What is Design?

• Design is to pull together something new or to arrange existing

things in a new way to satisfy a recognized need of society.
or
• The ability to design is both a science and an art. The science
can be learned through techniques and methods to be covered
in this text, but the art is best learned by doing design.

• Good design requires both Analysis and Synthesis.

• Analysis involves the simplification of the real world through models.
• Synthesis involves the identification of the design elements that will
comprise the product.

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 The Four C’s of Design

Creativity: Requires creation of something that has not existed

before or has not existed in the designer’s mind before

Complexity: Requires decisions on many variables and parameters

Choice: Requires making choices between many possible solutions

at all levels, from basic concepts to the smallest detail of shape

Compromise: Requires balancing multiple and sometimes

conflicting requirements

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 Engineering Design Process

• The engineering design process can be used to achieve several

different outcomes.

• Refrigerators, power tools, or DVD players, or highly complex

products such as a missile system or a jet transport plane. Another is
a complex engineered system such as an electrical power generating
station or a petrochemical plant.

• Design of a building or a bridge. However, the emphasis in this text is

on product design because it is an area in which many engineers will
apply their design skills.

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 Importance of the Engineering Design Process

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 Importance of the Engineering Design Process
• This shows that only a small fraction of the cost to produce a product (5 %) is involved
with the design process, while the other 95% of cost is consumed by the materials,
capital and labor to manufacture the product.

• The design process consists of the accumulation of many decisions that result in
design commitments that affect about 70 to 80 % of the manufactured cost of the
product.

• Decisions made in the design process cost very little in terms of the overall product
cost but have a major effect on the cost of the product.

• You cannot compensate in manufacturing for defects introduced in the design phase .

• The design process should be conducted so as to develop quality, cost-competitive

products in the shortest time possible.

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 Types of Designs

1. Original design/Innovative design:

– This form of design is at the top of the hierarchy.
– It employs an original, innovative concept to achieve a
need.
2. Adaptive design:
– This form of design occurs when the design team adapts a
known solution to satisfy a different need to produce a
novel application.
– E.g. Adapting the ink-jet printing concept to spray binder to
hold particles in place in a rapid prototyping machine

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 Types of Designs
1. Redesign:
– The task may be to redesign a component in a product that
is failing in service, or to redesign a component so as to
reduce its cost of manufacture. Often redesign is
accomplished without any change in the working principle
or concept of the original design.
2. Selection design:
– Most designs employ standard components such as
bearings, small motors, or pumps that are supplied by
vendors specializing in their manufacture and sale.
Therefore, in this case the design task consists of selecting
the components with the needed performance, quality,
and cost from the catalogs of potential vendors.
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 Ways To Think About The Engineering Design
Process

• We often talk about “designing a system.” By a system we mean

the entire combination of hardware, information, and people
necessary to accomplish some specified task.
• A system may be an electric power distribution network for a
region of the nation, a complex piece of machinery like an
aircraft jet engine, or a combination of production steps to
produce automobile parts.
• A large system usually is divided into subsystems , which in turn
are made up of components or parts .

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 A Simplified Iteration Model

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 A Simplified Iteration Model

• As per Morris Asimow, design process consisting of the above

elements as shown in fig.
• Examples of the operations might be,
• Exploring the alternative concepts that could satisfy the specified need.
• Formulating a mathematical model of the best system concept.
• Specifying specific parts to construct a subsystem.
• Selecting a material from which to manufacture a part.
• The iterative nature of design provides an opportunity to
improve the design on the basis of a preceding outcome.
• That, in turn, leads to the search for the best possible technical
condition—for example, maximum performance at minimum
weight (or cost).

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 Design Method Vs. Scientific Method

• The scientific method starts with a body of existing knowledge

based on observed natural phenomena.

• The design method starts with knowledge of the state of the

art. That includes scientific knowledge, but it also includes
devices, components, materials, manufacturing methods, and
market and economic conditions. Rather than scientific
curiosity, it is really the needs of society. When a need is
identified, it must be conceptualized as some kind of model.

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 Design Method Vs. Scientific Method

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 Design Method Vs. Scientific Method

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 A Problem-Solving Methodology

A problem-solving methodology that is useful in design consists of

the following steps.
• Definition of the problem:
– The formulation of the problem should start by writing down a problem statement.
– Problem definition often is called needs analysis.
– While it is important to identify the needs clearly at the beginning of a design
process.
• Gathering of information: The following are some of the questions concerned
with obtaining information:
– What do I need to find out?
– Where can I find it and how can I get it?
– How credible and accurate is the information?
– How should the information be interpreted for my specific need?
– When do I have enough information?
– What decisions result from the information?

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 Considerations of A Good Design

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 A Problem-Solving Methodology

• Generation of alternative solutions:

– It involves the use of creativity stimulation methods.
– the application of physical principles and qualitative reasoning.
– the ability to find and use information.
– experience helps greatly in this task.
• Evaluation of Alternatives and Decision Making:
– It involves systematic methods for selecting the best among several
concepts, often in the face of incomplete information.
– Engineering analysis procedures provide the basis for making decisions
about service performance. e.g. Design for manufacturing analyses &
and cost estimation.

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 A Problem-Solving Methodology

• Communication of the Results:

– It must always be kept in mind that the purpose of the design is to satisfy
the needs of a customer or client.
– The communication is usually by oral presentation to the sponsor as well
as by a written design report.
– Detailed engineering drawings, computer programs, 3-D computer
models, and working models are frequently among the “deliverables” to
the customer.

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 A Problem-Solving Methodology

• Communication of the Results:

– It must always be kept in mind that the purpose of the design is to satisfy
the needs of a customer or client.
– The communication is usually by oral presentation to the sponsor as well
as by a written design report.
– Detailed engineering drawings, computer programs, 3-D computer
models, and working models are frequently among the “deliverables” to
the customer.

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 Considerations of A Good Design

• Considerations of good design classified into three categories:

1. Achievement of performance requirements:
– Performance measures both the function and the behavior of the design,
that is, how well the device does what it is designed to do.
– Performance requirements can be divided into primary performance
requirements and complementary performance requirements.
E.g. Design may be required to grasp an object of a certain mass and move it 50 feet in one
minute, then Functional requirements are usually expressed in capacity measures such as
forces, strength, deflection, or energy & Complementary performance requirements are
concerns such as the useful life of the design, its robustness to factors occurring in the
service environment, its reliability, ease, economy, and safety of maintenance or power
output or consumption.
– Typical geometrical features would be fillets, holes, walls, and ribs. The
computer has had a major impact in this area by providing powerful
analytical tools based on finite element analysis.

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 Considerations of A Good Design

1. Achievement of performance requirements..

• The first concerns the service conditions under which the product must operate.
The extremes of temperature, humidity, corrosive conditions, dirt, vibration, and
noise, must be predicted and allowed for in the design. The second aspect of
environmental requirements pertains to how the product will behave with
regard to maintaining a safe and clean environment, that is, green design.
• Aesthetic requirements refer to “the sense of the beautiful.” They are concerned
with how the product is perceived by a customer because of its shape, color,
surface texture, and also such factors as balance, unity, and interest.
• An important design consideration is adequate attention to human factors
engineering, which uses the sciences of biomechanics, ergonomics, and
engineering psychology to assure that the design can be operated efficiently by
humans.
• The final major design requirement is cost.

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 Considerations of A Good Design

2. Life-cycle issues:
• The total life cycle of a part starts with the conception of a
need and ends with the retirement and disposal of the
product.
• Material selection is a key element in shaping the total life
cycle.
• There is an inherent connection between design and
material selection and the manufacturing processes.

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 IEDP- Assessment

Continuous Assessment:

Theory:

a. Attendance and Initiative 10 Marks

b. Mid Term Surprise Test 15 Marks

c. Five Assignments 25 Marks

Total Assessment 50 Marks

Laboratory Course:

Group Design Project 50 Marks

End-term examination based on entire syllabus 50 marks

Time Duration 2 Hours.

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 IEDP- Assessment

Continuous Assessment:

Theory:

a. Attendance and Initiative 10 Marks

b. Mid Term Surprise Test 15 Marks

c. Five Assignments 25 Marks

Total Assessment 50 Marks

Laboratory Course:

Group Design Project 50 Marks

End-term examination based on entire syllabus 50 marks

Time Duration 2 Hours.

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 IEDP- Assessment

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 Considerations of A Good Design

3. Regulatory and Social Issues:

• The standards produced by such societies as ASTM and ASME represent
voluntary agreement among many elements (users and producers) of
industry.
• When good design requires more than that, it may be necessary to develop
your own company or agency standards.
• The codes of ethics of all professional engineering societies require the
engineer to protect public health and safety.
• The requirements of the Occupational Safety and Health Administration
(OSHA), the Consumer Product Safety Commission (CPSC), the
Environmental Protection Agency (EPA), and the Department of Homeland
Security (DHS) place direct constraints on the designer in the interests of
protecting health, safety, and security.

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