how good is my design

7/27/2019 How Good is My Design

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Design Engineering Community is faced with many challenges in terms of Reliability, Performance, Cost

and Time. Simple Questions, when asked and answered, help Designs get better. Here are a fewsimple steps that help Design Engineers achieve Superior results and products. As a part of the Design

Process if the Engineering Team incorporates the checklist it saves the Organization, Time and Money,

resulting in enhanced Profit and Success.

What is my Design's Real Factor of Safety?

More often than not, actual answers are not known. A simple Simulation validates the Design

and gives the Designer a Factor of Safety Plot that gives true insight. This helps identifycritical regions where inspection dimensions can be used to protect component boundaries.

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Illustration 1: Factor of Safety Plot for Geneva Mechanism using SolidWorks Simulation

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When will My Product Fail?

Warranty period for products can be provided without risk of cost escalation if product life can be

estimated in advance. Fatigue life prediction helps estimate Minimum Life Guarantee for developing

fail-safe design and peace of mind. As a part of the Design Process if life is computed, it helps in the

designer specifying right choice of material after evaluating different material options and their

impending costs. This results in a win-win situation in terms of product cost and warranty resulting in

greater customer satisfaction. Assured performance during warranty period also provides for

considerable savings in terms of replacement costs, time and travel to customer place and above all

trust.

How Sustainable is my Design?

Raw-material selection, methods of manufacture and assembly, material re-cycling, consumption of

energy, water and air are influenced by Green Design Principles. Sustainable Designs are important for

market acceptability, profitability and above all, eco-friendly development of products for long term

growth and success. Air Acidification, Water Eutrophication, Energy Consumption and Carbon Footprint

assessments can be done at the Design Stage.

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Illustration 3: Life Estimation using SolidWorks

Fatigue Solver

Illustration 2: Assessments

for Sustainable Designs

using SolidWorks

Sustainability

Illustration 4: Alternative Material Evaluation for Sustainable Design



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Is my Design Cost-effective?

Material optimization, Weight Optimization and Functional optimization help reduce cost of the

product. Finite Element Analysis helps in reducing weight, number of parts and selection of

alternate materials for lower cost. This has a cascading effect in terms of power required, in

addition to handling and manufacturing costs resulting in substantial savings in overall

product cost.

Would I face Assembly Build & Quality Issues?

Allocation of tolerances at the part level, based on Process Capability and Functional

requirements eliminates re-work and performance issues. Effect of part tolerances on

assembly build quality is required to be studied using Tolerance Stack Up Analysis. This

approach leads to maximizing tolerance for assembly build requirements and performance

criteria while lowering cost of power quality. Estimation of rejections in terms of PPM

provides for a power process of evaluating alternatives at the design stage before Job 1. For

companies looking ahead to becoming innovators and technological leaders this is a crucial

and mandatory step in product development process.

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Illustration 5: Product Development Cycle for Optimization

Initial Design

RequirementsSatisfied?

AnyRoom for

Improvement?

Final Design

Change Design

Yes

Yes

No

No



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Checklist for Perfecting Designs Design for Safety Design for Manufacture

Design for Life Design for Assembly

Design for Sustainability Design for Quality

Design for Service Design for Performance

Design for Cost Design for Satisfaction

About EGS India:

Specialist Consultants in Design Engineering since 1993, EGS Computers India Private Limited

has been delivering Design Solutions to customers in India to address business challenges.

EGS India is the Authorised SolidWorks Sales, Technical Support, Training and Certification

Service Provider in India. Areas of Experties include Design Automation, Dimensional

Management, Geometric Dimensioning and Tolerancing, Finite Element Analysis and New

Product Development.

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Illustration 6: Predicting Assembly Build and PPM using SigmundWorks


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