Product Design May June 2017 SOLUTIONS

Q1

(i)

1 mark for listing types; 3 marks for three definitions

Incremental design
➢ Minor changes/improvements to an existing product
➢ Example: small change in body shape; small changes to materials
Adaptive design
➢ Significant changes/improvements to sub-systems
➢ Example: introduction of a new generation of Honda accord
➢ Example: introduction of airbags, crumple zones, ABS braking systems
Original design
➢ Major changes/improvements to whole sub-systems or systems
➢ The creation of an original product
➢ Example: change from IC engine to hybrid drive train in a car

(ii)

1 mark for importance; 3 marks for descriptions

Physical testing of prototype models is very important because computer models always have
some limitations. If a designer is unaware of weakness in a design they may not model it in
the software (because they don’t have knowledge of unknown unknowns).
Breadboard model
Checking the broad feasibility of a technology
Engineering model
Physically verifying the main performance aspects of a specific design solution
Qualification model
Checking the entire performance of a product compared to requirements
Often loads will go beyond performance to demonstrate safety margins
(iii)

2 marks for sketch; 4 marks for comments

Cost – relatively easy because the selling price is known and the running cost can be
estimated from fuel efficiency figures.
Environmental performance – relatively easy because fuel consumption and
emissions can be measured.
Reliability – quite hard to measure unless you have past data.
Aesthetics – very hard because beauty cannot be measured. However, special features
can be noted such as metallic paint, alloy wheels and special body features (for
example corrugated panels).
Luxury – fairly hard but some aspects can be measured such as the number of music
speakers and whether there is air conditioning and seat heating.
Technical performance – relatively easy – acceleration rates, top speed etc.
Safety – quite hard but there will be an NCAP report and a number of airbags
Ergonomics – quite hard because several aspects are subjective. But an assessment
could be made to see what proportion of the population can fit in the seats. Also
vibration measurements could be taken in the car.
(iv)

2 marks for definition; 4 marks for table/tree

➢ Function-means trees help to convert abstract functions (or objectives) into more
specific sub-functions and eventually into concrete features. This is sometimes called
functional decomposition. Going downward represents the “how” to fulfil the
function. Going upwards represents the “why” the features are necessary.
➢ Function-means trees help to identify requirements.
➢ Function-means trees can also be used for conceptual design.

↓ how ↑ why Car wheel design

Structurally sound Good thermal Concen- Easy Easy Good aesthetics

conduction tric wheel assembly assembly
and lightweight to car to tyre

Struct- Struct- Thermally Good Accurate Spigot Room for Attractive Attractive
urally urally efficient connect- manufact. assembly spokes material
efficient efficient material ions method tool
material shape with
other
parts

High Good High Large High Well Blending Al. alloy

specific flow of thermal surface pressure shape in
strength forces conduc- area on die rim Distinc- Mg alloy
material tion connec- casting tive
material -tions shapes

Al. No Al. alloy

alloy sharp
bends Mg alloy
Mg
alloy Use of
radii
Q2

(i)

4 marks:

(1) Legislation (reflecting public pressure)

Car CO2 & CO limits
Diesel smoke limits
NCAP (new car assess prog)
Car taxes based on engine size; car fuel taxes; BIK taxes
Seat belts; car seats etc
(2) Customer wishes
Reduce pollution
Reduce costs
Desire for novelty
(3) Technology breakthroughs
Li ion batteries; IT; new materials (Graphene 2D carbon coatings)
(4) Marketing
Car advertising is very effective at moulding customer expectations
Attractive body shape; speed; comfort; luxury; eco performance
(5) Innovators
Franz von Holzhausen – Tesla cars
(6) Elite activities
Formula 1; rally events
(7) Affluence
Growing Chinese and Indian markets (JLR)
(8) Competition
Improved products are necessary for survival.
(ii)

2 marks for advantages/disadvantages

2 marks for examples

Advantages
Concepts have been proven to work very efficiently in harsh environments
Very large range of concepts
Disadvantages
Often extremely complex and difficult to copy in detail (example molecular design)
Not necessarily designed for long life (example insects)

Examples of biomimetics in car design

➢ Almond-shaped eyes – inspired by wild cat’s eyes – Ford Cougar
➢ Streamlined body shape –inspired by wild cat – example: Jaguar
➢ Mercedes Benz bionic concept car 2005 – inspired by the box fish
➢ Iridescent paint (colour changes with angle of view) – inspired by peacock feathers
➢ Pulsed fuel injection – inspired by the bombardier beetle
➢ Fiat Multipla – inspired by the dolphin
➢ Friendly face – example: Nissan Micra
(iii)

0.5 mark per feature up to 4 marks

Designers make small SUVs look “strong” by using associations of strength:

(1) Corrugated panels (example: bonnet) (corrugation is strong)
(2) Thick sections (example: thick wheel spokes)
(3) Smaller windows (larger door barriers)
(4) Narrower above the shoulder line (makes doors seem deep in section and protective)
(5) High floor base (taller means stronger)
(6) Deep engine compartment (big barrier before driver)
(7) Thick black rim around base (reinforcement is strong)
(8) Big colours (white makes the car look bigger and wider)

(iv)

3 marks for seat ergonomics:

➢ Seat dimensions – seat width – seat depth - seat height

➢ Seat pitch (distance between seats)
➢ Seat back angle adjustment – range and button design
➢ Seat back stiffness
➢ Seat cushioning quality – memory foam
➢ Headrest design
➢ Seat tray design – cup holder -
➢ Air quality – air control – direction
➢ Noise

1 mark for gender question:

Hip width is greater for females than for males.
(v)

Figure Q2

0.5 mark each:

➢ 2.5 hours until the pilot feels vibration-fatigue affecting working performance
➢ 16 minutes for passenger reduced comfort
➢ Approximately 7 hours for exposure limit
➢ Exposure limit is defined as ‘halfway to pain’

2 marks:
➢ 0.1-1.25 Hz causes: difficulty balancing and motion sickness
Q3 (a)

(i)

The following factors are assessed in an FMEA:

• Occurrence (O) - The probability that a failure will take place, given that there is a fault
• Severity (S) - The effect the failure has on the user/environment, if the failure takes place
• Detectability (D) - The probability that the fault will go undetected before the failure takes
place (D).

Occurrence, Severity and Detectability are assessed on a scale of 1 to 10 as illustrated below:

RATING OCCURRENCE SEVERITY DETECTABILITY

1 Almost Never Hardly Noticeable Absolutely Obvious

Visible but could

Occasionally Dissatisfaction
go unnoticed

10 Often Serious Effect Undetectable

General Ratings for FMEA Occurrence, Severity and Detectability

The Risk Priority Number (RPN), is the Occurrence (O), Severity (S) and Detectability (D)
ratings multiplied together:

RPN = O x S x D

This number should be used as a guide to the most serious problems, with the highest numbers
(typically greater than 100) requiring the most urgent action, particularly if they have scored
high Severity Ratings.

[4 marks]
(ii)

FMEA Results for Car Brake Fluid Level Indicator System

It is evident that multiple causes of failure can be identified for the first failure mode. From the
results, seizure of the mechanical elements in the system is identified for further design effort.
(A Pareto chart may be drawn for clarity). One way to improve the system’s effectiveness is to
design the circuit so that the bulb lights when the level falls below the critical level, therefore,
the life of the bulb is extended.

[6 marks]
(b)

(i)

QFD Phase 1 Matrix for Can Opener

[6 marks]
(ii)

For DFA, the intent should be to (candidate to write 2):

• Reduce part count (and types) by consolidation and integration

• Reduce number of fasteners to a minimum
• Design for an optimum assembly sequence
• Provide a base for assembly to act as a fixture or work carrier
• Design the assembly process in a layered fashion (from above)
• Minimise overall product weight
• Design parts for multi-functional uses where possible
• Eliminate unnecessary joining processes
• Strive to eliminate adjustments (especially blind adjustments/shimming)
• Use standard components where possible
• Maximise part symmetry
• Design parts that cannot be installed incorrectly (use Poka Yoke principles)
• Minimise handling and re-orientation of parts
• Design parts for ease of handling from bulk (avoid nesting, tangling)
• Design parts to be stiff and rigid, not brittle or fragile
• Design parts to be self-aligning and self-locating (tapers, chamfers, radii)
• Use common, efficient fastening systems (when they must be used!)
• Avoid burrs and flash on component parts.

[2 marks]

For DFM, the intent should be to (candidate to write 2):

• Identify critical characteristics (tolerances, surface finishes)

• Identify factors that influence manufacture of critical characteristics
• Estimate manufacturing costs
• Minimise component cost
• Establish maximum tolerances for each characteristic
• Determine process capability of characteristics early
• Avoid tight tolerances
• Design the part to be easily inspectable
• Minimise number of machined surfaces
• Minimise number re-orientations during manufacture
• Use standard manufacturing processes where possible
• Use generous radii/fillets on castings, mouldings and machined parts
• Avoid secondary processes
• Design parts for easy tooling/jigging using standard systems

[2 marks]
Q4 (a)

An orthogonal array involving just four trials is used and the following data rows are chosen
in order that the process variable settings occur twice. (Note similar results are shown if the
student selects the other four trials in this exercise).

Temperature Pressure Cycle Time Av. Defects

-1 +1 -1 0.55
+1 +1 -1 3.39
-1 -1 +1 1.51
+1 -1 +1 4.59

Table - Orthogonal Array

[2 marks]

For temperature process variable:

Average defects at +1 = (3.39 + 4.59)/2 = 3.99

Average defects at -1 = (0.55 + 1.51)/2 = 1.03

[1 mark]

For pressure process variable:

Average defects at +1 = (0.55 + 3.39)/2 = 1.97

Average defects at -1 = (1.51 + 4.59)/2 = 3.05

[1 mark]

For cycle time process variable:

Average defects at +1 = (1.51 + 4.59)/2 = 3.05

Average defects at -1 = (0.55 + 3.39)/2 = 1.97

[1 mark]

The graphical results are shown in the figure below for individual effects.
 Figure – Individual Results Graphs

The gradient of the line drawn between average values of the results at the levels under
consideration is a measure of the significance of the factor. A high gradient indicates a high
significance, while a horizontal line infers no significance at all. The temperature has the most
significant influence on the defect level, with pressure and cycle time less so, but still
significant.

[3 marks]

Analysis of the effects of combinations of variables is a further investigation. Significant

combinations are inferred when the lines show a large difference in gradient. Strong
significance is indicated when lines cross. Parallel lines suggest no significance. Taking the
data from the orthogonal array table directly and plotting for temperature in combination with
pressure (as shown in the figure below) indicates that a low process temperature setting and a
high process pressure provides the lowest defect rate. The choice of a low cycle time is also
preferable, as indicated by the individual results graphs, and (based on economy of a shorter
cycle time).

5
Pressure (low)
4
Average Pressure (high)
Defects 3
2
1
0
Temp Temp
(low) (high)

Figure – Combination Results Graphs

[2 marks]
(b)

(i)

For the given data set, the sample mean, x , and standard deviation,  (best estimate) are:

x = 39.984 mm and  = 0.035 mm

[2 marks]

Process capability index, Cp:

t 0.05
Cp = = = 0.48
3 3(0.035)
[1 mark]

where,
t = bilateral tolerance
 = standard deviation.

x  Ln 39.984  39.95
Cpk = = = 0.32
3 3(0.035)

[1 mark]

where,
Ln = nearest tolerance limit
x = sample mean
 = standard deviation (best estimate).

Cp/Cpk « 1.33, so not process capable, and process shifted slightly due to Cpk less than Cp index,
therefore Cpk is a more suitable.

[1 mark]
(ii)

Quality loss function is given by:

2
L(Y) = k(Y - M)

where,
L = loss associated with a particular performance characteristic Y
M = performance target value
2
k = loss parameter (Lc/Do )
Lc = average loss to the customer when the performance characteristic is not within
the limit Do
Do = customer tolerance limit.

The loss parameter is:

6
k  £2,400 / mm
0.052
[1 mark]

Therefore the loss function is:

2
L(Y) = 2400(Y - 40)
2
For a loss of £1, 1 = 2400(Y - 40)

[1 mark]

2400Y2 – 192000Y + 3839999 = 0 and solving the quadratic:

Y = 192000  192000  (4  2400  3839999)

2

2  2400

Y = 400.02mm

[2 mark]

The powder metal sintering process would not be process capable at this tolerance either. A
process capability study of the machining process would also have to be conducted in order to
ascertain its long term viability.

[1 mark]