MORPHOLOGY OF

DESIGN
 Phase VI PLANNING FOR USE
 Consumer Oriented Process must be
incorporated in the design process
 User Oriented Process
 Ease of maintenance
 Reliabibility
 Product Safety
 Convience in Use ( Human Factor Engineering)
 Aesthetic Appeal
 Economy of Operation
 Duration of Servivice
 Planning
for the
Retirement of product
 The final step in the design process is the disposal of product
when it has reached end of useful life
 Useful life is determined by point where design can no longer
function
 Technological obsolescence in which competitive design cheaper
performs the function better or cheaper
 In Consumer product, it may come through changes in fashion
and taste
 Computer aided design --- CAD
 Computer Controlled Machine Tools
 CAD and CCM link is called design database in digital format
Design of New Product Steps
Product Specification

Develop Design Concept

Analyse Critical Design Historical and Current Test

Features Data

Create Detail Design

Analyze Detail Design

Generate Detail Drawing

Build Prototype

Test Prototype

Program N/C Machine Tools and Automated

Mfg. Equipment

Manufacture Product

Test Finished Product

Ship the Product

Monitor Field Performance

 Further consideration in Design

 The design process has followed time sequence of

events in the usual project
 To look design at another aspect, Design factor are
grouped into three categories
 Functional Requirements
 Total Life Cycle
 Further Major factors
 Functional Requirements

 Design must meet performance specification

 Performance specification in problem defination
 Overemphasis the specification of property
values and performance parameters
 Computer Aided Design (CAD) tool for
analytical analysis with interactive computer
graphics
 Product Liability

 Due to competitive nature business emphasized

has been given on reliability
 Reliability
 Maintainability
 Availability

 Repairability
 Reliability

 Reliability is defined as probability that device

will be perform adequately in service for the
period of time intended under specified
operating condition
 Maintainability

 Ease
 Economy
 Safety of performing function
 Minimize maintainace time
 Maximize time in productive service
ANTICIPATION FAILURE MODE
OF PRODUCT

 Fault Tree Analysis

 Failure Modes and Effect Analysis
 Hazard Analysis
 Design Review

 The design review is vital aspect of the design

process
 Design Review provides a systemic method for
identifying the problems with the design, aids in
determing the possible course of action
 Initiate action to correct problem areas
 Design Review Team
 Team Leader Project Manager: (technical
knowledge and know how for product)
 Design
 Manufacturing
 Marketing
 Purchasing
 Quality Control
 Reliability Engineering
 Field Service
 Design Review Checklist
 Design requirements
 Functional requirements
 Environmental requirements
 Manufacturing requirements
 Operational requirements
 Reliability requirements
 Chapter 2
DESIGN IN A
BROADERCONTEXT
 2.1 Spectrum of Engineering
Activities
 It is defined as application of science to the solution
of problem of society at a profit cost
 According to the ABET
 Engineering is the profession in which a knowledge of the
mathematical and natural sciences gained by study,
experience and practice is applied with judgment to
develop the ways to utilize , economically, the materials and
forces of nature for the benefit of mankind
 AIM OF ENINEERING

 Solution of specific society problem using

mathematics and science
 Limitation/ Constraints
 Legal
 Environmental

 Economic
 Engineering Functions
 Refer Fig 2.1 Engineering function starts with research,
closest to academic experience
 More emphasis is on financial and administrative matters
towards downwards of hierarchy
 Research
 Development
 Design
 Production and Construction
 Operation and Maintenance
 Sales
 Management
 Research
 R & D are the glamour end of engineering
 Research limited to scientist working in Lab to
explore the nature
 R & D Activities
 Research
 Exploratory Development

 Advance Development

 Engineering Development

 Management and Support

BASIC and Applied Research
 DESIGN
 The design is the function of creating a technical
plan to solve a problem
 It involves both analysis and syntheses
 Needs not only calculation on computer and lines
on drawing but much computer
 It involves planning of “how the thing designed
will be manufactured and how it will be maintained
 Production and Construction
 This activity translates the design into manufacturing process
, process plant or civil structure engineering structure
 Engineers are responsible to
 Taking the design through initial production to prove that product
can be manufactured in planned cost
 General list of employee to work with expert and organize the
schedule and complete task in allocated cost
 To supervise the plants workforce, material's flow and machine
 Meeting the production schedule while maintaing the product
quality
 Provide plant engineering function of providing plant utility
services, maintenance and modification
 Sales Engineering: liaison between customers and production
facilities
2.2 ORGANIZATION OF ENGINEERING
FUNCTION

 There are three types of organization structure

 Functional Organization
 Project Organization

 Project Functional Staff Organization

 Functional Organization
 Organization is grouped into separate identifiable
units based on functional specialties
 Similar work is performed in same organizational
unit
 All R & D and design work reports to a single vice
president and manufacturing activity is the
responsibility of other vice president
 Many functions are under a single vice president
 Functional Organization
Chart

Board of
Directors

Stack Holders

President

Vice President Vice President Vice President Vice President Vice President
 Project Organization

 The functions are organized around a single product

or major system
 Functions are redistributed based on need among a
number of project managers
 It is dynamic and time-limited since its life is based
on completion of project objective and then people
are reassigned
Project Organization Chart

President

Vice President

Manager Manager Manager

Project X Project Y Project Z
 Line Organization
 Line organization represents a chain of command
relationship in which supervisor reports to the
manager
 Line functions are concerned with achieving the
prime objective of the project
 Staff functions support the one or more line
organization
 SF provide special expertise and information to
achieve the objectives of organization
 SF are not the part of chain command.
 Project Functional Staff
Organization
 It is formed by merging of functional organization and
project team
 An organization consist of project team superimposed
on existing vertical functional structure of
organization
 An Engineer can switch one department to another
by providing technical assistance
 Matrix Organization
President

Other Vice President Vice President of

Researach and Engineering

Project Mechanical Electrical System

Management Design Design Engineering

Project
X

Project
Y

Project
Z
 Chapter 3
DESIGN METHODS
 3.1 INTRODUCTION

 Successful design calls for skills in problem solving and descision

making
 Conceptualization step is the most important since it constitute
engineering and scientific principles that constitute design
 Design methods are needed to assist complex process
 Computer based “design tools” are being developed using expert
system, mathematical modeling and advanced optimization
technique but scope of this chapter is simpler design methods
 Sketching or Drawing to help visulize design concept
 Systemizing the decision process in World War II developments in
operation research
 Management science and operation technique
 INTRODUCTION (Cont…)

 Of the design methods one tries to formalize the design

procedures and externalize the design thinking
 Aim of formalization is to prevent overlooked factors in
design process or the occurrence of errors
 In externalization thoughts and thinking out of designer‟s
head and put them in charts and diagram
 3.2 Creativity and Problem Solving
 Creativity is the ability to synthesize new combinations of ideas
and concepts into meaningful and useful form
 There is myth „ Creative ideas arrive with flash flash like
spontaneity – the flash of lighting and clap of thunder routine
 Ideas occur slow and can be enhanced with study and practice
 Creative process can be viewed as moving from
amorphous/shapeless idea to a well structured idea, from
implicit to explicit
 Creative ideas can not be turned on upon command
 Steps for Enhancement in Creative
Thinking
 Develop a creative attitude
 Develop self confidence to tackle the problem
 Build confidence with small success
 Unlock your imagination
 Come out of imagination
 Question ask again “why” and “what if”
 Thought games are designed to provide practice in unlocking
imagination
 Be persistent
 Creativity occurs with lighting strike
 It requires hard work and consistency since problems are not
solved in first attempt
 Steps for Enhancement in Creative
Thinking
 Develop an open mind
 Receptive to ideas from any and all sources
 Solutions are not the property of a particular discipline

 Suspend your judgment

 Critical attitude of Engineers
 Avoid judgment at early stage

 Set Problem Boundaries

 Establish the boundaries of problem defination
 Chapter 4
Modeling and Simulation
 MODELING

 A model is an idealization of a real world situation that aids in

analysis of problem
 Free body diagram, electric circuit diagram, sphere by earth

 A model may be classified as

 Descriptive : real world system or phenomenon e-g model of
an aircraft gas turbine. It does not predict the behavior of
system
 Predictive : used in engineering design in order to understand
and predict the behavior of system
 MATHEMATICAL
MODELING

 In MM the component of system are idealized by elements

having the same characteristics and behavior can be
described by mathematical equation
 A generalized picture of model for a system or component
is shown in Fig 4.3
 Engineering System is complex and can be easily
understood by breaking into smaller components and
modeling each of them
 Interaction of these components is to be defined
 Block Diagram

Coal Power Plant Electricity

Fig 4.1 . Overall Block Diagram of Power Plant

Combustion
Coal Steam Boiler Steam Turbine Generator Electricity
Chamber

Fig 4.2 . Block Diagram of major components of Power Plant

 Block Diagram Spray Water
Coal Electricity

Feeder Generator Cooling Pond

Coal
Ash Combustion Heat Steam
Boiler Tube Turbine Condenser
Chamber

Gases Water
Water

Stock Water
Heater Water

Pump
Pump
Water Gases

Fig 4.5 . Detailed system for a coal fired Power Plant

 Chapter 6
Material Selection Process
 Material Selection Process

 A Problem of material selection involves one of

two different situations
 Selection of the materials for a new product or new
design
 Reevaluation of an existing product or design to
reduce cost, increase reliability, improve performance
Steps in the Manufacturing Process

 Material selection is problem solving

process
 The steps in the process can be defined as
 Analysis of the materials requirements
 Screening of candidate materials

 Selection of candidate material

 Development of Design data

Analysis of material requirements

 Determine the conditions of service and

environment that the product must stand
 Translate then in critical material properties
 Screening of Candidate material

 Compare the needed properties ( responses) with

large material property data base to select a few
material that look promising for the application
 Selection of candidate material

 Analyze candidate material in terms of product

performance, cost , fabricability and availability
to select the best material for the application
 Development of Design Data
 Determine experimentally the key material
properties for the selected material to obtain
statistically reliable measures of the material
performance under the specific conditions
expected to be encountered in service
7.2 Classification of Manufacturing
Process
 Critical Path Method
 CPM is a a technique used