Section A Flashcards
What are the 8 aspects of a car product footprint?
Cost, Eco, Reliability, Aesthetics, Luxury, Technology, Safety and Ergonomics
What are the criteria for the 8 aspects of a car product footprint?
Cost - Recommended retail price + Fuel cost + Estimated maintenance cost
Eco - Fuel consumption + Emissions + Estimated recycle fraction
Reliability - Past data of recalls and breakdowns
Aesthetics - Subjective – surveys may help to give confidence
Luxury - Music quality & functionality + IT functions + seat heaters etc
Tech - Top speed + 0-60 time + Gear shift quality
Safety - Number of air bags + NCAP report
Ergo - Size of seat + height of car
3 justifications for having a product range? (automotive)
1) Need comprehensive range to reduce risk and reach
critical mass turnover
2) Loss-leaders may be necessary to help other parts of range
3) Small cars and/or hybrids/EVs are necessary
to meet average emissions targets
Justification for product range in aerospace?
a good spread of aircraft seating sizes for different customers
Dyson product range justification?
A good range of types to meet all user preferences
What is a Dry lease, wet lease and sale and lease back?
Dry Lease - An aircraft leased without insurance, crew,
ground staff, supporting equipment, etc.
Wet Lease- An aircraft is leased with complete crew,
maintenance, and insurance.
Sale and lease back - An airline which has bought an aircraft, sells the aircraft to a leasing company and
immediately leases the aircraft back.
What are the advantages and disadvantages of bought-out components?
Advantages of bought-out
(1) High quality
(2) Low cost
Disadvantages of bought-out
(1) Lack of control
(2) Shared profit
(3) Loss of knowledge
What is Man-machine interface?
The man-machine interface is the interface between a
human operator and a machine
What are the TRL levels? describe 1-9 for space application
TRL 1. Basic principles observed and reported
TRL 2. Technology concept and/or application formulated
TRL 3. Analytical and experimental critical function and/or characteristic
proof-of-concept
TRL 4. Component and/or breadboard functional verification in laboratory
environment
TRL 5. Component and/or breadboard critical function verification in
relevant environment
TRL 6. Model demonstrating the critical functions of the element in a
relevant environment
TRL 7. Model demonstrating the element performance for the operational
environment
TRL 8. Actual system completed and accepted for flight (“flight qualified”)
TRL 9. Actual system “flight proven” through successful mission operations
What is TRIZ and what is the method used? (3)
Problem solving methodology based on logic, data and research. Method
1) contradiction check list of 39 features that can be improved
2) contradiction improved with a list of 40 design principles
3) Contradiction Matrix is created with improving and worsening features
which contains numbers from the solution principles matrix
What four design techniques does TRIZ include?
‘Ideality’ is similar to the ‘Backwards’ design method
The checklists are similar to the structured questions method
Notice [13] ‘the other way around’. This is like the ‘inversion’ method
Notice several principles encourage use of physical principles,
for example: 15, 18, 19, 29, 37
What are the negatives of TRIZ?
Can be difficult to implement without lots of experience
What are 8 drives for technology? (include examples)
(1) Legislation (reflecting public pressure)
Example legislation for cars: CO2 & CO limits, Diesel smoke limits, NCAP (new car assessment programme), Seat belt design, Fuel tank location
(2) Customer wishes
Reduce pollution; reduce costs; novelty, diversity, customisation, luxury
(3) Technology breakthroughs
Li ion batteries; new materials (Graphene 2D carbon); new IT
(4) Marketing
Advertising is very effective at moulding customer expectations
Cars: attractive body shape; speed; comfort; luxury; eco performance
(5) Innovators
Franz von Holzhausen – Tesla cars
James Dyson – Vacuum cleaners, hand dryers, Ball-barrow
(6) Elite activities
Formula 1; Space travel; Olympics
(7) Affluence
Affluence in China and India is creating new opportunities
(8) Competition
Improved products are necessary for survival.
Worst case loading - what should you consider?
Not the worst likely load but the worst possible load
What are the pros (6) and cons (2) of modular design?
Advantages:
- ease of maintenance
- quality control over assembly
- sealed for life
- enables platform design
- easy integration of new technologies
Disadvantages:
- small defects can’t easily be prepared
- needs high volume to make sustainable
What are the advantages of platform design? (5)
- Easier inventory management - less parts
- lower development costs
- increased quality
- global standardization / standards
- greater product variety
What are the 5 different kinds of order a product can be made for?
Engineer- to-order : formula 1 car
Make-to-order: standard design but complex production related to customer spec (Rolls-Royce car)
Assemble-to-order: built to customer spec with standard parts (Ferrari)
Make-to-stock: products build against sales forecaset i.e. low end cars
Ship-to-stock: Stock is held with retailer roller chains, gears and belts
What’s the difference between a ‘first to market’ or ‘fast follower’
- some firms seek to be first in a market
- they seek ‘first to market’ advantage premium prcies that enable this
- Fast followers learn from mistake of the first to market. Be careful with copyright shit
Why do companies need high quality managements systems? (list 3 types)
Ensure adequate paper trails. Material sourcing, material sourcing, component sourcing, production testing, decision making.
Three types:
- Total quality management
- Lean manufacturing
- Six sigma
How is legislation driving electrification? (Five stages)
- Micro hybrid
- Mild hybrid
- Full hybrid
- Plug in Hybrid
- Battery electrical vehicle
What are hard and soft requirements? Metrics and constraints?
Metrics - used during design processes to monitor performance
Constraints - aspect which must be achieved
HRR - non-negotiable
SRR - are desirable
List 12 conceptual design methods
- Bio-inspiration: many examples, efficient, complex and short life - better to not to copy
- Brainstorming -
- Backwards design
- Structured questioning
- Inversion
- Study competition
- Study physical principles
- Technology opportunities
- Sketching
- Prototyping - excellent feedback
What are the four different kinds of design review?
Preliminary design review - review design concepts + breadboard model
Engineering design review - review detailed design + eng model
Qualification dr - review qualification model performance
Find design review - review of detailed model performance.
Why are design reviews useful? (3)
1) formal process for managers to sign off on progress
2) forces designers declare status
3) corrective actions can be assigned
9 stages of the product life cycle
Trigger - product planning - feasibility study - design - development - production - distribution - operation - disposal
Benefits of prototyping and 4 types?
- good feedback
- highlight things that can’t be modelled
- visualise your concept to show to others
breadboard - broad feasibility
engineering - main performance aspects
qualification - check entire performance of product compared to the requirements
delivered model - checking the actual product before delivering
What is the stage-gate model?
- process that puts emphasis on certain achievements before progressing
- regular design reviews at sets dates
- performance of the design
For man machine interfaces, what are the goals of display? (
1) alert operator
2) minimise distraction
3) maximise speed of communication
For man machine interfaces, what colours/lighting are used? (6) and what other things should be considered?
1) slow flash (warning)
2) fast flash - danger
3) red - danger
4) yellow - warning
5) green 0 safe
6) fast beep for danger
For man machine interfaces, what other things should be considered?
iconic images optimal proxy orientation size grouping emergency buttons
List ergonomics considerations (7)
1) Driver visibility - a pillars , height trade off (drag / visibility)
2) Mirrors - flat true view, curved mirrors
Describe the double diamond design process and state positives
Discover: user and market research (divergent)
Define: market+user requirement align with business objectives
Develop: range of design solutions developed and iterated
Deliver: convergent approach is used to complete thr product
Positives: break the task into stages with outputs, encourages clarification of the specification
Describe the Pahl and Beitz model (4 points + pros)
- design process i broken down into distinct stages
- 4 main phases: task clarification, concept design, empodidied design, detailed design
- top down process starting with abstract ideas - finish with complete ideas
- stages of design can be combined to speed up (cocurrent engineering)
Pros: shows interactions, work on things at the sametime
What are the four design process discussed?
The Pahl and Beitz
Double diamond process
The V model
The stage gate model
What are the three types of design?
1) Incremental design:
- minor changes/improvements to an existing product
- low risk design
- common in industries with mature designs + high volume
2) Adaptive design
- significant changes/improvements to whole sub system
- introduction of airbags, crumple zonesl ABS bracking systems
- common when new technologies come around
3) Original design
- major change/improvements to whole subsystem or system
- example: change from IC to hybrid
Why do we need design methods and methodologies?
- Complexity of products
- vast number of decisions
- many parts + high information content
- each part can be a complex technology
- make decisions effectively - Complexity of organisations
- multiple companies with multi-disciplinary teams
- many suppliers
- large teams requires systematic methods - Quality control
- commercial prducts need verification + documentation
- company executives are liable
- requires verification requires systematic design methods
What are then 10 strategic questions hen designing a new product?
1) Best product footprint
2) Best product family
3) Product or service?
4) First-to-market or fast follower?
5) when retire from market?
6) What kind of order is product made for?
7) what made in house and bought in?
8) multi-functional sub assembles?
9) mass customization
Describe the V model and what are the positives?
The v-model shows the produce lifecycle goes from top-down during the design phase to bottom up during verification and delivery.
Pros:
- plan system before the details
- no point testing systems if components don’t work
What is the stage-gate model?
- process that puts emphasis on certain activities before progressing
- regular design reviews at set dates
- performance of the design can be defined and recorded at set milestones
- managers can ‘sign off’ on progress
- unique to each product
- benefits from breaking down into small gates-
How would you define aesthetics?
- Aesthetics and subjectives
- there are objective features in aesthetics
- involves an emotional response - which is real
- association and conditioning are important in aesthetics
Two examples:
- Audi TT rear wheel slip
- millennium bridge
In the automotive industry, what can be used as a strength symbol? (6)
- small windows
- high floor base
- big colours
- thick black rim about the car
- thick sections (wheel spokes)
Symbolism in form designed will often give a form that makes their products associated with desirable symbols
Tints, Shades, Tones
Tints - Adding white
Shades - black
Tones - grey
Describe colour association?
- Colour can have emotions and systematic association
- colour also offers the clarity of shape
- colour association: i.e. white is high tech
Three ways of defining beauty (3)
1) Form and colour follow functions
2) Form follows function: colour follows styling
3) Form follows function and styling, colour follows function and styling
What are the effects of age and life style anothropemtric data
- life style doesn’t change a person’s height
- dramatically effects mass and width
- mass and width increase significantly with age in affluent societies
What is human factors?
is the practice of designing products, systems, or processes to take proper account of the interaction between them and the people who use them.
Why is six sigma quoted has having both 99.87% and 99.73%?
3 sigma is quoted to have probabilities of both 99.87% and 99.73%.
This can be illustrated by an example:
Proportion people smaller than +3 sigma is 100(1-0.9987) = 99.87%
The proportion people smaller than -3 sigma = 0.13%
The proportion of people between -3s and +3s = 99.73%
What sigma and percentage would you design an economy seat for?
Economy - 90% of the population which is 1.64sigma
What sigma and percentage would you design a premium seat for?
3sigma which is 97.73% of the population
What sigma should be used for ultimate design load
6 sigma
For strength data, what are the three factors to consider?
- Use factor
- Gender factor
- Age factor
What is product architecture?
Ulrich defines product architecture as the scheme by which the function of a product is
allocated to physical components. He argues that the architecture of the product can be a key
driver of the performance of the manufacturing firm, that firms have substantial latitude in
choosing a product architecture, and that the architecture of the product is therefore
important in managerial decision making.
Modular design
- Modular design is an approach that subdivides a
system into smaller parts (modules) - can be independently created and then used in
different systems to drive multiple functionalities.
Product family and relation to modular design
- A modular architecture may be used in the definition of product families
- ## a set of products that share technology and address related market applications,allowing reuse of components, processes and design solutions.
What is a product platform? how does it relate to modular designs and product families?
- A product platform in turn is the collection of assets (components, processes, knowledge, people) that are shared by a set of products in a family.
- The platform concept is characterised by modularisation of a product architecture and integration of common elements (components, functions, interfaces, design rules) over the product family
What is a integral structure? give an example
between modular and integral structures. The automobile body-in-white is a good example of an integral structure.
What is the difference between characteristics and properties?
Weber’s definitions were that the characteristics describe the product’s structure and shape, and can be directly determined by the designer.
The properties describe the product’s behaviour and can not be directly determined by the designer: the designer instead uses a variety of approaches to estimate what the behaviour is likely to be.
Describe how environmental factors are a driver for technology? (3)
Public pressure - global warming + pollution in cities
International and national legislation - emissions targets over a fleet of cars
Local laws - congestion charge
Discuss features that lead to aesthetic merit in a sports car (5)
Form, detailed form, noise, colour, performance
Overall form: Low profile. Cat like profile. Cat like eyes.
Detailed external form: Getting the right combination of the following features with a consistent theme and the rightbalance: Curves, blending, edges, flowing lines, borders, slenderness, embellishments, association,
branding, contrast
Noise: Racing car type sound – high pitch. Fast gear change.
Colour: Use of dynamic sporty colours such as red or yellow. Highlighting colours in areas like brakes, seats, seat belts, wing mirrors.
Performance
Fast acceleration. Fast top speed. Good road handling
What are the rows and columns called in a Functional decomposition chart?
Sub-functions (LHS) & Sub-solutions (RHS)
List possible sub-functions for a car in a Functional decomposition chart (13)
Body shape, engine, gearbox, drive, suspension, wheels, tyres, fuel, battery, body material, chassis, bumpers, doors, number of seats,
Why is colour important in car design?
Colour can have high emotional and symbolic associations.
Colour affects size perception.
Colour can emphasise shape.
Colour is sometimes used to highlight features brake callipers or seat belts.
Colour can have a high quality. Lustre is a measure of the intensity/quality of the colour.
Some painting methods/pigments give better colour finishes than others.
The texture of a surface affects its appearance. For example the texture of the cloth of seats
affects its colour.
Colour can have special features such as:
Metallic paint, Gloss – Lacquer
Colour also affects ergonomics. Red symbols are generally for warnings whereas green are for safe actions. Red lights are used to show the rear of a car. Yellow lights are used for indicators.
What is synthesis?
Synthesis is used to suggest what artefact
characteristics will give the necessary properties (e.g. a vehicle design process)
What is design for X?
Design for X can include both tools for predicting the artefact’s X properties given its characteristics (e.g. determining an assembly rating in DFA), and tools/methods/guidelines suggesting characteristics of the artefact to achieve a given performance in terms of X
