Download ENT 452: RAPID ENGINEERING (WEEK 1) : 1. Introduction to rapid

UNIMAP: SEM 1 2008/2009
[ENT 452: RAPID ENGINEERING (WEEK 1) : 1. INTRODUCTION TO RAPID ENGINEERING]
Table of Contents
1.1 RAPID ENGINEERING CONCEPTS ................................................................................................................................................... 1
Product Definition .......................................................................................................................................................................... 1
Engineering Design Process ............................................................................................................................................................ 1
1.2 PROTOTYPING IN PRODUCT DEVELOPMENT ................................................................................................................................ 2
Prototype Design ............................................................................................................................................................................ 2
Prototype Impact on Cost, Quality and Time ................................................................................................................................. 2
Prototype Key Requirement ........................................................................................................................................................... 2
1.3 PRODUCT PROTOTYPING .............................................................................................................................................................. 2
Product Prototyping ....................................................................................................................................................................... 2
Prototype Planning and Management ........................................................................................................................................... 2
Prototype Design Method .............................................................................................................................................................. 2
Product Prototype Cost Estimation ................................................................................................................................................ 2
CHAPTER EVALUATION ....................................................................................................................................................................... 3
Quiz 1 .............................................................................................................................................................................................. 3
Tutorial 1 ........................................................................................................................................................................................ 3
REFERENCES ........................................................................................................................................................................................ 3
1.1 RAPID ENGINEERING CONCEPTS
Product Definition
Product definition simply means “figuring out what to make before making it”. A product definition is a layout of what the
purpose of the product is, whom it is targeted toward, and how it will be built and manufactured. Product definition often is
conceived as the process translating customer needs into product design specifications.
Engineering Design Process
i.
ii.
Identifying customer’s needs
Who are your customers?
Do you know what they want?
Do they know what they want?
Have you documented their needs?
Does the documentation reflect their need?
Are you developing a product that fits with their needs?
Find the answer by interview, questionnaires, brainstorming and focus group.
Converting need into design specification
Quality function deployment (QFD) or house of quality can be used to convert the voice of customer into design
specification for the engineers. The objective here is to explore and untangle the complex relationship between
customer and functional requirement to connect technology with what people need and want. After identifying
customer and functional requirement explicitly, they are captured in a formal specification that product concepts can
then be evaluated against. One then screens and ranks, to select the preferred concepts that are later refined. The
desirable result will be that the product fits both the customer “wants” and the business “needs”.
iii. Engineering design
Engineering design is an iterative process and can be classified into conceptual design, preliminary design and detail
design.
CO1: Ability to explain and define the rapid engineering principles and their relationship with 2D and 3D modeling.
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UNIMAP: SEM 1 2008/2009
[ENT 452: RAPID ENGINEERING (WEEK 1) : 1. INTRODUCTION TO RAPID ENGINEERING]
1.2 PROTOTYPING IN PRODUCT DEVELOPMENT
Prototype Design
i.
Design is to invent. Most technical problems have alternative solution. A viable solution is simple, easy to produce,
good quality and low cost.
ii. Product prototyping can be used as an evaluation tool in the engineering design process and as a key role in product
innovation. Its also help to quickly develop a product by providing good tool for problem solving and validate the
concepts.
iii. A vital role for innovation because it can be used as a visual to help communicate product’s purpose and feel.
Prototype Impact on Cost, Quality and Time
i.
ii.
The direct impact of shorter product development time includes the opportunity to sell the product at the premium
prices early in the life cycle, enjoy longer market life cycle, faster breakeven, lower financial risk, greater overall profit
and higher return on investment (ROI).
The rate of ROI is an important index for the success of a product innovation. ROI can be estimated:
𝑁𝑒𝑡 𝑝𝑟𝑜𝑓𝑖𝑡
[(𝑡𝑜𝑡𝑎𝑙 𝑝𝑟𝑜𝑓𝑖𝑡) − (𝑑𝑒𝑣. 𝑐𝑜𝑠𝑡)]
=
[(𝐷𝑒𝑣. 𝑐𝑜𝑠𝑡)𝑥(𝑡𝑖𝑚𝑒 𝑡𝑜 𝑚𝑎𝑟𝑘𝑒𝑡)] [(𝑑𝑒𝑣. 𝑐𝑜𝑠𝑡)𝑥(𝑡𝑖𝑚𝑒 𝑡𝑜 𝑚𝑎𝑟𝑘𝑒𝑡)]
[(𝑡𝑜𝑡𝑎𝑙 𝑝𝑟𝑜𝑓𝑖𝑡) − (𝑡𝑖𝑚𝑒 𝑡𝑜 𝑚𝑎𝑟𝑘𝑒𝑡)𝑥(𝑎𝑛𝑛𝑢𝑎𝑙 𝑑𝑒𝑣. 𝑐𝑜𝑠𝑡)]
=
[(𝑡𝑖𝑚𝑒 𝑡𝑜 𝑚𝑎𝑟𝑘𝑒𝑡)𝑥(𝑎𝑛𝑛𝑢𝑎𝑙 𝑑𝑒𝑣. 𝑐𝑜𝑠𝑡)𝑥(𝑡𝑖𝑚𝑒 𝑡𝑜 𝑚𝑎𝑟𝑘𝑒𝑡)]
Prototype Key Requirement
i.
ii.
Know the customers: one should participate in the customer design process, capture the “voice of customer”, direct
discussions with the customer through interview, surveys, focus groups, customer specifications, observations,
warranty data, field report, etc.
Use modern prototyping technologies: to save time and reduce errors
1.3 PRODUCT PROTOTYPING
Product Prototyping
Prototyping is a quick way to incorporate direct feedback from real users into a design. A prototype can be created for the
purpose of how it will look, how it will feel, how it will function, where to get it made and how to make sure it will turn out the
way one wants it.
Prototype Planning and Management
i.
ii.
iii.
iv.
v.
Step1: Define the purpose of the prototype
Step 2: Establish the level of the approximation of the prototype
Step 3: Outline an experimental plan
Step 4: Create schedule for procurement, construction and testing
Step 5: Perform more detail prototype planning including time and cost
Prototype Design Method
i.
ii.
iii.
iv.
Task 1: Prototype Conceptual Design
Task 2: Configuration Design of Prototype Parts and Components
Task 3: Parametric Design
Task 4: Detailed Design
Product Prototype Cost Estimation
Cost estimation is the process of determining cost behaviour of a particular cost item and cost behaviour is the relationship
between cost and activity (cost driver). A cost driver is any activity or factor that causes costs to be incurred. Activity based
costing classifies cost into four categories:
i. Unit level: activities performed for each unit
ii. Batch level: activities performed for each batch
iii. Product level: activities performed for a product families
CO1: Ability to explain and define the rapid engineering principles and their relationship with 2D and 3D modeling.
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UNIMAP: SEM 1 2008/2009
[ENT 452: RAPID ENGINEERING (WEEK 1) : 1. INTRODUCTION TO RAPID ENGINEERING]
There is several cost estimation method:
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
x.
xi.
Estimation by Analogy: Comparison to similar available system and ability to normalize cost data. Quick and accurate,
estimation are based on actual product data and past experience. Drawback, this method is not applicable if another
similar product does not exist.
Bottom up estimation: System is broken up into lower-level components and costs rolled up.
Top down estimation: The cost is established by considering the overall functionality of the product and how that
functionality is provided by interacting sub function.
Expert judgement: Uses one or more experts in both system development and the application domain to predict
development costs.
Pricing to win: Used to win the bidding process. The cost will be fixed by the customer and the product must be
manufactured within the cost.
Estimating models: This method uses a model or equation to arrive at a final cost with input to the model is parametric
data such as mass, design and manufacturing complexity, new element of mechanical/electrical design, performance,
cycle time and cost.
High low method: Display the cost of the different models and show a range of process for the prototype.
Graphical or scatter graph method: Past observations are plotted on a graph and a line of the best fit by using software
pr mathematical equation.
Inspection of accounts method: Look at historical data and classifies all expenses as fixed, variable or semi-variable.
Engineering method: Direct observations of physical quantities required for an activity and then convert into cost
estimates.
Prototype cost estimation: Used black box approach, the total prototyping cost is the total expenditures of all inputs
and disposal of scraps and waste.
CHAPTER EVALUATION
Quiz 1
Tutorial 1
REFERENCES
CO1: Ability to explain and define the rapid engineering principles and their relationship with 2D and 3D modeling.
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