Product Design

ISBN-10: 0130212717

ISBN-13: 9780130212719

Edition: 2001

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Book details

List price: $253.80
Copyright year: 2001
Publisher: Prentice Hall PTR
Publication date: 11/28/2000
Binding: Paperback
Pages: 1104
Size: 7.00" wide x 9.50" long x 1.75" tall
Weight: 3.608
Language: English

Foreword
Preface
Journeys in Product Development
Chapter Roadmap
An Introduction to Product Design
Thoughts for the Reader and Student of Product Design
Product Development versus Design
Types of Design and Redesign
What is Engineering Design?
Modern Product Development
A Modern Product Development Process
A Reverse Engineering and Redesign Product Development Process
Examples of Product Development Processes
Systems: Xerox Corporation
Industrial Design: Design EDGE, Austin TX Product Design Firm
Rapid: Microsoft Corporation
Research Intensive: Raychem Corporation
Complex: Ford Motor Company
Technical: Raytheon Corporation
Theories and Methodologies in Design
Summary and "Golden Nuggets"
References
Product Development Process Tools
Chapter Roadmap
Product Development Teams
The Basics of Teams
Team Composition: Seeking Synergy, Unity, Competence, and Consensus
Strategies: Team Structures
Team Building (Basic Activities)
Team Evaluation
Closing: Product Development Teams
Product Development Planning
Planning Process
Basic Planning and Scheduling Tools
Summary and "Golden Nuggets"
References
Scoping Product Developments: Technical and Business Concerns
Chapter Roadmap
Determining What to Develop
S-Curves
S-Curves and New Product Development
Comments on S-curves and Technology Forecasting
Basic Method: Mission Statement and Technical Questioning
Technical Questioning
Mission Statements
Finger Nail Clipper: Clarification and Mission Statement
Advanced Method: Business Case Analysis
Harvard Business Case Methodology: Product Evolution
Product Development Economic Analysis
Advanced Method: Design Drivers
Design Drivers
Example: Finger Nail Clipper
Summary and "Golden Nuggets"
References
Understanding Customer Needs
Chapter Roadmap
Customer Satisfaction
Voice of the Customer
Customer Populations
Types of Customer Needs
Customer Need Models
Gathering Customer Needs
Need Gathering Methods
Conducting Interviews: Like/Dislike Method
Conducting Interviews: Articulated-Use Method
Customer Interviews: Product Feel and Industrial Design
Organizing and Prioritizing Customer Needs
Grouping Interpreted Needs
Grouping the Needs--Affinity Diagram Method
Determining Need Importance
Customer Use Patterns
Customer Needs Documentation
Summary and "Golden Nuggets"
References
Establishing Product Function
Chapter Roadmap
Why Functional Decomposition?
Motivation
Function Modeling Basics
Functions and Constraints
Modeling Process
A Simple Approach: Function Trees
The FAST Method
The Subtract and Operate Procedure
Establishing System Functionality: Creating a Function Structure
The Basics of Function Structures: Black Box and Definitions
The Function Structure Modeling Process
Develop Process Descriptions as Activity Diagrams
Formulate Subfunctions Through Task Listing
Aggregate Subfunctions into a Refined Function Structure
Validate the Functional Decomposition
Establish and Identify Product Architecture and Assemblies
Augmentation: From Simple Function Trees to Complete Models
An Example of Hierarchical Function Structure Decomposition
Bringing Flows into the Functional Hierarchical Decomposition
Aggregation Revisited: Simplicity of Shooting Darts
A Functional Common Basis
The Common Basis
Transforming Functional Models
Uses of a Common Basis
Aggregate Function Study
Critique of Functional Modeling Methods
Summary and "Golden Nuggets"
References
Product Teardown and Experimentation
Chapter Roadmap
Teardown Process
Overview
List the Design Issues
Prepare for Product Tear Downs
Examine the Distribution and Installation
Disassemble, Measure, and Analyze Data by Assemblies
Form a Bill of Materials
Teardown Methods
Subtract and Operate Procedure
SOP Examples
Force Flow (Energy Flow Field) Diagrams
Measurement and Experimentation
Post Teardown Reporting
Disassembly Plan and BOM
Exploded Views with Highlighted Features
Actual Product Function Structure (Network)
Applications of Product Teardown
Application: Slide-Out Auxiliary Visor
Case Study of an Automatic Iced Tea Maker
Summary and "Golden Nuggets"
References
Benchmarking and Establishing Engineering Specifications
Chapter Roadmap
Background: Know Your Enemy to Know Yourself
A Benchmarking Approach
Form a List of Design Issues
Form a List of Competitive or Related Products
Conduct an Information Search
Teardown Multiple Products in Class
Benchmark by Function
Establish Best in Class Competitors by Function
Plot Industry Trends
Benchmarking Example: Coffee Mills
Support Tools for the Benchmarking Process
Indented Assembly Cost Analysis
Function--Form Diagrams
Trend Analysis
Proposal on Opportunities for Re-design
Thoughts on Benchmarking the Competition
Setting Product Specifications
Specification Process
Basic Method: The House of Quality
Advanced Method: Value Analysis
Summary and "Golden Nuggets"
References
Product Portfolios and Portfolio Architecture
Chapter Roadmap
Product Portfolio Architecture
Background
Portfolio Architecture Types
Choosing an Architecture Type
Theory
Market Basis for Architecture Decisions
Platform Architecture
Negotiating a Modular Family Platform
Basic Method: Charts
Advanced Method: Functional Architecting
Advanced Method: Optimization Selection
Summary and "Golden Nuggets"
References
Architecture
Chapter Roadmap
Product Architectures
Introduction
Architecture Types
Architecture Examples
Product Modularity: Background
Types of Modularity
Modular Design: Basic Clustering Method
Create a Function Structure of the Product
Cluster the Elements into Module Chunks
Create a Rough Geometric Layout(s)
Define Interactions and Detail Performance Characteristics
Modular Design: An Advanced Functional Method
Function Dependencies
Module Heuristics
Process: Application of the Module Heuristics
Summary
Architecture-Based Development Teams
A Method of Forming Module Based Development Teams
Application of Module-Based Development Teams
Summary of the Development Team Method
Summary and "Golden Nuggets"
References
Generating Concepts
Chapter Roadmap
Concept Generation Process
Basic Methods: Information Gathering and Brainstorming
Information Gathering: Conventional Aids
Traditional Brainstorming
Brain-Ball
C-Sketch/6-3-5 Method
Idea Generators for Intuitive Techniques
Advanced Methods: Directed Search
Systematic Search with Physical Principles
Systematic Search with Classifying Schemes
Theory of Inventive Problem Solving
Morphological Analysis
Develop Concepts for Each Product Function
Combining Solution Principles (Concept Variants)
Digression/Caution: Function Sharing
Product Application: Fingernail Clipper
Product Application: Bilge Water Removal Product
Product Application: Smart Spoon to Assist Persons with Disabilities
Summary and "Golden Nuggets"
References
Concept Selection
Chapter Roadmap
Introduction
Factors that Determine Effective Decision Making
Design Evaluations
Information Quality
Estimating Technical Feasibility
Estimation
Example: Air Conditioning for an Electric Vehicle
Estimating Hints
A Concept Selection Process
Forming Consensus on the Criteria
Forming Consensus on the Alternatives
Ranking
Assessment
Attacking the Negatives
A Basic Method: Pugh Concept Selection Charts
Establish the Criteria and Alternatives
Select a Datum
Ranking and Assessment
Alternative Rank Ordering
Attacking the Negatives
Iteration and Solution
Example: Coffee Mill
Advanced Discussion: Measurement Theory
Set Structure of Evaluation
Ordinal Scales
Interval Scales
Ratio Scales
Extensively Measurable Scales
Advanced Method: Numerical Concept Scoring
Scoring with Interval Scales
Selection Error Analysis
Concept Selection with Error Analysis: Design of a Cat Litter Box Product
A Critique of Design Evaluation Schemes
Chapter Summary and "Golden Nuggets"
References
Concept Embodiment
Chapter Roadmap
Overview and Context
Basic Methods: Refining Geometry and Layout
General Process of Product Embodiment
Embodiment Checklist
Advanced Methods: Systems Modeling
Systems Modeling
Mechanical Embodiment Principles
FMEA Method: Linking Fault States to Systems Modeling
Case Study: Computer Monitor Stand for a Docking Station
Summary
Summary and "Golden Nuggets"
References
Modeling of Product Metrics
Chapter Roadmap
Introduction: Model Selection by Performance Specifications
Model Preparation and Selection Method
Product Application: Model Preparation and Selection
Mathematical Modeling versus Physical Prototyping
Example
Advanced Topic: What is a Product Model?
Informal Models
Formal Models
Constructing Product Models: basic Method
A Basic Modeling Approach
A Product Application in Constructing Basic Models: Iced Tea Maker
Constructing Product Models: Advanced Method
Approach
Method
Product Models: Cases
Electric Wok Product
Handle Temperature
Other Metrics to Integrate a Complete Model
Comments on Design Model Validation
Summary and "Golden Nuggets"
References
Design for Manufacture and Assembly
Chapter Roadmap
Overview and Motivation
Basic Method: Design Guidelines
Design for Assembly
Design for Piece Part Production
Advanced Method: Manufacturing Cost Analysis
Cost Driver Modeling
Manufacturing Cost Analysis
Critique of Design for Assembly Methods
Chapter Summary and Golden Nuggets
References
Design for the Environment
Chapter Roadmap
Why DFE?
Environmental Objectives
Global Issues
Regional and Local Issues
Basic DFE Methods: Design Guidelines
Application: Paper Carrier Design
Life Cycle Assessment
Overview
Basic Method: ATandT's Environmentally Responsible Product Assessment
Weighted Sum Assessment Method
Life Cycle Assessment Method
Techniques to Reduce Environmental Impact
Design to Minimize Material Usage
Design for Disassembly
Design for Recyclability
Design for Remanufacturing
Design for High-Impact Material Reduction
Design for Energy Efficiency
Design to Regulations and Standards
Chapter Summary and "Golden Nuggets"
References
Analytical and Numerical Model Solutions
Chapter Roadmap
Overview and Strategy
Solution Definition
Pareto Optimality
Basic Method: Spreadsheet Search
Product Application: Spreadsheet Search for a Toy Rocket Product
Summary
Fundamental Concepts in Optimization
Constraints
Objective Functions
Standard Null Form
Advanced Topic: A Discussion of Analytical Formulations
Unconstrained Problems
Lagrangians
Practical Optimization
Numerical Search
Stopping Criteria
Sensitivity Analysis
Global Optimality
Solution Method: Matlab
Solution Method: Spreadsheet Solvers
Product Applications
Application: Redesign of a TOMY "Push-n-Go" Train
Application: Electric Wok Product
Summary and "Golden Nuggets"
References
Physical Prototypes
Chapter Roadmap
Prototyping Essentials
What Are Physical Models/Prototypes
Types of Prototypes
Prototypes Goals
Uses of Prototypes
Mock-up Materials and Processes
Prototyping Processes
Rapid Prototyping Techniques
Rapid Prototyping: A Historical Prespective
Commercial Rapid Prototyping Processes
Choosing Rapid Prototyping for a Product?
Scale, Dimensional Analysis, and Similitude
Buckingham II Theorem and Scaled Testing
Buckle Design Example
Basic Method: Physical Prototype Design and Planning
Guidelines for Prototype Design
Sample Prototype Application
Summary and "Golden Nuggets"
References
Physical Models and Experimentation
Chapter Roadmap
Design of Experiments
Basics of Designed Experiments
Basic Method: Two Factorial Experiments
Extended Method: Interactions
A Basic Product Application: Redesign of a Toy Solar Car
Design of Experiments: Reduced Tests and Fractional Experiments
Full Factorial Inefficiencies
Orthogonality
Base Design Method
Higher Dimensions Fractional Factorial Designs
Statistical Analysis of Experiments
Degrees of Freedom
Correlation Coefficient
Standard Error of the Residual
t-Test
ANOVA: F-ratio Test
Other Indicators: Residual Plots
Summary: Advanced DOE Method for Product Testing
Product Applications of Physical Modeling and DOE
Product Application I: Nerf Missilestorm (Norrell, 1995)
Blender Panel Display Evaluation
Coffee Grinder Experimental Optimization
Summary and "Golden Nuggets"
References
Physical Models and Experimentation
Chapter Roadmpa
Quality Design Theory
General Robust Design Model
Robust Design Model Construction
Basic Method: Taguchi's Method
Noise Variable Matrix
Design Variable Matrix
Experimental Matrix
Signal to Noise Ratios
Selection of a Target Design
Parameter Design and the Taguchi Philosophy
Advanced Analysis: Probability Theory
Sizing the Variation
General Robust Design Problem Formulation
Chapter Summary and "Golden Nuggets"
Robust Design as a Design Philosophy
Golden Nuggets
References
Function Structure Definition
Flow Definitions
Material
Energy
Signal
Function Definitions
Channel
Support
Connect
Branch
Provide
Control Magnitude
Convert
Signal
Function Structures for Example Products
DOE Tables
Base Design Tables
L-Array Tables
TRIZ Relationship Table
Eco-Indicator Environment Assessment
Index
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