Konstfacks bibliotek : Product design : techniques in reverse engineering and new product development

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Product design : techniques in reverse engineering and new product development

Hylla	INDUSTRIDESIGN - Ihb
Personnamn	Otto, Kevin N.
Titel och upphov	Product design : techniques in reverse engineering and new product development
Utgivning, distribution etc.	Prentice Hall , Upper Saddle River ; London ; 2001 : cop. 2001
Utgivningsår	2001
	Språk: Engelska.
SAB klassifikationskod	Ihb
Fysisk beskrivning	1071 s. : ill.
Term	Industridesign
Indexterm - Okontrollerad	Produktdesign
ISBN	0-13-021271-7 0-13-021271-7
Antal i kö:	0 (0)

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*24510$aProduct design :$btechniques in reverse engineering and new product development  /$cKevin N. Otto, Kristin L. Wood
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Product Design presents an in-depth study of structured designed processes and methods. KEY TOPICS: Fundamental approach is that reverse engineering and teardowns offer a new better paradigm for design instruction, permitting a modern learning cycle of experience, hypothesis, understanding, and then execution. MARKET: For practicing engineers interested in learning about mechanical design.

Forewordp. xxi
Prefacep. xxiii
Journeys in Product Developmentp. 1

Chapter Roadmapp. 3
An Introduction to Product Designp. 3

Thoughts for the Reader and Student of Product Designp. 3
Product Development versus Designp. 5
Types of Design and Redesignp. 7
What is Engineering Design?p. 9

Modern Product Developmentp. 12

A Modern Product Development Processp. 13
A Reverse Engineering and Redesign Product Development Processp. 21

Examples of Product Development Processesp. 27

Systems: Xerox Corporationp. 27
Industrial Design: Design EDGE, Austin TX Product Design Firmp. 30
Rapid: Microsoft Corporationp. 32
Research Intensive: Raychem Corporationp. 35
Complex: Ford Motor Companyp. 38
Technical: Raytheon Corporationp. 40

Theories and Methodologies in Designp. 41
Summary and "Golden Nuggets"p. 48
Referencesp. 48

Product Development Process Toolsp. 51

Chapter Roadmapp. 53
Product Development Teamsp. 54

The Basics of Teamsp. 55
Team Composition: Seeking Synergy, Unity, Competence, and Consensusp. 56
Strategies: Team Structuresp. 62
Team Building (Basic Activities)p. 65
Team Evaluationp. 71
Closing: Product Development Teamsp. 74

Product Development Planningp. 74

Planning Processp. 75
Basic Planning and Scheduling Toolsp. 77

Summary and "Golden Nuggets"p. 79
Referencesp. 81

Scoping Product Developments: Technical and Business Concernsp. 83

Chapter Roadmapp. 85
Determining What to Developp. 86

S-Curvesp. 86
S-Curves and New Product Developmentp. 88
Comments on S-curves and Technology Forecastingp. 91

Basic Method: Mission Statement and Technical Questioningp. 93

Technical Questioningp. 93
Mission Statementsp. 94
Finger Nail Clipper: Clarification and Mission Statementp. 95

Advanced Method: Business Case Analysisp. 97

Harvard Business Case Methodology: Product Evolutionp. 98
Product Development Economic Analysisp. 99

Advanced Method: Design Driversp. 104

Design Driversp. 104
Example: Finger Nail Clipperp. 108

Summary and "Golden Nuggets"p. 110
Referencesp. 110

Understanding Customer Needsp. 111

Chapter Roadmapp. 112
Customer Satisfactionp. 112

Voice of the Customerp. 112
Customer Populationsp. 115
Types of Customer Needsp. 116
Customer Need Modelsp. 117

Gathering Customer Needsp. 118

Need Gathering Methodsp. 118
Conducting Interviews: Like/Dislike Methodp. 120
Conducting Interviews: Articulated-Use Methodp. 123
Customer Interviews: Product Feel and Industrial Designp. 129

Organizing and Prioritizing Customer Needsp. 130

Grouping Interpreted Needsp. 130
Grouping the Needs--Affinity Diagram Methodp. 130
Determining Need Importancep. 133
Customer Use Patternsp. 141
Customer Needs Documentationp. 144

Summary and "Golden Nuggets"p. 145
Referencesp. 145

Establishing Product Functionp. 147

Chapter Roadmapp. 148
Why Functional Decomposition?p. 148

Motivationp. 148
Function Modeling Basicsp. 151
Functions and Constraintsp. 152

Modeling Processp. 153
A Simple Approach: Function Treesp. 154

The FAST Methodp. 154
The Subtract and Operate Procedurep. 159

Establishing System Functionality: Creating a Function Structurep. 162

The Basics of Function Structures: Black Box and Definitionsp. 162
The Function Structure Modeling Processp. 167
Develop Process Descriptions as Activity Diagramsp. 167
Formulate Subfunctions Through Task Listingp. 168
Aggregate Subfunctions into a Refined Function Structurep. 174
Validate the Functional Decompositionp. 174
Establish and Identify Product Architecture and Assembliesp. 176

Augmentation: From Simple Function Trees to Complete Modelsp. 177

An Example of Hierarchical Function Structure Decompositionp. 179
Bringing Flows into the Functional Hierarchical Decompositionp. 180

Aggregation Revisited: Simplicity of Shooting Dartsp. 181
A Functional Common Basisp. 187

The Common Basisp. 188
Transforming Functional Modelsp. 189
Uses of a Common Basisp. 190
Aggregate Function Studyp. 191

Critique of Functional Modeling Methodsp. 192
Summary and "Golden Nuggets"p. 194
Referencesp. 194

Product Teardown and Experimentationp. 197

Chapter Roadmapp. 198
Teardown Processp. 200

Overviewp. 200
List the Design Issuesp. 201
Prepare for Product Tear Downsp. 202
Examine the Distribution and Installationp. 202
Disassemble, Measure, and Analyze Data by Assembliesp. 203
Form a Bill of Materialsp. 203

Teardown Methodsp. 204

Subtract and Operate Procedurep. 204
SOP Examplesp. 206
Force Flow (Energy Flow Field) Diagramsp. 212
Measurement and Experimentationp. 220

Post Teardown Reportingp. 234

Disassembly Plan and BOMp. 234
Exploded Views with Highlighted Featuresp. 236
Actual Product Function Structure (Network)p. 236

Applications of Product Teardownp. 238

Application: Slide-Out Auxiliary Visorp. 239
Case Study of an Automatic Iced Tea Makerp. 249

Summary and "Golden Nuggets"p. 256
Referencesp. 256

Benchmarking and Establishing Engineering Specificationsp. 259

Chapter Roadmapp. 260
Background: Know Your Enemy to Know Yourselfp. 260
A Benchmarking Approachp. 262

Form a List of Design Issuesp. 262
Form a List of Competitive or Related Productsp. 263
Conduct an Information Searchp. 263
Teardown Multiple Products in Classp. 268
Benchmark by Functionp. 268
Establish Best in Class Competitors by Functionp. 268
Plot Industry Trendsp. 269
Benchmarking Example: Coffee Millsp. 270

Support Tools for the Benchmarking Processp. 274

Indented Assembly Cost Analysisp. 274
Function--Form Diagramsp. 275
Trend Analysisp. 278
Proposal on Opportunities for Re-designp. 279
Thoughts on Benchmarking the Competitionp. 280

Setting Product Specificationsp. 283

Specification Processp. 284
Basic Method: The House of Qualityp. 289
Advanced Method: Value Analysisp. 297

Summary and "Golden Nuggets"p. 302
Referencesp. 302

Product Portfolios and Portfolio Architecturep. 303

Chapter Roadmapp. 304
Product Portfolio Architecturep. 304

Backgroundp. 304
Portfolio Architecture Typesp. 306

Choosing an Architecture Typep. 315

Theoryp. 316
Market Basis for Architecture Decisionsp. 318

Platform Architecturep. 331

Negotiating a Modular Family Platformp. 332
Basic Method: Chartsp. 334
Advanced Method: Functional Architectingp. 339
Advanced Method: Optimization Selectionp. 345

Summary and "Golden Nuggets"p. 354
Referencesp. 355

Architecturep. 357

Chapter Roadmapp. 358
Product Architecturesp. 359

Introductionp. 359
Architecture Typesp. 360
Architecture Examplesp. 361

Product Modularity: Backgroundp. 362

Types of Modularityp. 363

Modular Design: Basic Clustering Methodp. 370

Create a Function Structure of the Productp. 370
Cluster the Elements into Module Chunksp. 371
Create a Rough Geometric Layout(s)p. 374
Define Interactions and Detail Performance Characteristicsp. 376

Modular Design: An Advanced Functional Methodp. 378

Function Dependenciesp. 378
Module Heuristicsp. 379
Process: Application of the Module Heuristicsp. 391
Summaryp. 398

Architecture-Based Development Teamsp. 399

A Method of Forming Module Based Development Teamsp. 400
Application of Module-Based Development Teamsp. 401
Summary of the Development Team Methodp. 408

Summary and "Golden Nuggets"p. 408
Referencesp. 409

Generating Conceptsp. 411

Chapter Roadmapp. 413
Concept Generation Processp. 414
Basic Methods: Information Gathering and Brainstormingp. 416

Information Gathering: Conventional Aidsp. 417
Traditional Brainstormingp. 419
Brain-Ballp. 424
C-Sketch/6-3-5 Methodp. 425
Idea Generators for Intuitive Techniquesp. 432

Advanced Methods: Directed Searchp. 433

Systematic Search with Physical Principlesp. 433
Systematic Search with Classifying Schemesp. 435
Theory of Inventive Problem Solvingp. 443

Morphological Analysisp. 454

Develop Concepts for Each Product Functionp. 455

Combining Solution Principles (Concept Variants)p. 456

Digression/Caution: Function Sharingp. 459
Product Application: Fingernail Clipperp. 460
Product Application: Bilge Water Removal Productp. 461
Product Application: Smart Spoon to Assist Persons with Disabilitiesp. 464

Summary and "Golden Nuggets"p. 475
Referencesp. 476

Concept Selectionp. 477

Chapter Roadmapp. 478
Introductionp. 478

Factors that Determine Effective Decision Makingp. 479
Design Evaluationsp. 480
Information Qualityp. 480

Estimating Technical Feasibilityp. 482

Estimationp. 483
Example: Air Conditioning for an Electric Vehiclep. 484
Estimating Hintsp. 486

A Concept Selection Processp. 487

Forming Consensus on the Criteriap. 489
Forming Consensus on the Alternativesp. 491
Rankingp. 492
Assessmentp. 492
Attacking the Negativesp. 493

A Basic Method: Pugh Concept Selection Chartsp. 493

Establish the Criteria and Alternativesp. 494
Select a Datump. 494
Ranking and Assessmentp. 495
Alternative Rank Orderingp. 496
Attacking the Negativesp. 496
Iteration and Solutionp. 497
Example: Coffee Millp. 497

Advanced Discussion: Measurement Theoryp. 500

Set Structure of Evaluationp. 500
Ordinal Scalesp. 501
Interval Scalesp. 506
Ratio Scalesp. 511
Extensively Measurable Scalesp. 513

Advanced Method: Numerical Concept Scoringp. 513

Scoring with Interval Scalesp. 513
Selection Error Analysisp. 517
Concept Selection with Error Analysis: Design of a Cat Litter Box Productp. 527

A Critique of Design Evaluation Schemesp. 532
Chapter Summary and "Golden Nuggets"p. 533
Referencesp. 533

Concept Embodimentp. 535

Chapter Roadmapp. 536
Overview and Contextp. 537
Basic Methods: Refining Geometry and Layoutp. 542

General Process of Product Embodimentp. 543
Embodiment Checklistp. 546

Advanced Methods: Systems Modelingp. 550

Systems Modelingp. 550
Mechanical Embodiment Principlesp. 555
FMEA Method: Linking Fault States to Systems Modelingp. 565

Case Study: Computer Monitor Stand for a Docking Stationp. 571

Summaryp. 595

Summary and "Golden Nuggets"p. 596
Referencesp. 600

Modeling of Product Metricsp. 603

Chapter Roadmapp. 604
Introduction: Model Selection by Performance Specificationsp. 604

Model Preparation and Selection Methodp. 606
Product Application: Model Preparation and Selectionp. 607

Mathematical Modeling versus Physical Prototypingp. 610

Examplep. 610

Advanced Topic: What is a Product Model?p. 614

Informal Modelsp. 614
Formal Modelsp. 615

Constructing Product Models: basic Methodp. 622

A Basic Modeling Approachp. 623
A Product Application in Constructing Basic Models: Iced Tea Makerp. 632

Constructing Product Models: Advanced Methodp. 644

Approachp. 645
Methodp. 645

Product Models: Casesp. 648

Electric Wok Productp. 648
Handle Temperaturep. 654
Other Metrics to Integrate a Complete Modelp. 658
Comments on Design Model Validationp. 660

Summary and "Golden Nuggets"p. 661
Referencesp. 662

Design for Manufacture and Assemblyp. 663

Chapter Roadmapp. 664
Overview and Motivationp. 665
Basic Method: Design Guidelinesp. 666

Design for Assemblyp. 667
Design for Piece Part Productionp. 675

Advanced Method: Manufacturing Cost Analysisp. 685

Cost Driver Modelingp. 686
Manufacturing Cost Analysisp. 690

Critique of Design for Assembly Methodsp. 709
Chapter Summary and Golden Nuggetsp. 716
Referencesp. 716

Design for the Environmentp. 719

Chapter Roadmapp. 721
Why DFE?p. 722
Environmental Objectivesp. 722

Global Issuesp. 723
Regional and Local Issuesp. 724

Basic DFE Methods: Design Guidelinesp. 725

Application: Paper Carrier Designp. 725

Life Cycle Assessmentp. 733

Overviewp. 733
Basic Method: ATandT's Environmentally Responsible Product Assessmentp. 738
Weighted Sum Assessment Methodp. 744
Life Cycle Assessment Methodp. 752

Techniques to Reduce Environmental Impactp. 753

Design to Minimize Material Usagep. 754
Design for Disassemblyp. 756
Design for Recyclabilityp. 764
Design for Remanufacturingp. 767
Design for High-Impact Material Reductionp. 769
Design for Energy Efficiencyp. 771
Design to Regulations and Standardsp. 771

Chapter Summary and "Golden Nuggets"p. 777
Referencesp. 778

Analytical and Numerical Model Solutionsp. 781

Chapter Roadmapp. 782
Overview and Strategyp. 783

Solution Definitionp. 786
Pareto Optimalityp. 787

Basic Method: Spreadsheet Searchp. 789

Product Application: Spreadsheet Search for a Toy Rocket Productp. 792
Summaryp. 800

Fundamental Concepts in Optimizationp. 801

Constraintsp. 801
Objective Functionsp. 803
Standard Null Formp. 803

Advanced Topic: A Discussion of Analytical Formulationsp. 805

Unconstrained Problemsp. 805
Lagrangiansp. 806

Practical Optimizationp. 811

Numerical Searchp. 812
Stopping Criteriap. 813
Sensitivity Analysisp. 814
Global Optimalityp. 815
Solution Method: Matlabp. 815
Solution Method: Spreadsheet Solversp. 817

Product Applicationsp. 822

Application: Redesign of a TOMY "Push-n-Go" Trainp. 822
Application: Electric Wok Productp. 828

Summary and "Golden Nuggets"p. 830
Referencesp. 831

Physical Prototypesp. 833

Chapter Roadmapp. 834
Prototyping Essentialsp. 836

What Are Physical Models/Prototypesp. 838

Types of Prototypesp. 839

Prototypes Goalsp. 845

Uses of Prototypesp. 846

Mock-up Materials and Processesp. 848
Prototyping Processesp. 852

Rapid Prototyping Techniquesp. 854

Rapid Prototyping: A Historical Prespectivep. 856
Commercial Rapid Prototyping Processesp. 858
Choosing Rapid Prototyping for a Product?p. 864

Scale, Dimensional Analysis, and Similitudep. 866

Buckingham II Theorem and Scaled Testingp. 866
Buckle Design Examplep. 868

Basic Method: Physical Prototype Design and Planningp. 871

Guidelines for Prototype Designp. 872
Sample Prototype Applicationp. 873

Summary and "Golden Nuggets"p. 887
Referencesp. 887

Physical Models and Experimentationp. 891

Chapter Roadmapp. 892
Design of Experimentsp. 893

Basics of Designed Experimentsp. 894
Basic Method: Two Factorial Experimentsp. 901
Extended Method: Interactionsp. 916
A Basic Product Application: Redesign of a Toy Solar Carp. 922

Design of Experiments: Reduced Tests and Fractional Experimentsp. 929

Full Factorial Inefficienciesp. 929
Orthogonalityp. 933
Base Design Methodp. 934
Higher Dimensions Fractional Factorial Designsp. 936

Statistical Analysis of Experimentsp. 938

Degrees of Freedomp. 938
Correlation Coefficientp. 939
Standard Error of the Residualp. 940
t-Testp. 940
ANOVA: F-ratio Testp. 942
Other Indicators: Residual Plotsp. 949
Summary: Advanced DOE Method for Product Testingp. 949

Product Applications of Physical Modeling and DOEp. 950

Product Application I: Nerf Missilestorm (Norrell, 1995)p. 950
Blender Panel Display Evaluationp. 959
Coffee Grinder Experimental Optimizationp. 965

Summary and "Golden Nuggets"p. 977
Referencesp. 977

Physical Models and Experimentationp. 979

Chapter Roadmpap. 980
Quality Design Theoryp. 980

General Robust Design Modelp. 981
Robust Design Model Constructionp. 983

Basic Method: Taguchi's Methodp. 987

Noise Variable Matrixp. 987
Design Variable Matrixp. 989
Experimental Matrixp. 989
Signal to Noise Ratiosp. 991
Selection of a Target Designp. 994
Parameter Design and the Taguchi Philosophyp. 994

Advanced Analysis: Probability Theoryp. 1001

Sizing the Variationp. 1002
General Robust Design Problem Formulationp. 1004

Chapter Summary and "Golden Nuggets"p. 1008

Robust Design as a Design Philosophyp. 1008
Golden Nuggetsp. 1010

Referencesp. 1010

Function Structure Definitionp. 1011

Flow Definitionsp. 1011

Materialp. 1012
Energyp. 1012
Signalp. 1016

Function Definitionsp. 1017

Channelp. 1017
Supportp. 1018
Connectp. 1018
Branchp. 1019
Providep. 1020
Control Magnitudep. 1020
Convertp. 1020
Signalp. 1021

Function Structures for Example Productsp. 1021

DOE Tablesp. 1033

Base Design Tablesp. 1033
L-Array Tablesp. 1036

TRIZ Relationship Tablep. 1039
Eco-Indicator Environment Assessmentp. 1043
Indexp. 1051

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