DESIGN AND ENGINEERING

(S4)

Dr. K. B. Radhakrishnan
Professor & Head
Department of BT&BCE
SCTCE
Expediency, Economics and Environment in Design Engineering

 DESIGN FOR PRODUCTION

 Design for manufacturing (DFM) is design based on minimizing the costs of

production and/or the time to market for a product, while maintaining an
appropriate level of quality.
 •DFM begins with the formation of the design team.
 •In commercial settings, design teams committed to DFM tend to be multidisciplinary,
and they include engineers, manufacturing managers, logistics specialists, cost
accountants, and marketing and sales professionals.
 Each brings particular interests and experience to a design project, but all must
move beyond their primary expertise to focus on the project itself.
DESIGN FOR MANUFACTURING (DFM)
 A basic methodology for DFM consists of six steps:
 • Estimate the manufacturing costs for a given design alternative;
 • Reduce the costs of components;
 • Reduce the costs of assembly;
 • Reduce the costs of supporting production;
 • Consider the effects of DFM on other objectives; and
 • If the results are not acceptable, revise the design once again.
DFM
 Keep in mind when do DFM.
 •Consulting with experts on manufacturing can often reveal manufacturing
techniques that will (or will not) work with your design.
 •Production costs can usually be reduced by using commercially available
inputs rather than custom parts.
 •DFM must always be done with the client’s objectives in mind.
DESIGN FOR ASSEMBLY (DFA)

 Assembly refers to the way in which the various parts,

components, and subsystems are joined, attached, or otherwise
grouped together to form the final product.
 •Handles parts or components (i.e., retrieves and positions them
appropriately relative to each other).
 •Inserts (or mates or combines) the parts into a finished
subsystem or system.
Design for use
 Design for use“ displays an intuitive, easy to learn
concept of set adjustments.
 Driver seat of vehicles
 Door handles
 Reliability, Availability and maintainability of designs
are to be considered while designing. These are linked
to the productivity of the process.
DESIGN FOR USE

 Reliability
 Reliability is defined as the probability that a product, system, or service will perform
its intended function adequately for a specified period of time, or will operate in a
defined environment without failure.
 Reliability of a machine or equipment is the probability that the equipment will give failure
free performance of its intended functions during that time
 •We can properly measure the reliability of a component or system only
under the assumption that it has been or will be used under some specified
conditions.
 It is measured as Mean Time Between Failure (MTBF). It is the average time
between two consecutive failures.
Availability

 The availability of machine or equipment is

different from reliability.
 A machine or equipment may be highly reliable as
the failure rate is negligible and it fails only one or
two times in a given period.
 But availability may be very bad because once it
fails it takes very long to repair.
DESIGN FOR USE (Contd…)

 Maintainability
 Maintainability can be defined as “the probability that a failed component
or system will be restored or repaired to a specific condition within a
period of time when maintenance is performed within prescribed
procedures.
 It is a characteristics of design and installation which is expressed as the probability
that an item will be restored to specified conditions within a given period of time
when maintenance action is performed in accordance with prescribed procedures
and resources.
 Numerically maintainability is calculated as the Mean
Time To Repair (MTTR) which is defined as the statistical
mean of the distribution of times to repair.
 The cumulative of active repair times during a given
period of time divided by the total number of
malfunctions during the same time interval
DESIGN FOR USE (Contd…)
 This can take a number of forms, including:
 Selecting parts that are easily accessed and repaired
 Providing redundancy so that systems can be operated while maintenance
continues (providing substitute systems-ex. Additional Pumps )
 Specifying preventive or predictive maintenance procedures and
 Indicating the number and type of spare parts that should be held in
inventories in order to reduce downtime when systems fail.
DESIGN FOR SUSTAINABILITY

 The American Society of Mechanical Engineers ( stipulates that “Engineers shall consider
environmental impact in the performance of their duties)
 Environmental Issues and Design
 We can often characterize the environmental implications of a design in terms of the effects
on air quality, water quality, energy consumption, and waste generation.
 Air quality almost immediately springs to mind when we list environmental concerns
 related to design.
 Environmentally conscious engineers should also concern themselves with issues of water quality
and water consumption.
DESIGN FOR SUSTAINABILITY

 Environmental Life Cycle Assessments

 Life cycle assessment is a tool that was developed
to help product designers understand, analyse, and
document the full range of environmental effects of
design, manufacturing, transport, sale, use, and
disposal of products.
DESIGN FOR SUSTAINABILITY

 LCA has three essential steps

 Inventory analysis lists all inputs (raw materials and energy) and outputs
(wastes, and energy), as well as any intermediate outputs.
 Impact analysis lists all of the effects on the environment of each item
identified in the inventory analysis, and quantifying or qualitatively
describing the consequences (eg, adverse health effects, impacts on
ecosystems, or resource depletion).
 Improvement analysis lists, measures, and evaluates the needs and
opportunities to address adverse effects found in the first two steps.
ENGINEERING ECONOMICS IN DESIGN

 COST ESTIMATION: HOW MUCH DOES THIS PARTICULAR DESIGN COST?

 In practice, cost estimation is a complex business that requires skill
and experience.
 However, there are several ways that we can break out the cost
structure of a device that we are designing.

 The simplest, is to estimate labour, materials, and overhead costs.

LABOR, MATERIALS, AND OVERHEAD COSTS

 Costs are often broken up into the categories of labour,

material, and overhead costs.
 Labour : costs include payments to the employees who build
the designed device, as well as to support personnel who
perform necessary but often invisible tasks such as taking and
filling orders, packaging, and shipping the device.
 Labour costs also include a variety of indirect costs that are
less evident because they are generally not paid directly to
employees.
LABOUR, MATERIALS, AND OVERHEAD COSTS (Contd..)

 These indirect costs are sometimes called fringe

benefits and include health and life insurance,
retirement benefits, employers’ contributions to Social
Security, and other mandated payroll taxes.
 A simple starting point for estimating costs is to keep
good records or the activities needed to build our
design’s prototype.
LABOR, MATERIALS, AND OVERHEAD COSTS (Contd..)

 Materials include those items and inputs

directly used in building the device, along
with intermediate materials and
inventories that are consumed in the
manufacturing process
 A key tool for estimating the materials
cost of an artefact is the bill of materials
(the list of all of the parts in our design,
including the quantities of each part
required for complete assembly
LABOR, MATERIALS, AND OVERHEAD COSTS (Contd..)

 The BOM is particularly useful since it is

usually developed directly from the
assembly drawings, and so it reflects our
final design intentions.
 Materials costs can often be reduced
significantly by using commercial off the
shelf materials rather than making our own.

 This is because outside vendors have the

machinery and expertise to make very
large numbers of parts for a lot of
customers.
LABOR, MATERIALS, AND OVERHEAD COSTS (Contd..)

 The costs incurred by a manufacturer that cannot be directly assigned to a

single product are termed overhead.
 Estimating the costs of producing a design requires careful consultation with
clients or their suppliers.
 In practice, each engineering discipline has its own approaches to cost
estimating that are captured by general guidelines.
 THE COST OF DESIGN AND THE COST OF THE DESIGNED DEVICE

 There is an important distinction between the cost of designing, prototyping, and testing
a product and the cost of the product after manufacturing and distribution .
 While costing is an important element in the profitability of a design, it is generally not
a key factor in the pricing of the artefact.
 Costs are an important element in the profit equation. Revenues, on the other hand, are
determined by the price charged for an item multiplied by the number of item sold.
 For most profit maximizing firms, prices are not set on the basis of costs, but rather in
terms of what the market is willing to pay.
 The responsibilities of marketing professionals on a design team usually include
identifying design attributes that make consumers willing to pay a high price for a new
product design.
 DESIGN RIGHTS

 What is a design right?

 If you have created a new design, it’s worthwhile considering registering it
to effectively prevent others from copying or exploiting your design.
 A registered design is an excellent and cost effective tool to protect your
rights against copying and counterfeiting.
 DESIGN RIGHTS

 A design registration means you can register the look of your product. It
gives you an exclusive right to your design for a limited time.
 Designs can be registered to protect the look of your whole product, a part
of your product, or even just a small detail.

 Your product might be something functional, like a mobile phone, a drill, or

a toothbrush, or something more decorative like a vase or a piece of
jewellery.
 DESIGN RIGHTS

 You can also protect graphical symbols, logos, computer icons, user
interface graphics, even typefaces with a registered design.

 The design must be new and have individual character over prior design
registrations in order to be registered.
 ETHICS IN DESIGN

 To design means to accept responsibility for

creating designs. Designers are influenced by the
society in which they work, and designed products
influence society.
 That is why we must consider ethics and ethical
behaviour in our examination of how engineers
design things.
 ETHICS: UNDERSTANDING OBLIGATIONS

 Words like ethics, morals, obligations, and duty are used in a variety of
ways in everyday life, including seemingly contradictory or unclear ones
 Ethics
 is the discipline dealing with what is good and bad and with moral duty
and obligation
 is a set of moral principles or values
 is a theory or system of moral values
 Is the principles of conduct governing an individual or group.
 ETHICS: UNDERSTANDING OBLIGATIONS

 Moral
 relating to principles of right or wrong in behaviour
 expressing or teaching a conception of right behaviour
 These definitions define ethics as a set of guiding principles or a system that
people can use to help them behave well.
 CODES OF ETHICS: WHAT ARE OUR
PROFESSIONAL OBLIGATIONS?

 The professional societies also undertook other kinds of activities, including

promulgating design standards, and providing forums for reporting
research and innovations in practice.

 The professional engineering societies continue to play a leading role in

setting ethical standards for designers and engineers.
 CODES OF ETHICS: WHAT ARE OUR
PROFESSIONAL OBLIGATIONS?

 These ethical standards clearly speak to the various and often conflicting
obligations that an engineer must meet.
 The societies also provide mechanisms for helping engineers resolve
conflicting obligations, and, when asked, they provide the means for
investigating and evaluating ethical behaviour.
 Most professional engineering societies have published codes of ethics.
 CODES OF ETHICS: WHAT ARE OUR
PROFESSIONAL OBLIGATIONS?

 There are some points to make regarding the professional societies and
their codes.
 The differences in the codes reflect different styles of engineering practice
in the various disciplines much more than differences in their views of the
importance of ethics.
 CODES OF ETHICS: WHAT ARE OUR
PROFESSIONAL OBLIGATIONS?

 The professional societies, notwithstanding their promulgation of codes of

ethics, have not always been seen as active and visible protectors of
whistleblowers and other professionals who raise concerns about specific
engineering or design instances.
 The codes of ethics we have described are not necessarily the same as
those in all parts of the world.
 CODES OF ETHICS: WHAT ARE OUR
PROFESSIONAL OBLIGATIONS?

 Ultimately, ethics is intensely personal

 There is no way to predict when a serious conflict of obligations and loyalties will arise in our
individual lives.
 Nor can we know the specific personal and professional circumstances within which such
conflicts will be embedded.
 Nor, unfortunately, is there a single answer to many of the questions posed.
 If faced with a daunting conflict, we can only hope that we are prepared by our upbringing,
our maturity, and our ability to think and reflect about the issues that we have briefly raised.
 SAMPLE QUESTIONS

 Examine the changes in the design of a foot wear with constraints of 1) production methods, 2)
life span requirement, 3) reliability issues and 4) environmental factors. Use hand sketches and
give proper rationalization for the changes in design.
Sample question
 Describe the how to estimate the cost of a particular design using ANY of the following:
 i ) a website,
 ii) the layout of a plant,
 iii) the elevation of a building,
 iv) an electrical or electronic system or device and
 v) a car.
 Show how economics will influence the engineering designs. Use hand sketches to support your
arguments.