8/3/2019 Product Design 01
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Course Objectives
Understand the different goals of product design(Assembly,
disassembly, Maintenance, Use, etc)
Learn by Doing
Apply tools learned in class
Apply & share existing knowledge
Improve team work & communications skills
Improve project management skills
Get exposed to real manufacturing tasks & havehands-on
experience
Have Fun
Grade Breakdown
Assignments & Attendance 7.5%
Mid-term 10%
Project 22.5%
Progress during the term 2.5%
Final report 10%
Presentation & Oral test 10%
Final Exam 60%
8/3/2019 Product Design 01
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Project Description
To choose a manageable product (10-20parts).
To disassemble the product, count andmodel all different
components using solidmodeling software.
To assemble the product and recordassembly time.
To calculate assembly time using equations& tables provided
in class.
To apply different techniques taught inclass to modify the
product components forease of assembly.
To Model the new parts using solidmodeling software.
To calculate the new assembly time and theefficiency
..The Team
Team Leader
Solid ModelingEngineer
Manufacturing& Assembly
Engineer
DesignEngineer
Team Projects
Team Structure (2 - 4 students)
Feedback to Professor every 2 weeks(10 minutes / team)
Project Requirements
Discuss ideas from each team
Suggested projects (Iron, Hair dryer, WallClock)
Every team has 2-minute proposal next week
Hand in a 1-page proposal by the end of theday to TA (Engineer/
Mohamed Khalil)
Proposal Guidelines
Choose a product:
Small & manageable (10-20 parts)
Has capacity for re-design and innovation
Hint: Search the internet for some ideas first to see internal
components
Product DesignResearch & Development
R D
TechnologyDevelopment
Product Development& Redesign
Our focus is onProduct redesign
for ease ofassembly
Goals of DFM/DFA
Historically, conventionally
reduce costs, simplify processes
improve awareness of manufacturing issues duringdesign
More broadly (a goal of this course)
align fabrication and assembly methods to larger goals ability
to automate, systematize, raise quality, be flexible
access to assembly-driven business methods like delayed
commitment
innovative designs, outsourcing (Siemens intake manifold)
Inevitably pushes DFM/DFA earlier into the productdevelopment
process where it blends with architecture
8/3/2019 Product Design 01
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Sample Cost Breakdowns
VCRs: 90% parts, 5% labor
Car engines: 75% parts, 7% labor, 7% capital, 7%
consumables
Mini computers: 65% parts, 25% labor
Fighter planes: 50% parts and tooling, 40% labor
Engine Sub-assemblies
The Assembly from Heaven
Can be assembled one-handed by a blind person
wearing a boxing glove
Is stable and self-aligning
Tolerances are loose and forgiving
Few fasteners
Few tools and fixtures
Parts presented in the right orientation
Parts asymmetric for easy feeding
Parts easy to grasp and insert
