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PART - B

ENGINEERINGMANAGEMENT

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Chapter 5. MANAGINGENGINEERING DESIGN &

DEVELOPMENT5.1 Product & Technology life cycles

Product life cycle begins with an identification of needor suggestion of a product opportunity. The productmust be subjected to a screening process to select fromthe many ideas available those that are technically andeconomically feasible and to propose a program fortheir successful design and development.

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5.1.1 Steps or Functions and typical activitiesin the product life cycle.

PRODUCT LIFECYCLE

Consumer

Identification of Need

Wants or desires for products (becauseobvious deficiencies/problems are made

evident through basic research results)

Producer

ProductPlanningfunction

Marketing analysis; feasibility study;advanced product planning; planningreview; proposal

Productresearch

function

Basic research; applied research (needoriented); research methods; result of

research; evolution from basic research toproduct design and development

Productdesignfunction

Design requirements; conceptual design;preliminary system design; detailed design;design support; engineeringmodel/prototype development; transition

from design to productionProductionorConstruction function

Production or construction requirements;industrial engineering and operationsanalysis; quality control; productionoperations

Productevaluation

Evaluation requirements; categories of testand evaluation; test preparation

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5.1.1 Steps or Functions and typical activitiesin the product life cycle

PRODUC

T LIFECYCLE

Producer

ProductionorConstruction function

Production or construction requirements;industrial engineering and operationsanalysis; quality control; productionoperations

Product

evaluationfunction

Evaluation requirements; categories of test

and evaluation; test preparationphase(planning, resourcerequirements,etc);formal test andevaluation; data collection ,analysis,reporting and corrective action; retesting

Consumer

Product useandLogisticsupportfunction

Product distribution and operational use;elements of logistics and life cyclemaintenance support; product evaluation;modifications, product phase-out; materialdisposal, reclamation, or recycling

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5.1.2 Technology Life Cycle

Technology

development

Application

launch

Applications

growth

Mature

technologyTechnology

substitution

and obsolescenceTime

Market

volume

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Stages in the Product Life Cycle

Introduction Growth Maturity Decline

The time at each stage variesgreatly

Page 336 in 8th Edition

Page 260 in 9th Edition

DVD

Mini-disc

Electric cars

VR*

*= virtual reality

Digital cameras

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Introduction

The seller tries to stimulate demand

Promotion campaigns to get increase public awareness

Explain how the product is used,

Features Advantages BenefitsYou will lose money, but you expect to make profits in the future

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Introduction

Sales are low, and profits are below the line because your costs are greater

than the amount of money you make

you have negative profit

Need to spend a lot of money on promotion

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Growth

A lot is sold - The seller tries to sell as much as possible

Other competitor companies watch, and decide about joining in with a

competitor product

success breeds imitation (Text)

Growth will continue until too many competitors in the market - and the market

is saturated

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Growth

At the end of the growth stage, profits start to decline when competition means

you have to spend more money on promotion to keep sales going.

Spending money on promotion cuts into your profit

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Maturity

Many competitors have joined - the market is saturated

The only way to sell is to begin to lower the price - and profits decrease

It is difficult to tell the different between products since most have the same

F.A.B. - Features, Advantages & Benefits

Competition can get Nasty and commercials are intense

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Maturity

Persuasive Promotion becomes more important during this stage

That is to say, you have commercials almost begging the customer to still buy

your product because you still make it just as good.

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Decline

Newer products are now more attractive - even a low low price does not make

consumers want to buy.

Profit margin declines - and so the only way to make money is to sell a high

volume

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Decline

To increase volume you try to

1. Increase the number of customers - get new customers

2. Increase the amount each customer uses

Extend

ingthe

Produc

tLife

Cycle

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5.2 Nature of Research & Development

R & D are commonly used together and definitions

commonly used by National Science Foundation are as follows5.2.1 Research

Systematic, intensive study directed toward fuller scientificknowledge of the subject studied.

5.2.2 Basic Research

Research devoted to achieving a fuller knowledge orunderstanding, rather than a practical application of thesubject under study may be in the field of present or potentialinterest to the company.

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5.2 Nature of Research &Development..

5.2.3 Applied ResearchDirected toward the practical

application of knowledge.

5.2.4 Development

Systematic use of scientific knowledge

directed toward the production of usefulmaterials, devices, systems, or methods includingdesign and development of prototypes and

processes.

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5.3 Research Strategy and Organization

Ansoff & Stewart suggest four new

product strategies as follows;

5.3.1 First to market

5.3.2 Follow the leader

5.3.3 Me too

5.3.4 Application engineering

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5.4 Selecting R & D Projects

Need for selection

Initial Screening

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Screening of researchproject ideas

2 prototypes for physical and market test,

1 profitable product

to obtain

to find

12 ideas worthy of further evaluation through Preliminary engineering design Market research and cost/benefit analysis

6 potential products worthy of Further design development and analysis

resulting in

3 prototypes for physical and market test,

60 unstated new product ideas are screened forTechnical feasibility

Financial feasibility

Suitability to corporate resource and

objectives

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5.5 Protection of Ideas, Creativity

5.5.1 Protection of ideas

There are four legal means to protect an

organization's (or individuals) ideas andright to benefit from those ideas which are;

PatentsPatent is an exclusive property right to aninvention. A design patent is granted to theinventor on the new, original and

ornamental design of an article ofmanufacture for a term of 14 years from thedate of design patent is granted

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5.5 Protection of Ideas, Creativity5.5.1 Protection of ideas

Patents. The utility patent is concerned with how it looks.

The design must be primarily ornamental rather thanfunctional.

Plant patents are granted to distinct and new varietyof plant for 20 years from date of application

Copyrights

Copyright is a bundle of rights to reproduce, derive,

distribute, perform and display an original creativework in a tangible form for the life of the author, plus70 more years thereafter.

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Copyrights

Copyrights can be given

literary works;

musical works;pantomimes and choreographic works;

Pictorial, graphic and sculptural works;

motion pictures and other audio visual works;

a copyright protects expressions, not ideas.

5.5 Protection of Ideas,Creativity

5.5.1 Protection ofideas..

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Trademarks and other marks

A Trademark is used by amanufacturer or merchant to identifyhis goods and distinguish them from

those manufactured and sold byothers

A trade mark differs from a tradename.

A Service mark is associatedwith services rather than goods.

A certification mark marked

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5.5.2 Creativity

Nature of creativity

The Creative Process

1. Preparation

2. Frustration and incubation3. Inspiration or illumination

4. Verification

Brainstorming and Other Techniques forCreativity

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Characteristics of Creative People

Self Confidence and independence Independent in thought & action and tend toreduce group pressures.

Curiosity

Drive for knowledge about how & why thingswork

good observers with good memories

build broad knowledge about wide range of

subjects

5.5.2 Creativity..

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Characteristics of Creative People..

Approach to problems -

Open minded and uncritical in the early stagesof problem solving, generating many ideas.

Enjoy abstract thinking

Employ method, precision and exactness intheir work,

they concentrate intensively on problems

Some Personal attributes-

Some personal attributes more comfortablewith things than people

5.5.2 Creativity..

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5.6 Nature of Engineering Design

Design is the process of creating amodel, described in terms ofdrawings and specifications of asystem that will meet an identified

need of customer.

Engineering designprocess

Customerinternal or

external

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5.6 Nature of Engineering Design..

Engineering design is a process oftransforming information.

Information provides input to process; Astatement of problem to be solved,

design standards, design methods,methods of engineering science.

Through Engineering design process,

the engineer performs sequence ofactivities, decisions and analysis todevelop a solution to the problem.

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5.7 System Engineering / New ProductDevelopment

The Design of a complex engineeredsystem, from the realization of a needthrough production to engineering support

in use is known as systems engineering oras new product development.

Systems Engineering is a robust approachto the Design, Creation & Operation of

systems.

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5.7 System Engineering / New Product Development..The approach consists of- Identification and quantification of system goals

- creation of alternative system design concepts- verification of design- post implement assessment of meeting the goals

The approach is usually applied repeatedly and recursively.

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5.7 System Engineering / New ProductDevelopment..

Systems engineering process includesthe following activities,

Requirements Analysis

Financial Analysis/Allocation

Synthesis

System Analysis and Control

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5.7 System Engineering / New ProductDevelopment..

Stages in Systems Engineering or New ProductDevelopment

Conceptual Stage

Technical Feasibility Stage

Development Stage

Commercial Validation and Production-Preparation Stage

Full-Scale production Stage

Product Support Stage

Disposal Stage

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5.8 Control Systems in Design

Drawing / Design release

Configuration Management

Design Review

Management Audit of the Design Function

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5.9 Product Liability & Safety

Development of Product Liability

Reducing Liability

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5.10 Designing for Reliability

5.10.1 Significance of Reliability

A. Reliability

Reliability is the probability that a systemwill demonstrate specified performance for

a stated period of time when operatedunder specified conditions.

B. Risk

Defined as the chance (i,e., probability)of injury, damage or loss.

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5.10.2 Simple reliability models

When designing systems we

estimate the reliability of the individualcomponents

- Simple Series Model

- Simple Parallel Model

- Series Parallel Model

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5.10.3 Bathtub curve model

Useful life Wear-outInfantmortality

Life

H

azard

rate

Figure : The bathtubcurve

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5.10.4 Developing reliability over theProduct life cycle

- Planning and Apportionment

- Designing for reliability

- Flattening the Bathtub Curve

- Reliability Growth

- The Reliability Profession

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5.11 Other ability in Design

- Maintainability

- Availability

- Human factors

- Standardization- Producibility

- Value Engineering / Analysis

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Chapter 6. MANAGINGPRODUCTION OPERATIONS

6.1 Assuring Product Quality

Some Definitions

Quality - has been described as fitness for

use or customer satisfaction.

Quality has two parts

Quality of design

Quality of conformance

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Quality Costs

Prevention Costs

Incurred in advance of manufacture toprevent failures

Ex:- quality planning, training, data analysis,

process control & motivation programs Appraisal costs

Include the costs of inspection of

incoming parts and materials,inspection and test of product inprocess and finished product andmaintenance of test equipment

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Internal failure costs

Those that would not appear if there were no defects in

the product before shipment to the customer. Theyinclude scrap, rework, down time and yield losses causedby defects, cost of material review and disposition ofdefectives.

External failure costscaused by defects found after the customer

receives the replacing the product.

Ex:- Cost of investigating and adjustingcomplaints, the costs of replacing defectiveproduct returned by customer

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Figure : Effect of quality improvement onquality costs

Total Quality cost

Failurecost

Appraisal

cost

Prevention

cost

Qua

lityCosts

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Statistics of Quality

Process Control Chart

Figure: Process control chart

UpperControl

limit

Central line

Lower

Control

limit

1 2 3 4 5 6 7 8 9

Sample number

Sample

mean

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Inspection and Sampling

Taguchi Methods

Figure : Taguchi loss factor

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6.2 Productivity

Definition of Productivity

= Output/ Input

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6.3 Work Measurement

Work measurement is the art ofdetermining reasonable and fair timesfor performing various work tasks. Theseare called time standards.

Informal Time Standards

Engineered Time Standards

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6.4 Maintenance & Facilities(Plant) Engineering

Scope of Maintenance

Maintenance of existing plant equipment. Maintenance of existing plant buildings and

grounds.

Equipment inspection and lubrication.

Utilities generation and distribution. Alterations to existing equipment and buildings.

New installations of equipment and buildings.

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6.4.1 Types of Maintenance

CorrectiveSimply repair and work

Preventive - Establishment of most cost-

effective schedule for inspection

Predictive Preventive type ofmaintenance that involves the use of

sensitive instruments to predict trouble.

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6.4.2 Some Maintenance ManagementConsiderations

Size of Maintenance Staff

Work orders

Work SchedulingRepair parts inventory

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6.5 Other Manufacturing Functions

Human Resources (personnel)

Management

Purchasing and MaterialsManagement

Chapter 7. ENGINEERING IN

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7.1 Marketing & The Engineer

Types of Marketing Relationships

Transaction-Based Relationships

More sustained Relationships

Highly committed Relationships

Engineering Innovation in Marketing

Industrial ProductsAfter-sales services

Introducing New technology into the Market

Chapter 7. ENGINEERING INMARKETING & SERVICE

ACTIVITIES

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7.2 Engineers in Service Organizations

Importance of Service-ProducingIndustries

Characteristics of the Service

Sector

Some Specific Service industry examples

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p y p

-Computer Applications

Computerappliance

controls

Financial andBanking

Business

Manufacturing

Medical

Telecommunication

Government

Transportation

Semi conductors

Transistors

Integrated circuits

Increasedcapability;

decreased cost,size, power

requirement forCOMPUTERS

Figure : Impact of computer technology on service-

producing industry

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-Government Service

-College teaching andResearch

-Biomedical Engineering andthe health services

Ch t 8 PROJECT PLANNING

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8.1 Characteristics of a project

A Project represents a collection oftasks aimed toward a single set of

objectives, culminating a definableend point and having a finite lifespan and budget.

Figure: The Three legged Stoolof successful project management

Chapter 8. PROJECT PLANNING& ACQUISITION

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8.2 The Project Proposal Process

Preproposal EffortProposal preparation

Proposal contents

8.3 Project Planning ToolsScope

Schedule

costs

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8.4 Types of Contracts

Fixed Price contracts- Firm fixed price

Cost Contracts

Cost plus incentive fee

Cost plus fixed fee

Time & materials

Chapter 9 FINANCIAL

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9.1 Overview of tools for financialperformance measurement

Chapter 9. FINANCIALMANAGEMENT FOR ENGINEERS

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