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Design Methodology: (Pierre Lambert) : Chapter 1: Introduction
Design Methodology: (Pierre Lambert) : Chapter 1: Introduction
The
basic
premise
for
concurrent
engineering
revolves
around
two
concepts.
The
first
is
the
idea
that
all
elements
of
a
products
life-cycle,
from
functionality,
producibility,
assembly,
testability,
maintenance
issues,
environmental
impact
and
finally
disposal
and
recycling,
should
be
taken
into
careful
consideration
in
the
early
design
phases.
The
second
concept
is
that
the
preceding
design
activities
should
all
be
occurring
at
the
same
time,
or
concurrently.
The
overall
goal
being
that
the
concurrent
nature
of
these
processes
significantly
increases
productivity
and
product
quality,
aspects
that
are
obviously
important
in
todays
fast-paced
market.
It
is
essential
to
integrate
all
constraints
as
soon
as
possible
in
the
design
process.
Changes
made
in
early
stages
have
reduced
cost
and
huge
impact
on
the
final
cost
of
the
product.
It
is
important
to
note
that
products
will
only
be
successful
when
they:
Satisfy
the
customer
needs
(requirements);
Reach
the
market
at
the
right
time;
Are
sold
at
the
right
price.
To
this
aim,
scheduling
is
important
because
the
project
or
product
must
be
finished
at
a
certain
point
in
time,
and
intermediate
results
are
required
on
specific
dates.
Moreover,
not
every
task
can
be
executed
by
every
member
of
the
team,
i.e.
there
is
a
resource
constraint.
1.
PRODUCT
PLANNING
Product
planning
is
the
systematic
search
for,
the
selection
and
development
of
promising
products
ideas.
New
products
can
be
driven
by
the
market
driven
or
the
company.
(Current,
development,
innovation
product
/
technology
&
market)
2.
FUNCTION
ANALYSIS
Function
analysis
is
a
methodology
targeting
the
identification
of
the
products
functions
required
to
satisfy
the
needs
of
a
customer.
Indeed,
in
order
to
satisfy
a
customer,
a
product
must
offer
several
functions.
The
functions
are
usually
searched
intuitively,
which
leads
to
the
correct
identification
of
only
50-60%
of
the
functions.
The
main
reasons
for
a
lack
of
quality
rely
on:
Non
or
bad
identification
of
some
functions;
Incorrect
assessment
of
the
importance
of
the
identified
functions;
Incorrect
materials
selection;
Manufacturing
defaults.
To
summary
the
justification
of
functional
analysis,
let
us
say
that
it
is
necessary
to
know
(identify)
the
need
in
order
to
satisfy
it,
express
it
in
terms
of
functions
in
order
to
understand
it,
and
that
the
identification
of
these
functions
requires
analysis
methods.
The
goal
of
function
analysis
is
to
transpose
the
customers
needs
into
products
functions.
It
is
important
to
consider
or
identify
objective
needs:
Performances,
characteristics,
ergonomy,
security,
availability,
sustainability,
maintainability,
weight,
...
But
also
subjective
needs,
which
are
much
more
difficult
to
quantify,
such
as:
Comfort,
lifestyle,
fashion,
relaxation,
aesthetics,
classicism,
originality,
mood
and
atmosphere,
scarcity
(rarete),
smartness,
distinction,
luxury,
appearance,
...
To
this
aim,
a
basic
step
consists
in
answering
three
questions:
1.
What
is
the
products
utility?
Who
can
take
benefit
from
it
(A
qui
rend-il
service)?
2.
What
or
who
does
the
product
interfere
with
(Sur
quoi
ou
sur
qui
agit-il)?
3.
To
which
purpose
this
product
has
to
be
developed
(Dans
quel
but
le
systme
existe-t-il,
quel
besoin
rpond-il)?
There
are
different
categories
of
functions:
The
external
functions,
identified
before
the
conceptual
design:
these
functions
are
directly
useful
to
the
customer;
principal
functions:
for
which
the
product
is
designed,
which
satisfy
the
primary
need
of
the
customer.
complementary
functions:
which
satisfy
a
complementary
need
of
the
customer.
Complementary
functions
must
be
satisfied
too,
they
are
not
secondary
functions.
The
constraints,
imposed
by
the
normative
environment,
the
environment,
the
technology,
the
non
satisfied
customer
The
internal
or
technical
functions,
which
are
not
directly
useful
to
the
user,
but
are
induced
by
the
chosen
design.
An
indicator
of
design
quality
is
the
ratio
of
external
functions
(required
by
the
customer
need)
over
the
internal
functions
(required
by
the
designer
or
the
manufacturer):
Design
Quality
=
Number
of
external
functions
Number
of
internal
functions
Functions
can
also
be
sorted
according
to
their
nature:
Active
functions:
move
a
load,
cool
a
room,
ensure
a
motion...
Passive
functions:
be
nice-looking,
corrosion-proof...
One
more
time,
it
is
important
to
note
that
the
function
describes
an
expected
result,
and
not
the
solution
leading
to
this
result.
Each
function
must
be
written
accurately.
The
functions
list
will
be
presented
in
a
table,
which
includes
for
each
function:
A
ranking
number;
A
description;
K,
a
coefficient
describing
the
importance
of
this
function;
If
possible,
criteria
which
can
be
used
to
assess
the
product
relatively
to
this
function;
For
each
criterion,
a
range
of
admissible
values;
F,
a
coefficient
describing
the
flexibility
One
single
function
may
correspond
to
different
criteria
(holding
size).
Levels
will
be
associated
to
these
criteria,
which
can
vary
or
not
among
a
given
range:
this
range
of
acceptable
levels
corresponds
to
the
flexibility.
The
flexibility
is
not
always
for
free.
Functional
specification
Methods
for
external
functions
identification
:
Intuitive
Search
or
brainstorming
1.
Clarify
the
objectives;
2.
Gather
documentation;
3.
Search
for
functions;
4.
Define
more
clearly
each
function;
5.
Define
characteristics,
expected
values
and
flexibility
Product
Life
Cycle
:
The
functions
to
be
fulfilled
by
the
product
can
also
be
found
by
considering
the
product
life-cycle
FMEA:
The
study
of
the
possible
failure
modes
is
also
a
good
way
to
identify
the
functions
of
a
product.
Environment
:
The
environment
of
a
product
is
made
of
human
beings,
physical
effects,
intangible
elements.
The
environment
can
be:
internal
/
external
changing
/
unchanging
usual
/
exceptional
It
is
important
to
clearly
set
the
boundaries
of
the
environment
in
order
to
focus
on
the
essential
functions,
and
also
to
consider
how
the
product
can
interact
with
its
environment.
Sequential
Analysis
of
Functional
Elements
(SAFE)
:
This
method
consists
in
thinking
to
a
typical
sequence
operated
by
the
future
user
of
the
product,
in
order
to
identify
the
required
functions.
Study
of
Efforts
and
Motions
:
Mechanical
strength
is
an
important
property
for
many
products:
cars,
tools,
buildings,
machines...
It
can
be
useful
to
analyse
the
force
flows
and
motions
in
the
product
to
identify
functions,
both
in
normal
or
exceptional
use.
Reverse
Engineering
:
Reverse
engineering
consists
in
studying
an
existing
product,
either
from
your
company
or
from
the
competitors.
Before
studying
which
functions
this
product
does
really
fulfil,
it
is
useful
to
apply
the
previously
presented
techniques
to
find
the
functions
that
this
product
should
fulfil
and
therefore
compare
with
what
it
really
does.
Normative
Documentation
:
Norms
also
define
functions
to
respect,
usually
with
characteristics
and
associated
levels.
This
norm
specifies
the
minimum
requirements
and
describes
the
corresponding
method
of
test.
3.
The
resilience
R
measures
the
maximum
energy
stored
elastically
without
any
damage
to
the
material,
and
which
is
released
again
on
unloading.
It
is
the
area
under
the
elastic
part
of
the
stress-strain
curve;
4.
The
toughness
and
the
fracture
toughness
measure
the
resistance
of
the
material
to
the
propagation
of
a
crack
5.
The
loss
coefficient
h
measures
the
degree
to
which
a
material
dissipates
vibrational
energy.
6.
The
thermal
conductivity
measures
the
rate
at
which
heat
is
conducted
through
a
solid.
7.
The
thermal
diffusivity
a
describes
heat
flow
in
transient
regimes,
and
depends
on
thermal
conductivity
!
,
density
! and
specific
heat
Cp.
The
thermal
diffusivity
can
be
measured
by
measuring
the
decay
of
a
temperature
pulse
when
a
heat
source
initially
applied
to
the
material
is
switched
off.
8.
The
linear
thermal
expansion
coefficient
! measures
the
strain
per
degree
changed
induced
by
temperature
change
10
11
12
13
4.
Assembly
(a)
Ensure
that
assembly
is
possible;
(b)
Ensure
that
each
operating
machined
surface
on
a
component
has
a
corresponding
machined
surface
on
the
mating
component;
(c)
Avoid
interferences
5.
Accuracy
and
Surface
Finish
(a)
Specifythewidesttolerancesandroughestsurfacethatwillgivetherequire
performance
for
operating
surfaces;
(b)
Ensure
that
surfaces
to
be
finish-ground
never
intersect
to
form
internal
corners
Case
studies
(Exercices
p
118-120
!!!)
6.
DESIGN
FOR
ASSEMBLY
Guidelines
for
Manual
Assembly
Design
Guidelines
for
Part
Handling
The
designer
should
attempt
to
1.
Design
parts
that
have
end-to-end
symmetry
and
rotational
symmetry
about
the
axis
of
insertion.
If
this
cannot
be
achieved,
try
to
design
parts
having
the
maxi-
mum
possible
symmetry.
2.
Design
parts
that,
in
those
instances
where
the
part
cannot
be
made
symmetric,
are
obviously
asymmetric.
3.
Provide
features
that
will
prevent
jamming
of
parts
that
tend
to
nest
or
stack
when
stored
in
bulk.
4.
Avoid
features
that
will
allow
tangling
of
parts
when
stored
in
bulk.
5.
Avoid
parts
that
stick
together
or
are
slippery,
delicate,
flexible,
very
small.
Design
Guidelines
for
Insertion
and
Fastening
The
designer
should
attempt
to:
1.
Design
so
that
there
is
little
or
no
resistance
to
insertion
and
provide
chamfers
to
guide
insertion
of
two
mating
parts.
Generous
clearance
should
be
provided,
but
care
must
be
taken
to
avoid
clearances
that
will
result
in
a
tendency
for
parts
to
jam
or
hang-up
during
insertion.
2.
Standardize
by
using
common
parts,
processes
and
methods
(Figure
4.85);
3.
Use
pyramid
assembly
-
provide
for
progressive
assembly
about
one
axis
of
reference.
In
general
it
is
best
to
assemble
from
above.
4.
Avoid,
the
necessity
of
holding
parts
down
to
maintain
their
orientation
during
manipulation
of
the
subassembly
or
during
the
placement
of
another
part.
If
holding
down
is
required,
then
try
to
design
so
that
the
part
is
secured
as
soon
as
possible
after
it
has
been
inserted.
5.
Design
so
that
a
part
is
located
before
it
is
released.
A
potential
source
of
problems
arises
from
a
part
being
placed
where,
due
to
design
constraints,
it
must
be
released
before
it
is
positively
located
in
the
assembly.
Under
these
circumstances,
reliance
is
placed
on
the
trajectory
of
the
part
being
sufficiently
repeat-
able
to
locate
it
consistently.
6.
When
common
mechanical
fasteners
are
used
the
following
sequence
indicates
the
relative
cost
of
different
fastening
processes,
listed
in
order
of
increasing
manual
assembly
cost:
(a)
snap
fitting,
(b)
plastic
bending,
(c)
riveting,
(d)
screw
fastening.
7.
Avoid
the
need
to
reposition
the
partially
completed
assembly
in
the
fixture.
Additional
Guidelines
1.
Avoid
connections
2.
Design
so
that
access
for
assembly
operations
is
not
restricted
3.
Avoid
adjustments
4.
Use
kinematic
design
principles
Conclusions
These
qualitative
guidelines
are
useful
but
do
not
provide
any
quantification
of
assembly
ease.
A
more
structured
methodology
would
be
welcome:
this
will
be
described
in
the
next
Section.
Systematic
Methodology
for
DFA
(Boothroyd)
A
proposed
classification
of
assembly
tasks
and
related
standard
durations,
based
on
an
exhaustive
study
of
many
assembly
processes,
taking
into
account
the
following
parameters
of
the
parts:
symmetry,
size,
weight,
thickness,
flexibility,
geometry,
use
of
chamfers.
14
Assembly
Efficiency
From
this
study
he
could
identify
that
the
efficiency
of
a
design
for
assembly
usually
depend
on
the
number
of
parts
and
their
ease
of
handling,
insertion
and
fixturing.
A
measure
of
this
efficiency
is
provided
by
the
following
ratio:
Ema
the
assembly
efficiency
!!"# . !!
Nmin
the
theoretical
minimum
number
of
parts
!!" =
ta
the
assembly
time
of
the
most
simple
part
!!"
tma
the
current
assembly
time
of
the
design.
The
minimum
number
of
parts
(Nmin)
is
identified
thanks
to
a
functional
analysis
of
the
assembly.
Actually,
a
part
should
be
suppressed
if
1.
It
does
not
undergo
any
relative
motion
with
respect
to
the
existing
assembly;
2.
Different
materials
is
not
required
(heterogeneity);
3.
It
does
not
ease
the
assembly
of
already
existing
parts.
Classification
system
for
manual
handling
This
classification
system
is
based
on
the
following
characteristics:
size,
thickness,
weight,
nesting,
tangling,
fragility,
flexibility,
slipperiness,
stickiness,
necessity
for
using
two
hands,
necessity
for
using
grasping
tools,
necessity
for
optical
magnification,
necessity
for
mechanical
assistance
(FIGURE
4.98
page
131)
First
number
(rows):
Between
0
and
3:
for
parts
that
can
be
grasped
and
manipulated
with
one
hand
without
the
aid
of
grasping
tools;
Between
4
and
7:
for
parts
that
require
handling
tools;
8:
for
parts
that
tend
to
nest
or
tangle;
9:
for
parts
which
require
two
hands,
two
persons,
a
mechanical
assistance
Second
number
(columns):
1.
If
the
first
number
is
between
0
and
3,
the
second
number
depends
on
size
and
thickness;
2.
If
the
first
number
is
between
4
and
7,
the
second
number
depends
on
thickness,
tool
or
necessity
for
optical
magnification;
3.
If
the
first
number
is
equal
to
8,
the
second
number
is
related
to
size
and
symmetry;
4.
If
the
first
number
is
equal
to
9,
the
second
number
is
related
to
symmetry,
weight
and
parameters
ruling
interferences.
The
symmetry
is
evaluated
through
and
b
symmetry
depends
on
the
angle
through
which
a
part
must
be
rotated
about
an
axis
perpendicular
to
the
axis
of
the
axis
of
insertion
to
repeat
its
orientation;
b
symmetry
depends
on
the
angle
through
which
a
part
must
be
rotated
about
the
axis
of
insertion
to
repeat
its
orientation;
Classification
system
for
manual
insertion
This
classification
system
is
based
on
the
following
characteristics:
accessibility,
ease
of
handling
the
tool,
insertion
depth,
ease
of
alignment
and
positioning
(FIGURE
4.100
page
134)
First
number
(rows):
Between
0
and
2:
the
part
is
only
fixed
after
insertion;
Between
3
and
5:
the
part
is
self-fixed
or
help
fixing
another
part
just
after
insertion
;
9:
process
involving
parts
which
are
already
positioned.
Second
number
(columns):
1.
If
the
first
number
is
between
0
and
2,
the
second
number
depends
on
size
and
thickness;
2.
If
the
first
number
is
between
3
and
5,
the
second
number
is
related
to
the
ease
of
insertion
and
fixturing;
3.
If
the
first
number
is
equal
to
9,
the
second
number
indicates
the
assembly
process:
mechanical,
chemical.
easy
to
align
and
position
means
that
the
insertion
is
facilitated
by
well
designed
chamfers
or
similar
features;
obstructed
access
means
that
the
space
available
for
the
assembly
operation
causes
a
significant
increase
in
the
assembly
time;
restricted
vision
means
that
the
operator
has
to
rely
mainly
on
tactile
sensing
during
the
assembly
process
15
7.
DESIGN
TO
STANDARDS
Standards
and
norms
concern
all
aspects
of
product
design.
ISO
norms
are
sorted
according
to
International
Classification
Standards
(ICS).
Some
of
these
ICS
have
subcategories,
which
may
include
several
norms.
8.
DESIGN
FOR
COST
(
Page
137
)
see
the
slides
(lecture
n8)
9.
ADDITIONAL
GUIDELINES
(Page
138-155
but
not
in
the
slides
.)
Chapter
5
:
Detail
Design
(Page
157
194
but
not
in
the
slides
.)
Recycling-related
tasks
allocated
to
the
phases
of
the
design
process
16
17