UME1421:Product Design and
Development
Unit 1
PRODUCT DEVELOPMENT PROCESS
Unit – I
Introduction: Classification/ Specifications of Products-
Product life cycle. Product mix- Introduction to product
design- Modern product development process-
Innovative thinking - Morphology of design
Course Outcome
On Successful completion of Unit 1 students will be able
to understand the basics of product design, product
development process and morphology of design
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Lecture Plan and Reference
Lecture Topic Pg no:
Number
1 Introduction
1-10
2 Classification/ Specifications of Products 91-114
3 Product life cycle Refer Study
Material
4 Introduction to product design 1-10
5 Modern product development process 11-32
6 Modern product development process 11-32
7 Innovative thinking
8 Morphology of design
Reference Text Book
Karl T Ulrich, Steven D Eppinger, Product Design & Development,
Tata McGrawhill, New Delhi 2003
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Development Processes and
Organizations
Teaching materials to accompany:
Product Design and Development
Chapter 2
Karl T. Ulrich and Steven D. Eppinger
5th Edition, Irwin McGraw-Hill, 2012.
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Product Design and Development
Karl T. Ulrich and Steven D. Eppinger
5th edition, Irwin McGraw-Hill, 2012.
Chapter Table of Contents:
1. Introduction
2. Development Processes and Organizations
3. Opportunity Identification
4. Product Planning
5. Identifying Customer Needs
6. Product Specifications
7. Concept Generation
8. Concept Selection
9. Concept Testing
10. Product Architecture
11. Industrial Design
12. Design for Environment
13. Design for Manufacturing
14. Prototyping
15. Robust Design
16. Patents and Intellectual Property
5 17. Product Development Economics v 1.0
18. Managing Projects
product development cycle
The product development cycle starts with developing the product
concept, evolving the design, engineering the product, manufacturing the
part, marketing and servicing.
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Product development Cycle
The Design Process
Design Collecting
Design definitions, relevant
needs specifications,
and
design
information Synthesis
requirements and feasibility
Analysis study
Design Design Design
Design Design Design
documentation modeling conceptualizatio
evaluatio optimizatio analysis
and and n
n n
communication simulation
The Manufacturing Process
Production
planning
Design and
procurement
Process
of new tools Productio Quality Packaging
planning Shipping
n control
Order
materials
NC, CNC, DNC
programming
Marketing
7 7
Product Development Spiral
In actual practice product development activities form a spiral
The product goes through a series of continuous refinement and
improvements, additions
Example: software package improved versions of which are released as
new versions at periodic intervals
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Modern product development process
Concept or idea generation
Synthesis
Analysis
No
Checking
Yes
Applying basic engineering
Detailed design
Product development
Prototype
Yes
9 Operation v 1.0 Checking
No
Concept Development Process
Mission Development
Statement Establish Generate Select Test Set Plan Plan
Identify
Target Product Product Product Final Downstream
Customer Needs Concepts Concept(s) Concept(s)
Specifications Specifications Development
Perform Economic Analysis
Benchmark Competitive Products
Build and Test Models and Prototypes
10
Generic Product Development Process
Concept System-Level
Level Detail Testing and Production
Planning Development Design Design Refinement Ramp-Up
Mission Concept System Spec Critical Design Production
Approval Review Review Review Approval
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12
Core development stages
• Solution approach
• Concept design
• Architectural design
• Detailed design
• Process design
• Fabrication and assembly
• Test and deployment
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Solution Approach
• Concept for solutions
• DFX
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Concept development
• A description of the form, function, and features of a product
• A set of specifications
• An economic justification of the project.
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System (architectural) design
• Definition of product architecture, with an assembly layout.
• Division of the product into subsystems and components, each
with a functional specification.
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Detailed design
• Complete specification of the geometry, materials, and
tolerances of each of the unique parts
• Identification of all standard parts to be purchased.
• Establishment of a process plan and tooling
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Test and refinement
• Construction and evaluation of multiple pre-production
versions of the product.
• Early (alpha) prototypes are usually built with production-
intent parts (but may not be with the intended production
processes) for testing in the designer's environment, if the
design intent and key customer needs are met.
• Later (beta) prototypes are built with parts supplied by the
intended production processes (but may not be with the
intended-assembly process), tested by customers in their
environment, and to evaluate product performance and
reliability.
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Production ramp-up
• The product is made using the intended production system.
• To train the work force and to work out any remaining
problems in the production processes.
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A generic concept development process
1. Identifying customer needs
2. Establishing target specifications
3. Concept generation
4. Concept selection
5. Concept testing
6. Setting final specifications
7. Project planning
8. Economic analysis
9. Benchmarking of competitive products
10. Modeling and prototyping
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Rapid Iteration PD Process
Many Iteration Cycles
Concept System-Level
Level Production
Planning Design Build Test
Development Design Ramp-Up
Mission Concept Cycle Plan Cycle
Approval Review Review Review
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Complex System PD Process
Design Test
Design Test
Concept System-Level
Level Integrate Validation
Planning Development Design and Test and Ramp-UpUp
Design Test
Mission Concept System Production
Approval Review Review Approval
Design Test
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Concept Development Process
Mission Development
Statement Identify Establish Generate Select Test Set Plan Plan
Customer Target Product Product Product Final Downstream
Needs Specifications Concepts Concept(s) Concept(s) Specifications Development
Perform Economic Analysis
Benchmark Competitive Products
Build and Test Models and Prototypes
• Front-end of PD need not be a fuzzy process.
• Structured methods exist for each process step
(see text chapters 4 to 8).
• This is not strictly sequential -- generally a
parallel and iterative process.
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Tyco Product Development Process
DEFINE CONCEIVE DESIGN OPTIMIZE VERIFY
Project Concept Feasibility Preliminary Final Product Process Post-Launch
Launch
Registration Definition and Planning Design Design Verification Verification Assessment
RP RP RP RP RP RP RP RP RP
0 1 2 3 4 5 6 7 8
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Tyco Product Development Process
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Summary
• Product Development Cycle
• Product Development Cycle - Spiral
• Stages of Product Development
• Difference between Rapid and Complex Product
Development Process
• Tyco Product Development Process
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Self Assessment
• Explain Product Development Cycle
• Explain the Modern Product Development Process
• Discuss in detail Concept Generation
• With a case study illustrate the Product Development Process
• Focus on materials selection for an existing product
• Steps:
• 1. Examine each component of a product (an incandescent bulb, stapler, can opener).
• 2. Break the product or decompose it, avoiding injury to eyes or hands and damage to the
other components.
• 3. Construct and complete a table consisting the following items on its columns.
– a. list each component of the product
– b. define the function of each component
– c. identify the material used
– d. reason why it was selected
– e. select possible alternative.
• 4. List five failure mechanisms
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Thank You
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