Bahan Kuliah By DR A. Riza Wahono
Structure of Design Process Inti dari desain adalah penalaran dari fungsi menuju bentuk Function ===> Form Seringkali penalaran logika tidak benar, dan tidak konklusif
Metodologi : Task untuk mendapat reliable, effektif dan efisien desain Jenis model dalam proses desain: 1. problem solving model 2. proses model (level abstraksi) 3. phase model of product development proses
Terminologi: penyamaan ttg arti dalam penggunaan kata
Dr A. Riza Wahono :
Product Development
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Structure of design Process 1. PROBLEM SOLVING MODEL Desain dilakukan dalam bentuk spesifik problem solving dimana steps atau tahapan tahapannya dapat dengan jelas dibedakan satu sama lain, dan membentukdaur yang berperan dalam dalam setiap fase dari produk desain dan proses pengembangan produk Daur empiris adalah model dasar untuk problem solving Dengan menyesuaikan daur empiris pada proses pemecahan masalah desain akan menhasilkan sebuah ‘basic desain cycle’ (daur desain dasar) Basic design cycle merupakan sebuah model fundamental dari proses desain
Dr A. Riza Wahono :
Product Development
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Structure of design Process 1. PROBLEM SOLVING MODEL Siklus Empiris observasi => supposisi => Ekspektasi =>testing=> Evaluasi karakteristik a. trying, problem solving, thus designing (trial & error) b. trying dalam bentuk imaginasi tidak dalam realitas c. pengembangan mengikuti pola spiral (melalui siklus yang sama beberapa kali) Dr A. Riza Wahono :
Product Development
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Structure of Design Process 1. PROBLEM SOLVING MODEL Siklus Empiris penggunaan aktual dari siklus tidak harus sama untuk keilmuan yang berbeda misalnya saja untuk sains empiris observasi=> induksi => deduksi => testing => evaluasi observasi : pengumpulan dan pengelompokkan bahan empiris serta pembentukan hypothesis induksi : formulasi dari hypothesis deduksi : konsekwensi spesial yang didapat dengan hasil prediksi yang eksplisit & akurat melaui testing evaluasi : interpretasi dari hasil test Dr A. Riza Wahono :
Product Development
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Structure of Design Process 1. PROBLEM SOLVING MODEL Siklus Empiris : preskriptif model untuk pemecahan problem praktis ( Hall) a. Pendefinisian Problem (study ttg kebutuhan & lingkungan) b. Nilai dari desain sistim (penetapan objectif dan kriteria) c. Sintesa sistim ( pengembangan alternatif solusi) d. Analisa sistim (deduksi konsekwensi dari setiap alternatif) e. seleksi yang terbaik (perbandingan konsekwensi dgn kriteria) f. Perencanaan untuk tindakan (implementasi ) Dr A. Riza Wahono :
Product Development
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Basic Design Process
Industri & Bisnis
Elektrik & Elektronik Aplikasi Komputer
Nilai dan Peradaban
Presentasi Evaluasi
Analisis & Optimisasi Sintesis Pendefinisian problem Kebutuhan
Dr A. Riza Wahono :
Product Development
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Structure of Design Process 1. PROBLEM SOLVING MODEL Siklus Dasar (Basic cycle) Function, Analysis, criteria, synthesis, provisional design, simulation, expected properties, Evaluation, value of design, decision, approved design Considered as Fundamental model of designing
Dr A. Riza Wahono :
Product Development
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Structure of Design Process 1. PROBLEM SOLVING MODEL • Fungsi
Siklus Dasar Analisa Sinthesa
• Desain Awal
Simulasi
• Karakteristik
Evaluasi Keputusan Dr A. Riza Wahono :
• Kriteria
Product Development
yang diharapkan
• Penilaian sebuah desain • Bentuk Desain disetujui “ Struktur Proses Desain ” Modul 9
9
Structure of Design Process 1. PROBLEM SOLVING MODEL Siklus Dasar Spec 1 Design 1
Design 2 Design 3
Dr A. Riza Wahono :
Spec 2 Properties
Perbandingan Perbandingan
Spec 3 Properties
Perbandingan
Properties Proses iterative dalam desain
Product Development
Final Desain
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Structure of Design Process 2. MODEL PRODUCT DESIGN Pada model ini, proses desain dikerjakan dalam beberapa tingkatan dari proses abstraksi. Tingkatan ini didasarkan pada representasi pembuatan desain seperti, Struktur fungsi, solusi prinsipal, dan preliminari desain 1. Struktur dari fungsi : representasi dari fungsi yang diinginkan pada produk dan elemen elemennya 2. Pemecahan solusi secara prinsip: melalui pendefinisian prinsip kerja, model tindakan, 3. ‘pengejawantahan’ (embodiment) desain : sebuah penggambaran (gambar teknik) dari geometri dan physicochemical Dr A. Riza Wahono :
Product Development
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Structure of Design Process TAHAPAN PROSES DESAIN PRODUK F 1. Struktur dari fungsi : ϕ
Human Box Tanah Ground Dr A. Riza Wahono :
Batang pengungkit
Batu Product Development
• Elemen • Batasan sistim • Hubungan
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Structure of Design Process TAHAPAN PROSES DESAIN PRODUK 1. Struktur dari fungsi : F F1
F
Batang Pengungkit + batu
F1
Batu
F2
F2
F2 F2’ F2’ F2 Dr A. Riza Wahono :
FUNGSI SUBSYTEM
Product Development
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Structure of Design Process TAHAPAN PROSES DESAIN PRODUK 1. Struktur dari fungsi :
S
Instrument F
Pengungkit
F2
ϕ
Box
F2’ Batu
Dr A. Riza Wahono :
Product Development
F2
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Structure of Design Process TAHAPAN PROSES DESAIN PRODUK 2. Pemecahan secara prinsip: Pemecahan secara prinsip adalah sebuah skema ideal yang merepresentasikan struktur dari sebuah sistim/subsistim, dimana karakteristik dari tiap elemen dan hubungan antara elemen yang berperan dalam mendapatkan fungsi/kegunaan dapat diukur secara kualitatif
Dr A. Riza Wahono :
Product Development
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Structure of Design Process TAHAPAN PROSES DESAIN PRODUK 2. Pemecahan secara prinsip: Effek fisik
Sub Fungsi
tak terpengaruh oleh solusi
T1
Transfer Torque
T1
F1
Amplify Force
F2
J υ
Close contact
Dr A. Riza Wahono :
Pecahan secara prinsip efek fisik dan membentuk fitur desain
T1
Product Development
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Structure of Design Process TAHAPAN PROSES DESAIN PRODUK 3. Embodiment desain: pengembangan dari sebuah solusi pronsipal menuju desain detil merupakn proses mel;etakkan standar akurasi yang lebih tinggi, dan lebih banyak karatketristik dari produk baru. Desain properties (karakteristik pada desain detil) struktur dari keseluruhan produk (arrangement dari setiap elemen) dan juga masing masing elemennya bentuk, dimensi, material, kualitas permukaan, toleransi, metoda manufaktur
biasanya proses dari solusi prinsip menuju desain definitif cukup komplex maka diberikan tahapan desain konsep dan desain prelimenary (desain sketch) Dr A. Riza Wahono :
Product Development
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Structure of Design Process TAHAPAN PROSES DESAIN PRODUK 3. Embodiment desain: Properties of Technical Systems Codes of Practise EXTERNAL Standards PROPERTIES Regulations Law Laws Conformances Properties INTERNAL Quality Operational Cost Price
PROPERTIES DESIGN PROPERTIES
Manuftrng Properties
Delivery Planning Properties
Transportability Packing Storage Space
Distribution Properties
Appearances Strength
Structure Aesthetic Corrosion Tolerance Properties Form Resistance Surface Dimension Manufacturing Method Durability Materials Ergonomic Properties Liquidation Manufacturing Properties Properties
Economic Properties
Wastes Re-Cycling
Function Function
Dr A. Riza Wahono :
Delivery deadline
Reliabilit y
Functionally Determined Properties
Product Development
Operational Properties
Colour Surface Quality Operation
Maintenance Weight/Mass
Space requirement
Durability Life
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Basic Design Process OUTPUT
ACTION TASK Task Clarification Specification Conceptual Design Concept Embodiment Design
Definitive design/ Layout Detail Design PRODUCT DESIGN Dr A. Riza Wahono :
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TASK FASE I
1
Klarifikasi &definisi Task
2
Penetapan Fungsi & struktur
3
Pencarian solusi prinsip serta kombinasi
4
Pembagian pada modul yang dapat dikerjakan
5
Pengembangan Layout dari modul kunci
6
Layout keseluruhan
7
Persiapan produksi dan prosedur operasi
Specification
Struktur Fungsi FASE II Solusi secara prinsip
Struktur Modul FASE III Desain Preliminer
Desain definitif FASE IV
dokumentasi Produk
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TASKS Selected Task
Overall Function Sub Functions Solutions principles Selected Solutions principles Selected combination Solution Concept
Combination of principles Concept Variant Dimensioned layout
Improved layout
Selected assemblies
Form design variant of assemblies Optimum assembly
Final Layout Detail Design of Components
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Product Development
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TASK FORMULATION Market
Company
External Information
Internal Information
Market Situation
Company Objectives
Company Potential
Economic Policy
SEARCH FIELD ‘IDEA FINDING’
New Technologies
Discovery of Product Ideas
Other Information
Laws, Regulation
Selection of Product Ideas New Product Idea Dr A. Riza Wahono :
Product Development
TASK
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TASKS Dalam mendapatkan kesuksesan dalam proyek desain ada dua hal yang harus dengan tepat diciptakan semenjak awal proyek 1. Statemen yang jelas tentang permasalahan yang akan dipecahkan, (TASK) 2. Sekumpulan kebutuhan dan limitasi dimana solusi desain akan dievaluasi (SPECIFICATIONS) Dr A. Riza Wahono :
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TASK CLARIFICATION • Tendensi alami untuk menerima problem sebagaimana yang diberikan, dan lalu mulai berfikir solusi. Hal ini perlu dihindari agar tidak terjadi salah presepsi dalam menghadapi problema yang ada • waktu yang cukup harus dikerahkan untuk membuat klarifikasi task. Menuliskan permasalahan merupakan sebuah praktek yang baik sebagi langkah awal. (seringkali problem desain tidak seperti yang dibayangkan pertama kali, dia berubah bersamaan dengan waktu dan akumulasi informasi) Dr A. Riza Wahono :
Product Development
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TASK CLARIFICATION • Cobalah memformulasikan problem pada tingkatan yang abstraksi yang lebih tinggi , Pahl and Beitz melakukan sbb : . . . . . .
Apa yang sesungguhnya terkandung dalam task tsb ? Apa keinginan implisit dan ekspektasi lain yang terlibat ? Apakah kontrains yang diperkirakan benar benar ada ? Kemana langkah pengembangan yang masih terbuka ? Karakteristik apa yang harus dimiliki oleh solusi ? Karakteristik apa yang harus tidak dimiliki oleh solusi ?
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DESIGN SPECIFICATIONS Spesifikasi desain adalah bentuk dokumen kerja formal yang didapat dari kompilasi daftar Demand dan Wishes atau didapat dari proses QFD
• • • •
Merupakan jalur kehidupan yang tak mungkin dilewati atau dihindari, oleh karenanya perlu mendapat perhatian serius. Comprehensive design specification Divide the document into sections Itemised each contribution and identify as Demand or Wish Tabel aspek Quantitave and qualitative (Requirement should if possible be quantified and defined in clearest possible terms)
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Product Development
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DESIGN SPECIFICATIONS DEMAND : Requirements that must be met under all circumtances, in other words, requirements without whose fulfilment the solutions is not acceptable For example a qualitative demand such as “suitable for tropical condition”, “Splash proof” Minimum demands must be fomulated as such ( for example P>20KW, L>400mm Dr A. Riza Wahono :
Product Development
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DESIGN SPECIFICATIONS WISHES : Requirements that should be taken into consideration whenever possible, perhaps with the stipulation that they only warrant limited increases in cost It is adviseable to classify wishes as being of major, medium or minor importance The distinction between Demand and Wishes is important in evaluation, since selection depends on the fulfilment of demands while evaluation bears only such variants as already meet the demand Dr A. Riza Wahono :
Product Development
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DESIGN SPECIFICATIONS QUANTITY : All data involving numbers and magnitude, such as number of items required, maximum weight, power output, throughput, volume flow rate etc QUALITY : All data involving permissible variation or special requirements such as waterproof, corrosion proof shock proof etc Dr A. Riza Wahono :
Product Development
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DESIGN SPECIFICATIONS Requirement
Contributing Factors
Points To Consider
Overall Geometry Motion of Parts Forces Involved Energy Needed Materials To be Used Control System Information Flow
Size, Height, Width, Length, Diameter, Space, Number, Arrangement Type, direction of motion, velocities, acceleration, kinematics Load direction, magnitude, weight, load, impact, stiffness, inertia Heating, cooling, conversion, efficiency, pressure, temperature, storage Flow, transport, properties, implications, regulation, life-cycle Electrical, electronic, hydraulic, pneumatic, mechanical Inputs, outputs, form, display, computer
Safety
Operational Human Environmental
Direct, indirect, hazards elimination, safeguarding Warning, training, instruction, personal protection Land, sea, air, noise, radiation, reaction, transport emergencies
Quality
Quality Assurance Quality Control Reliability
Regulations, Standards, code, accreditation Inspection, Testing, measuring tolerances, labeling Design life, failures, statistic
Functional
Production of component Manufacturing Purchase of components Assembly Transport Design Schedule Timing Development Schedule Production Schedule Elivery Schedule Dr A. Riza Wahono :
Factory limitation, maximum dimension, means of production, waste Supplier quality and reliability, inspection Special regulations, installation, sitting, foundation, bolting, welding Material handling, clearance, packaging Project planning, project control Design detailing, in-house tests, compliance tests Manufacture, assembly, quality assurance, packing, transport Delivery date, distribution network
Product Development
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DESIGN SPECIFICATIONS Requirement Economic
Ergonomic
Ecological Aesthetic
Life Cycle
Contributing Factors
Points To Consider
Marketing analysis Design Costs Development Costs Manufacturing Costs Distribution Costs
Size of market, strength of market, distribution, servicing Design team, computing, information retrieval, reproduction Design detailing, supplier costs, testing costs Tooling Labour, overhead, assembly, inspection, cost to customer Packing, transport, service centres, spareparts, warranty
User needs Ergonomic Design Cybernetic Design Material Selection Working Fluid selection
Type of operations, instructions, warning Human interface ralationships, operation, height, layout, comfort Controls, Layout, Clarity, Interaction
Customer Appeal Fashion Future expectation
Shape, colour, texture, form, feel, smell Culture, hsitory, trends Rate of change, trend
Distribution Operation Maintenance Disposal
Means of transport, nature & condition of dispatch, rules & regulation Quietness, wear, special uses, working environment, foreseeable misuse Servicing intervals, inspection, exchange, and repair, painting, cleaning Recycle, scrap
Dr A. Riza Wahono :
Solids, liquid, gas, stability, protection, toxicity, safety Liquid, gas, flammability, toxicity
Product Development
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DESIGN SPECIFICATIONS Page
ISSUE DATE :
NAME OF PROJECT :
of
REQUIREMENTS : Functional
Manufacturing
Ergonomic
Safety
Timing
Ecological
Quality
Economic
Life-Cycle
Other
DEMAND/WISH
Dr A. Riza Wahono :
ITEMISED LIST :
Product Development
Aesthetic
NAME OF CONTRIBUTOR:
DATE OF CHANGE
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DESIGN SPECIFICATIONS TIPS TO MANAGEMENT : • Define the task in word or symbol • Use questioning checklist or QFD to itemise demand and wishes or equivalent • ensure that a realistic project plan is prepared acceptable to all parties • Compile a detailed design specifications with input from all people involved • Label all design specification item with the name of contributor • Circulate design specification to all those involved for comment and approval • Lists all changes and additions with dates and name of contributor • Obtain formal approval for document in writing Dr A. Riza Wahono :
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CONCEPTUAL DESIGN Conceptual design adalah bagian dari proses desain dimaan identifikasi problem yang esential melalui abstraksi, dengan pembuatan struktur fungsi, serta pencaharian solusi prinsip yang sesuai beserta kombinasi. Solusi dasar didapatkan melalui elaborasi dari konsep solusi Dr A. Riza Wahono :
Product Development
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CONCEPTUAL DESIGN Design Specification Abstract to Identify the Essential Problem Establish Function Structures Overall Function - Sub-functions Search for Solution Principles To Fulfill Sub-functions Combine Solution Principles To Fulfill Overall Functions Select Suitable Combinations Firm up Into Concept Variant Evaluate Concept Variant Against Technical and Economic Criteria Dr A. Riza Wahono :
Product Development
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CONCEPTUAL DESIGN Requirement
Contributing Factors
Points To Consider
Overall Geometry Motion of Parts Forces Involved Energy Needed Materials To be Used Control System Information Flow
Spatial constraints, access for assembly/operation/maintenance Practically, accuracy, backlash, wind-up, lead and lag, smoothness Strength, Stiffness, leverage, deflection, buckling, dynamics Efficiency, power sources alternatives New materials, treatment, material design, compatibility, life recycling Start-up, operation, shut-down, maintenance Input, output, storage, display
Safety
Operational Human Environmental
Design safety, safety standards, weak spots in design Use, misuse, outside intervention, protection, built-in safety Storage, transport, contamination, disposal
Quality
Quality Assurance Quality Control Reliability
Quality criteria, quality management, quality improvement techniques Quality measurements, quality vs cost Specified life, cost constraints, weak spot
Functional
Production of component Manufacturing Purchase of components Assembly Transport Design Schedule Timing Development Schedule Production Schedule Delivery Schedule Dr A. Riza Wahono :
Ease of manufacture, near net shape, finish costs Meeting specification, transport, delivery, inspection, costs Ease of assembly, number of parts, sequencing of operation Internal transport/transfer, external transport modes, packaging Realistic time frame, long lead items, delay consequences Testing new technology, technological risks Tooling, long lead items Realistic time frame, Field testing, commissioning
Product Development
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CONCEPTUAL DESIGN Requirement Economic
Ergonomic
Ecological Aesthetic
Life Cycle
Contributing Factors
Points To Consider
Marketing analysis Design Costs Development Costs Manufacturing Costs Distribution Costs
Adequacy of analysis, user expectation, customer expectations Historical data, design effort, team availability Test equipment, test plan, modeling, prototyping Process involved, equipment needed, tooling Storing, packaging, transport and selling
User needs Ergonomic Design Cybernetic Design Material Selection Working Fluid selection
Specification requirements, types of user, different user Condition of use, misuse, dificulties, instructions, clarity of use Control of product in operation, runaway problem, shutdown modes
Customer Appeal Fashion Future expectation
Field testing, surveys, national cultures, cultural differences Presentation, trade shows, timing, competition Trend, age group, new technology
Distribution Operation Maintenance Disposal
Method of distribution, advertising, promoting, national/international Life expectancies, instructions, manuals, training, safety Frequency, simplicity, instruction, repair, spare parts Regulation, compatible materials, recycling, rebuilding
Dr A. Riza Wahono :
Recycling, disposal material, interactions, operational life Harmful effect, regulation, recycling, disposal
Product Development
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CONCEPTUAL DESIGN
Requirement
Contributing Factors
Current Status
Required Action
( Good, Marginal , Poor)
(Proceed, Revise, No Action)
Overall Geometry Functional Motion of Parts Forces Involved Energy Needed Materials To be Used Control System Information Flow Operational Safety Human Environmental Quality Assurance Quality Quality Control Reliability Production of component Manufacturing Purchase of components Assembly Transport Design Schedule Timing Development Schedule Production Schedule Delivery Schedule Dr A. Riza Wahono :
Product Development
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CONCEPTUAL DESIGN Requirement
Economic
Ergonomic
Ecological Aesthetic
Life Cycle
Dr A. Riza Wahono :
Contributing Factors
Current Status
Required Action
( Good, Marginal , Poor)
(Proceed, Revise, No Action)
Marketing analysis Design Costs Development Costs Manufacturing Costs Distribution Costs User needs Ergonomic Design Cybernetic Design Material Selection Working Fluid selection Customer Appeal Fashion Future expectation Distribution Operation Maintenance Disposal
Product Development
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CONCEPTUAL DESIGN TIPS TO MANAGEMENT : • • • • • • • • • •
Understand divergent and convergent thinking Abstract the problem to get to the real issue Make sure many different ideas are generated, never just one or two Use available methods and techniques for systematic selection and evaluation Make sure that the right concept is chosen Search for the weak spot in the final concept and understand the implications Produce and itemised budget cost estimate, reflecting the current degree of confidence Present the finally chosen concept in a formal and professional manner Consider patenting novel concept Use check list and work sheet to review the design prior to approval
Dr A. Riza Wahono :
Product Development
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EMBODIMENT DESIGN Embodiment design is that part of the design process in which starting from the concept of a technical product, the design is developed in accordance with technical and economic criteria and in the light of further information, to the point where subsequent detail design can lead to production Dr A. Riza Wahono :
Product Development
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EMBODIMENT DESIGN CONCEPT Identify embodiment determining requirement Produce scale drawing of spatial constraint identify embodiment determining main function carrier Develop preliminary layout and forms design Select suitable preliminary lay-out Develop preliminary lay-out and forms design for remaining main function carrier Evaluate against technical and economics Dr A. Riza Wahono :
Product Development
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EMBODIMENT DESIGN BASIC RULES IN EMBODIMENT CLARITY, SIMPLICITY AND SAFETY : Function Working Principle Layout and form design Safety Ergonomic Production and Quality Controls Assembly and transport Operation and maintenance
Dr A. Riza Wahono :
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EMBODIMENT DESIGN BASIC RULES IN EMBODIMENT SIMPLICITY not complex, easily understood and easily done - Function - Working Principle - Layout and form designs - Ergonomic
Dr A. Riza Wahono :
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EMBODIMENT DESIGN Requirement Functional
Safety
Quality
Contributing Factors
Points To Consider
Overall Geometry Motion of Parts Forces Involved Energy Needed Materials To be Used Control System Information Flow
Fit of parts, assembly of parts Will it work, other functions needed, working principles Strength, stability, stiffness, fatigue life, side effects Supply, storage, efficiency Degradation, wear, corrosions, expansion and contration Reliability, assembly, testing, trouble shooting Necessary, sufficient
Operational Human Environmental Quality Assurance Quality Control Reliability
Safety hierarchy Regulations, standards, codes, history Harmful effects
Production of component Manufacturing Purchase of components Assembly Transport Design Schedule Timing Development Schedule Production Schedule Delivery Schedule Dr A. Riza Wahono :
Over all system, life-cycle Manufacturing quality, measurement, monitoring Operation, maintenance , user environment Can parts be made, layout and drawing adequate Reliable sources, timing, quality assurance Simple assembly, clear sequence Safe internal transport, safe external transport Current status, planning problems Test equipment, test plan, documents, certification Timing, material supply On time or not, ways of improving
Product Development
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EMBODIMENT DESIGN Requirement Economic
Ergonomic
Ecological Aesthetic
Life Cycle
Contributing Factors
Points To Consider
Marketing analysis Design Costs Development Costs Manufacturing Costs Distribution Costs
Review and update Percent completion, phase diagram, cost overruns Phase diagram, supplier estimates, item by item estimates Tooling cost update, materials additional cost How to be shipped, distribution network
User needs Ergonomic Design Cybernetic Design Material Selection Working Fluid selection
Reliable and easy to use User friendly, good physical layout Good controls
Customer Appeal Fashion Future expectation
Survey, comments Competition Reliability of predictions
Distribution Operation Maintenance Disposal
Quietness, vibration, handling Simple inspection Simple maintenance, user safety, who does it Recycle, scrap
Dr A. Riza Wahono :
Source, supply, disposal, mixture, safety Safety , toxicity, replenishment
Product Development
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EMBODIMENT DESIGN
Requirement
Contributing Factors
Current Status
Required Action
( Good, Marginal , Poor)
(Proceed, Revise, No Action)
Overall Geometry Functional Motion of Parts Forces Involved Energy Needed Materials To be Used Control System Information Flow Operational Safety Human Environmental Quality Assurance Quality Quality Control Reliability Production of component Manufacturing Purchase of components Assembly Transport Design Schedule Timing Development Schedule Production Schedule Delivery Schedule Dr A. Riza Wahono :
Product Development
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EMBODIMENT DESIGN Requirement
Economic
Ergonomic
Ecological Aesthetic
Life Cycle
Dr A. Riza Wahono :
Contributing Factors
Current Status
Required Action
( Good, Marginal , Poor)
(Proceed, Revise, No Action)
Marketing analysis Design Costs Development Costs Manufacturing Costs Distribution Costs User needs Ergonomic Design Cybernetic Design Material Selection Working Fluid selection Customer Appeal Fashion Future expectation Distribution Operation Maintenance Disposal
Product Development
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EMBODIMENT DESIGN TIPS TO MANAGEMENT : OVERALL PRODUCT • Test for functional performance - the product must meet or exceed the customer expectation • check for economic feasibility - the cost must be acceptable to the customer • Check the safety performance - the product must meet applicable safety standards • test for ergonomic performance - the expectation of the user must be satisfied Dr A. Riza Wahono :
Product Development
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EMBODIMENT DESIGN TIPS TO MANAGEMENT : OVERALL DESIGN • Insist on clarity, simplicity and safety in design • ensure that force transmission path will be satisfactory • Ensure that allocation of functional tasks to component is satisfactory • ensure that self-help has been appropriately incorporated • Ensure that self-damaging effects have been investigated • Ensure that the design will perform in a stable manner • If planned instability is used, ensure that required effect will be achieved
Dr A. Riza Wahono :
Product Development
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EMBODIMENT DESIGN TIPS TO MANAGEMENT : GENERAL • Ensure that sufficient calculations have been done and recorded in a professional manner • ensure that most appropriate material have been selected • ensure that design standards and codes are satisfied • ensure that te purchase components have been incorporated effectively • Ensure that models, layout, printout and drawing have been used to the best advantages Dr A. Riza Wahono :
Product Development
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DETAIL DESIGN Detail design is that part of the design process in which starting from the concept of a technical product, the design is developed in accordance with technical and economic criteria and in the light of further information, to the point where subsequent detail design can lead to production Dr A. Riza Wahono :
Product Development
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DETAIL DESIGN PRELIMINARY LAYOUT Search for solution to auxiliary functions Develop detailed layout and forms design for the main function and compatibility with auxiliary function carriers Develop detailed layout and form design for the auxiliary function carrier and complete overall layout Check and refine the overall layout
Evaluate against technical and economic criteria Dr A. Riza Wahono :
Product Development
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DETAIL DESIGN Requirement
Contributing Factors
Functional
Overall Geometry Motion of Parts Forces Involved
Safety
Energy Needed Materials To be Used Control System Information Flow Operational Human Environmental Quality Assurance Quality Control Reliability
Quality
Production of component Manufacturing Purchase of components Assembly Transport Design Schedule Timing Development Schedule Production Schedule Delivery Schedule Dr A. Riza Wahono :
Points To Consider Interference, assembly sequence, tolerances, surface finish Displacement, velocity, acceleration, position, fatigue, stiffness Weight of components, deflection, vibration, resonance, creep, flow, strength, residual stress Torque, speed, horse power, power transmission Hardness, surface finish, friction, lubrication, replacement Button/switch design/layout, emergencies, safety, operation Assembly, operation, maintenance, safety Modes of operation, abusive operation, maintenance Failure modes, effect analysis Specific issues related to design Certification, design and manufacture records Inspection and component testing, production document Simulated test/field tests/statistical analyses Manufactured as designed/revisions Inspection records Stacking, fir of parts, minimising operation, ease of assembly Packaging, protection storage, invertory and control Disruption caused by revisions Problem diagnosis, debugging procedure, testing materials Inventory controls Acceptance criteria, commissioning
Product Development
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DETAIL DESIGN Requirement Economic
Ergonomic
Ecological Aesthetic
Life Cycle
Contributing Factors
Points To Consider
Marketing analysis Design Costs Development Costs Manufacturing Costs Distribution Costs
Customer reaction, user field test, data collection Recording problems and solutions Cost of redesign Record of manufacturing problems/costs Record of packaging/distribution costs
User needs Ergonomic Design Cybernetic Design Material Selection Working Fluid selection
Functional performance, suggested improvement Understanding/use of instruction manual/controls/ease of use Reaction of machine to control, feedback to user
Customer Appeal Fashion Future expectation
Surface finish, overall quality, colours, textures, consistency User reaction/comment/consumer reports Comments from field test/ commissioning
Distribution Operation Maintenance Disposal
Loading/unloading, labeling, transport mode Monitoring, feedback return, recalls Spare parts supply, inventory/tracking, service facilities Rebuild, remanufacture
Dr A. Riza Wahono :
Machining, assembly or operational problems found ? Filing, spillage, leakage, maintenance, filtration
Product Development
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Requirement
DETAIL DESIGN
Contributing Factors
Current Status
Required Action
( Good, Marginal , Poor)
(Proceed, Revise, No Action)
Overall Geometry Functional Motion of Parts Forces Involved Energy Needed Materials To be Used Control System Information Flow Operational Safety Human Environmental Quality Assurance Quality Quality Control Reliability Production of component Manufacturing Purchase of components Assembly Transport Design Schedule Timing Development Schedule Production Schedule Delivery Schedule Dr A. Riza Wahono :
Product Development
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DETAIL DESIGN Requirement
Economic
Ergonomic
Ecological Aesthetic
Life Cycle
Dr A. Riza Wahono :
Contributing Factors
Current Status
Required Action
( Good, Marginal , Poor)
(Proceed, Revise, No Action)
Marketing analysis Design Costs Development Costs Manufacturing Costs Distribution Costs User needs Ergonomic Design Cybernetic Design Material Selection Working Fluid selection Customer Appeal Fashion Future expectation Distribution Operation Maintenance Disposal
Product Development
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DETAIL DESIGN TIPS TO MANAGEMENT : • Detail design is of critical importance to a successful product • Carefully check sufficient details to ensure that design quality is acceptable • pay careful attention to the interaction between shape, material and manufacture • check component for adequate strength and stiffness • check for problem with fatigue, residual stresses, flaws, tolerances and surface finish • Check that most appropriate material selection have been used • check to see that heat treatment and surface treatment have been properly specified Dr A. Riza Wahono :
Product Development
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DETAIL DESIGN TIPS TO MANAGEMENT : • Consider as many failure modes as possible, by formal analysis if necessary • check standards component have used • check the assembling according to drawing • ensure that adequate etsting and commisioning procedure have been compiled • ensure that all manufacturing and production documents are properly in order Dr A. Riza Wahono :
Product Development
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Flow Diagram of Design Process TASKS Selected Task
Overall Function Sub Functions Solutions principles Selected Solutions principles Selected combination Solution Concept
Combination of principles Concept Variant Dimensioned layout
Improved layout
Selected assemblies
Form design variant of assemblies Optimum assembly
Final Layout Detail Design of Components
Production Document Dr A. Riza Wahono :
Product Development
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Basic Design Process TASK Task Clarification Market Analysis
Problem Analysis
Specification
Conceptual Design Alternative Solution
Concept Testing & development
Embodiment Design Design for Function /safety/Manufacture
Definitive design / Layout Components and Assembly Manufacturing Data Manufacture and assembly Product Testing &delivery Working Product Use of product Discarded Product Dr A. Riza Wahono :
Product Development
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Product Development Process Management ProjectCompany Design
Competition Brief TASK
Task Clarification
Adminsitration Services
Specification Conceptual Design Concept Embodiment Design Layout Manufacturing Data
Funding
Personnel
Services
Marketing
Information
ENGINEERING Process Planning
Supplier
Finance
R&D
Detail Design
RESOURCES
TECHNOLOGY Materials Energy
Purchasing
Prod document
Q A/ Q C
Manufacture/Inspection Components
Accounts
Assembly/Testing
Sales
New Product
Costumer Service
Distribution/Delivery Working Product Worn Product
Operation
Maintenance
Disposal
Discarded Product Dr A. Riza Wahono :
Product Development
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