Product Design Methods and Practices

by Stoll

• ISBN13: 9780824775650
• ISBN10: 0824775651
• Edition: 1st
• Format: Hardcover
• Copyright: 1999-06-01
• Publisher: CRC Press

Summary

"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. "

Table of Contents

Preface	iii
Introduction	1	(6)
Good Design	1	(1)
Team Approach	2	(1)
Structured Design Methods	3	(3)
Plan of the Book	6	(1)
Considerations of Good Design
The Product Design Environment	7	(12)
Introduction	7	(1)
Standards	7	(1)
Marketing and Manufacturing Strategy	8	(1)
Product Design Situations	9	(3)
The Manufacturing Enterprise	12	(4)
Managing Interactions	16	(2)
Key Takeaways	18	(1)
Design for Profitability	19	(19)
Introduction	19	(2)
Total Product Value	21	(1)
Total Product Quality	22	(10)
Total Cost	32	(1)
Total Time	33	(3)
Key Takeaways	36	(2)
Improving Early Design Decisions	38	(9)
Introduction	38	(1)
Engineering Design Process	38	(2)
Conceptual Design	40	(2)
Detail Design	42	(1)
Best Practices	43	(3)
Key Takeaways	46	(1)
Principles of Good Design	47	(18)
Introduction	47	(1)
Principles	47	(1)
Methodology	48	(1)
Product/Process Interactions	49	(3)
Product Variety	52	(2)
Force Flow/Geometry Interactions	54	(2)
Force Flow/Stiffness Interactions	56	(6)
Design for Manufacture and Assembly	62	(2)
Key Takeaways	64	(1)
Total Cost Reduction	65	(13)
Introduction	65	(1)
Cost Estimation	65	(4)
Information Content and Total Cost	69	(7)
Guided Common Sense	76	(1)
Key Takeaways	77	(1)
Design Process Improvement	78	(13)
Introduction	78	(1)
Design Iteration	78	(1)
Engineering Change and the Ripple Effect	79	(2)
Prescription for Improvement	81	(2)
Team Approach	83	(3)
Formal Design Reviews	86	(1)
Design Guideline	87	(3)
Key Takeaways	90	(1)
Conceptual Design
Customer Focused Concept Design	91	(19)
Introduction	91	(1)
Methodology	92	(1)
Understand	93	(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