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/ AEL 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 SAMATA MUJUMDAR

NITIN KOTKUNTE, SAMATA MUJUMDAR, GANESH

Instructor in Charge
KAKANDIKAR

Version No 3.0

Date 23-07-2024

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.
George E. Dieter, Linda C. Schmidt, "Engineering Design", 4/e (Indian Edition), McGraw
R3
Hill Education (India) Pvt. Ltd., New Delhi, 2009.

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
2.5 Detailed Design
2.5.1 Engineering drawings
2.5.2 Limits, fits and tolerances.
M3. Industrial Design and Prototyping
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
3.1.5. Elements of Aesthetic Design
3.1.6. Elements of Ergonomic Design
3.1.7. Physiological considerations in design
3.2. Prototyping
3.2.1. Understanding Prototypes
3.2.2. Principles of Prototyping
3.2.3. Prototyping Technologies
3.2.4. Planning for Prototypes

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 Safety, Reliability and Maintainability
4.3.1. Design for Safety
4.3.2. Design for Reliability
4.3.3. Design for Maintainability
4.4. Product development economics
4.1.1. Cost Reduction via Design
4.1.2. Manufacturing Cost Estimation
4.1.3. Qualitative Analysis
4.1.4. Quantitative Analysis
4.5.Patents and Intellectual Property
4.5.1 What is Intellectual Property?
4.5.2 Formulate a Strategy and Plan
4.5.3 Steps in Writing
4.5.4 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. T1 (4)
Identifying Customer Requirements 1.3.1 to 1.3.4 3
R3 (3)
4. T1 (5)
Developing Product Specifications 1.4.1 to 1.4.4 4

5. T1 (6)
Concept Generation 2.1.1 to 2.1.4 5
R3 (6)
6. T1 (7)
Concept Evaluation and Testing 2.2.1 to 2.2.4 6
R3 (7)
7. Product Architecture 2.3.1 to 2.3.4 T1 (8) 7
8. Detailed Design 2.5.1 to 2.5.2 R3 (9) 8
9. Industrial Design 3.1.1 to 3.1.7 T1 (10) 9
10. Prototyping 3.4.1 to 3.4.4 T1 (14) 12
11. Design for Manufacturing 4.1.1 to 4.1.4 T1 (13) 10
12. Design for Assembly 3.3.1 to 3.3.4 T1 (13) 11

13. T1(12)
Design for Environment 4.2.1 to 4.2.4 14
R2 (15)
14. Design for Safety, Reliability and R3(14)
4.3.1 to 4.3.3
Maintainability
15. T1 (15)
Product development economics 4.3.1 to 4.3.4 15
R3 (17)
16. Patents and Intellectual Property 4.5.1 to 4.5.4 ISM 16
 CS: Contact Session (2Hrs); ISM: Instructor Supplied Material; T1: Text Book, R1, R2, R3:
Reference books
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 – Graded Through online portal
for 20%
▪
▪ Evaluation Scheme:
▪ Legend: EC = Evaluation Component; AN = After Noon Session; FN = Fore Noon Session

Evaluatio Name Type Evalua Weigh Duratio Day, Date, Session,

n (Quiz, Lab, Project, (Open tion t n Time
Compon Mid-term exam, End book, compo
ent semester exam, etc.) Closed nent
book,
Online,
etc.)
Theory- Quiz1 and Online 30 10% 2 Quiz1 – Pre Midsem
Quiz2 Weeks Quiz2 – Post Midsem
EC - 1
Lab Assignment Online 45 15% October 10-20, 2024
Lab Quiz Online 15 05% November 1-10, 2024
Mid-Semester Test Closed 90 30% 2 hours Sunday, 22/09/2024
EC - 2
Book (FN)
Comprehensive Exam Open 120 40% 2½ Sunday, 24/11/2024
EC - 3
Book hours (FN)

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:
Simulation Lab: DFMA

Contents:

1. Scope of Lab
2. Objective of Lab
3. Learning Outcomes of Lab
4. List of Simulation Experiments (Software Tool Used: DFMA)
5. Instruction Schedule
6. Evaluation Scheme

Faculty Name, Prof. B K Mishra/Dr. Gauri Mahalle

Email Id bkmishra@wilp.bits-pilani.ac.in/
mahalle.gauri@wilp.bits-pilani.ac.in
Contact Details
9892009755/8056130859
1.Scope of the lab:
 DFMA simulation lab enables the students to understand and implement analytical approach for
manufacturing and assembly of products to enhance the organization performance and process.
2.Objectives of Lab:
 To simulate and analyse various manufacturing and assembly environments to solve
 academic & industrial assignments.
3.Learning Outcome of the lab
 Able to model and simulate design for manufacturing.
 Able to model and simulate design for assembly
 Able to analyse the time and profit parameters and design index.
 Able system and suggest improvements.
 Able to model, analyse and identify various types of processes to satisfy the manufacturing &
assembly criteria to improve the industrial gain..
4. List of simulation experiments
Tut. No. Practice Tutorial Description
Simulation and understanding of DFM
Concurrent Costing to be used to make
Assembly Fabrication Analysis
1 cost comparisons to determine if a
(DFM)
fabricated assembly is more cost effective
than manufacturing the item as a single
part
Simulation and understanding of DFM
Concurrent Costing to use various primary
2 Die Casting Analysis (DFM)
& secondary manufacturing
mathodologies to optimise the cost and life
volume relation.
Simulation and understanding of DFM
Concurrent Costing to use various
3 Sheet metal working Analysis (DFM) complex forming corresponding finishing
processes to optimise the cost, time & and
life volume relation.
Simulation and understanding of DFM
Concurrent Costing to analyse the
Deep Drawing –Sheet metal work manufacturing process of a cup or box
4 (DFM) shaped part is produced from sheet metal,
one possible processing alternative is deep
drawing. Comparative & analytical
approach will be explained
Analysis of a small assembly in the DFA
5 Pneumatic control Assembly (DFA) Product Simplification and then redesign
that assembly by combining or eliminating
parts to simplify the product structure.
Understanding and analyse of a complex
cable harness assembly using the
6 Cable Harness Assembly (DFA)
operations contained in DFA’s Operation
Library to optimize and benchmarking the
operation methodology.

5. Instruction Schedule

Lab Session 1 TBD

Lab Session 2 TBD

Lab Session 3 TBD

Lab Session 4 TBD

 7. Evaluation Scheme

Evaluation Component Name Type Marks

Lab Quiz- 1 Online
EC - I Lab Practice Online
Lab Assignment Online

NOTE: Any changes in lab schedule, evaluation component or other changes related to EC-1
will be informed by theory or lab instructor.

Instructor-in-charge