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DESIGN
Dr. Shouri P.V.
Associate Prof. in Mechanical Engineering,
Model Engineering College,
Thrkkakara, Cochin 682 021, Kerala.
E-mail: pvshouri@mec.ac.in
Design Process
Product Design
Ultimate Goal of a
Designer
Design - An Iterative
Process
Is Product Design a
Compromise?
Viability, Feasibility,
Desirability
Break-Even Analysis
Some managerial questions:
How much should we produce to break
even?
For a specific volume, should we
manufacture the product ourselves, or
outsource?
For machine alternatives A and B, at what
volumes should we use machine A and at
what volumes, machine B?
Break-even Chart
Spiral of Progress in
Quality
(2
)
External
Cost
Failure
Appraisal Cost
(4
)
Prevention Cost
Optimum Quality
In
the
beginning
as
you
add
features/functionality there is a good rise in
user experience. But it plateaus quickly with a
sharp degradation.
Point of Re-invention
Cost of Design
Cost of design is relatively low for a product.
However design is significantly responsible for
the cost of its realization
A good design always brings down the cost
Hence a good design should focus on cost
aspects of the product beyond its function and
strength
This should be taken care of during every phase
of design
Cost of Change
Reliability Defined
Reliability is "quality changing over
time
As time tends to infinity reliability tends to
zero.
Reliability terminates with a failure that is,
unreliability occurs.
Elements of Reliability:
(1) Probability
(2) Function
(3) Working Conditions
Emergence of Reliability
Engineering
The first recorded usage of the word
reliability dates back to the 1800s, and
was referred to a person and not a
technical system
The word reliability was first coined by
the English poet Samuel T. Coleridge, who
along with William Wordsworth started
the English romantic movement.
V1
V2
SCUD
F a ilu re R a te
In c r e a s in g
F a ilu re
R a te
T im e
Problem to be Addressed
by the Reliability Engineer
Time
Life Expectancy
India 65.5
Kerala - 74
Madhya Pradesh 58
U. S. 78.2
Singapore 81.6
Japan 82.9
China 73.3
Sri Lanka 74.7
R (t ) e
Z ( t ) dt
0
R(t ) e
(t)
Time
1
MTBF R(t )dt e dt
0
0
t
5000
(per hour)
t = 200 hours
R(200) e
200
5000
Characteristics of Product /
System Design
1
2
3
4
5
6
7
8
9
Components----------------------Subsystems
Interrelated components
Boundary
Purpose
Environment
Interfaces
Input
Output
Constraints
System Reliability
Reliability of a process or system may be the
product of many different reliability terms, such
as
R (t ) R (t ) Component1 R (t ) Component 2 R (t ) Component 3 etc.
Series Configuration
R (t ) R1 R2 R3 Rn
Parallel Configuration
R (t ) 1 1 R1 (1 R2 ) (1 R n )
Mixed Configuration
R (t ) R1 R2 1 (1 R3 )(1 R4 )(1 R5 ) R6
Cells in vital
organs are
connected in
parallel
Reliability Increasing
Techniques
Reliability Optimization
It is usually necessary to perform trade-off
calculations to determine the advisability of
parallel redundancy versus improvement of the
reliability of the basic subsystem by other means.
0.9
0.73
Parts Derating
Other Reliability
Improvement Methods
Automotive Reliability
The proportion of electronic components used in
motor vehicles has been increasing steeply in
recent years. In fact, many industry observers
expect electronic components to account for 40%
of total car production costs in the near future.
However there is a concern that the life of the
electronic components is relatively low thereby
affecting reliability.
Development of highly reliable, large-scale
software programs for microcomputer control has
become a crucial matter for the automakers.
Need for
tellsSynchronization
of Henry Fords buying scrapped
A story
Ford
cars
and
having
his
engineers
disassemble them to see which parts failed
and which were still in good shape. Engineers
assumed this was done to find the weak parts
and make them stronger.
Ford explained that he wanted to find the
parts that were still in good shape. The
company could save money if they redesigned
these parts to fail at the same time as the
others.
Availability
Availability is the ratio of time a system or
component is functional to the total time it is
required or expected to function.
MTBF
Availabili ty
MTBF MTTR
Concept of Energy
Productivity
Outputs
Productivity =
Inputs
Outputs
Energy Productivity
EnergyInput
=
Minimizing Energy
Consumption at the Cost of
Reliability ?
Google's Redundancy
Approach Towards
Reliability
Thank You..