Product Design Methods and Practices

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ISBN: 9780824775650 | 0824775651
Cover: Hardcover
Copyright: 6/1/1999

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"Focuses on functional, aesthetically pleasing, mechanically reliable, and easily made products that improve profitability for manufacturers and provide long-term satisfaction for customers. Offers concrete, practical insight immediately applicable to new product design and development projects. "

Preface

iii

Introduction

(6)

Good Design

(1)

Team Approach

(1)

Structured Design Methods

(3)

Plan of the Book

(1)

Considerations of Good Design

The Product Design Environment

(12)

Introduction

(1)

Standards

(1)

Marketing and Manufacturing Strategy

(1)

Product Design Situations

(3)

The Manufacturing Enterprise

(4)

Managing Interactions

(2)

Key Takeaways

(1)

Design for Profitability

(19)

Introduction

(2)

Total Product Value

(1)

Total Product Quality

(10)

Total Cost

(1)

Total Time

(3)

Key Takeaways

(2)

Improving Early Design Decisions

(9)

Introduction

(1)

Engineering Design Process

(2)

Conceptual Design

(2)

Detail Design

(1)

Best Practices

(3)

Key Takeaways

(1)

Principles of Good Design

(18)

Introduction

(1)

Principles

(1)

Methodology

(1)

Product/Process Interactions

(3)

Product Variety

(2)

Force Flow/Geometry Interactions

(2)

Force Flow/Stiffness Interactions

(6)

Design for Manufacture and Assembly

(2)

Key Takeaways

(1)

Total Cost Reduction

(13)

Introduction

(1)

Cost Estimation

(4)

Information Content and Total Cost

(7)

Guided Common Sense

(1)

Key Takeaways

(1)

Design Process Improvement

(13)

Introduction

(1)

Design Iteration

(1)

Engineering Change and the Ripple Effect

(2)

Prescription for Improvement

(2)

Team Approach

(3)

Formal Design Reviews

(1)

Design Guideline

(3)

Key Takeaways

(1)

Conceptual Design

Customer Focused Concept Design

(19)

Introduction

(1)

Methodology

(1)

Understand

(9)

Create

102

(4)

Refine

106

(2)

Key Takeaways

108

(2)

The Rational Building Block Method

110

(12)

Introduction

110

(1)

Methodology

110

(3)

Quick-Operating Fastener Example

113

(7)

Decoupled Design

120

(1)

Key Takeaways

121

(1)

Formal Concept Selection Methods

122

(9)

Introduction

122

(1)

The Utility Function Method

123

(5)

Pugh's Method

128

(2)

Key Takeaways

130

(1)

Model-Driven Design

131

(9)

Introduction

131

(1)

Models and the Design Process

131

(3)

``Just Build It''

134

(1)

Avoid ``Test and Fix'' Hardware Iterations

135

(2)

Construct Prototypes and DVUs Quickly

137

(2)

Key Takeaways

139

(1)

Design for Efficient Manufacture

Process-Driven Design

140

(26)

Introduction

140

(1)

Methodology

141

(15)

Observations and Comments

156

(1)

Case Study

157

(8)

Key Takeaways

165

(1)

Part Elimination Strategies

166

(15)

Introduction

166

(1)

Candidates for Elimination

166

(2)

Consolidate Parts Into an Integral Design

168

(3)

Eliminate Separate Fasteners

171

(5)

Reduce the Number of Theoretical Parts

176

(1)

Create Hybrid Parts

176

(3)

Standardize

179

(1)

Key Takeaways

180

(1)

Assembly Design

181

(17)

Introduction

181

(1)

Assembly Cost Drivers

182

(1)

Methodology

183

(1)

Component Handling

184

(3)

Component Insertion

187

(4)

Component Securing

191

(1)

Assembly Surfaces and Directions

192

(1)

Adjustments

193

(1)

Separate Operations

193

(1)

Error Checking

194

(1)

Formal Design for Assembly Methods

194

(1)

Boothroyd-Dewhurst DFA Method

195

(1)

Key Takeaways

196

(2)

Tolerance Design

198

(22)

Introduction

198

(1)

Methodology

199

(1)

Illustrative Example

200

(4)

Exact Constraint Design

204

(2)

Unavoidable Tolerance Stack-up

206

(3)

Statistical Tolerancing

209

(9)

Key Takeaways

218

(2)

Component Design

220

(24)

Introduction

220

(1)

Methodology

220

(3)

Process-Specific Design

223

(13)

Facility-Specific Design

236

(1)

Structured Team Approach

237

(6)

Key Takeaways

243

(1)

Manufacturability Improvement Method

244

(20)

Introduction

244

(1)

Methodology

244

(11)

Undesirable Interactions

255

(1)

Metrics

255

(1)

Simple Example

256

(7)

Key Takeaways

263

(1)

Total Cost Reduction

Elimination and Simplification Strategies

264

(24)

Introduction

264

(1)

Use Group Technology

264

(5)

Use ``Previously Designed'' Parts

269

(3)

Reduce Process Count and Process Types

272

(1)

Develop a Robust Design

272

(4)

Make Products and Parts Small

276

(1)

Maximize Commonality

276

(1)

Coordinate the Product and Process

277

(1)

Design for Serviceability

278

(1)

Design for Recyclability

279

(1)

Design for the Environment

280

(1)

Design for Material Handling

281

(3)

Harmonize the Product Mix

284

(3)

Key Takeaways

287

(1)

Standardization Design

288

(13)

Introduction

288

(1)

Methodology

288

(1)

Identify Candidate Opportunities

289

(1)

Evaluate Qualitatively

290

(7)

Evaluate Quantitively

297

(3)

Key Takeaways

300

(1)

Standardization and Rationalization

301

(9)

Introduction

301

(1)

Methodology

302

(1)

Case Study

303

(6)

Key Takeaways

309

(1)

Internal Standard Components

310

(13)

Introduction

310

(1)

Develop a Modular Product

311

(3)

Consider Standardizing Large Parts

314

(1)

Standardize Unique Parts

314

(1)

Standardize Common Parts

315

(3)

Create a ``Building Block'' Design

318

(1)

Design With Standard Features

319

(3)

Key Takeaways

322

(1)

Design for Quality

Design Improvement Methods

323

(28)

Introduction

323

(3)

Guided Iteration

323

(3)

Analytical Optimization

326

(3)

Taguchi Method

329

(6)

Probabilistic Design

335

(8)

Value Engineering

343

(7)

Key Takeaways

350

(1)

Failure Mode and Effects Analysis

351

(11)

Introduction

351

(2)

Methodology

353

(5)

FMEA Procedure

358

(2)

Simple Example

360

(1)

Key Takeaways

361

(1)

Design Review Checklist

362

(9)

Introduction

362

(1)

Customer Satisfaction Assessment

362

(2)

Business Assessment

364

(1)

Robustness Assessment

365

(1)

Manufacturability Assessment

366

(2)

Reliability Assessment

368

(2)

Key Takeaways

370

(1)

References

371

(5)

Appendix

376

(1)

Index

377

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Product Design Methods and Practices

Summary

Table of Contents

Supplemental Materials