Part B: Section 1

1.1 The Phases of Design

Need Identification
Problem Definition
(Client statement ?)

Conceptual Design

Preliminary Design

Detailed Design

Final Design
(Fabrication Design
Specifications & Communication
Documentation)

Main Phases of the Engineering Design Process

NeedNeed Identification
Identification
Problem Definition
(Client statement ?)
(Client statement ?)

Conceptual Design

Preliminary Design

Detailed Design

Final Design
(Fabrication Design
Specifications & Communication
Documentation)
 Problem
Need Identification
(Client statement ?) Definition
Problem Definition

Conceptual Design

Preliminary Design

Detailed Design

Final Design
(Fabrication Design
Specifications & Communication
Documentation)
Problem Definition

Input:
Clients statement

Tasks:
Clarify design objectives (1)
Establish user requirements (2)
Identify constraints (3)
Establish functions (4)

Output:
Revised problem statement
Refined objectives
Constraints
User requirements
Functions
Problem Definition
Sources of Information:
Literature on the state-of-the art
Experts
Standards and codes
Regulations

Means:
Literature review
Brainstorming
User surveys and questionnaries
Interviews
Methods:
Objectives tree
Function-means tree
Requirements matrix
Objective tree
Function-means tree
Need Identification
Problem Definition
(Client statement ?)

Conceptual
Conceptual Design
Design
Preliminary Design

Detailed Design

Final Design
(Fabrication Design
Specifications & Communication
Documentation)
Conceptual Design
Input:
Revised problem statement
Refined objectives
Constraints
User requirements
Functions

Tasks:
Establish design specifications
Generate design alternatives

Output:
Conceptual design(s)
Design specifications
Conceptual Design

Sources of Information:
Competitive products

Means:
Brainstorming, synectics and
analogies, benchmarking and
reverse engineering
Conceptual Design

Methods:
Quality function deployment (QFD)?
Morphological chart?
 QFD Quality Function Deployment
Is a planning and problem-solving tool that is
finding growing acceptance for translating
customer requirement into the engineering
characteristics of a product.
Morphological Chart
Arranges the functions and subfunctions in logical
order, and for each subfunction list the possible
hows.

10/28/2014 13
Need Identification
Problem Definition
(Client statement ?)

Conceptual Design

Preliminary
Preliminary Design
Design
Detailed Design

Final Design
(Fabrication Design
Specifications & Communication
Documentation)
Preliminary Design

Input:
Conceptual design(s)
Design specifications

Tasks:
Model and analyze conceptual design
Test and evaluate conceptual design

Output:
A selected design
Test and evaluation results
Preliminary Design
Sources of Information:
Rules of thumb
Simple models
Known physical relationships

Means:
Laboratory experiments,
prototype development,
simulation and computer analysis

Methods:
Refined objectives tree
Comparison charts
Need Identification
Problem Definition
(Client statement ?)

Conceptual Design

Preliminary Design

Detailed Design
Detailed Design

Final Design
(Fabrication Design
Specifications & Communication
Documentation)
Detailed Design

Input:
A selected design
Test and evaluation results

Tasks:
Refine and optimize the chosen design (9)

Output:
Proposed manufacturing
specifications
Final design review for
client
Detailed Design

Sources of Information:
Design codes
Handbooks
Local laws and regulations
Suppliers component specifications

Means:
Formal review
Public hearing

Methods:
CADD-Computer Aided
Design and Drafting
Need Identification
Problem Definition
(Client statement ?)

Conceptual Design

Preliminary Design

Detailed Design

Final Design
(Fabrication Design
Design
Specifications & Communication
Documentation) Communication
Main Phases of the Engineering Design Process
Design Communication

Input:
Manufacturing specifications

Tasks:
Document the completed design (10)

Output:
Final report to client
containing manufacturing
specifications
Design Communication

Sources of Information:
Feedback from clients and users
 Part B: Section 1

1.2 Sustainable Development

 Sustainable Development
Definitions
Normative definition
Development that meets the needs and aspirations of
the current generation without compromising the
ability to meet those of future generations.
Other definition
Development which enables individuals and
communities in underdeveloped regions of the world
to raise living standards through profitable products,
consistent with minimizing adverse environmental
effects
 Sustainability
Major components:
Environmental
Economic
Social
Political
 Environmental Sustainability
Reduce, Reuse, Recycle
Developing countries are really GOOD at this!

Eco-efficiency
Being less bad
Environmental Sustainability

Manufacturer is responsible for the product

through entire life-cycle
Create products that are designed for
upcycling
No waste, not less waste
 Sustainability Automotive
(Ford)
Recycling
Discover our commitment to improving
the health of your neighborhood,
through conservation and preservation.
Cleaner Manufacturing
Find out how refurbished
manufacturing plants are reducing the
amount of existing hazardous materials.

Nature & Wildlife Air & Climate

Discover why we're a globally
Think globally, but act locallyread
recognized leader in emissions
about ecological priorities, from the
technology.
Wildlife Habitat Council to rainforest
preservation.
 Proton
Is this for real? Is Proton really creating
sustainable products?
Can companies be green?
 System
A systems approach:
How do we make sustainable
communities?
How do we make sustainable business
eco systems?
How do we initiate the process?
 Economic Sustainability
Who is paying for your product?
User
NGO
Government
Will they keep paying?
Why?
What is the value your product brings?
 Social Sustainability
Does your product fit into its social context?
Are there people with the level of skill needed
to repair/maintain your product?
Does your product make peoples lives
better?
Does any part of making/using/disposing of
your product harm people?
 Appropriate Technology
Simple, Low-cost, Local (but effective)
Labor-intensive methods
Low capital costs
Junk is good
Use, Maintenance are simple
Why Appropriate Technology?
Socially sustainable
semi-skilled labor jobs
employs available skills, teaches new ones
fits into social context
familiar
Why Appropriate Technology?
Economically sustainable
uses readily available labor
avoids using scarce capital (having fewer
resources than needed to fill human wants and
needs)
avoids work stoppages associated with importing
spare parts, foreign experts
Large factories in developing countries often run
below capacity
Consider issues of poor transportation and
communication
 Markets: what are they good
for?
People will only pay for things they actually
want
Measurable
Reality check
Can be efficient method of allocating
resource
Discipline against just pleasing yourself
 And what are they bad at
Some people cant afford to pay for
anything
e.g. wheelchairs
Getting products to unprofitable markets
Taking care of all stakeholders

Our assumption is that our products

will be affordable-even by the poor
 Stakeholder analysis
A systematic way to make sure you
address everyone who will be affected
by your product.
 Why is this important?
Some of these people can affect the success
of your project (government officials,
prominent citizens)
Despite of making products that poor people
can afford, we care about development, not
just profits.
But profits are the best of measuring the
effectiveness of the products and this can be
misconstrued
Stakeholder Analysis
1. Define clearly who the stakeholder is
2. Define how important this stakeholder is for the
success of the business
3. What precisely do I need from this stakeholder?
positive contribution? Avoidance of negative?
4. What motivates this stakeholder? How is this
stakeholder rewarded?
5. How to reach the Stakeholder? Influencers?
6. How can I get the stakeholder to help me in my goal?
7. What do I do if the stakeholder is negative (risk
reduction)?
 Part B: Section 1

1.3 Health & Safety Regulations

and Legal Issues
 Introduction
Modern society
Emphasis on avoiding risk
Insisting on products that last longer
Require less service

This requires greater attention to risk

assessment at design stage that will increase
the reliability of the product/system.
2
 Health & Safety Regulations
Important issue in product design.
Always take for granted recall unsafe
product can be very costly in terms of
Product liability suits
Replaced product
Tarnished reputation

3
 Safe Product
A safe product
No accident, does not cause injury or property
loss, no damage to environment.
It comes from a focus on safety during design,
knowing and following some basic rules.

Safety freedom from danger

4
 Three aspects to design for safety.
Make a product save how?
If it is not possible, then design in protective
devices give examples guards, cutoff switches,
pressure relief valve.
If still cannot remove all hazards, then warn the
user labels, flashing lights and loud sounds.

5
 Fail-safe Design
A fail-safe design
To ensure that the failure will either not affect the
product no injury and no damage will occur.

Three variants of fail-safe designs

1) Fail passive design
2) Fail active design
3) Fail operational design
6
 Fail Passive Design
When a failure occurs, the system is reduced
to its lowest energy state and the product will
not operate until corrective action is taken.

Example a circuit breaker.

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 Fail Active Design
When failure occurs, the system remains
energized and in a safe operating mode.

Example a system/machine kept on standby.

8
 Fail Operational Design
The design is such that the device continues to
provide its critical function even though a part
has failed.

Example a valve that is designed so that it

will remain in open position if it fails.

9
 Potential Dangers
Acceleration/deceleration
Chemical contamination
Electrical
Environment
Ergonomic
Explosions
Fire
Human factors
Etc.

(give examples for all stated above)

(George E. Dieter, pp. 566)

10
 Product Hazards
Hazard potential for damage.
Are often controlled by government regulation
SIRIM, NIOSH - OSHA, Factory and Machinery Act
1967.
Products designed for children are held to much
higher safety standards.
The design must be cognizant that in addition to
providing a safe product to customer, manufacture,
sell, install, and service.
11
 For example products that cause harm
invariantly result in court suits for damages
under the product liability laws.

Design engineers must understand the

consequences of these laws and how they
must practice to minimize safety issues.

12
 Guidelines for Design for Safety

Identify the actual and potential hazards

Thoroughly test prototypes
Easier to use safely than unsafely
If safety problem determine the root cause, redesign to
eliminate the hazard
User-friendly humans will do foolish things
Minimize the use of flammable materials

13
 Paint and surface finishing materials should comply with
OSHA regulations for toxicity user and when they are burned,
recycled and discarded
Think about repair, service and maintenance adequate
access without pinch to the repairer
Electrical product should be grounded to prevent shock.

14
Classifications of hazardous
materials include the following:
Class 1 Explosives
Class 2 Gases
Class 3 Flammable liquids
Class 4 Flammable solid
Class 5 Oxidizer
Class 6 Poison
Class 7 Radioactive
Class 8 Corrosive
Class 9 Miscellaneous
PPT-044-01 21
16
 Documents
SIRIM Product Certification Requirements
OSHA
Factory and Machinery Act 1967
Factory and Machinery Act 1967 and its
regulations

17
 Engineer must be able
to identify hazards to the design
to evaluate the risk
to understand when conditions constitute a
danger

18
 Legal Issuess
Design engineers might be concerned with legal and ethical issues
Preparing a contract to secure the services of a product data
management firm.
Reviewing a contract to determine whether a contractor who built an
automated production facility has satisfactorily fullfilled the terms of a
contract.
Deciding whether it is legal and ethical to reverse engineer a product.
Managing a design project to avoid the possibility of a product liability
suit.
Protecting the intellectual property created as part of a new product
development activity.
Deciding whether to take a job with a direct competitor that is bidding
on a contract in the area where you are now working.

19
 Contracts
A contract is a promise by one person to another to do or not to do something.The
three elements of a contract are:

Contract = offer + acceptance + consideration

An offer is an expression made by one person that leads another person to

reasonably expect that the promisor wishes to create an agreement. The offer
must be clear, definite, and specific, with no room for serious misunderstanding.

An acceptance of the offer is necessary to make a contract legally binding. Both the
offer and the acceptance must be voluntary acts. A contract cannot be forced on
anyone.

A contract is not enforceable by law unless it contains an agreement to exchange

promises with value, the consideration.

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 Types of Contracts
Express contract
Implied contract
Bilateral contract
Unilateral contract

21
 Types of Contracts
Express contract

A contract in which all of the terms are agreed upon and

expressed in words, either written or oral. An oral contract,
once made, can be just as legal as a written contract, but it
is much more difficult to prove and enforce.
Moreover, many states have statutes of fraud that require
writing for certain contracts to be enforceable.

22
 Implied contract

A contract in which the agreement between parties is inferred by the

legal system wholly or in part by their actions. For example, Jim goes
to the local convenience store, where he has an account. He picks up a
Sunday New York Times and holds it up so the clerk sees him take it
and the clerk nods in return as he leaves the store with the paper. Jim
has made an implied contract to pay for the newspaper.

The contract agreed by non- verbal conduct, rather than by explicit

words

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 Bilateral contract

A contract in which two parties have both made a

promise to each other. A promise is made in
return for a promise. Each party is both a promisor
and a promisee.

24
 Unilateral contract

Is one in which the promisor does not receive a promise as

consideration for her promise but instead agrees to pay if
she receives an act or service.
For example, Mrs. Jones says to Johnny Smith, I promise
to pay you $100 tomorrow if you will clean out my
basement and garage today. Johnny immediately goes to
work. This constitutes acceptance of the offer and creates
a unilateral contract.

25
 General Form of a Contract
In general, every business contract should contain the
following information:
Introduction to the agreement. Include title and date.
Name and address of all parties. If one of the parties is a
corporation, it should be so stated.
Complete details of the agreement. State all promises to
be performed. Include such details as specifications and
expected outcomes. Give details on promises of payments,
including amounts, timing of payments, and interest.

26
 Include supporting documents such as technical
information, drawings, specifications, and statements of
any conditions on which the agreement depends.
Time and date of the start of the work and of the expected
completion.
Terms of payment.
Damages to be assessed in case of nonperformance.
Statement of how disputes are to be arbitrated.
Other general provisions of the agreement.
Final legal wording. Signatures of parties, witnesses, and
notary public.

27
 Breach of Contract
A breach of contract occurs when one party fails to
perform his or her part of the contract. A legal injury
is said to have occurred, and the injured party can
sue in court for damages.

General or compensatory damages are awarded to

make up for the damage that occurred. Special
damages are awarded for the direct financial loss
due to the breach.
28
 Liability
Liability means being bound or obligated to
pay damages. Two ways to incur liability are
breaking a contract or
committing a tort, such as fraud or negligence.

29
 A breach of contract refers to violating a
contracts promise.
Failure to deliver detail drawings of a new
machine by the date specified in the contract
is a breach of contract.
It makes no difference whether this was done
intentionally or not.

30
 Fraud is intentional deceitful action aimed at
depriving another party of his or her rights or
causing injury in some respect.

Examples would be double billing a client or

falsely certifying that a component had passed
the ASME pressure vessel Code.

31
 Negligence is failure to exercise proper care
and provide expertise in accordance with the
standards of the profession that results in
damage to property or injury to persons.

For example, an engineer fails to include a

major source of loading in design calculations
for a public project so that the design fails.

32
 Tort Law
Contract law and tort law are the major
divisions within civil law.

A tort is a civil wrong that involves damage

committed against a person or his or her
property, business, or reputation. It is a breach
of the rights of an individual to be secure in
his or her person and property.
33
 Tort suits involving engineers usually are
concerned with one of four types of actions:
1) Misrepresentation
2) Nuisance
3) Negligence
4) Product liability

34
 Misrepresentation is a false statement by a person of a fact that is known
to be false, with the intent to deceive another person.

Nuisance concerns the annoyance or disturbance of a person such that the

use of property becomes physically uncomfortable. Nuisances that affect
the community, such as a blaring boom box at an open window, become a
public nuisance.

Negligence was defined as in previous slide.

Product liability is the action whereby an injured party seeks to recover

damages for injury to person or property from a manufacturer or seller
when the plaintiff alleges that a defective product or design caused the
injury.
35
 Product Liability
Product liability refers to the legal actions by
which an injured party seeks to recover
damages for personal injury or property loss
from the producer or seller of a product.

Product liability suits are pursued under the

laws of tort.

36
 Goals of Product Liability Law

100 years ago - the accident victim, not the

manufacturer, should bear the economic
burdens of injury.

37
 Starting in the mid-20th century the law
began to assume a more active role.
Product liability law evolved to serve four
basic societal goals:
1) loss spreading
2) punishment
3) deterrence
4) symbolic affirmation of social values
38
 Design Aspect of Product Liability
The following aspects of the design process should be emphasized to
minimize potential problems from product liability.

Take every precaution to assure that there is strict adherence to

industry and government standards. Conformance to standards does
not relieve or protect the manufacturer from liability, but it certainly
lessens the possibility of product defects.

All products should be thoroughly tested before being released for

sale. An attempt should be made to identify the possible ways a
product can become unsafe, and tests should be devised to evaluate
those aspects of the design. When failure modes are discovered, the
design should be modified to remove the potential cause of failure.

39
 The finest quality-control techniques available will not absolve the
manufacturer of a product liability if, in fact, the product being
marketed is defective. However, the strong emphasis on product
liability has placed renewed emphasis on quality engineering as a way
to limit the incidence of product liability.

Make a careful study of the relationships between your product and

upstream and downstream components. You are required to know
how malfunctions upstream and downstream of your product may
cause failure to your product. You should warn users of any hazards of
foreseeable misuses based on these system relationships.

Documentation of the design, testing, and quality activities can be

very important. If there is a product recall, it is necessary to be able to
pinpoint products by serial or lot number. If there is a product liability
suit, the existence of good, complete records will help establish an
atmosphere of competent behavior.
40
 The design of warning labels and user instruction manuals should be
an integral part of the design process. The appropriate symbols, color,
and size and the precise wording of the label must be developed after
joint meetings of the engineering, legal, marketing, and manufacturing
staffs. Use international warning symbols.

Create a means of incorporating legal developments in product

liability into the design decision process. It is particularly important to
get legal advice from the product liability angle on innovative and
unfamiliar designs.

There should be a formal design review before the product is released

for production.

41
 Business Procedures to Minimize
Risk of Product Liability
There should be an active product liability and safety committee responsible for an
effective product liability loss control and product safety program. This committee
should have representatives from the advertising, engineering, insurance, legal,
manufacturing, marketing, materials, purchasing, and quality-control departments
of the corporation.

Insurance protection for product liability suits and product recall expenses should
be obtained.

Develop a product usage and incident-reporting system just as soon as a new

product moves into the marketplace. It will enable the manufacturer to establish
whether the product has good customer acceptance and to detect early signs of
previously unsuspected product hazards or other quality deficiencies.

42
 Protecting Intellectual Property

Intellectual property (IP) is protected by patents,

copyrights, trademarks, and trade secrets.

43
 Utility Patent
The functional features of a design can be
protected with utility patents.

The utility patent protects not only the specific

embodiments of the idea shown in the patent
application but functional equivalents as well.

44
 Design Patent
A different type of patent, the design patent, covers the
ornamental aspects of a product such as its shape,
configuration, or surface decoration.
Design patents are easier to obtain than utility patents, and
they are easier to enforce in court.
If a competitive design has essentially the same overall
appearance, then it is in violation of your patent.
A design patent can have only one claim, which is a serious
disadvantage, because it means that every unique aspect of a
products design requires a separate patent.
This can be expensive.
45
 Copyright
A copyright has only limited usefulness in
protecting product designs. This form of
intellectual property is primarily intended to
protect writing.

46
 Trademark
Trademarks are used to protect the names or
symbols (logo) of products.
A related form of protection is known as trade
dress.

47
 Trade Secret
Process innovations are more often protected
by trade secrets than product innovations.
Companies sometimes require nondisclosure
agreements from their employees and may
attempt to legally prevent an employee who
leaves their employ with sensitive trade
knowledge from working for a competitor in
order to protect a trade secret.
48
 Codes Of Ethics
These are the standards that every rational
person wants every other person to follow
and include standards such as the following:
Respect the rights of others.
Show fairness in your dealings with others.
Be honest in all actions.
Keep promises and contracts.
Consider the welfare of others.
Show compassion to others.
49
 Professional Ethics
Some values that are pertinent to professional ethics include:
Honesty and truth
Honor showing respect, integrity, and reputation for
achievement
Knowledge gained through education and experience
Efficiency producing effectively with minimum of
unnecessary effort
Diligence persistent effort
Loyalty allegiance to employers goals
Confidentiality dependable in safeguarding information
Protecting public safety and health
50