product design and development syl 2011-3-30 final
TRANSCRIPT
Defence Engineering CollegeDepartment of Production
Course Syllabus
1. Instructor InformationName Charlton S. Inao
Office LocationPhone Number
E-mail [email protected] 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
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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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