Question bank for 22MEC1563 – Product Design and Development (PDnD)

Tentative and representative Marks of each question is mentioned at the end in parenthesis

Module 1: Introduction to Product Design and Development

Module 1a – Basics of Product Design: Chapter 1 of Karl Ulrich & Steven Eppinger
1. Define these in the context of this PDnD course: ‘Product’, ‘Engineering Design’ and ‘Product
Development’
2. Explain briefly the organization challenges faced by the development team in actual scenario
… OR … What are the typical challenges a PDnD team faces?
Module 1b – Product Development Process: Chapter 2 of Karl Ulrich & Steven Eppinger
1. Define with a diagram the generic 6-phase product development process?
2. What are the major activities (tasks) carried out in each of the phases of the 6-phase
development process?
3. What are the major functions of an organization that are associated with product
development process? Explain phase wise the typical activities of each of these major
functions?
4. Define a typical software development process? Explain how this maps on to the 6-phase
generic product development process.
5. Define Organization Structure and what are the main factors used for forming an
organization? … OR … What is the importance of Organization Structure in PDnD?
6. What are the 4 typical organization structures employed in a product development process?
Depict these 4 organizations in diagrammatic forms.
7. Explain the strengths, weaknesses, and other major aspects of each of these 4 organization
structures?
8. Explain in detail the strengths and weaknesses of Functional Organization and a Project
/Product Organization
9. What are the main factors that have led to the formation of ‘Distributed Product
Development Teams’?
10. How effective are the Distributed Teams with respect to conventional organization
structures? What technological changes have helped these become more prominent and
effective over a period of time?

Module 1c – Product Life Cycle (PLC): Data taken from Internet

1. Show, using the Revenue (Sales Growth) and Profit curves in a graphical representation, the
various stages of a typical product life cycle? Using this in the background, briefly explain the
typical product lifecycle.
2. How does the knowledge of product life cycle help the development team in formulating
their action plan in each of the phases. … OR … How does the knowledge of PLC help
Product Design and Development (PDnD)? … OR … What is the importance of PLC in PDnD?
Module 1d – Customer Needs and Requirements: Chapter 5 of Karl Ulrich & Steven Eppinger
1. What are the core objectives of capturing customer needs? … OR … Why is it important to
Capture Customer Needs for Product Design and Development? … OR … What is the
importance of capturing customer needs in PDnD? … What is meant by ‘Voice of Customer
(VoC)’ (Customer Centricity or Customer Voice or Customer Focus) and how is this important
in PDnD?
2. What are the generic types of customer needs? Briefly explain each of them.
3. Why is it important to explore latent needs in detail? Explain with an example of a latent
need.
4. What is a typical Five Step Process of Identifying Customer Needs?
5. Which are the three commonly used methods for capturing raw data (customer needs
data)? Explain in detail the three methods and how do they compare with each other?
6. How does One-on-One Interviews compare with Focus Group Discussion for Customer
Needs data gathering? Explain in detail.
7. What is a Lead User and an Extreme User? How does customer need data gathering from
these users work and is useful?
8. Explain typical ‘Market Research Process’ employed while capturing the Customer Needs …
Slide 39 of Module 1 PDF

Module 2: Concept Generation and Selection

Module 2a – Idea Generation Techniques: Data from CoPilot / ChatGPT … M2 Part1 PDF
1. Explain briefly 5 typical most used idea generation techniques used in concept development
stage? (Slides 4 to 10 of M2 Part1 PDF) … OR … Explain Brainstorming process and Mind
Mapping process and their importance in PDnD. (Slide 4 and Slide 28 for Brainstorming )
Module 2b – Concept Development: Chapter 7 of Karl Ulrich & Steven Eppinger … M2 Part1
PDF
1. What are the most important aspects that ensures a thorough concept outcome? (Slide 17)
2. Using a flow diagram explain 5 step process of concept generation. Explanation should
include typical sub-steps used in each of the 5 steps.
3. What are three methods typically used in problem decomposition? Explain each of them
briefly and what is the immediate next critical decision taken after finalizing the
decomposition? … (answer for this last part: The immediate next critical decision is to
identify the most important sub-problem that is expected to give maximum benefits and
then further work on such a sub-problem)
4. Explain using an example and block diagrams the Functional Decomposition process used in
problem decomposition.
5. Explain briefly Internal Search and External Search process used during concept generation
phase.
6. What is competitive benchmarking of a product and how is this important in concept
generation of a product development process?
7. What are the two methods used in the step ‘Explore Systematically’?
Module 2c – Concept Selection: Chapter 8 of Karl Ulrich & Steven Eppinger … M2 Part2 PDF
1. What is concept selection and name a few methods used for selecting a concept post
concept generation phase? … Slide 6
2. What are the two Decision Matrix based Concept Selection processes? Briefly explain each
of these processes using a set of selection criteria and a representative ranking matrix /
table. … Pick points from Slide 10, 11, 12, 14 & 15 … … What is Pugh Matrix / Pugh Concept
Selection process – Explain. … Slides 11 and 12
Module 2d – Concept Prototyping and Testing: Chapter 9 of Karl Ulrich & Steven Eppinger +
Internet for Rapid Prototyping … M2 Part2 PDF
1. Explain the objective, the brief process and the outcome of Concept Prototyping and
Testing?
2. Explain briefly each step of the 7 Step Concept Testing Phase.
3. What are the different survey formats that can be used for conducting Concept Testing
Surveys.
4. During the Concept Prototyping and Testing phase, explain briefly the different approaches
used to Communicate the Concept to the target group.
5. Show using a table how each concept communication mode matches with each of the
concept survey format?
Additional Section – Final Product Prototyping during Refinement and Testing Phase: Chapter
14 (in brief) of Karl Ulrich & Steven Eppinger … M2 Part2 PDF
1. Define a typical prototype built before the product launch phase and explain the purpose of
building such prototypes.
2. Prototypes can be classified in two dimensions – Discuss in detail the two-dimensional
aspects of prototype displaying various possibilities in a quadrant.
3. How each category of the prototypes classified in two dimensions is useful for each of the
four purposes of a prototype.
4. Compare the analytical and the physical prototypes on various aspects like flexibility, the
usefulness, the versatility, cost perspective, etc.
Module 3: Design for Manufacturing and Assembly (DFMA)
Module 3a – DFMA Principles: Chapter 13 of Karl Ulrich & Steven Eppinger … M3 Part 1 PDF
1. What are the general issues addressed by DFMA? … Slides 4 and 5 … OR … What is the
importance of DFMA process in PDnD process?
2. Illustrate a typical seven step DFMA process using a flow chart.
Module 3b – Cost Analysis – Cost Drivers & Cost Estimation: Chapter 13 of Karl Ulrich &
Steven Eppinger … M3 Part 1 PDF
1. Which are all the different types of Manufacturing Facilities available to companies? Briefly
explain each one of them?
2. Illustrate using a flow diagram various elements of manufacturing costs of a product? (8)
3. Define Direct Cost, Indirect Cost, Fixed Cost and Variable cost and illustrate with an example
each type of these cost elements?
4. Explain briefly the Overhead costs? What are 3 types of Overhead Costs?
5. What is a Bill of Materials (BOM)? Explain briefly five different types of BOMs?
Module 3c – Selection of Materials and Processes: Chapter 13 of Karl Ulrich & Steven Eppinger
… M3 Part 2 PDF
1. How Economies of Scale impacts DFMA decisions? Illustrate Economies of Scale using a
graphical representation of Fixed Cost and Variable Costs of a part manufactured in big
volumes
2. Explain briefly four possible options available for reducing the cost of a part?
3. Explain briefly three possible options available for reducing the cost of an assembly?
4. What are the ideal characteristics of a part that enables ease of assembly – Explain each of
them briefly.
Module 3d – Quality and Reliability: Text Books by A.K. Chitale & R.C. Gupta and another one
by M. Mahajan … M3 Part 2 PDF
1. How is Product Quality defined? Illustrate and elaborate the product quality concept using
three typical measures used.
2. What is a Control Chart? Explain briefly how it is useful in controlling a manufacturing
process. Slides 34 and 35 … OR … What is Statistical Process Control and What is the
importance in PDnD?
3. What is meant by Reliable Product? Illustrate various failure pattern of a complex product
using ‘Bath Tub Curve’ over the life time of typical complex product.
4. Illustrate and explain Cost of Reliability using the reliability cost graph.
5. Explain what is meant by Product Design for Sigma. Explain briefly two DFSS methodologies.
… OR / additionally … What is the importance of Six Sigma Methodology in PDnD OR How
Six Sigma Design Methodology is beneficial to PDnD?
Module 4: Advanced Product Design Techniques
Module 4a – Computer Aided Design: (Source: Internet and Other References) … M4 Part 1
PDF
1. Explain the terms CAD, CAM and CAE illustrating their purpose, application and benefits in
the industry.
Module 4b – Finite Element Analysis / Method (FEA or FEM): (Source: Other References) … M4
Part 1 PDF
1. Define FEM and Discuss various applications of FEM in different domains
2. Discuss in brief using a block diagram the various steps involved in the Finite Element
Method
3. Discuss various advantages and disadvantages of Finite Element Method
4. What are the three different stages modules of commercial FEM software and explain briefly
the functionality of each of the stage module.
Module 4c – Ergonomics and Human Factors – Industrial Design: Chapter 11 of Karl Ulrich &
Steven Eppinger … M4 Part 1 PDF
1. What is the objective and scope of Industrial Design. Explain in detail.
2. Illustrate in a graphical form what percentage of product development budget is typically
used towards industrial design efforts for various types of typical consumer and industrial
products.
3. Describe briefly the Six Step Industrial Design Process elaborating on typical key activities
carried out in each step.
4. Using a simple diagram illustrate and classify the importance of Industrial Design in
Technology Driven versus the User Driven products.
5. Illustrate using a linear flow diagram the timing and timelines of Industrial Design efforts
with respect to Product Development Process.
Module 4d – Sustainable Design: Chapter 12 of Karl Ulrich & Steven Eppinger … M4 Part 2 PDF
1. What is the objective and scope of Design for Environment and Sustainable Design. Explain
in detail.
2. Explain briefly the various environmental impact factors considered during Design for
Environment and Sustainable Design.
3. Discuss briefly the three areas a product design team would work on during Design for
Environment.
4. Illustrate using a flow diagram the Seven Step Design for Environment process depicting
alongside the corresponding phases of the product development process.
5. What is life cycle assessment of Sustainable Product Design
Answer: See end of this Question Bank
Module 5: Project Management and Legal Aspects
Module 5a – Project Management Fundamentals: Chapter 19 of Karl Ulrich & Steven Eppinger
1. Explain Project Management Process in detail. What is the importance and benefits of
project management process in product development activity?
2. What are the three types of tasks considered in project management? Illustrate the
dependencies of these tasks using a flow diagram?
3. Illustrate using a diagram typical Gantt and PERT charts and explain these. Illustrate a critical
path on the PERT chart and explain the importance of Critical Path.
4. What is a base line project plan? Explain briefly each element of the base line plan.
5. Categorize various possible actions that can be taken to accelerate a project when
a. Trying to cut down the duration of tasks on critical paths
b. Trying to reorganize the coupled tasks and
c. Taking overall project specific actions
6. Explain briefly the Project Execution process focusing on Team Coordination, Project Status
Reporting, and Corrective Action Initiation
Module 5b – Agile Product Development: (Source: Internet and Other References)
1. Explain Agile product development process and their variants. Explain briefly how this is
effective in a physical product development and in a software product development project
Module 5c – Intellectual Property (IP): Chapter 16 of Karl Ulrich & Steven Eppinger
1. Explain what is meant by Intellectual Property and its importance in industries. How does
this compare with Physical Property.
2. Illustrate pictorially different types of IPs as applicable in product design and development
area. Explain briefly each of these IPs.
3. Explain the Invention Disclosure process. … OR … Explain briefly each of the Seven Step
Patent Filing process
Module 5d – Regulatory and Ethical Considerations: (Source: Internet and Other References)
1. Explain why it is important to be compliant with regulatory norms, industry standards and
ethical practices during a new product development process.

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A few answers:
1. What is life cycle assessment of Sustainable Product Design.

Answer: Life Cycle Assessment (LCA) is a critical tool for evaluating the environmental
impact of a product throughout its entire life cycle, from raw material extraction to disposal
or recycling. LCA is particularly important in sustainable product design as it helps designers
and manufacturers understand the potential environmental impacts of their products,
identify areas for improvement, and make informed decisions that minimize negative
impacts on the environment

Key Stages of LCA in Sustainable Product Design

1. Goal and Scope Definition
o Goal: The first step is defining the purpose of the LCA study. This could include
comparing different design alternatives, improving an existing product, or
identifying the environmental impacts of a new product.
o Scope: This includes setting the boundaries of the study. For example, will the
study focus only on the product itself, or will it also consider the entire supply
chain (including raw material extraction, manufacturing, transportation, use
phase, and disposal)? The system boundaries must be defined clearly to avoid
ambiguity.
2. Inventory Analysis (Life Cycle Inventory - LCI)
o This stage involves gathering data on all inputs (e.g., materials, energy, water)
and outputs (e.g., emissions, waste) at each stage of the product's life cycle.
3. Impact Assessment (Life Cycle Impact Assessment - LCIA)
▪ Once the inventory data is collected, the next step is to assess the
potential environmental impacts. This includes evaluating the effects of
different inputs and outputs on various environmental categories, such
as: Global warming potential (GWP), Eutrophication (the potential for
excess nutrients (e.g., nitrogen or phosphorus) to cause algae blooms in
water bodies), Acidification (the potential for emissions (e.g., sulfur
dioxide, nitrogen oxides) to acidify soil and water bodies), Ozone
depletion, Resource depletion, Human toxicity and eco-toxicity.
4. Interpretation
o The final stage of an LCA is to interpret the results and draw conclusions. This
includes identifying the most significant environmental impacts, determining
trade-offs between different impact categories, and suggesting ways to reduce
these impacts by way of using materials with right chemistry, ensuring minimum
energy consumption and using renewable energy, and highest level of
recyclability