Product Design Overview
What is Design? • The word “design” is often used as a generic term that refers to anything that was made by a conscious human effort. • Design is also a process that is used to solve problems.
Design Process • A design processis a systematic problem-solving strategy, with criteria and constraints, used to develop many possible solutions to solve or satisfy human needs or wants and to narrow down the possible solutions to one final choice. • – ITEA Standards for Technological Literacy
Design Process • A design processis a strategy used to develop solutions to solve human needs or wants.
Example Design Process • Identify problem(s) • Investigate and research options • Generate alternative solutions • Choose a solution • Developmental work • Model and/or prototype • Test and evaluate • Redesign and improve
Components • Individual parts of products • Simple • Wire • Complicated • Engine parts
Assembly • When assembly operations begin, all of the necessary parts must be available in the right quantities. • Sometimes assembly work is completed by hand. • Sometimes automatic assembly machines are used.
Automatic Processing • Computers are used to control processing. • These computer-controlled methods for processing materials are referred to as automatic processing.
Computer Numerical-Controlled Machining • In the past all machines were controlled by operators. • Now CNC is commonly used. • The numerical directions are contained in a computer program. • Not only can the computer give directions to machines, it can also receive feedback. • For example, it a cutting tool is broken, the computer is sent this information. The machine will then stop.
New Technology for Cutting • For many years, cutting had to be done using a saw, knife blade, or cutter. • Thanks to new technology, new processes are being developed. • Waterjet Cutting is the process of using a highly pressurized jet of water to cut a material. • Squirting water at a rate of 50,000 PSI turns the water into a knife blade. • The waterjet follows a path guided by a computer program.
New Technology for Cutting • Laser Cutting is the process of using a concentrated, high energy beam of light to cut materials. • Laser cutting is used to engrave the molds used to make CDs. • Like Waterjet Cutting, laser cutting is computer-controlled.
Production Control • Production control is controlling what is made and when it is made. • How do workers know when to start on a certain product? • How many parts should be made at one time? • When will products be ready to ship to the customer? • A plan for controlling production provides answers to these questions.
Production Control • Production Schedule-time chart that lists parts and shows how many of each the company plans to make in a certain period of time • Work in Process(WIP)-all material that is being worked on • Shop Floor Control-used to keep track of work that has been completed
Inventory Control • Inventory is the quantity of items on hand. • Keeping Inventory means keeping track of • Raw materials -any material before it enters processing • Purchased parts -ready-made parts that the company buys • Supplies -items needed to keep the plant running smoothly • Finished goods -completed products not yet sold
Quality Assurance • Prevention involves doing everything possible to prevent variation in materials or processes before parts are made. • Detection means inspecting to find variations in parts or products after they have been produced.
Quality Assurance • Quality Assurance means making sure the product is produced according to plans and meets all specifications. QUALITY ASSURANCE PREVENTION DETECTION Statistical Process Control Inspection Control Charting Reworking
Inspection • To inspect something means to look at it and compare it to a standard. • Specifications are the detailed descriptions of the design standards for a part or product. • Materials • Size • Shape • Function • Performance
Evolution of Product Design
History of Products • Why do we change products? • Who impacts these changes?
Room Key History of Products • When do changes take place? • Where do these changes come from? • What advantages and disadvantages are associated with these changes?
Example of Product Evolution • MIT Invention Index at the Massachusetts Institute of Technology, asked which of five inventions Americans could not live without. • “The toothbrush emerged as the undisputed champ, beating out the car, the personal computer, the cell phone, and the microwave, in that order, as the most prized innovation.”
Example of Product Evolution • Some records indicate a version of the toothbrush dates back as far as 5000 years ago. Babylonians rubbed a “chew stick” on their teeth and mouth to keep them clean.
Example of Product Evolution • Companies in the U.S. started mass producing the toothbrush around 1885. • Most Americans did not brush their teeth until Army soldiers in World War II were taught the habit of tooth brushing and brought their enforced habit back home after the War.
Example of Product Evolution • Natural bristles were used in toothbrushes until nylon was discovered. In 1938, nylon, invented by Dupont, replaced the natural bristle. One of the first nylon toothbrushes to commercialize the industry was called Doctor West’s Miracle toothbrush.
Example of Product Evolution • In 1960 the first commercialized electric toothbrush was marketed in the United States. The technology was developed in Switzerland in 1939.
Example of Product Evolution
Example of Product Evolution vs.
Example of Product Evolution • Toothbrush designs are now starting to include electronics. The Radius™ toothbrush has a built-in timer that blinks light or plays music to let you know how long to brush.
