Defence Engineering CollegeDepartment of Production

Course Syllabus

1. Instructor InformationName Charlton S. Inao

Office LocationPhone Number

E-mail charl21us@yahoo.comOffice Hours

2. Course InformationCourse Name Product Design and DevelopmentCourse Code PE-6231Credit hours 4-3-3Pre -requisite Project Management, DFMA, Statistics

3. Course Description

Aim: To understand the whole process involved in product development, from design concept to disposal and how to manage it.

Description: Introduction; Development Processes and Organizations; Product Planning; Identifying Customer Needs; Product Specifications; Concept Generation; Concept Selection; Concept Testing; Product Architecture; Industrial Design; Design for Manufacturing; Prototyping; Robust design; Patents and Intellectual Property; Product Development Economics; Managing Projects.

4. Method of InstructionClass lectures 2 fifty minutes lecture hours every week

Active learning (involves the full participation of students)

Teach inductively and to be followed by deductive assertions

Use multi-media and animated models /product demonstrations.

In-class Tutorial 3 fifty minutes tutorial hours every alternative week

Student shall prepare on given assignments/reports and solve/present them in classes

Hold discussions on complex real-world problems related to the subject

Study of lecture notes This is fully the responsibility of the students/candidates

Demonstrations Different product demonstrations; Demonstration in

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concept selection and product evaluation; DFMA.Lab assignments 3 fifty minutes tutorial hours every alternative

week Perform the respective experiments and produce

laboratory report Come prepared when coming to lab Viva-voice as part of continuous assessment scheme

Group Assignment Work in groups in not more than 4 member Recognize individual contribution

Project Level of work in terms of literature and documentation Apply scientific, statistical and management philosophy/

methods5. Learning Outcomes

After the completion of the course the student will have the following attributes:5.1 Knowledge 5.1.1 Understand the factors and processes involved in developing a product from concept to

market, and finally to its disposal.

5.1.2 Explain the functions and structure of Product Development Organization.

5.1.3 Evaluate opportunities, priorities and resources in planning a product.

5.1.4 Apply data gathering techniques and data interpretation in identifying customer’s

needs.

5.1.5 Understand how to establish and set product specifications.

5.1.6 Understand the various methods and techniques in generating product concept.

5.1.7 Apply Pugh concept, product function analysis and life cycle analysis in concept

selection of a product.

5.1.8 Measure customers’ response and interpret results in testing the concept of a product.

5.1.9 Explain product architecture, product differentiation and various level design issues in

product development.

5.2 .0 Understand the principle and impact of industrial design in product design and development.

5.2.1 Apply the tools used for the Design for Manufacturing and Assembly.

5.2.2 Understand the various methods and working principles of prototyping .

5.2.3 Apply the Taguchi Methods of Robust Engineering Design in Product Development.

5.2.4 Explain the role of Patents and Intellectual Property in new product development.

5.2.5 Understand product development economics and product/project management.

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5.3 Intellectual and practical skills

5.3.1 Perform statistical data gathering and analysis in product design and development.

5.3.2 Simulate survey for product research and product evaluation.

5.3.3 Apply principles of industrial design in product development.

5.3.4 Calculate GR & R and Cp/Cpk , FMEA RPN to evaluate the manufacturability of the

product.

5.3.5 Plan and perform Taguchi Robust Design Experiments for product design and

development applications.

5.3.6 Perform part and assembly costing and cost reduction techniques.

5.3.7 Apply project management software in managing projects.

5.4 Attitude and behavior

Appreciate the value of product design and development.

Appreciate the usefulness of product delivery process by using statistical and project

management tools.

Develop team work sprit

6. Course OutlineChapter

Week

Topics to be covered (Lecture hours)

Learning Outcomes

Assignments/activity/Practicum

Chapter : 1

Introduction to Product Design

And Development

1 Characteristic of Successful Product Development

Who Design and Develops Products?

Duration and Cost of Product Development

The Challenges of Product Development

5.1.1Lecture and

demonstration is

delivered .Report

topics will be

assigned to the

students.

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Chapter :2

Development Process and

Organizations

2 A Generic Development Process Concept Development: The

Front End Process Adapting the Generic Product

Development Process Technology Push

Products Platform Products Process Intensive

products Customized products High -Risk Product Quick Build Products Complex Systems

Product Development Process Flows

Product Development Process Organizations

5.1.2

Assigned Student

does the reporting.

Lecturer facilitates

discussion.

Chapter: 3 Product Planning

3 The Product Planning Process Four Types of Product

Development Projects The Process

Identify Opportunities Evaluate and Prioritize Projects Allocation of Resources and

Plan timing Complete Pre- Project Planning Reflect on the Results and the

Process

5.1.3

Assigned Student

does the reporting.

Lecturer facilitates

discussion.

Chapter: 4Identifying

Customer Needs

4 Gather Raw Data from Customers

Interpretation of Raw Data in Terms of Customers Need

Organize the Needs into Hierarchy

Establish the Relative Importance Needs

Reflect on the Results and Process

5.1.4

Assigned Student

does the reporting.

Lecturer facilitates

discussion.

4

Chapter: 5Product

Specifications

5 What are Specifications? When are Specifications

Established? Establishing Target

Specifications Setting the Final Specifications

Develop Technical Models of the Products Develop a Cost Model

of the Product Refine the

Specifications, Making trade Offs Where Necessary Flow Down the

Specifications as Appropriate Reflect on the Results

and the Process Target Costing( Lab Activity)

5.1.1

5.1.5

Assigned Student

does the reporting.

Lecturer facilitates

discussion.

Students do the lab

exercises.

Chapter: 6Concept Generation

6 The Activity of Concept Generation

A Five Step Method Clarify the Problem Search Externally Search Internally Explore Systematically Reflect on the Solutions

and the Process

5.1.6

Assigned Student

does the reporting.

Lecturer facilitates

discussion.

Chapter: 7Concept Selection

7 Concept Selection : An Integral Part of the Product Development Process

Methods for Choosing a Concept A Structured Method Offers

Several Benefits Overview of Methodology Concept Screening, Concept Scoring A Concept Screening

Matrix(Lab) Concept Scoring Matrix(Lab)

5.1.7

Assigned Student

does the reporting.

Lecturer facilitates

discussion.

Students do the lab

exercises.

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Chapter: 8Concept Testing

8 Defining the Purpose of the Concept Test

Choosing s Survey Population Choosing a Survey Format Communicating the Concept Measuring the Customers

Response Interpreting the Results Reflecting on the Results and the

Process Estimating Market Sizes

5.1.8

Assigned Student

does the reporting.

Lecturer facilitates

discussion.

Students do the lab

exercises.

9 Midterm- Examination

Chapter: 9Product Architecture

10 What is Product Architecture?

Types of Modularity Definition of Product

Architecture Implications of the Architecture

Product Change Product Variety Standardization Performance Manufacturability

Definition of Product Establishing the Architecture Delayed Differentiation Platform Planning Related System Level Design

Issues

5.1.9

Assigned Student

does the reporting.

Lecturer facilitates

discussion.

Chapter: 10Industrial Design

11 What is Industrial Design? Assessing the Need for Industrial

Design The Impact of Industrial Design The Industrial Design Process Management of the Industrial

Design Process Assessing the Quality of Industrial

Design

5.2.0

Assigned Student

does the reporting.

Lecturer facilitates

discussion.

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Chapter: 11Design for

Manufacturing

12 Introduction Estimation of Manufacturing Cost Components Cost Reduction Reduction of the Costs of Assembly Reduction of the Costs of

Supporting Production Impact of DFM Decisions on Other

Factors Material Costs Component Manufacturing Costs Assembly Costs Manufacturing Process Capability

Study(Lab) Dimensional Evaluation(FAI)(Lab) Gauge Repeatability and

Reproducibility(Lab) FMEA(Lab)

5.2.1

Assigned Student

does the reporting.

Lecturer facilitates

discussion.

Students do the lab

exercises.

Chapter 12Prototyping

13 Introduction Understanding Prototypes Principles of Prototyping Prototyping Technologies

Stereo Lithography Silicon Rubber Molding Solid Ground Cutting Selective Laser Sintering Laminated Object

Manufacturing Planning for Prototypes

5.2.2

Assigned Student

does the reporting.

Lecturer facilitates

discussion.

Chapter: 13Robust Design

14 What is Robust Design? Design of Experiments

The Robust Design Process Identify Control Factors,

Noise factors and Performance Metrics Formulate an Objective

Function Develop the

Experimental Plan Run the Experiment Conduct the Analysis Select and Confirm

Factor Set points Reflect and Repeat Orthogonal Arrays(Lab

Activity)

5.2.3

Assigned Student

does the reporting.

Lecturer facilitates

discussion.

Students do the lab

exercises.

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Chapter:14

Patents and Intellectual Property

15 What is Intellectual Property?

Utility Patents Preparing a Disclosure

Formulate a Strategy and Plan Study prior Inventions Outline Claims Write the Description of

the Invention Refine Claims Reflect on the Results

and the Process Trademarks

Advice to Individual Inventors

5.2.4

Assigned Student

does the reporting.

Lecturer facilitates

discussion.

Chapter: 15

Product

Development

Economics

16 Elements of Economic Analysis

Economic Analysis Process

Build a Base Case Financial Model Perform Sensitivity

Analysis Use Sensitivity Analysis

to understand Project trade Offs Consider the Influence of

Qualitative Factors on Project Success

Time Value of Money and the NPV

technique (lab work)

Modeling Uncertain Cash Flows

Using Net Present value Analysis(lab

work)

5.2.5

Assigned Student

does the reporting.

Lecturer facilitates

discussion.

Students do the lab

exercises.

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Chapter: 16

Managing Projects

17 Introduction Understanding and

Representing Tasks Sequential, Parallel, Coupled Tasks Design Structure Matrix Gantt Charts The Critical Path Method

Baseline Project Planning The Contract Book Project Task List Team Staffing and Organization Project Schedule Project Budget Project Risk Plan Modifying the Baseline Plan

Accelerating Project Project Execution

Coordination Mechanisms Assessing Project Status Corrective Actions

Post Mortem Project Evaluation

Design Structure Matrix Example(lab work)

5.2.5 Assigned Student

does the reporting.

Lecturer facilitates

discussion.

Students to present

the product/project

with complete

documentation(fun

damental function

report)

18/19 Final Examination period

7. Laboratory /Practicum Activities

No Experiments Title

1 Market Needs Survey for a New product

2 Brainstorming for New Product Design

3 Pugh Selection Method /Concept Screening Matrix for a Specific Product

4 Taguchi Methods /Robust Design of Experiments

5 Target Costing/ Cost Exposure/ Cost Reduction

6 Rapid Prototyping/SLA of a Product

8. Required Text and Reference

9

Text Book

K. Ulrich , and S. Eppinger, “ Product Design and Development,:4th

Ed. , Mc Graw Hill , 2007

Reference Books 1. A. C. Chitale and R. C. Gupta, “ Product Design and

Manufacturing”, PHI, 2nd Ed, 2005.

2. Tim Jones, “New Product Development: An introduction to a

Multi- functional Process,” Butterworth Heinemann, 1996

3. Geoffrey B., Peter Dewhurst, and Winston Knight,” Product

Design for Manufacture and Assembly, CRC Press, 3rd Ed, 2010.

4. Paul Trott, :” Innovation Management and New Product

Development,”4th Ed, Pearson Education Ltd., 1995

5. Jonathan Cagan and Craig Vogel, “ Creating Breakthrough

Products: Innovation from Product Planning to Program Approval,

FT Press, 1st Ed, 2010.

Software Required Rhino 3D Surface Modeling, Minitab 16, MS Project Management

Software, Siemens Unigraphics, CATIA, Autocad

9. Assessment

Type Weight Due date Behavior and Criteria

Mid semester Exam 25% 9th week of the semester Examination will be set to

address learning outcomes

5.1.1, 5.1.2, 5.1.3, 5.2.2 and

5.2.3 and the criteria is to

get all questions answered

correctly

Final semester Exam 30% 17th week of the semester Examination will be set to address learning outcomes5.1.3, 5.1., 5.1.6 and 5.1.7 and the criteria is to get all

questions answered correctly

Assignment 10% TBD Individually unique questions will be given to check the level of

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confidence and the criteria is to get correct answer.

Lab Practice 10% Every alternative weeks Perform all the stated experiments completely and report accordingly

Individual Report 25% TBD Problems related to modeling and simulation of physical systems will be given and the criteria is to produce relevant document, scientific approach to solve the problem in question, and presentation skill

10. Academic HonestyCopying from any outside sources (e.g. Fellow students, and Internet, etc.) on any material to be graded is not permitted, and will be considered cheating. Cheating will result in failure of the assignment, failure of the class and/or face possible disciplinary action. Each student is responsible for securing his or her work from copying. Each student is expected to abide by college policies on academic conduct.

11. Due DateAll assignments must be turned in the class on the due date for full credit. No assignment will be accepted after class on the due date. Since the group assignment is due in week 14, papers for this presentation should be submitted before one week of the 14th week. Failure of submission and presentation of the group assignment in week 14 will be awarded as zero out of 10 points.

12. Classroom BehaviorAnything that disturbs your instructor or your colleagues during the class period is considered a troublesome behavior. Examples include: Using mobiles, PDA, making offensive remarks, sleeping, working on assignments related to other courses, etc. troublesome behaviors are completely prohibited.

13. Approval (Affidavit)Name : Signature DateInstructor:Section Head:Department Head:

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