Birla Institute of Technology & Science, Pilani

Work Integrated Learning Programmes Division

M.Tech. Design Engineering
Digital Learning Handout

Summary
Course Title Product Design
Course No(s) AE ZG531/ DE ZG541 /DM ZG541/ MM ZG541
Credit Units 5
1-1-2
Credit Model (32 Hours of Class-room Instruction + 32 Hours of
Assignments + 64 Hours of Student Preparation)
Course Author KIRAN D MALI
Version No 2.0
Lead Instructor GLYNN JOHN

Course Description
Introduction to creative design; user research and requirements analysis; problem
specification; creative problem solving; solution synthesis and analysis; modular design;
design economics: cost analysis, cost reduction and value analysis techniques; design for
manufacture and assembly; design for environment; Industrial design: aesthetics and
ergonomic considerations in design decision making; managing projects; legal factors;
intellectual property rights and patents. Extensive assignments, and hands-on problem solving
for term project.

Course Objectives:

No Course Objectives

CO1 Help students to identify the opportunity, collect, analyze and transform the requirements
into specifications.

CO2 Impart the knowledge on various processes, tools and techniques required for concept
generation, evaluation and selection.

CO3 Help develop an understanding of the industrial design aspects

CO4 Discuss the knowledge required to apply the various design for X techniques during
product design

CO5 Create an opportunity to us the learned knowledge in solving an actual problem

Teaching Methodology
The pedagogy for this course consists of class-room instruction explaining formal methods
and techniques of product development enriched with application of learned knowledge in
various assignments.
This course plan concerns to impart the knowledge required to develop a new product –
understand the opportunity, collect the requirements, develop specifications, generate,
evaluate and select a promising concept.

After the successful completion of this course, students shall be able to understand and
implement the various processes, tools and techniques required for designing a product:
product specification development; concept generation, concept selection, concept testing and
embodiment; product architecture; industrial design; design for X; environmental, economic
and social issues in product development; patents and intellectual properties.
Throughout the program emphasis will be on applications, using real examples from the areas
mentioned above, and test the acquired skills.
Text Books
Karl T. Ulrich and Steven D. Eppinger, “Product Design and Development”, 4th Edition
T1 (SIE), McGraw Hill Education (India), 2013.

Reference Books & other Resources

David G. Ullman, “The Mechanical Design Process”, 4th Edition, McGraw-Hill Higher
R1
Education, 2009.
Kevin Otto and Kristin Wood, “Product Design: Techniques in Reverse Engineering and
R2
New Product Development”, Pearson Education, 2001.

Modular Content Structure

.
M1. Product Development - Introduction, Product Planning, Identifying Customer
Needs and Product Specification Development
1.1. Introduction
1.1.1. Characteristics of Successful Product Development
1.1.2. Challenges of Product Development
1.1.3. Generic product development process
1.1.4. Product Development Organisations
1.2. Product Planning
1.2.1. Identifying opportunities
1.2.2. Evaluate and prioritize projects
1.2.3. Allocate resources and Plan timing
 1.2.4. Complete Pre-Project Planning
1.3. Identifying Customer Needs
1.3.1. Gather Raw Data from Customers
1.3.2. Interpret Raw Data in terms of Customer Needs
1.3.3. Organise the needs into a Hierarchy
1.3.4. Establish the relative importance of the needs
1.4. Product Specification Development
1.4.1. What are specifications?
1.4.2. When are specifications established?
1.4.3. Establishing target specifications
1.4.4. Setting the final specifications

M2. Concept Generation, Evaluation, Testing

2.1. Concept Generation
2.1.1. Clarify the Problem
2.1.2. Search Externally
2.1.3. Search Internally
2.1.4. Explore Systematically
2.2. Concept Evaluation
2.2.1. What is Concept Evaluation?
2.2.2. Different Concept Evaluation Methods
2.2.3. Concept Screening
2.2.4. Concept Scoring
2.3. Concept Testing
2.3.1. Define the purpose of Concept Test
2.3.2. Choosing Population and Format
2.3.3. Communicate the Concept and Measure Customer Response
2.3.4. Interpret the Results
2.4. Product Architecture
2.4.1. What is Product Architecture
2.4.2. Implications of the Architecture
2.4.3. Establishing Architecture
2.4.4. Modularity Design
M3. Industrial Design, Prototyping and Project Management
3.1. Industrial Design
 3.1.1. Need of Industrial Design
3.1.2. Industrial Design Process
3.1.3. Management of the Industrial Design Process
3.1.4. Assessing the quality of Industrial Design
3.2. Aesthetics and Ergonomics
3.2.1. Elements of Aesthetic Design
3.2.2. Elements of Ergonomic Design
3.2.3. Physiological considerations in design
3.3. Prototyping
3.3.1. Understanding Prototypes
3.3.2. Principles of Prototyping
3.3.3. Prototyping Technologies
3.3.4. Planning for Prototypes
3.4. Project Management
3.4.1. Understanding and Representing Tasks
3.4.2. Project Planning
3.4.3. Project Execution
3.4.4. Project Evaluation

M4. Design for X

4.1. Design for Manufacturing and Assembly
4.1.1. What is DFM and DFA
4.1.2. DFM Methods
4.1.3. DFA Methods
4.1.4. DFMA Procedure
4.2. Design for Environment
4.2.1. Material Life Cycle
4.2.2. MET Matrix
4.2.3. Life Cycle Assessment
4.2.4. DFE Guidelines
4.3. Design for cost
4.3.1. Cost Reduction via Design
4.3.2. Manufacturing Cost Estimation
4.3.3. Qualitative Analysis
4.3.4. Quantitative Analysis
4.4. Patents and Intellectual Property
4.4.1. What is Intellectual Property?
4.4.2. Formulate a Strategy and Plan
4.4.3. Steps in Writing
4.4.4. Pursue Application
 Part B: Course Handout

Session Schedule / Plan of Self-Study

(Each Contact Session is of 2 Hours duration)
CS
SESSION TOPIC MODULES REF Assignments
#
T1 (1, 2)
T1-
Chapter
1. Introduction 1.1.1 to 1.1.4 1 1
T1-
Chapter
2
2. Product Planning 1.2.1 to 1.2.4 T1 (3) 2
3. Identifying Customer Requirements 1.3.1 to 1.3.4 T1 (4) 3
4. Developing Product Specifications 1.4.1 to 1.4.4 T1 (5) 4
5. Concept Generation 2.1.1 to 2.1.4 T1 (6) 5
6. Concept Evaluation 2.2.1 to 2.2.4 T1 (7) 6
7. Concept Testing 2.3.1 to 2.3.4 T1 (8) 7
8. Product Architecture 2.4.1 to 2.4.4 T1 (9) 8
9. Industrial Design 3.1.1 to 3.1.4 T1 (10) 9
10. Aesthetics and Ergonomics 3.2.1 to 3.2.3 ISM 10
11. Prototyping 3.3.1 to 3.3.4 T1 (12) 11
12. Project Management 3.4.1 to 3.4.4 T1 (16) 12
13. Design for Manufacturing & Assembly 4.1.1 to 4.1.4 R2 (14) 13
14. Design for Environment 4.2.1 to 4.2.4 R2 (15) 14
15. Design for Cost 4.3.1 to 4.3.4 T1 (15) 15
16. Patents and Intellectual Property 4.4.1 to 4.4.4 T1 (14) 16

CS: Contact Session (2Hrs); ISM: Instructor Supplied Material;

Assignments: Work on typical situational problems experienced by practising executives.

Assignments
▪ Each student is given an individual assignment on any of the topics discussed
in the class
▪ Assignment Topics are based on practical problems experienced or part of
work-items or tools used by collaborating organization’s project managers
▪ Assignments are take-home and deadline-driven (typically of 7 days duration)
announced throughout the course (2 assignments per week)
▪ Students to spend at least 1 hour of work in study, research, discussion and
preparation of the report and presentation for each assignment.
 ▪ As part of deliverables, the student is expected to prepare a report and make a
short-presentation in the class
▪ Project Activity/ Experiential Lab:
▪
Sr No Lab Details/ Project Details Access
01 DFMA On-ramp Through online portal
02 Virtual Lab: DFMA software: – 16 hours of practice – Through online portal
Graded for 20%
▪
▪ Evaluation Scheme:
▪ Legend: EC = Evaluation Component; AN = After Noon Session; FN = Fore Noon Session

Evaluation Name Type (Open Weight Duration Day, Date,

Component (Quiz, Lab, Project, Mid- book, Session, Time
term exam, End semester Closed
exam, etc.) book,
Online, etc.)
Theory- Quiz/Assignment Online 10% 2 Weeks February 1-15,
2021
Lab Assignment Online 16% March 1-15,
EC - 1
2021
Lab Quiz Online 04% April 1-15,
2021
Mid-Semester Test Closed Book 30% 2 hours Sunday,
07/03/2021
EC - 2 (FN)
10 AM - 12
Noon
Comprehensive Exam Open Book 40% 3 hours Sunday,
02/05/2021
EC - 3 (FN)
9 AM – 12
Noon

Closed Book: No reference material of any kind will be permitted inside the exam hall.
Open Book: Use of any printed / written reference material (books and notebooks) will be
permitted inside the exam hall. Loose sheets, Photocopies and Laser printouts of any material
will not be permitted. Computers of any kind will not be allowed inside the exam hall. Use of
calculators will be allowed in all exams. No exchange of any material will be allowed.

Note:
It shall be the responsibility of the individual student to be regular in maintaining the self-
study schedule as given in the course handout, attend the online/on demand lectures as per
details that would be put up in the BITS eLearn (Taxila) website elearn.bits-pilani.ac.in
and take all the prescribed components of the evaluation such as Assignments/Quizzes, Mid
Semester and End Semester Examination according to the Evaluation Scheme given in the
respective Course Handout. If the student is unable to appear for the Regular Examination
due to genuine exigencies, the student must refer to the procedure for applying for Make-up
Examination, which will be available through the Important Information link on the eLearn
website on the date of the Regular Examination. The Make-up Tests/Exams will be
conducted only at selected exam centres on the dates to be announced later.

Instructor-in-Charge
 Lab-Course Hand-out:

1. Scope of the lab

To support the theory learned in engineering design course with Design for assembly
and Design for Manufacturing to understand the intuitive question-and-answer interface
that identifies opportunities for substantial cost reduction in a product and immediate,
thorough understanding of the primary cost drivers associated with manufacturing
product.

2. Objectives of Lab
Developing skill set to analyse design for assembly and manufacturing (DFMA) for
small assemblies using appropriate different manufacturing processes and selecting
correct set of machines.

3. Learning Outcome of the lab

 To perform DFA analysis for small assemblies.
 To create operation library in an analysis for existing operation to estimate the
process time and process cost.
 To estimate the total cost of manufacturing a component using different
manufacturing processes i.e. fabrication, die casting, machining and sheet metal
working.

4. List of simulation experiments: Software Tool used: DFMA

Tutorials will be shared once the lab started

Tut. Tut. Name Solving Quiz Assignment

No. Time Marks Marks
A Design for Assembly 4 Marks 16
1 Performing DFA analysis Marks
2 Operation library
3 Cable harness assembly
B Design for Manufacturing
1 Assembly fabrication analysis
3 Die casting analysis
4 Machining full analysis
5 Machining quick estimate
6 Machining cell analysis
7 Sheet metal working analysis
Sheet metalworking Deep
8
Drawing Analysis
9 Develop User Process
10 Printed Circuit Board Assembly
 Analysis
Total Marks 20

5. Evaluation Scheme

Evaluation Name Type Weight Duration

Component

EC - 1 Quiz (8 marks) Online 8% 2 hrs

EC – 2 Assignment (12 marks) Online 12% 2 hrs

Instruction Schedule

Lab Class work Instructions Online TBA 2 Hrs

Delivery

Evaluation Scheme
Evaluation Name Type Marks Dates Lab Exam Date Duration
Componen
t

Quiz based Online 06

on virtual lab

Assignment Online 14 Regular                          TBA

based on TBA
EC - I virtual lab
(12 for Makeup                          TBA
assignment TBA
and 4 for
practise
screenshots)

Note: After completion of every practice tutorial problem, take a snapshot and include the
same in the final assignment PPT lastly. Quiz questions will be based on the practice tutorial
problems and results.

Link for lab dates and other details (copy the link and paste it in your browser).

Instructor-in-Charge