] idendification of independent approach 3] refine problem
DMCE PDD lab manual-2

Step -5 : reflect on the solution and the process: This activity focuse on find alternative function ,
alternative resources and generated new idea. This tool are used for refine concept or idea base on
energy consmtion and save time.
Q2. Explain concept development and evaluation of Pugh’s criteria for product?
Solution: Pugh‘s total design activiti model : Method Steps-Wise Solution

Step-1 : choose comparison criteria

 If alternative has same level of requirement fulfilled, then use design criteria.
 Critical- level of importance according to design team, a) absolute factor= this scale from (0 to10)
 b) Relative scale = this is map exact relative to each other than given (100) and less (0 to 100).

Step-2 : Selects the alternative to be compared:

 All alternative generated in morphology chart, some alternative are remove because not satisfy
customer need. Next removing alternatives are finial stage. This stages few alternatives remove
comparative basis. In final stages only select six alternatives for development process.

Step-3 : Genarate score

Score generation is divided into two methods, A) Pugh method

Pugh’s Evaluation Matrix :

 Pugh‘s model is used to minimize the option or alternate solution .pughs matrix rating 0,+,–.
Zero (0) = rating means if option is same reference point/basic line of product
Plus (+) = posion of rating if option is beter than the reference line
Minus (–) = minus rating if option is below or less then datum(reference point) level
 After that concept compare with respect datum level then four score is considered as follows
1) Number of (+) score
2) Number of (–) score
3) Overall total =sum of (+) – Sum of (–)
4) Weighted total = sum of each score X weight factor
 This criterion is applicable to development of office Table product.
DMCE PDD lab manual-2

Create morphology chart :

Pugh’s Evalution matrix for all option:

 The pugh matrix, first column represents customer rating out of 10 for each raw. The customer
gives rating for tensile strength is 7, reliblity of table 10, use to easy 5 and looking of table is 4
,color is 10 and cost is 6. Total weigth is caculetd above formula for all option. The morphology
char represented number of option for each part of component. + sign indicate maximum reting to
customer and – sign indicate less than 0
Coustmer Weight Opt-1 Opt-2 Opt-3 Opt-4 Opt-5
reqirement /10

Tensile strength 7 0 + 0 + +
of material

Reliability of 10 + – + 0 0
table

Use to easy 5 – 0 + 0 +

Look 4 – 0 0 + 0

Color 10 + 0 0 – +

Cost 6 – 0 + 0 +

Total (+) 2 1 3 2 4

Total (–) 3 1 0 1 0
DMCE PDD lab manual-2

Overall total –1 0 3 1 4

Weighted total 5 –3 21 1 38

Weight total calculation in detail given by

Weight total is calulted by using multification and sum of cell in weight column and option column
. take + means +1 and – means -1 sample calculation is given for option-1
Opt-1 = 7  0 + 10  1 – 5  1 – 4  1 + 10  1 – 6  1 = 5
Weight total is calulted by using multification and sum of cell in weight column and option
column . take + means +1 and – means -1 sample calculation is given for option-2,option 3-5.
Opt-2 = 7–10 = – 3
Opt-3 = 10 + 5 + 6 = 21
Opt-4 = 7 + 4 – 10 = 1
Opt-5 = 7 + 5 + 10 + 16 = 16 + 22 = 38
 Above concept selection is based on max Weight value. Hence, we have selected option 5, the
value is 38
 So, option 5 is best for design and development of official Table product.
 Compare with pugh evaluation matrix and morphology chart, and which tatal weighted value is
larger for option that will be select option in morphology chart.
 Present problem we have select option 5 becouse total weigth is 38. Similary you can apply this
technique for all type of product like desing and developmet of chair,laptop,mobile,
cupboard,householding storage device etc.

Q3. Apply creativity method for any product

Solution: find any book

Q4. What is morphology analysis for redeveloped product?

Solution: For example morphology analysis for redeveloped product like (chair )
This criterion is applicable to development of official Table product.
DMCE PDD lab manual-2

Created Morphology Chart

Option-1 Option -2 Option 3 Option 4 Option 5

Table plate Plywood Steel sheet Stainless Plastic pale Polymer

material Steel Fiber
(low carbon) plate(SS-
plate)

Table ledge Pentagon

shape

Cylindrical Square Hexagonal

Diamond
shape
Table ledge Triangular Pentagon
Cap
Hollow Square conical shape
Shape cylindrical
DMCE PDD lab manual-2

Assignment –IV (Mini-Project)

Q1. What is detail design specification of product?
Solution: Product Design Specification
The process of target specification contains four steps :
1) To make list of specification of product
2) The information regarding competitor
3) Set tentative acceptable target
4) Reflect on the results and process
Step-1 : To make list of specification of product : customer need is expressed in language, that
should list out on customer need table. The detail customer need table is shown below for developing
official Table.

Need Detail description of need value Value Unit

Number

1 Light weight of official Table 10 kg

2 High ultimate tensile strength 250 MPa

3 Looking with color - Excellent

4 Low cost 2000/- RS RS

5 High stiffness of frame of official Table 100 N/mm

100

6 Table Cap strength by using rubber 50 MPa

material

7 Bending strength of frame structure of 250 MPa

Table

8 Corrosion resistance material --- Coating-redox ide

9 Handling with easy & required force 10 N

10 Height of Table 4.5 Feet

Step-2 : The information regarding competitor : in this stage collect the informant about present
product in market . Then prepare competitive benchmark chart: as shown below
Need Description of need Value unit Competitor value available in market
1 Light weight 10 10 Kg 10 20 30 40
2 cost 2000/– Rs 3000 2500 4000 40
DMCE PDD lab manual-2

3 Stiffness of frame 25 N/mm 40 30 35 5000

4 W/L ratio of Table 1.1 1 1.5 2 2.5 50
Step-3 : Set Ideal and Marginal Acceptance Target Value : in this step can analysis of the actual
value of product in market corresponding to customer requirement/specification. The ideal value and
marginal value of product is given table below
Need Unite Marginal acceptable value Ideal value
Light weight kg 12 15
Cost Rs 2000 4000
Stiffness of frame N/mm 200 175
W/L ratio of table Mm/mm 1.1 1
Ideal value = depends upon best results
Marginal value = actual market value of product in market place.
Set Target of Product Based On Following Criteria:
1) At least value of (X): the target value is lower, therefore X = need of customer. (cost=2000/-)
2) At Most value of (X); the target value is large, (X = cost = 4000/-)
3) In between value of (X): set value of cost is in between 2000 to 4000, X =3000/-
4) Average value of (X): set target value of light weight of table, as given customer need, 10, 7,9 ,8,
11 kg. avg (X) = (7 + 8 + 9 + 10 + 11)/5 = 9 kg , set target value of light weight is 9 kg.
Step-4 : Reflects on the results and process : this process is verification of target value based on
customer reply.

Setting the Final Specification

Four steps of setting the specification of product as follows :
1 Develop technical model of the product
2. Develop cost model of product.
3. Refine specification
4. Flow down specification as appropriated.
5. Reflect on results and process
Q2. Apply the principle of industrial design method for any product.
Solution: Industrial Design:
the detail stepwise solution is given according to industrial design aspect. Industrial design for PDD
process :
- Industrial design principle: large manufacturing plant have separate industrial design departmental and
small company use contract service from industrial design. Industrial design should have special interest
on functional product development. The Engineer has generated and evaluate concept of product
development process. The industrial designer should follow designing aesthetic and ergonomic of
product. It has generated multiple concepts based on following points:
DMCE PDD lab manual-2

Investigation of customer need

Conceptualization

Preliminary refinement

Further refinement and final concept selection

Control drawing and model

Co-ordinate with engineering manufacturing

and external vendor

1] Investigation of customer need: industrial design team beginning with need of customer voice of
customer. The customer needs office Table use in official work. Then research teams go to customer
office and see the location, design specification or dimension which required for design official Table.
Industrial designer is studied on conducting customer interview and group discussion regarding
manufacturing of office table product. When, customer requirement is given to industrial design
department, then I.D. (industrial Design) start with aesthetic and ergonomic consideration of official
Table. I.D. is involving critical customer need.
2] Conceptualization:
First stages we got information or need of customer then industrial design starts with develop
conceptualize product. During concept generation process, design engineer is major attention on finding
technical solution of product. I.D is focused on creating product for user interface industrial engineering
produce free hand sketches (thumbnail sketches) of each product concept.
DMCE PDD lab manual-2

The I.D. is work on color and looking good of chair . The free hand sketch is shown in fig. 11

Load of each ledge

=221N
P=90 kg=90x9.81
=883N

20 cm

W=20cm 20cm
D=1.25cm

Load
reaction=221
R1=221 R2=221
N N
N

11.Free hand sketch of chair

So, industrial engineer is involving concept generation, looking and appearance good.
3] Preliminary refinement: in this phase industrial designs make concept models. Next step makes soft
model and evaluation of concept. 3D models are developed for expressed and visualization of product
concept, such activity initiated by development team. Concept evaluation by industrial designer, these
are mainly attention on marketing, feeling and modifying product model. Designer will be created for
depending on time and financial aspect, model should be simple in nature.
4] Further Refinement and Final Concept Section:
In this stage, industrial designer switch from soft model to hard model according to free sketcher. The
final refinement step before selecting concept is to create hard model. The hard model is very realistic
looks and feel. They are made up of wood dense foam, plastic and metal. Painted and textured model is
good and feeling well. The actual types of products, hard model is fabricated to have small size, density,
weight density, surface and color. Hard model is used to industrial designer to further refine and
concept specification. This model is also help of customer feedback, advertised the product and trade
shows sell order.
5] Control Drawing or model: I.D. are required control drawing or model for final development
process. Control model which has to follows functionality, features, size, colors, surface finish and key
dimension. Only required engineering drawing, and then can be fabricate final design model or
prototypes. This model/drawing are prepared by design engineer. The detail drawing is given as shown
fig. for office table product.
DMCE PDD lab manual-2

Width (w) of plywood plate

Length of plywood (L)

Height of Ledge (h)

Sr. No. Name of part quantity Material

1 plate 1 plywood
Diameter Ledge (d) 2 Ledge 4 steel
3 Ledge cap 4 Rubber

Inner diameter (d1)

External diameter
Cap Height
Of ledge Cap(D1)

6] Coordination with engineering, manufacturing and External Vendor:

Industrial designer is continuous work with engineering manufacturing department throughout product
development process. Industrial designer should consult to engineering design section and management
of materials, tooling, and component and assembly services.

The two types of external vendors as follows: technology driven and user-driven.
Technology Driven User-Driven
Identification of customer I.D. has no involvement Customer interview &
need marketing
Marketing &engineering: Generated multiple
Concept generation -human factor are concepts to I.D. process
&selection addressed &safety, flow
material handling issue
Concept Testing I.D. helps Engg. to create
considered I.D. Leads in creation of
hard model & shows model to be tested with
customer
I.D. has feedback
less customer in market
System level Design I.D. has minimizing
involvement concept & refinement
processing approach
Detail design, testing & I.D. responsibility for Select fine concept
refinement packaging product has coordination with Engg.
need addressed. I.D. Manufacturing &
received product marketing to finalize
specification & marketing
design.
requirement.
DMCE PDD lab manual-2

Q3. Consider the human factor for designing the product?

Solution: refer to use book

Q4. Design for environmental is to be considered for re-developing product?

Solution: refer to any book