DESIGN AND DEVELOPMENT

PROCESS
R&D department
LEEL Bhiwadi.
DESIGN PROCESS ?
Design process is a collection of
procedures and habits that help teams
design better products
The Process of Design
Designing is the process of making many
decisions that converts an abstract concept
into a hardware reality.
Concept Product
R&D DEPARTMENT
NPD ( new product development)
C&D ( continuous and derivatives)
ONGOING PROJECTS
NPD
DMRC HVAC 14 TR Unit
BMRC HVAC 14 TR Unit
RMVU Ventilation Unit
GETS CAB HVAC Unit
ICF Ventilation Unit
Hot case

C&D ( continuous and derivatives)
RMPU 407c
RMPU reverse cycle
LHB

GUIDING PRINCIPLES FOR NPD
PROCESS DESIGN
Develop a comprehensive process that caters to
various types of projects undertaken by Lloyd
Electrical and Engineering Limited.

Ensure that the process is easy to understand and
is user friendly

Define clear scope of the NPD process and clarify
project initiation point

Enable fact based and timely decision making at
appropriate levels (senior management, functional
heads, and project team) during project execution.

Define business and technical criteria for effective
decision making

Provide clarity on process deliverables, their
ownership, timing for completion, and related inputs.

Improve NPD quality by integrating design for
functional excellence (DFS, DFM,DFA) and design for
six sigma (DFMEA, PFMEA) concepts in the process

Enable cross-functional and concurrent execution of
projects.

Integrate Qualicon process and leverage the materials
wherever relevant
Lloyds 7-Step Design Process
1. Project definition (management/Engg.)
2. External Search (Research)
3. Internal Search (Brainstorming)
4. Evaluation and Selection (Engineering)
5. Detail Design (Engineering)
6. Prototyping (Testing)
7. Documentation (Engineering)

NPD Process gate structure for leel
( following IRIS standards)
Identification of
design inputs
Design activity
planning
Designing
Design review
and verification
Drawing release
and changes
Design Validation
Documentation
GATE 1
GATE 2
GATE 3
GATE 3
IDENTIFICATION OF DESIGN
INPUTS
Following design inputs are considered while
planning the design and development activities:-

Customers functional & performance requirements /
specifications and relevant standards
Information from previous similar designs.
Material selection charts.
Engineers Designs Hand books.
Technical Literature on similar products
Feed back from customer on product quality on
previously designed similar product.
Statutory & Regulatory requirements related to the
product.
DESIGN ACTIVITY PLANNING
Design activity planning involves identification
of design stages including review, verification ,
validation and responsibility & authority for
each design stage.

Project plan will be made
Target dates
Responsibilities
DESIGNING
Product Design and its modification is evolved by
qualified and experienced design engineers, using
Auto CAD / Design-PRO/Solid works software.

General arrangement drawing is prepared and positioning of
components and their matching is seen on 3-D scales with
the objective to visualize the fitment and placing of parts

Following analyses are applicable to ensure the design;-
Thermal analysis (CFD)
Structure analysis (FEA)
Airofoil analysis
Shock and vibration analysis

Component selection from rolling stock approved vendors
only.
DESIGN REVIEWS &
VERIFICATION

Design reviews are conducted at each stage of design by the
R & D engineer, to evaluate the ability of the results of design
and to identify any problem. Where ever appropriate,
representatives of Production Deptt., Marketing, Purchase &
Quality Assurance also attend design review meetings. Design
outputs are approved by Head Design / Design Engineer,
before these are released for procurement & production..

Internal brain storming sessions for design review.
Problem identification and their root cause analyses.
DESIGN RELEASE &
SUBSEQUENT CHANGES
Design Outputs, Related data, Material
specifications are frozen after Design Verification
and are released for procurement of materials and
implementation. Changes to technical data made
during design sequences & design reviews are
recorded in corresponding product file.
DESIGN VALIDATION
Design validation is done after commissioning of
the machine as per customers usage condition. Type
test for the designed parameters are conducted and
report is prepared which acts as Validation Record.

Validation design and performance target
achievement through proto build.
Factory tests
Field trials
Report preparation.
Customer approval
Work station release

DOCUMENTATION
After design validation and performance target
achievement through proto build these documents to
be prepared

Service manuals
Test reports
Installation drawings
Training presentation
Final BOM

LIST OF DELIVERABLES AS
PER IRIS STANDARD
GATE 1

GATE 2 FROM AJAY

GATE 3

GATE 4











Product Design Specifications
Customer Needs
Cooling capacity
Affordable as a birthday present
Fully assembled
Uses alternate power source for emergency
It is safe
Looks good
Heating capacity
Automatic controls
Last a long time


Product Design Specifications
Engineering Specs
Climbs at 1 ft/s or faster
Retail cost is to be less than $30
Uses 2 AA batteries (not included)
Has no removable small parts
Music loudness between 20-30 db
Luminosity is to be more than 5 W
Works for more than 3 hours on 2 AA







External Search
Level-I
Rope climbing toys / machines
Rope climbers (sports or circus)
Nature (spiders, bats, etc)
Level-II (Team uses friction wheels)
Hoists
Trolleys
Ski Lifts








Internal Search & Evaluation
Brainstorming
Generate many ideas
Evaluate against PDS
Select one to engineer

Lift and Drag Coefficients
(as effected by ground promimity)
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0 0.05 0.1 0.15
h/L
C
o
e
f
f
i
c
i
e
n
t
Drag Coefficient
Lift Coefficient
Detail Design (Engineering)
More Abstract
Engineering
Less Abstract
Design Process
Top-level problem definition is called PDS
(Product Design Specifications)

Problem definitions at lower levels derive
from PDS:
Sub-system design specifications.
Component design specifications.
Feature design specifications.
Product Development Process



Market Research
Product Design Specifications & QFD
Design Brief (Mission Statement)
Product Planning
Product Development Process
Concept Synthesis
PDS
Concept Evaluation
Candidate Design
Detail Design
Candidate Design
Release for Production
Prototyping
Detail Design
Parameter Design
Candidate Design
Release for Production
System-Level Design
Prototype Testing
Components
No Numbers
Numbers
Customers
People who are affected by the product
Team
Company
(Internal)
Globe
(External)
External Customers
EXTERNAL
End
Users
Maintenance
Society
Retailer
Buyers
Government
&
Standards
Internal Customers
Internal
Marketing
Legal
Manufacturing
&
Procurement
Management
Shipping
What Do They Want?
End Users
Performance & Functionality
Affordability
Ease of use including ergonomics
Reliability and Long life
Versatility
Safety
Low maintenance and easy assembly
Esthetics


External Customers
Buying managers
Low Cost/Performance
Safety
Ruggedness (abuse resistance)
Ergonomics
Long warrantees
Reliable with Low downtime
Low operating cost





External Customers
Retailers
Small and attractive packaging
Long shelf life
Low cost/performance and Exciting features

Maintenance
Ease of maintenance




External Customers
Government / Standards / Society
Conformance to laws and regulations
Promotion of public health and safety
Protection of environment
Solution to chronic problems in society
Traffic
Energy
Noise
Drugs, abuse and other crimes
Diversity / Social tolerance / Security







Internal Customers
Management
Make a big profit
On time delivery
Low failure risk
Documentation
Process: Conformance to company
product development process






Internal Customers
Marketing
Attractive features to target buyers
Low production cost
Esthetics
Attractive packaging
On time delivery
Long Warrantees









Internal Customers
Manufacturing
Manufacturability using standard
methods and schedules.
Conformance to company documentation
formats.
Use of products from preferred
vendors.











Internal Customers
Legal
No patent infringements
Safety
All required safety warnings and labels
Designed protection against reasonable
abuse
Codes and regulations












Internal Customers
Shipping and Packaging
Ease of user assembly
Small packaged size
Ability of locking or fixing sensitive
components
Resistance against damage due to
dropping, vibrations, moisture, heat, and
cold.













Performance cost Ease of use Reliability Safety
Users ***** ***** ***** ***** *****
Buyers **** ***** ** ***** *****
Retailers *** *** *** ** **
Govrnmnt ****
Mangmnt ** **** ** ** ***
Marketng **** ***** *** **** ***
Product Design
Specification
Elements of PDS
Performance (User)
Speed,
Capacity,
Power,
Accuracy,
etc.
Elements of PDS
Environment: (User)
Temperature range, humidity, dust and dirt,
etc.
Life in service: (User)
10 years, 5000 cycles, etc.
Maintenance: (User)
What is the market policy, what customers
accept
Target production cost: (User)
Cost of comparable products and company
policy.

Elements of PDS
Shipping:
Package sizes
Damage resistance


Elements of PDS
Quantity (Manufacturing)
Determined by market analysis.
Manufacturing facility (Manufacturing)
Is the design constrained by existing facility?
Are parts to be contracted and assembled in-
house?
Does the company policy dictate certain
facilities?
Element of PDS
Size and shape (Marketing)
Weight (Marketing)
What is the desired weight?
Should handles or lifting points be
provided?
Should it be modular for better
handling?
Aesthetics (Marketing,User)
Color, shape, form, texture, finish.
Market research.

Elements of PDS
Materials (Marketing, Codes, Regulations)
Left to designers unless company
guidelines or regulations restrict certain
materials (asbestos, lead).
Product life span (Marketing, Manufacturing)
Life of a product as a marketable entity.
Several months or several years?

Elements of PDS

Laws, Codes, and standards (Government)

Ergonomics (User)

Elements of PDS
Quality and reliability (Marketing)
Company policy regarding warranties
Competitors warranty policies
Testing (Marketing, QA)
What tests would be performed to verify
performance
Standard tests

Elements of PDS
Shelf life (storage) - Retail
Possibility of rust, decay, deterioration
Processes (company guidelines)
Use of certain standards (GD&T for
example)
Use of certain procedures
Time-scales (deadlines) - Management
Whole design project, milestones

Elements of PDS
Safety (User, Government, Legal)
What safety requirements are
mandated by government
Professional society's codes and
standards
Need for warning labels
Likely degrees of abuse or
misinterpretation of operating
procedures.
Elements of PDS
Company constraints (Management)
Compatibility with other products
Documentation (Management Legal)
A product design must include a full
formal documentation per company
guidelines.
Safety, Operation, and Service
documents.
Etc.

Elements of PDS
Legal (Lawyers)
What product liability law suits are
associated with similar products and
why.
Note the legal terms:
defect of specification
defect of design
defect of manufacture
Relevant patents

Element of PDS
Installation (Installers)
Many products must interface with
other products or be assembled with
other products.
Disposal (Society)
Should any parts by recyclable?
bio-degradable?



Wording of the PDS
Document
Format of most statements in PDS:
The device must ..
The device is to
The device is desired to .
Avoid mixing requirements.
One sentence per requirement.
Cast PDS statements in a positive
format
PDS is a Dynamic
Document
A design statement usually begins as
a vague statement
The device is to be easy to use
The device is to be safe
The device is to be inexpensive
The device is to be rugged and reliable
The device is to be portable

Wording of the PDS
Document
Example: ESCOs Pin Remover
The pin-remover is to be light.
The pin-remover must work in a wet,
cold, and dusty environment.
The Pin-remover must be safe
The Pin-remover must have a 3-year
warranty.

PDS Example
The PR is to be rugged.
must work with air pressure.
is be easy to use.
is to pass HTS tests.
is to last 5 years in normal usage.
is to be easy to carry.

PDS Example
is to sell for less than $150.
is to costless than $50 to make.
is to have low maintenance needs.
is to be difficult to use as a
hammer.
must not infringe on patented
devices.
Production volume is to be 300 per
year



PDS Example
is to be tested by June 2006.
is to be released by Sep. 2006.
is to be used with Dredge Point
models.
is to work faster than the hammer

Engineering
Specifications
What is
Fast, accurate, high-performing?
Light, Small, portable?
Easy to use?
Safe?
Stylish?

Engineering Specifications
Verifiable PDS statements
Developed for important PDS
statements
Have associated target
numbers (Yes/No OK)
Engineering Specifications
Tips
Set up metrics and targets
so the designer has
maximum options in
accomplishing the PDS

Engineering Specifications
Tips
PDS: The Dog Feeder must not tip
over when bumped or pushed by a dog.
Bad: The DF must weigh 50 lbs
Good: The dog feeder must
withstand 30 lbs applied to its
top from side

A Typical PDS Page
Requirement: PR is to be easy to
maintain
Primary customer: End users
Priority: High
Metrics and Targets
Daily maintenance: None
Weekly maintenance: < 10 minutes field
Yearly maintenance: < 1 hour Shop
Cost of weekly maintenance < 10c
Cost of yearly maintenance < $10





Customer
Needs
PDS
Statements
Engineering Requirements
Competition
I
M
P
O
R
T
A
N
C
E
Competition
Relation Between
Engineering and
Customer
Requirements
Target