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    Welcome to Engineering Design, At UMD-MIEwe say:

    Student teams use design and analysis methodslearned in previous courses to develop, design orimprove an industrial system problem. These designproblems are, generally, drawn from real-worldsystem problems existing in industrial organization inthe region.

    We consider that design is a customer-centricprocess that will lead to mutually beneficial outcomes

    It is truly a process so we start with a clear problemanalysis and then propose and pursue a final designin hardware, software, and/or system improvement

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    Welcome to Engineering Design

    Function to form

    Phases of design

    Product realization process

    Roles for engineers

    Concurrent engineering

    Teamwork

    Summary

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    Engineering Design

    machines sketch / draw customer desiresmechanisms predict behavior company constraintsmotion test / experiment synthesize alternatives

    energy conversion materials analyze

    manufacturing evaluate

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    What is Design, really?

    Which of the following is design and which is analysis?

    A. Given that the customer wishes to fasten together two steel

    plates, select appropriate sizes for the bolt, nut and washer.

    B. Given the cross-section geometry of a new airplane wing

    we determine the lift it produces by conducting wind tunnel

    experiments.

    Design Analysis

    Form is the solution to a design problem.

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    How are Function and Form related

    Design

    controlhold

    move

    protect

    store

    decision making processes

    shape

    configuration

    size

    materialsmanufacturing

    processes

    Function

    Form

    Form Ever Follows Function

    Luis Sullivan

    o

    r

    m

    E

    v

    e

    r

    F

    o

    l

    l

    o

    w

    s

    F

    u

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    c

    t

    i

    o

    n

    .

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    Designdefinition

    Set of decision making processesand activities

    to determine the formof an object,

    given the customers desired function.

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    Making Decisions? Use the design process

    Establish functional requirementsDetermine constraints

    Set performance targets

    Generating

    Alternatives

    Formulating

    Problem

    Analyzing

    Alternatives

    Evaluating

    Alternatives

    Create alternative forms

    (shape, configuration, size, materials,

    manufacturing processes)

    all alternatives

    feasible alternatives

    Redesign

    iteration

    Design specifications

    best alternative design candidate

    Manufacturing specifications

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    Are there phases of design?

    How do design decisions change over time?

    Is there a logical grouping of decisions?

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    Example design problem - Stop a spinning shaft

    (8 inch diameter, 1000 lbs, steel, 3000 rpm)

    Decide upon a satisfactory rate of deceleration Determine the length of the shaft

    Determine where it is supported

    Determine what actuating energy is available

    Decide to reverse engineer an existing product

    Choose to research brakes in the library

    Formulation Phase

    Early in the design process, we decide upon the specifics

    of the function to be performed:

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    Decisions relating to concept?

    1. surface friction (e.g. drum brake, disk/caliper)

    2. opposing magnetic fields (e.g. inverse motor) 3. air friction (e.g. fan blades)

    Assume we decide on surface friction

    Decidephysical principlesthat will perform the function

    Concept Design Phase

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    Decisions on configuring productsand new components?

    Product configuration:

    disk/caliper, or drum, or band brakelocation on shaft (right. left, middle)

    (Assume we decide on a disk/caliper brake)

    Part configuration:

    relative size of hub to disk

    relative size of rotor thickness to diameter

    Configuration Design Phase

    Decide upon product components& how they are arranged

    Decide upon partfeatures& how they are arranged

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    1. rotor diameter (outer)

    2. rotor thickness3. brake pad width

    4. pad material

    5. hydraulic pressure on piston

    Values for Parameters?

    Decide upon specific values for design variables

    Parametric Design Phase

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    machined rotor tolerances

    pad bonding resin

    assembly/testing procedure

    Completing the details

    Detail Design Phase

    Decide upon the remaining manufacturing specifications

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    Function---- stop a spinning shaft

    Final Form is the solution to a design problem

    Form

    rotor: 10 inch diameter, CG Cast Iron, 3/8-inch thick, cooling

    passages

    forged steel caliper/housingbrake pads, 2 opposing, 4 sq. in., metal particles/epoxy matrix

    steel piston,1-inch diameter, with elastomeric seals

    100 psi hydraulic piston pressure

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    Design Phases

    Formulation

    Detail

    Parametric

    Configuration

    Concept

    Embodiment

    Design

    Preliminary

    Design

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    Design versus the Product Realization Process?

    Industrial Design

    Engineering Design

    Production Design

    Manufacturing

    (Production)

    Distribution

    ServiceDisposal

    Customer

    Need

    Realized

    Product

    Sales / Marketing

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    Phases in the life of a product

    Manufacture

    Retire

    Design

    Use

    establish functiondetermine form

    fabricate

    assemble

    distribute

    set up

    operate

    maintain

    repair

    take downdisassemble

    recycle

    dispose

    To satisfy the consumer

    We must consider allthe phases in the life of a product

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    Inco

    me

    Investm

    ent

    Introduction Growth Maturity Saturation Decline

    Sales

    Time

    ProductDevelopment

    Product realization begins the ProductLife Cycle

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    How do we, as engineers, fit into the PRP?

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    (U.S. Department of Labor, 2000).

    Manufacturing 732 50

    Engineering Services 401 27

    Government (Federal, State & Local) 179 12

    Self-employed 43 3

    Other 110 8

    Total 1465 100

    Employer Thousands %

    Where do engineers work?

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    Engineering Roles in Design & Manufacturing

    Job Title Description

    Sales &Marketing

    Sales Engineer Meets customers, determinesneeds, presents product offerings

    Applications Engineer Assists sales & marketing solving

    technical issues with respect to the

    use of product

    Field Service Engineer Installs, maintains and repairs

    equipment at customers sites

    Research &

    Development

    Industrial Designer Establishes essential product

    appearance, human factors

    Design Engineer Decides part or product form

    including: shape, size,

    configuration, materials, and

    manufacturing processes

    Materials Engineer Investigates and develops improved

    materials

    Test Engineer Designs and conducts performance

    and safety tests

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    Engineering Roles in Design & Mfg

    Manufacturing Industrial Engineer Designs fabrication,

    assembly and warehousing

    systems

    Manufacturing

    Engineer

    Develops manufacturing

    tools and fixtures

    Quality ControlEngineer

    Establishes and maintainsraw materials and finished

    goods quality controls

    Processing /

    Operations

    Plant Engineer Designs and maintains

    processing plant facilitiesProject Engineer Coordinates project work

    tasks, budgets and

    schedules

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    typical manufacturing company

    Functional organization chart

    PurchasingEstimating

    Expediting

    Purchasing

    Production OperationsQuality Control

    Industrial Engineering

    Manufacturing Engineering

    Production Planning

    Tooling

    Manufacturing

    Design EngineeringIndustrial Design

    Prototyping

    Testing

    Materials Research

    Research & Development

    SalesCustomer Service

    Marketing

    Advertising

    Sales & Marketing

    AccountingBudgeting

    Planning

    Finance

    President

    Board of Directors

    Stockholders

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    Design

    Engineering

    Mfg.

    Engineering ProductionSales

    Marketing

    Product

    Manager

    Industrial

    Design

    Industrial

    Engineering Purchasing

    Concurrentengineering design team

    No moreover the wall

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    Teamwork is a professional teamsport!

    Professional Team Industry

    Competitors Companies

    Team owners Investors

    Coaches Managers

    Referees, umpires Lawyers, judges

    Communication Coordination

    Fumbles, injuries Mistakes, losses

    Individual skills Specialized jobs

    Team skills People skills

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    Summary

    Design is decision making

    Product realization process includes engineering design

    Design process requires formulating, generating,

    analyzing, evaluating, refining Form follows function

    Product realization is a professional teamsport