Design & Analysis Design & Analysis Applications Applications

in in Industry & Senior DesignIndustry & Senior Design

Hodge Jenkins, Ph.D., P.E.Hodge Jenkins, Ph.D., P.E.

Associate Professor of Mechanical Associate Professor of Mechanical EngineeringEngineering

Mercer UniversityMercer University

Product or Process Design Product or Process Design in Industryin Industry

�� Project initiated by product, or process goalProject initiated by product, or process goal�� Design process motivated by Design process motivated by

new product/process specificationnew product/process specification•• Target new markets.Target new markets.•• Target new markets.Target new markets.

•• Reduce costs.Reduce costs.

•• Improve product specifications for customer or marketing Improve product specifications for customer or marketing demands.demands.

�� GenerallyGenerally, design is an , design is an enhancementenhancement to product or to product or process as opposed to a brand new designprocess as opposed to a brand new design..

Design is a Process in Industry Design is a Process in Industry

�� Feasibility StudyFeasibility Study

�� Assemble Technical TeamAssemble Technical Team

�� Develop Project ScheduleDevelop Project Schedule

�� Design & ImplementationDesign & Implementation�� Design & ImplementationDesign & Implementation�� Brainstorming, Designs, Analysis, Brainstorming, Designs, Analysis,

�� Selection, Approval,Selection, Approval,

�� Prototype, TestPrototype, Test

�� Assessment of ResultsAssessment of Results

�� Repeat as necessaryRepeat as necessary

Feasibility Study is Feasibility Study is Made 1Made 1stst

�� Determine impact of proposed new Determine impact of proposed new process/product/features.process/product/features.

•• New competitive edge, increase market share.New competitive edge, increase market share.

•• Open new markets.Open new markets.

�� Estimate rough costs and potential scheduleEstimate rough costs and potential schedule..Estimate rough costs and potential scheduleEstimate rough costs and potential schedule..•• Is it physically possible? How long will it take? Is it physically possible? How long will it take?

•• What will it take ($ and time)?What will it take ($ and time)?

�� Assess whether design is economically worthy?Assess whether design is economically worthy?•• Implement or discard the idea. Implement or discard the idea.

•• Return on Investments (Return on Investments (ROIROI), Timing, (>30% ), Timing, (>30% ROIROI is often required)is often required)

•• (Limited engineering, accounting, manufacturing resources.)(Limited engineering, accounting, manufacturing resources.)

Assemble Technical TeamAssemble Technical Team

�� Assign members from different appropriate Assign members from different appropriate disciplines:disciplines:

�� EngineeringEngineering

•• ME, CE, EE, IE, etc.ME, CE, EE, IE, etc.•• ME, CE, EE, IE, etc.ME, CE, EE, IE, etc.

�� IT professionalsIT professionals

�� Technology specific vendorsTechnology specific vendors

�� ConstructionConstruction

�� Accounting, Marketing, etc.Accounting, Marketing, etc.

�� Project ManagerProject Manager

Develop ProjectDevelop Project ScheduleSchedule

�� Design and AnalysisDesign and Analysis ::(Typical projects)(Typical projects)•• ProductProduct

•• Manufacturing processManufacturing process

•• Product data flowProduct data flow

�� Prototyping/ProvePrototyping/Prove--ininTim

e

�� Prototyping/ProvePrototyping/Prove--inin

�� Facility construction/equipment installationFacility construction/equipment installation

�� Testing and Analysis of ResultsTesting and Analysis of Results

�� Refinement of Design and ProcessRefinement of Design and Process

�� Production TrialsProduction Trials

�� RTM (Ready to manufacture)RTM (Ready to manufacture)

Design and Analysis Design and Analysis Requirements in IndustryRequirements in Industry

�� Quantity mattersQuantity matters

�� How many are we going to make?How many are we going to make?•• Is the design for a product? Is the design for a product?

•• How big is the market? How big is the market?

•• Is the design for an internal use production machine?Is the design for an internal use production machine?•• Is the design for an internal use production machine?Is the design for an internal use production machine?

Design and Analysis Design and Analysis RequirementsRequirements

(How much analysis to do?)(How much analysis to do?)

�� Safety, Cost, and Quality matterSafety, Cost, and Quality matter�� How costly is a mistake?How costly is a mistake?

•• Is personal safety affected by this design? Is personal safety affected by this design? (aircraft part, high speed equipment).(aircraft part, high speed equipment).(aircraft part, high speed equipment).(aircraft part, high speed equipment).

•• Is the cost of repair large? Is the cost of repair large? (Space shuttle, Hubbel telescope, production down(Space shuttle, Hubbel telescope, production down--time)time)

•• Is the item a critical component of an expensive system Is the item a critical component of an expensive system (manufacturing line, luxury vehicle)?(manufacturing line, luxury vehicle)?

Why Simulate Why Simulate & Analyze?& Analyze?

�� Determine what Determine what isis the problem to be solved.the problem to be solved.Obvious Obvious symptom symptom or solution may or solution may not not be be right right oneone..

�� Cannot test everything (e.g., earthquakes, wind, etc).Cannot test everything (e.g., earthquakes, wind, etc).

�� Analysis takes less time than build & testAnalysis takes less time than build & test

Virtual prototyping Virtual prototyping costs lesscosts less than buildingthan building�� Virtual prototyping Virtual prototyping costs lesscosts less than buildingthan building

�� Evaluate Evaluate moremore potential solutions.potential solutions.

�� See what See what newnew problemsproblems the solutions cause.the solutions cause.

�� Explore multiple solutionsExplore multiple solutions:: Determine best designDetermine best design�� Merit Analysis (Decision Matrix)Merit Analysis (Decision Matrix)

�� Controlled Convergence of a workable solutionControlled Convergence of a workable solution

Types of AnalysisTypes of Analysis

�� Product/process Product/process functionfunction & & performanceperformance�� Does it work like it should? New features?Does it work like it should? New features?

�� Is it faster or ‘better’ than other solutions?Is it faster or ‘better’ than other solutions?

�� Product/process Product/process integrityintegrityWill it fail under some potential conditions?Will it fail under some potential conditions?�� Will it fail under some potential conditions?Will it fail under some potential conditions?

�� Will it last long enough?Will it last long enough?

�� Product/processProduct/process human impacthuman impact�� ErgonomicsErgonomics

�� SafetySafety

�� Environmental effect (production & disposalEnvironmental effect (production & disposal))

�� Societal problems createdSocietal problems created

Types of Design AnalysisTypes of Design Analysis�� SingleSingle--answer analysisanswer analysis::

�� Hand Hand calcscalcs: A 600 lb. container is supported by the 3/8” rope. : A 600 lb. container is supported by the 3/8” rope. Determine if rope fails.Determine if rope fails.

�� Do I have a large enough power supply? (V*A)Do I have a large enough power supply? (V*A)

�� Performance analysis:Performance analysis:

: : FEAFEA�� Strength & Mechanical AnalysisStrength & Mechanical Analysis: : FEAFEA (Pro/E, (Pro/E, AnsysAnsys))

�� PP--Spice, Spice, MATLABMATLAB: Will new CPU work, be fast enough? : Will new CPU work, be fast enough? Is robot stable?Is robot stable?

�� Arena, ExcelArena, Excel: Can the plant produce more?: Can the plant produce more?

�� Ergonomics (Human Data)Ergonomics (Human Data)::

�� Size, force requirements, heights, etc.Size, force requirements, heights, etc.

Design and Analysis EffortsDesign and Analysis Efforts

�� High Design and Analysis EffortsHigh Design and Analysis Efforts::�� Inexpensive, high volumeInexpensive, high volume products (Telephones, razors)products (Telephones, razors)

�� Low volume, Low volume, critical productscritical products (NASA rocket, nuclear power plant)(NASA rocket, nuclear power plant)

�� Safety related productsSafety related products (elevators, eye lasers, hard hats, ladders )(elevators, eye lasers, hard hats, ladders )

�� Unable to test adequatelyUnable to test adequately (deep sea, costly production, etc.).(deep sea, costly production, etc.).

�� Senior design projectsSenior design projects�� Senior design projectsSenior design projects

Industry Design Example:Industry Design Example:Safety Related ComponentsSafety Related Components

�� Nuclear Power Plant ComponentsNuclear Power Plant Components�� Required by US Code of Federal Regulations Required by US Code of Federal Regulations

•• (e.g., 10CFR50)(e.g., 10CFR50)

�� Potential (hypothetical) failures are analyzed.Potential (hypothetical) failures are analyzed.�� Loss of coolant accidents (LOCA)Loss of coolant accidents (LOCA)

�� EarthquakesEarthquakes

�� Operational transientsOperational transients

�� Extensive modelingExtensive modelingand simulation. and simulation. (FEA, CFD, FMA,(FEA, CFD, FMA,PLC simulations)PLC simulations)

Industry Design Examples:Industry Design Examples:Large Volume ProductLarge Volume Product

�� Every year the USA produces:Every year the USA produces:�� 1 billion foil1 billion foil--lined fruit juice boxes lined fruit juice boxes

�� 25 billion styrofoam cups 25 billion styrofoam cups

�� 1.6 billion disposable pens 1.6 billion disposable pens

�� 2 billion disposable razors 2 billion disposable razors

16 billion disposable diapers16 billion disposable diapers�� 16 billion disposable diapers16 billion disposable diapers

�� High volume allows the cost of design and analysis to be spread High volume allows the cost of design and analysis to be spread over a large number of pieces.over a large number of pieces.

�� A mistake would be repeated millions or billions of times.A mistake would be repeated millions or billions of times.

�� Manufacturing tooling is expensive.Manufacturing tooling is expensive.

The Gillette Mach3TurboThe Gillette Mach3Turbo

�� Gillette's tripleGillette's triple--blade shaving system is “the most blade shaving system is “the most technologically advanced shaving system in the technologically advanced shaving system in the world provides a number of important world provides a number of important designdesignfeatures.”features.”

•• Protected by Protected by 45 patents: 45 patents: ”innovations, including new Anti”innovations, including new Anti--•• Protected by Protected by 45 patents: 45 patents: ”innovations, including new Anti”innovations, including new Anti--

FrictionFrictionTMTM blades, an ultrablades, an ultra--soft protective skin guard, a soft protective skin guard, a patented Indicator® lubrication system and an improved razor patented Indicator® lubrication system and an improved razor handle.”handle.”

•• $$300 Million 300 Million Development CostDevelopment Cost

•• Generated $300 million Generated $300 million in sales the first yearin sales the first year

Gillette FusionGillette Fusion

�� 5 Blade Shaving Surface™ Technology 5 Blade Shaving Surface™ Technology

�� Protected by more than Protected by more than 70 patents70 patents, granted or , granted or pending pending pending pending

�� P&GP&G has about has about 27,000 patented 27,000 patented technologies.technologies.

�� 550 new patents550 new patentsin 2010 for in 2010 for P&GP&G ..

The Design and Analysis approach The Design and Analysis approach changes with technology changes with technology

�� New design software tools.New design software tools.

�� New easy integrated analysis softwareNew easy integrated analysis software�� (e.g.,P(e.g.,P--spice, Pro/Engineer, Ansys, CFX, Simulink…..)spice, Pro/Engineer, Ansys, CFX, Simulink…..)

�� Skill level requirements are lessening.Skill level requirements are lessening.�� Skill level requirements are lessening.Skill level requirements are lessening.

�� Smaller cost to analyze. Smaller cost to analyze.

�� More cost to create and testMore cost to create and testthan to than to virtual prototypevirtual prototype..

�� Direct Digital ManufacturingDirect Digital Manufacturing

Modeling and Analysis Time Modeling and Analysis Time Decreasing with Technology!Decreasing with Technology!

AnalysisModel

Simulate design before buildingSimulate design before building

CLADX&

COREX&

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TCORE

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Clad Torch Pull Speed(Constant)

Core Growth Rate(Pull Speed)

∫

xCORE

xCLAD

-LCORE

H2 Flow

+

LO

+

G XDOT,T

GLCORE,TEMP

+

+

∆L

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TCORE,H2

GTEMP, H2

∆TCORE,∆L

TCORE

COREX&TCLAD

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Fix errors

OptimizeParameters

DANGER!DANGER!�� Inaccurate /over simplified modelsInaccurate /over simplified models

�� Results may have convergence errorResults may have convergence error

�� Model input may not be correct, or correctly appliedModel input may not be correct, or correctly applied

�� Boundary conditions, assumptions, etc.Boundary conditions, assumptions, etc.

�� Physical world differences from modelPhysical world differences from model

�� Misapplied analysis and assumptionsMisapplied analysis and assumptions�� Misapplied analysis and assumptionsMisapplied analysis and assumptions�� Analysis limitations (linear, nonAnalysis limitations (linear, non--linear)linear)

�� FEA makes a good engineer better…FEA makes a good engineer better…makes a bad engineer dangerousmakes a bad engineer dangerous

��Testing still required!Testing still required!

Design is often iterativeDesign is often iterative(many approaches)(many approaches)Develop potential Solutions

Select ‘best’ Solution

Understand & Define Problems

Assess Situation for new designor improvement

Implement Solution

Case Study in Design Case Study in Design for Optical Fiber Productionfor Optical Fiber Production

�� Optical fiber produced in Optical fiber produced in 2004 2004 was over was over 55,000,000,00055,000,000,000 meters. meters.

�� (Enough to go around the world over 1300 times!) (Enough to go around the world over 1300 times!)

�� Production machines generally produce on the order of 1 Production machines generally produce on the order of 1 �� Production machines generally produce on the order of 1 Production machines generally produce on the order of 1 million meters of optical fiber per day.million meters of optical fiber per day.

�� Cost improvements on the order of 0.1% are significant Cost improvements on the order of 0.1% are significant in terms of dollars (millions of dollars per year).in terms of dollars (millions of dollars per year).

�� Designs changes for tightening specifications, yield and Designs changes for tightening specifications, yield and productivity are done continuously.productivity are done continuously.

Fiber Manufacturing ProcessFiber Manufacturing ProcessMany design opportunitities.Many design opportunitities.

Problem: Customers Require More Problem: Customers Require More Uniform Lengths of Fiber on Uniform Lengths of Fiber on

Spools, so short length sell for less.Spools, so short length sell for less.

�� Customers purchase specific lengths of fiber Customers purchase specific lengths of fiber (12.5km, 25km, 37.5km, 50km)(12.5km, 25km, 37.5km, 50km)

�� The probability of breaks in the fiber during The probability of breaks in the fiber during fabrication is somewhat random (lengths vary).fabrication is somewhat random (lengths vary).fabrication is somewhat random (lengths vary).fabrication is somewhat random (lengths vary).

�� Longer inLonger in--process lengths will reduce the process lengths will reduce the manufactured breaks in the fiber.manufactured breaks in the fiber.

�� Action from feasibility study:Action from feasibility study: Design and Design and deploy machines and process with greater deploy machines and process with greater spooling capacity greater than 500 km per spool spooling capacity greater than 500 km per spool instead of 100 kminstead of 100 km..

Longer Lengths of Fiber on a Spool?Longer Lengths of Fiber on a Spool?

�� Solution Seems SimpleSolution Seems Simple: : Get Larger Spools!…..butGet Larger Spools!…..but

�� New machineryNew machinery required for processing larger spoolsrequired for processing larger spools

�� New materials handling equipmentNew materials handling equipment required required

�� New process proceduresNew process procedures required required

�� New test equipmentNew test equipment required required

�� InIn--process lag on quality feedbackprocess lag on quality feedback

Design and Manufacturing are a System.Change in one area effects the others.

Planning and Project Management is required

Large Spool ProjectLarge Spool Project�� Feasibility StudyFeasibility Study

�� Project schedule initially formedProject schedule initially formed

�� Design and Analyses performedDesign and Analyses performed

�� Design selected & fully documentedDesign selected & fully documented

�� Prototypes constructed, evaluated, improvedPrototypes constructed, evaluated, improved

�� Prototypes installed and production line testingPrototypes installed and production line testing

PDRPDR

CDRCDR�� Prototypes installed and production line testingPrototypes installed and production line testing

�� Data gathered and evaluatedData gathered and evaluated

�� OnOn--line design modifications while continue testingline design modifications while continue testing

�� Tests successful (from data), RecommendationsTests successful (from data), Recommendations

�� Design upgraded for productionDesign upgraded for production

�� Implemented design in facility and retrofitsImplemented design in facility and retrofits

CDRCDR

Testing & Analyses Performed Testing & Analyses Performed and Repeatedand Repeated

�� Feasibility of Process ChangeFeasibility of Process Change

�� Process Design & Analyses Process Design & Analyses

�� Machine Design & AnalysesMachine Design & Analyses�� Mechanisms, structuresMechanisms, structures

�� Control, electrical powerControl, electrical power�� Control, electrical powerControl, electrical power

�� Manufacturing/ Test Data: Manufacturing/ Test Data: Did it do what we set out to accomplish.Did it do what we set out to accomplish.(machine & process)?(machine & process)?

�� REPEAT if neededREPEAT if needed

Generations of Development

Latest Design

First Prototype

Summary:Summary:Obtain Successful New Design through Obtain Successful New Design through

PlannedPlanned Design, Analysis & Testing Design, Analysis & Testing ::�� Select a Good teamSelect a Good team

�� Understand current situation: systems and opportunitiesUnderstand current situation: systems and opportunities

�� Thorough design and analysisThorough design and analysis

�� Changing/Designing as a system.Changing/Designing as a system.�� Changing/Designing as a system.Changing/Designing as a system.

�� Not just a collection of wellNot just a collection of well--designed partsdesigned parts

�� Effective exchange of information to Effective exchange of information to allall groups affected groups affected by a proposed changeby a proposed change

�� Extensive testing and evaluationExtensive testing and evaluation

�� Detailed planning & continuous project monitoringDetailed planning & continuous project monitoring

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