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MS5016 Design Methodology & Optimization

by I Wayan Suweca, KK-PM ITB

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MS5011 Design Methodology and Optimization

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MS5016 Design Methodology & Optimization
by I Wayan Suweca, KK-PM ITB

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MS5011 Design Methodology and Optimization

Chapter 1
DESIGN METHODOLOGY

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MS5016 Design Methodology & Optimization
by I Wayan Suweca, KK-PM ITB

1.1 What is Design?


Physical
space

Mapping
Products
Needs

Functional
space

Design is defined as the mapping process from functional space to


the physical space to satisfy the designer-specified goals or objectives

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MS5011 Design Methodology and Optimization

1.2 Classes of Design (Brown & Chandrasekaran, 1985)


Routine design
All possible solution types are enumerated (that is, all the
attributes,
tt ib t applicable
li bl useful
f l methods,
th d andd the
th strategies
t t i
are known a priori).
Innovative design
The knowledge base is already known and available to
designer. The solutions are novel, but no new knowledge
is added.
Creative design
Neither the attributes nor the strategies are known ahead
of time. New variables and new knowledge bases are
added to the system.
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MS5016 Design Methodology & Optimization
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1.3 Design Methodology


Design methodology is a prescribed sequence of action in
design process.
It is important
p to know in what context a given
g
methodology is applicable and for what problem types it is
useful.
Some examples of design methodology are:
French method
Ibrahim Zeid method
Ull
Ullman method
h d
VDI method
Pahl & Beitz method
Dieter method
Hatamura method
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MS5011 Design Methodology and Optimization

Needs

Analysis of problem
French Method
Statement
of problem

Conceptual
design : Process

Selected
Scheme
s

Embodiment of
: Result
schemes

Detailing

Working
drawing
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MS5016 Design Methodology & Optimization
by I Wayan Suweca, KK-PM ITB

Ibrahim Zeid Method


Design Process
Synthesis
Design Design Feasibility study with
need specifications collecting design information

Analysis

Design Design
Design Design Analysis
analysis, Design concept-
documentation evaluation model
optimization ualization

CAD + CAE

Process Production Quality


Production Packaging Shipping
planning planning control

Design and
procurement
of new tools

CAM Order
Marketing
materials

NC/CNC/
DNC Pro-
gramming

Manufacturing Process
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MS5011 Design Methodology and Optimization

Project Specification Conceptual Product Product


Definition & Planning Definition Design Development Support
Start

Customer Create Produce Sales


Identification Concept Product Support
Team
Establishment
ct evaluation

Evaluate
Establish Concept Performance &
Customer Needs Strength
Technical
Job Modification
Development
Produc

Make Decision C t
Cost
Competitor for the Concept
Yes

Evaluation Production Customer


Yes

Market
Yes

Support
Yes

Analysis
Documentation &
Establish Communication Make Decision
Technical for the product
Cost & schedule Specification Manufacturing &
estimation Assembling
Change
Support
the plan Documentation &
Determine Communication
Target

Project plan End


approved? Concept
Yes

Production
Spec. approved? approved?
Yes
Yes

approved?
Yes

No
No No
No
Improve?
Improve?
Improve? Improve? Ullman
No
No No
Method
Stop No
Stop Stop 12
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MS5016 Design Methodology & Optimization
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Task
Market, company, economy

clarifying the task


Planning and
Plan and clarify the task

mization of the
Requirement list

principle
ments list

(Design specification)

Conceptual
dessign
Develop the principles

Optim
Information adapt the requirem

Upgrade and improve


Concept

Opttimization of the layout,


(Principle solution)

fforms and materials


Develop the construction structure

Embodiment
design
Preliminary layout

n of the
productiion
Define the construction structure

Optimization
Definitive layout

Prepare production and

design
Detail
operating documents

Product documentatation

Solution Pahl & Beitz Method 13


MS5011 Design Methodology and Optimization

Plan and clarify the task:


Analyze the market & the company situation
Find & select product ideas
Formulate a product proposal
Clarify the task
Elaborate a requirements list

Develop the principle solution:


Identify essential problems
Establish function structures
Search for working principles and working structures
Combine and firm up into concept variants
Evaluate against technical and economic criteria

Develop the construction structure:


Preliminary form design, material selection and calculation
Select best preliminary layouts
Refine and improve layouts
Evaluate against technical and economic criteria

Develop the construction structure:


Eliminate weak spots
Check for errors, disturbing influences and minimum costs
Prepare the preliminary parts list and production and assembly documents

Prepare production and operating documents:


Elaborate detail drawing and parts lists
Complete production, assembly, transport and operating instructions
Check all documents
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MS5016 Design Methodology & Optimization
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Product Specification Dieter Method


Develop Design Concept

Historical and
Analysis Critical Design Features
Current Test Data

Create Detail Design Modify Design


CAD
D

Analysis Detail Design

Generate Detailed Drawings

Build Prototype

Test Prototype
Design Database
Program N/C Machine Tools and
Automated
A tomated Man
Manufacturing
fact ing Equipment
Eq ipment
CAM

Manufacturing Product

Test Finished Product

Ship Product

Monitor Field Performance


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MS5011 Design Methodology and Optimization

STAGES RESULTS PHASES


Task

Clarify & define


1 Phase I
d following stages

the task
Specification
Determine function
2
and their structure
d backwards between previous and

Function structures
Search for solution principles Phase II
3
Fulfill and adapt requirement

and their combinations


Principles solutions
Divide into
4
realizable modules
Module structure

Develop layout of
5 Phase III
key modules
Iterate forwards and

Preliminary layouts
Complete overall
6
modules
Definitive layouts

Prepare production and


7 Phase IV
operating instructions
Product documents

Further Realization
MS5011 Design Methodology and Optimization VDI Method 16

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MS5016 Design Methodology & Optimization
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< Task stage > < Outcomes >

Total project planning Project proposal document

Design planning document


Design planning
Design specification document

Sketch drawing

nse
Design in a narrow sen

Design in a broad sense


Scheme drawing Scheme drawing

Final scheme drawing


Final scheme drawing Design document (including design calculation)

Parts drawing
Parts drawing Part list
Assembly drawing
Fabrication specification document
Assembly drawing Operation instruction document
Inspection specification document

Parts fabrication

Assembly

Inspection Hatamura Method 17


MS5011 Design Methodology and Optimization

1.4 Functional Based Approach


NEEDS
ncreasing Detaiil

sing Abstraction
n

SPECIFICATION

FUNCTIONAL LEVEL
In

Increas

CONCEPTUAL LEVEL

COMPONENT LEVEL
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MS5016 Design Methodology & Optimization
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Lowering level of abstraction

Functional Level
ncreasing Detaiil

Domain-independent
Domain independent

sing Abstraction
n
representation

Conceptual Level
Existing solution
information
In

Increas
Component Level
Detail information

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MS5011 Design Methodology and Optimization

Lowering level of abstraction

Functional level
The level at which design requirements and systems are
represented
p generically
g y with no mention of conceptual
p
or physical realization.
Conceptual level
The level at which systems are modeled in terms of
possible solution principles for fulfillment of the design
requirements or specifications .
Component level
The level at which systems are modeled in terms of
specific, physical entities that may realize the chosen
concepts and/or fulfill the design requirements.

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MS5016 Design Methodology & Optimization
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1.5FunctionalbasedDesign
Needidentification

EstablishProduct
Specification

DefineProductFunction

SelectMechanism/
StructuretoSatisfy
Function

DetailingMechanism/
Structure

ProduceDetailDrawing
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MS5011 Design Methodology and Optimization

Function:
A function of a product is a statement of a clear,
reproducible relationship between the available
input and the desired output of a product,
independent of any particular form.
Product function:
Product function is the overall intended function of
the product what it is to do.
Sub
Sub--function:
Sub--function is a component of a product function.
Sub
An overall function can,, and often must,, be divided
into identifiable sub
sub--functions corresponding to
subtasks.

Inputs Product Function Outputs


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MS5016 Design Methodology and Optimization

Product Function and Function Structure

Clipped Nail, Clean Finger


Finger Force

Finger Nail
CUT Kinetic Energy in nail, sounds

Hands NAIL Kinetic Energy

Hands

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MS5016 Design Methodology and Optimization

References:

Nam P. Suh, The Principal of Design, Oxford University Press, 1990.


Yotaro Hatamura, The Practice of Machine Design, Clarendon Press-
Oxford, 1st Edition, 1999.
Ibrahim Zeid, CAD/CAM Theory and Practice, McGraw-Hill, Int. Edition,
1991.
Chris McMahon and Jimmie Browne, CAD/CAM Principles, Practice
and Manufacturing Management, Addison-Wesley, 2nd Edition, 1998.
Kevin N. Otto and Kristin L. Wood, Product Design Techniques in
Reverse Engineering and New Product Development, Prentice Hall, 1st
Edition, 2001.

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