Part 1 - The challenge of Product Design

Question 1

Technology Readines Levels (TRLs)

Answer 1

Defines the maturity of a product. There are man stages required to design a new product

TRL 0: Idea - Unproven Concept - no testing
TRL 1: Basic Research - Principles postualted but no experimental proof.
TRL 2: Technology Formulation - Concept and application have been formulated
TRL 3: Applied Research - First lab tests are completed
TRL 4: Small scale prototype - Test in Lab environment
TRL 5: Large scale prototype - Test in Intended environment
TRL 6: Prototype System - Closer to expected performance
TRL 7: Demonstration System- Operating in environment ( pre-comercial sale)
TRL 8: First of a kind commercial system- Manufacturing issues solved.
TRL 9: Full comercial application- Technology for consumers.

Question 2

Form

Answer 2

Shape of a product

Question 3

Function

Answer 3

The function of a product

Question 4

Ergonomics

Answer 4

Design for human interface

Question 5

Aesthetics

Answer 5

Design for beautiful appeal

Question 6

Why are products complicaticated (3)?

Answer 6

1- Complex Product. Lots of parts each requiring lots of information for manufacture.
2- Large Organisations - Multi-disciplinary design teams containing lots of people must work together and communicate effectively.
3- Verification - Products must be verified and tested. All parts must have a paper trail.

Question 7

What are Product Objectives

Answer 7

When designing, many objectives must be considered and prioritised. Evaluation against the objectives requires large amounts of work e.g. Life cycle analysis.

Examples of Objectives- Cost, Ergonomics, Safety, Reliability, Luxury, Environmental, Aesthetics.

Question 8

Why is reliability difficult to design for? (Case Study)

Answer 8

Customers expect products to be reliable. When designing there are vast amounts of unknown unknowns.

Toyota recalled cars as accelerator could get stuck under floor mats. Huge cost implications to resolve design problems. Whilst making the majority of correct decisions, one mistake can have a big effect

Question 9

Retaining Knowledge

Answer 9

Products that develop over time must try to keep the same heritage whilst keeping up to date with new technologies

Question 10

What is the Form Function conflict

Answer 10

Ensuring that a product performs as expected whilst also being aesthetically pleasing can be challenging.

Question 11

What Environmental Conditions must be considered when designing a product?

Answer 11

New legislation can dictate how products are designed. E.g. taxes on diesel cars

Question 12

State 7 Challenges of Design:

Answer 12

1- Many Stages required to develop a new product
2- Products are complicated 
3- Products have multiple objectives 
4- Products must be reliable 
5- Retaining Knowledge 
6- Form v Function Conflict 
7 - Environmental Legislation

Question 13

Why is a design process required?

Answer 13

To systematically coordinate the efforts of large multi disciplinary teams.

Question 14

State 3 types of design

Answer 14

Incremental - Minor changes to sub system
Adaptive - Significant changes/ replace whole sub system. Normally occurs due to new technologies.
Original- Major changes to whole system (more risky- sometimes reduced risk by government incentives)

Question 15

Define the Product Lifecycle

Answer 15

Motivation: Need for a product -> Product Plan -> Feasibility Study. ->

Creation: Design -> Development -> Production ->

Operation: Distribution -> Operation

Disposal: Disposal

This process is nearly always iterative

Question 16

What is the Pahl and Beitz Model

Answer 16

Design process broken down into distinct stages making process more manageable. ( Task Clarification, Conceptual Design Embodiment Design, Detail Design)

Stages sometimes overlapped to reduce time most suitable for incremental design.

Question 17

What is the Double Diamond including benefits

Answer 17

Discover - (Divergent) Research markets, understand task.
Define - (Convergent) Align market research is aligned with business objectives.
Develop ( Divergent) A wide range of design solutions are explored.
Deliver (Convergent) Complete product definition.

Benefits: Breaks task into stages with outputs, encourages the designer to clarify specification.

Question 18

What is the V model

Answer 18

Project Definition: Concept of Operation _> Requirement and Architecture _> Detailed Design

IMPLEMENTATION

Project Test and Integration: Integration, Test, Validation -> System Verification -> Operations and Maintenance.

Product life cycle is top down for design phase and bottom up for verification and delivery.

This is advantageous as it is good to have an overall picture before designing the details and if a component fails then so would the sub system so bottom up testing is suitable.

Question 19

What is the Stage Gate Model

Answer 19

Suits formal industry

Emphasis that certain achievements are required in order to progress.

Design reviews at set dates.

Performance of design can be defined and recorded at milestones for which managers can sign off on.

Question 20

State 4 types of prototype models

Answer 20

Breadboard Model - Check broad feasibility
Engineering Model - Physically verify main performance aspects
Qualification Model - Check entire performance compared to requirements. (Include Safety Margins)
Delivered Model - Actual product performance before delivery.

Question 21

State 4 Design Reviews

Answer 21

PDR - Concept Design (Breadboard Model)
Engineering Design Review- Detailed Design ( Engineering Model)
Qualification Design Review - Review of Qualification Model
FDR - Review of delivered model performance

Question 22

What is important to consider when creating a problem statement?

Answer 22

Solution - neutral as failure to do so can discourage innovative solutions

Question 23

How can you ensure a complete list of specification requirements

Answer 23

Multidisciplinary checklist for requirements in each area.
Check with relevant design authorities.
Use of function means tree to create specs that ensure objectives are reached.
Consider worst case loading. Maximum possible, not expected loading.
Clarify information with client

Question 24

What are the challenges of Conceptual Design (3)?

Answer 24

Designing in 2D can inhibit creativity
Engineers are trained to be cautious - inhibits design,
Inspiration cant be forced.

Question 25

What Drives Innovation (7)?

Answer 25

Legislation 
Customer Wishes 
Technology Breakthroughs 
Innovators/Entrepreneurs
Elite Activities (F1) 
Affluence 
Competition

Question 26

State Conceptual Design Methods (12)

Answer 26

Study Competition - Cars, Phones (Samsung v Apple)
Insight - Understand physics of the problem (Large ships fuel proportional to volume, drag proportional to frontal area)
Bio Inspiration- large range of concepts already proven, however life spans may not be long, often quite complicated.
Technology Transfer- Dyson vacuum from factory application, ball barrow.
Functional Decomposition (Morphological Charts)
Backwards Design - Idealist solution and work back to solve. Floating train -> use magnets.
Prototyping- Quick feedback, may show unknown unknowns.
Brainstorming
Structured Questioning - What can / can’t be done to solve a problem.
Inversion - Existing design can be done differently. Caterpillar tracks over wheels
Technology Opportunities- AI, Magnetic Levitation, Smart Materials.
Sketching - Easy to annotate, Good for collaboration. (3,2 point perspective, isometric, oblique)

Question 27

What is TRIZ?

Answer 27

Creation of contradiction matrix that improves features without worsening others using list of 40 design principles.

Question 28

How can you quantify decision making processes?

Answer 28

Use of Pugh Matrix