product design

and
value ENGINEERING


By
Dr. M. A. Bulsara and Dr. H. R. Thakkar
nd
Edition : 2 Edition : 2015
ISBN : 978-93-85039-14-0
Size : 170 mm × 240 mm
Binding : Paperback with 4 Color Jacket Cover
Pages : 200 + 16
` 225.00

About the book CONTENT

The text-book aims at presenting the topics of Product Design and Value Engineering in a simple   1 : PRODUCT DEVELOPMENT: A PREAMBLE
manner. Each topic of the book has been arranged in such a way that reader is empowered with   2 : PRODUCTS and Product DEVELOPMENT
in-depth knowledge in the subject. processes
First five chapters contains topics on Product Design. Product development is a challenging task   3 : Product DEVELOPMENT PLAN
and can be learnt through experience. Many good universities have incorporated this course   4 : Identifying Customer Needs
to introduce the challenges and difficulties in product development process, to the students.   5 : Deciding product specifications
A product can be developed at lowest possible cost if the process is planned systematically.   6 : Value Engineering: An overview
  7 : Value Engineering Job Plan
Initial few chapters of the book cover systematic procedure for “Product Development” in detail,
 8 : Value Engineering: Project Selection and
supported with relevant examples.
Value standard
Subsequent chapters of the book cover the Value Engineering concept. Value Engineering   9 : FAST DIAGRAM AND LIFE CYCLE COST
approach is used to eliminate the unnecessary cost from the product. The implementation 10 : Initiating value engineering program
of Value Engineering concept has been elaborately described as value engineering job plan 11 : Design for manufacture
along with value engineering project selection, FAST diagram and Life Cycle Cost with relevant Annexure i : typical training program for a 40-
case studies. Last chapters deals with practical aspects of manufacturing, affecting the design hour value engineering training
considerations. workshop course
Annexure II : Case study: Market Pull Product \
The salient features of this book are: development of Bicycle
F Lucid description of Product Development process and Value Engineering Annexure III : paper solution of gtu
Concept. examinations
Index
F Illustrative examples within the text.
F Comprehensive summary at the end of each chapter.
F Exercise at the end of each chapter.
F Solved sample papers (GTU).
F Case study of window air conditioner to illustrate product development process.
F Value Engineering Training programme course.
F Illustrative engineering drawings to understand design for manufacture.
The book covers major syllabus of the subject Product Design and Value Engineering (Subject
code 171904 for B.E. Semester VII of Mechanical Engineering branch)prescribed by Gujarat
Technical University (GTU) and other Indian Universities. The book will also be of immense help
to the practicing engineers.

Checklist
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 PRODUCT DESIGN AND VALUE ENGINEERING
Detailed Contents
Chapter 01 PRODUCT DEVELOPMENT: A PREAMBLE (6) Finalizing concept and specifications
1-1. Introduction (7) Comparison with competitive products
(i) Based on physical existence (8) Economic analysis
(ii) Based on users (9) Modelling and prototyping
(iii) Based on engineering science 2-7. Product development organizational structure
1-2. Reasons for Product Development (1) Design, research and development department (What to
1-3. Factors Affecting Product produce?)
Development (2) Planning department (How to produce?)
(1) Changing needs of customer (3) Manufacturing department (Produce)
(2) Technological advancement (4) Inspection and quality control department (Quality
(3) Economic development of country Control)
(4) Competition in market (5) Purchase department (Procurement of raw material)
(5) Changes in government policies (6) Tool design department (Jig, fixture design)
1-4. Characteristics of successful product development (7) Servicing department (After sales services)
(1) Product function (8) Administration department (Managing human resource)
(2) Product quality (9) Sales and Marketing Department (How much to produce?)
(3) Product cost 2-8. An overview
(4) Development time EXERCISE 2
(5) Development cost
(6) Development capability Chapter 03 Product DEVELOPMENT PLAN
1-5. Design and Development of Product: A Team Work 3-1. Introduction
1-6. Duration and Cost of Product Development 3-2. Product Life Cycle
1-7. Challenges of Product Development 3-3. Appropriate time for introducing new product
(1) Creativity (1) During growth phase
(2) Cost 3-4. Planning the product development process
(3) Ever changing customer needs (1) Proposing organization goal
(4) Economics (2) Identify potential products
(5) Time constraint (3) Evaluation and selection of product
(6) Target customer segment (4) Resource allocation
(7) Team selection (5) Deciding product development goals
1-8. Evaluation of Product Development Process (6) Review of product planning
1-9. An overview 3-5. An Overview
Exercise 1 Exercise 3
Chapter 02 PRODUCTS and Product DEVELOPMENT Chapter 04 Identifying Customer Needs
processes 4-1. Introduction
2-1. Introduction (i) Major specifications of the product
2-2. Product classification (ii) Inclusion of a sub assembly
(1) Based on users (iii) Methodology of Design
(2) Based on engineering sciences (iv) Technology to be incorporated
(3) Based on infrastructure available with organization (v) Innovative ideas
(4) Based on the technological requirement for product (1) Product name
manufacturing (2) Basic Function
(5) Process intensive product (3) Outstanding features
(6) Customized product (4) Business goal
(7) High risk product (5) Financial constraint
(8) Quick build product (6) Market segment
(9) Complex product (7) Customers
2.3 Product Development Processes (8) Major constraints
2-4. A typical (generic) product (9) Expected selling price
development process (10) Time frame to introduce the product
(1) Planning (11) Use of existing resources and technology
(2) Concept development 4-2. Gather information from customer
(3) System level design (1) Selection of customer
(4) Detailed design (2) Methods for gathering customer needs
(5) Prototype building / model simulation (3) Eliciting customer needs
(6) Prototype / simulated model testing (4) Documentation of customer needs
(7) Revisions and improvement (1) Audio recording
(8) Production (2) Video Recording
2-5. Advantages of systematic product development process (3) Text writing
(1) Planning 4-3. Interpretation of raw data
(2) Coordination 4-4. Arrange customer needs based on hierarchy
(3) Time management 4-5. Establish significance of customers needs
(4) Financial management 4-6. Trade–off in deciding importance of the needs
(5) Process monitoring 4-7. Review and Revision
(6) Quality 4-8. An Overview
2-6. Concept development (The front end process) (1) Establishing the mission statement
(1) Identifying customer needs (2) Gather information from customers
(2) Establishing target specifications (3) Interpretation of raw data
(3) Concept generation (4) Trade-off in deciding importance of needs
(4) Concept selection (5) Review and revisions
(5) Concept testing Exercise 4

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 PRODUCT DESIGN AND VALUE ENGINEERING
Detailed Contents
Chapter 05 Deciding product specifications (6) Ease of manufacture
5-1. Introduction (7) Use of standardized parts
5-2. Establishing target specifications (8) Service and maintenance of equipment
(1) Prepare a list of measurable (9) Availability of vendor and their reliability
(2) Collect competitors’ data (Bench marking) 7-6. Investigation Phase (Development phase)
(3) Set the range of target values 7-7. Recommendation (Presentation) and Implementation Phase
5-3. Setting the final specifications 7-8. Overview
(1) Develop different concepts of design Exercise 7
(2) Calculate cost of product according to each design
(3) Strike out final specification based on trade-off Chapter 08 Value Engineering: Project Selection
5-4. Review and Revisions and Value standard
5-5. Overview 8-1. Value Engineering (VE) Project selection
Exercise 5 8-2. Methods used for VE project selection
(1) Felt need
Chapter 06 Value Engineering: An overview (2) Review by steering committee
6-1. Introduction (3) Suggestion schemes
6-2. Cost reduction techniques (4) Seminars / brain storming
(1) Operation research
(5) Relative ranking
(2) Time and motion study
(6) Why-Why analysis
(3) Use of mass production techniques
(7) Assessment of Value index
(4) Standardization
8-3. Application of value engineering methodology
(5) Make-buy decision
(1) Application of Value Engineering during Product . . .
(6) Simplification
Development Process
6-3. Definition of Value Engineering
(2) Application of Value Engineering during Product Life
6-4. What is value?
Cycle
(1) Use value
(2) Esteem value 8-4. Value standard
(3) Exchange value (1) Information Phase
(4) Cost value (2) Function Analysis Phase
6-5. Value Engineering Programme (VEP) (3) Creation Phase
(1) Selecting a product or service for study (4) Evaluation Phase
(2) Obtaining and recording information (5) Development Phase
(3) Analyzing the information and evaluating the product (6) Presentation Phase
(4) Working out alternatives 8-5. Overview
(5) Selecting the least cost alternative Exercise 8
(6) Recommendation Chapter 09 FAST DIAGRAM AND LIFE CYCLE COST
(7) Implementation 9-1. Introduction
6-6. Advantages of value engineering 9-2. Layout of FAST diagram
6-7. Reasons for unnecessary cost 9-3. Case study
6-8. Concept of value engineering 9-3-1.Case Study 1: Overhead projector
(1) What is the product? (Selection of product) 9-3-2.Case Study 2: Lathe Machine
(2) What must it do? (Evaluation of function) 9-3-3.Case study 3: Air conditioner
(3) What does it cost? (Evaluation of cost) 9-4. Tips for preparing FAST diagram
(4) What is it’s worth? (Evaluation of worth) 9-5. Life Cycle Cost (LCC)
(5) What else would work? (Working out alternatives) (1) Direct Material Cost
(6) What does it cost? (Evaluation of cost of alternatives) (2) Direct Labour Cost
6-9. Overview (3) General expenses
Exercise 6 (4) Factory expenses
Chapter 07 Value Engineering Job Plan (5) Sales expenses
7-1. Orientation phase 9-5-1.Time Value of Money
7-2. Information phase 9-5-2.Evaluation of life cycle cost
7-3. Function phase 9-6. Overview
(i) Express function in two words Exercise 9
(ii) Quantify noun Chapter 10 Initiating value engineering program
(iii) Choose broad verbs 10-1. VE training program: Introduction
(iv) Categorize function 10-2. Implementation of VE training program
(v) Emphasize on aesthetics (1) Training coordinator
7-4. Creation Phase (2) Training plan
(1) Brain storming (3) Training capability
(2) Blast, Create and Refine 10-3. Categories of training
(3) Check list (1) Limited training (Level I)
(4) Morphological analysis (2) Intensive training (Level II)
(5) Delphi method (3) On the job training
(6) Attribute listing (4) Training by rotational job assignment
(7) FAST Diagram (5) Contractual training
7-5. Evaluation phase (6) Informal training
(1) Number of components in assembly 10-4. Workshop / Seminar
(2) Number of features on component (1) Priority of Attendance
(3) Design features to be machined in single set-up (2) Duration and Session Schedule
(4) Use of symmetry (3) Participants
(5) Ease of assembly (4) Team Organization and Responsibility

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 PRODUCT DESIGN AND VALUE ENGINEERING
Detailed Contents
(5) Workshop Projects (12) Avoid machining if possible
(6) Workshop Leadership (13) Avoid machining in narrow space
(7) Vendors (14) Provide relief for tool
(8) Curriculum 11-7. Design guidelines for cast components
10-5. Career development for VE specialities (1) Prevent hot spot at sharp corners
10-6. Overview (2) Provide draft in pattern
Exercise 10 (3) Maintain uniform thickness of cross-section
(4) Design junction to avoid hot spot
Chapter 11 Design for manufacture
(5) Material distribution
11-1. Introduction
(6) Web design in pulley
11-2. Capability and capacity of machine
(7) Relative size of section
11-3. Advantages of design for manufacture
(8) Avoid sharp corners
11-4. Common Manufacturing processes
(9) Cored holes
11-5. Design guidelines for sheet metal work
(10) Spacing of ribs
(1) Width to thickness ratio for punching
(11) Avoid solid hub
(2) Accuracy of punched hole
(12) Design for straight parting line
(3) Bending of sheet
(13) Avoid abrupt changes in cross-section
(4) Height to thickness ratio
11-8. Design guidelines for welded joints
(5) Placement of hole
11-9. Design guidelines for injection moulded components
(6) Relieving the Bend
(1) Optimize the section thickness
(7) Bending in perpendicular directions
(2) Provide suitable draft
(8) Reduce wastage
(3) Avoid sharp corners
(9) Limitation of roll bending
(4) Avoid abrupt changes in cross-section
(10) Grain orientation and bending
(5) Design bosses carefully
11-6. Design guidelines for machined part
11-10.Overview
(1) Design for reduced setups
Exercise 11
(2) Design shape according to standard cutters
(3) Avoid deep hole drilling Annexure I : typical training program for a 40-
(4) Drill can produce only straight holes hour value engineering training
(5) Drilling on inclined surface workshop course
(6) Depth of blind hole for post drilling operation
(7) Placement of hole Annexure II : Case study: Market Pull Product \
(8) Design section to resist cutting and/or clamping force development of Bicycle
(9) Chamfers are preferred over fillet
(10) Clamping of work piece Annexure III : paper solution of gtu examinations
(11) Provide free space for drill jig Index

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Telephone: (02692) 256237, Fax: (02692) 240089, e-mail: charotar@cphbooks.com, Website: www.cphbooks.in