Module 2 – a

ES . I N
Number Nof
O T
Lectures- 2
KTU
Practice - 2

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 Design Process
• Introduction to Design
• Initiating Design
• Structured Design Process
• Defining the Design Space .IN
O T ES
• Analogies
KT U N
• Thinking outside the box
• Quality Function Deployment
• Design Evaluation
• Choosing a Design

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 Introduction to Design
Steps towards design.

Clarity on the problem, searching for

concepts or ideas for a solution, finalizing the
concept and proceeding with the design.
ES . I N
N O T
KTU

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 Example
• Need : Generation of electricity
• Problem : Power plant
• Solutions : Thermal, hydro, diesel, nuclear,
wind, solar etc..
ES . I N
• Select the right one: N O T
• Design
KTU

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 Introduction to Design
 What is a good design?
 Design being the result of substantial cognitive
effort requires multiple iterations and the

T ES INoptimal.
outcome is not always perfect .or
UNO
T is based on how the artifact
 Quality of theKdesign
meets the user demands.
 This primarily depends on how best the steps
towards design have been taken.

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 Introduction to Design
 Is there a difference between Design and Problem
solving?
 This is not easily understood as both of them follow
the same process to achieve the objective.
E S . I N
 Design process results
N O
in T
a plan of action.
KTU
 Realization of the design only will solve the problem.
 For this the design is to be engineered (produced).
 By designing one cannot solve the problem.
 Engineered design only solves the problem.
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 Introduction to Design
 Functional Design
Here the function of the product is important and
the strength considerations are secondary.
E.g. Watch, Ball point pen, an amplifier, a software.
ES . I N
N O T
KTU

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 Strength Design
Here forces acting and environmental
factors are critical to the design, in addition
to the function.
E.g. Automobile, Dam, Crane, Ship,
Rocket.

ES . I N
N O T
KTU

In many designs, both are of importance.

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 Introduction to Design
Taxonomy or classification of Problems (need gaps)
 There are two main classifications and under each
a sub classification:

1. Design Problems :- NewE S . I

artifactN (no reference,
N O T
U to solve )
no idea aboutKThow
 By Structured Design Process
 By Design Selection (Selection from known alternativ

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2. Design Improvement Problems
(functional improvement eg: petrol,
natural gas, mixed version)

By Tuning of subsystems:-IN changing the

T ES .
U N O
variables, experimentation.
KT

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 Introduction to Design

Two other types of problems are:

Crisis Problems
(time less, how solve with limitted time?)
Fokushima disaster
ES . I N
N O T
Key strengths-Experience and Resources
KTU
“Eternal” Problems- Territory disputes, Wars,
( conflicting goals of stakeholders)
Key strengths-Special skills, specialization,
practice,patience.

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 Introduction - Initiating Design
 Design is a cognitive process requiring knowledge in
many areas.
 Such a background allows to think of ways of meeting
the design goals.

ES . I N
 For this the staring point is to have as many ideas as
N O T
KTU
possible for the problem to be solved.
 Ideas are available from different sources as well as from
different people.
 To extract this we resort to brain storming.
 Such a systematic procedure allows to close on to a
workable design.
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 Structured Design Process
Most of the design problems we undertake as
professionals do require a structured process of
design.
The advantage of this may not be seen first but in
S . I N
the long run it shows its
U N TE
Oadvantages.
An elegant K T
design is the ultimate goal of a
designer.
It is a design that is original, appealing, cost
effective, user friendly, safe and green.
Example: Bifocal spectacles
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Bifocal Spectacles – Old

Bifocal Spectacles – Improved

ES . I N
N O T
KTU

Variable focus Spectacles

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 Structured Design Process
Design process has many stages
1. Product or Problem identification
2. Problem Definition
3. I N
Design goals and functions
E S .
4. Gather U N O T
sufficient data or
K T
get new knowledge through research
5. Brainstorming and ideation
6. Evaluation of potential solutions
7. Conceptual design
8. Design Detailing
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 Structured Design Process
8. Standardization needs
9. Prototyping / 1st product
10. Testing (Important in some cases eg: medicine)
11. Design Modifications
ES . I N
U N
12. Freezing theTdesignO T
K
13. Cost analysis
14. Realization/Manufacturing
15. Quality Assurance
16. Feed back analysis for design improvement.

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 Product / Problem Identification
 Here the need gap is the focus.
 This is often spelt out in a vague and general
fashion - Need something to lift a very heavy
box.
S .IN identification
 In certain cases insteadTofEproblem
U N O
T product identification.
one can focusKon
- Need a container for 25 l of mineral water.
 One cannot proceed much with such vague
problem identification.
 Clear problem definition is critical to design.

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 Problem Definition
 Clarity on the problem can be obtained by
questioning.

Problem: Transportation of 30l of N mineral water.

T E S . I
Vague definition:- A
U N O
container is to be designed.
KT
 Why a container is required?
 Where is it be used?
 How much weight is to be transported?

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 Problem Definition

 Is the water in one or more bottles?

 What is the size limitation for the container?
 Is container lifted, pushed, turned? If so how?
S . I N
E in a truck?
 Are the containers N O T
transported
K TU
 Has the truck any provisions for this?

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Problem: The tap water is not good for drinking.
• Work out the way by which you can define the
problem clearly.

Problem/Need: To have a toy for a 3year old

• What are the factors to be taken to define the
N
T ES . I
problem.
N O
KTU
Problem: Old people needs to move in the room in the
night.

Ask what, why, when, which, where

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 Problem Definition

 What?, Why?, When?, Who?, Where? are the

questions to be clarified at every stage of the
design process.
 From the answers to these,
E S .
one I N
can define the
N O T
problem withK TUclarity.
more
 This is essential for proceeding with the design.
 Otherwise, at later stages, one may encounter
“design gaps”.

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 Design Functions
 They are the things that a designed
device(system) is supposed to do.

Examples – lift a load, turn a N lever, deliver a

E S . I
voltage etc,. NOT
KTU
 Functions are classified as Basic and Secondary.
 Basic function is the main objective of the design.

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 ES . I N
N O T
KTU

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 Design Functions

 To have that, there has to be many secondary

functions.
 While doing the function the design
. I N may produce
O T E S
unwanted secondary
K T U N functions. (heat, noise,
smell)
 Discuss the design function, secondary functions
and unwanted functions produced by above
products.

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 Design Functions
 Functional Analysis:-
 Like functions in mathematics, it is the
transformer of inputs to out puts.

ES . I N
N O T
KTU

Example: Electric Drilling machine

Inputs: Energy, Clamping force, Control
Output: Rotating Drill , Heat, Noise, Vibration.
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 Design Functions
Functional Analysis:-
To focus on the design one has to further
understand the functions based on the input to
achieve the output.
E
In the case of the drill, Power S
is. I
an Ninput. One
U N O T
function will beKtoTget the power – connection using
wires.
Conversion of electrical power into mechanical
power- another function
Control- Control by a switch
Force – To hold the drill bit – by a suitable method.
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 Design Functions
Known functional designs- Electric motor
Listing all sub functions for achieving the final
function.
Speed changes for the drill- gears, shifting gears.
ES . I N
U N O T
K T
Function –Means Trees
This is a simple graphical representation of a
design’s basic and secondary functions and the
ways of achieving them.

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 Design Functions
Function – Means Trees

ES . I N
N O T
KTU

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 Specifying Functions

Functional needs are to be well defined for

achieving the design objectives.
For this we have to specify the functions.
In engineering this is termed as Specifications.
ES . I N
U N O T
K T
These could be in any of the following ways.
Specify the values – Drilling machine- Wattage.
Specify the procedures – As per IS -21X
Specify performance level – Should drill concrete.

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 Defining the Design Space
This is an imaginary space for design alternatives for
a problem. Simply this means the vastness of the
possibilities.
Now that the design requirements have been clearly
spelt out, all the design optionsS
E . I N
available should be
explored. U N O T
K T
A large design space means there are many design
options available.
Totally new designs may have small design space.
Buildings for example have a large design space.
Give an example of a product with limited design
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 Defining the Design Space
Design space is generated by the functions and
means discussed earlier.
By having a table incorporating these two one can
assess the design space.
A chart can be made that can show N the different
ES . I
NOT
possibilities for a design.*
KTU

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 Defining the Design Space
To generate a good design, we need divergent ideas
and later converge on the ideas.
Generating ideas is an intellectual exercise.
Thinking without constraints, allows to bring in a lot
of ideas (workable or not) - Brain
E S . I N
storming.
O T
N writing ideas in brief and
Sitting around a K TUand
table
then circulating them among the members for their
short written comments and further exploring based
on the comments can provide different ways of
looking at the solution.
( One can also use black boards, or slips of paper )
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 Defining the Design Space
Brain Storming:-
No criticism or evaluation of ideas
Uninhibited approach to thinking
Bring in ideas fast and spontaneous
Here at the initial stage, Quantity
ES . I Nis desired over
quality U N O T
K T
Combine or modify ideas
Build upon another ‘s ideas
Bring in the solutions to similar problems

AT THE END CRITICIZE, EVALUATE AND RANK

THE OPTIONS.
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 Defining the Design Space
For a totally new product the design space is limited.
If the design space is small, to get workable solutions
one has to do through study of many other systems or
products that are similar and look for ideas.
At times innovative ideas are to be
E S . I N
experimented and
decided upon. U N O T
K T
Designs in advanced areas often need research
inputs.
In brief the Design Space allows us to explore the
possibilities and evaluate their suitability for a good
design.

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 Analogies in Design
Design by Analogy:
Analogy is the process of connecting two
seemingly different domains that share something
in common.
Make use of existing examples
E S .
toI N
initiate ideas to
N O T
KTU
solve a new problem.
Creative people use analogical reasoning to arrive
at solutions.

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 Analogies in Design
This involves relating the existing problem to some
segments of solved problems.
This gives possible solutions from existing
solutions.
ES . I N
Certain plant seedsU N O T
(Arctium plants) have clinging
K T
properties as an excellent mechanism for seed
propagation. From this came the invention of
Velcro.
A GOOD DESIGNER HAS TO BE KEEN
OBSERVER.
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 Analogies in Design

ES . I N
N O T
KTU

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 Analogies in Design
Wind Turbines generating electricity need to be
quiet as people who live near demand quiet
operation.

E S . I
Owls are famously silent predators,N able to surprise
N O T
toUsound dampening wings.
their prey thanksT
K
Blade design can be analogues to the wings of
owls.

Such analogies from nature are also termed as

biomimentics.
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 Thinking outside the box
We are all in a box. We are surrounded by things
that are well known to us. We see how people
behave, how they react, what they say, what
they use, how they use and so on.
ES . I N
N
Such a surrounding
U O T
envelopes us.
KT
WE ARE IN A BOX !
If you want to be different ( creative) then
thinking and doing differently is the only option.
So think outside the box.
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 Thinking outside the box
To be creative, step out of the box, change your
mindsets and attitudes, leave all your experiences
behind and start to look at things from different
perspectives.
E S . I N
U N O
Think of crazy ideas that T
are non workable at the
first thought. K T
Bring in negative approaches to look at the
situation.

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 Thinking outside the box
Be uninhibited and unbiased and open for
suggestions.
Go against the tide- question the popular
approaches. N
TE S . I
“Every cloud hasUaN
T O
silver lining.”
K
Why not it be “ Every silver lining has a cloud
behind it.”

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 Quality Function Deployment [QFD]

Engineers and scientists are comfortable with units

and quantities for all specifications.
But the consumers of their products are ordinary
S .
individuals who can expressEtheir I N
needs only in
simple terms. KTU N O T
“ I need a silent air conditioner that is good ”
This is the specification for the product by the user.
Now how to convert this into engineering
specifications that are quantified.
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 Quality Function Deployment [QFD]
This is achieved through the House of Quality
[HOQ] There are excellent examples of how to
workout HOQ

ES . I N
N O T
KTU

http://www.webducate.net/qfd/qfd.html

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Quality Function Deployment [QFD]

ES . I N
N O T
KTU

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 Evaluation and choosing a design
• Design Evaluation:

ES . I N
N O T
KTU

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Evaluation and choosing a design

Design Strengths:
What are the idea’s advantages?
What can the idea be successful in?
E S
What are the current existing . I
ideaN resources?
U N O T
How others K
mayT see the strength of the idea?

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Evaluation and choosing a design

Design Weaknesses:
How can the idea can be improved?
What does the idea lack in term of
S .
experience, team and resources?
E I N
U N O T
T
K the idea from success?
What can prevent
How do others see the idea in terms of
weaknesses?

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Evaluation and choosing a design

Design Opportunities:

What opportunities does the idea have in the

market? E S . I N
U N O T
T
K can help the idea to
How the company
succeed?

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 Evaluation and choosing a design
Design Threats:
What are the obstacles that face the idea?
Do the idea weakness represent any threat to its
success? N
T E S . I
What are the financial
T U N O
needs that may face the
idea? K
It is also possible to quantify these to compare
designs
Always remember that no design is final.
Designs are always evolving.
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 Module 2 – b

ES . I N
Number of
N O T
Lectures- 3
KTU
Practice - 4

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 Contents
• Communication in Design
• Concept to Configuration
• Sketching, Drawing, Modelling
• Concept of “Complex is E S .
Simple”I N
U N O T
• K T
Design for Function and Strength
• Material Selection

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 Contents
• Design visualization – Solid Modeling
• Detailing- 2D drawings
• Tolerancing
• Standard item in Design S.IN
N O T E
• T
Research needs U
K in Design
• Energy needs

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 Communication in Design
Design is a cognitive process.
However it needs inputs and outputs that are oral,
written or sketched out.
For this communication skills are to be honed in all
S . I N
the three.
T U NOTE
K the written segments give
While the oral and
critical inputs to design, drawings are the medium
for design outputs.
What cannot be expressed orally or in writing can
be well communicated through drawings.
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 Communication in Design
Hence the significance of sketching and
drawing in design.
Design emerges through sketches which in

E S . I N
turn changes to free hand drawings and later
to Computer Aided
U N O T
Design and Drafting
(CAD). K T
CAD system with freeform software can do
clay modeling.
Designs need additional details for its
realization or manufacturing.
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 Communication in Design
CAD systems available are capable of
providing all these to the designer.
Visualization of the design through solid

T ES .IN to design.
modeling is providing a new angle
This was not T
KpossibleUNOearlier and today this is
often the starting point of a conceived design.

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 Communication in Design
Though the Solid model gives a better
comprehension of the object than 2D views, 2D
drawings are essential to provide details on the
design as well as for the part manufacture.
In certain domains of design,
ES . I N
instead of sketches
U N O T
K T
pictorial representations could be used.
Examples: Circuit diagrams; Flow charts; Block
diagrams.

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 Communication in Design
So seeing is believing!
“Was die Augen sehen, glaubt das Herz;”
“Die Ohren glaubt was anderan sagt”
E S . I N
(Eyes believe what they
U N O T
see, the ears believe what
others say) KT

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 Communication in Design
Communications of all types play a major role in
engineering design.
User manual, Safety standards, Assembly and
packaging instructions, and of course in marketing.
Communications could changeE S .
theI Nmind set of
N O T
people. KTU
Instead of stating that i Phone is “Made by Apple“ it
is written as “Designed by Apple”.
At different stages of design, designers have to
convince other team members about their ideas
clearly- both orally and in writing.
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 Concept to Configuration
The strength of a designer lies in the ability to
transform the design concept to a workable
configuration.
The complexity of the product poses major
challenges. ES . I N
N O T
KTU
The only consolation is that all designs are
evolving and one can have a reference of an
older version for a new one.

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 Concept to Configuration

This is the reason why new designs are only

staring points. *Module1- Changing design with
Experience.pptx
Complex designs needs sub
E S . I N
system designs.
N O T
KTU
Designs are configured out of such subsystem.
Discuss an example for this- A bicycle.

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 Sketching, Drawing, Modeling

A good designer initially starts off with sketches.

With experience on can directly do this 3D CAD.
Sketching give the designer ample of opportunity
ES .
to transform the design concept I N
as a visible soft
N O T
design. KTU
Many CAD systems now allow this to be done
directly.

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 Sketching, Drawing, Modeling

While the soft designs can be visualized in 3D as

well at different view angles, there is still the need
for a physical model as the perception on the
screen is not real enough.
E S . I N
Now virtual reality U N
(VR)O T
do assist us to a certain
K T
extend. (designing the work space)
Full scale physical models are attempted in certain
products to realistically evaluate the design for its
finer aspects like colour, shape, finish etc.

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 Complex is Simple
Many engineering designs are complex in nature.
They have large number of sub assemblies and in
turn a very large number of parts.
Final product realization is through assembly.
ES . I N
Assembly is stillT U N O
manual.
T
Manual assemblies take
K
time and cost escalation.
Designs should reduce the number of assemblies
to reduce the time.
Here comes the concept of “Complex is Simple”
*Module1- Simple is Complex.pptx
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