From Project to Production

313 Pages·1970·6.48 MB·English

by  A. M. Brichta, Peter E. M. Sharp, R Brown, G. Chandler and W. A. Davis (Auth.)

Also by PETER E . M . S H A R P :
Sound and Vision, a Design Centre Publication,
Macdonald & Co. (Publishers) Ltd., 1967
FROM PROJECT
TO P R O D U C T I O N
BY
A . M. BRICHTA, C.Eng., M.I.Mech.E., M.I.Prod.E.
A N D
PETER Å. M. S H A R P , A.C.G.I . , B.SC. (Eng.), F.I.E.E.
P E R G A M O N P R E S S Sfe
Oxford ' London ' Edinburgh ' New York *?rtr
196
Toronto ' Sydney ' Paris ' Braunschweig
PERGAMON PRESS LTD.,
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Copyright © 1970 Pergamon Press Ltd.
First edition 1970
All Rights Reserved. No part of this publication may be
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08 006639 9 (flexicover)
08 006638 0 (hard cover)
LIST OF TABLES, PLATES AND
ILLUSTRATIONS
TABLE S
1. U.D.C.—Example of Subdivision of Main Tables. (By courtesy
of the British Standard Institution, 2 Park Lane, London W.l.) 90/91
2. Rotary Knife of Slip Inserter. (By courtesy of P. J. Booker, and
the Enginering Designer.) 128
3. Car Windscreen Material. (By courtesy of R. Bauerfeind and
Maschinenbau Technik.) 143
4. Structural Criteria of Design. (By courtesy of G. B. R. Feilden,
Buleid Memorial Lecture.) 159
5. General Tolerances. 206/207
6. Tol Limits and Finish. 207
7. Implications of the Queueing Problems—Methods of Reducing
Delays. (By courtesy of K. J. Shone and Time & Motion Study.) 268
PLATES
1. Magic lantern late nineteenth century. (By courtesy of Science
Museum, London.) 103
2. Aldis Star slide projector. (By courtesy of the makers.) 104
3. Aldis '303* slide projector. (By courtesy of the makers.) 104
4. Aldis 'XT434' slide projector. (By courtesy of the makers.) 105
5. Old type overhead crane cabin. (By courtesy of B.I.S.R.A.,
London.) 109
6. Modernised cabin. (By courtesy of B.I.S.R.A., London.) 10
7. Modern version currently being supplied. (By courtesy of
Siemens-Schuckertwerke A.G., Germany.) 1
8. Model of a shaver. (By courtesy of K. Grange, R.D.I., F.S.I.A.,
Industrial Designer, London.) 18
9. Electric shaver. Duke of Edinburgh's Award 1963. (By courtesy
of the Council of Industrial Design, London.) 19
10. Leitz Pradovit slide projector. (By courtesy of the makers.) 136
1. Kodak Carousel slide projector. (By courtesy of the makers.) 137
12. Sawyers Rototray slide projector. (By courtesy of the makers.) 138
13. Electric typewriter IBM 72. (By courtesy of the makers.) 139
14. Heavy-duty routing machine older type. (By courtesy of the
makers and Knap Design Asociates.) 140
ix
X LIST OF T A B L E S , PLATES A N D I L L U S T R A T I O N S
15. Heavy-duty routing machine redesigned. (By courtesy of the
makers and Knap Design Asociates.) 141
16. Shipyard crane. (By courtesy of Krup-Ardelt.) 16
17. Theodolite. (By courtesy of Theis & Co. K.G.) 167
18. Radial drill with pillar detail. (By courtesy of Raboma Maschin-
enfabrik, Herman Schoening.) 168
19. Turret lathe. (By courtesy of Werkzeugmaschinen-Fabrik
Gildemeister & Co., A.G.) 169
20. Reflector telescope. ( By courtesy of Carl Zeis, Oberkochen. 170
21. Guillotine. By courtesy of Vereinigte Drehbank-Fabriken
V.D.F., H. Wohlenberg K.G.) 171
22. Telephone apparatus. (By courtesy of Standard Telephones
and Cables Ltd.) 171
23. Ringmaster communication unit. (By courtesy of Gustav A.
Ring, A.S., Oslo.) 172
24. Twin-screw kneader. (By courtesy of Werner & Pfleiderer
Machinenfabrik und Ofenbau.) 172
25. Piano-Miller. (By courtesy of Werkzeugmaschinen-Fabrik
Gildemeister & Co., A.G.) 173
26. I.B.M. Executive typewriter. (By courtesy of the makers.) 174
27. 'Mondiale gallic' lathe. (By courtesy of Soag Machine Tools
Ltd.) 174
28. Internal communication unit. (By courtesy of Siemens & Halske,
A.G.) 175
29. Instrument console of a power station. (By courtesy of Siemens
& Halske, A.G.) 175
30. Stress distribution in the vicinity of surface forces in bodies of
small volume and large loaded surface. (By courtesy of
J. B. Hartman, R. E. Bener and Machine Design.) 2
31. Three silicon rubber models of a main bearing support of a
Diesel engine. (By courtesy of G. B. R. Feilden and Ruston &
Hornsby Ltd.) 25
32. Time-exposure of the left-hand rubber model in Plate 31 marked
with black spots. 25
33. Typical fatigue crack. (By courtesy of G. A. Cottel and the
Institution of Mechanical Enginers.) 28
34. Fractured landing gear pivot shaft. (By courtesy of J. A. Bennett
and the Institution of Mechanical Enginers.) 29
35. Fatigue crack opposite where fracture originated. (By courtesy
of J. A. Benet and the Institution of Mechanical Enginers.) 29
36. Failure in T-headed bolt. (By courtesy of G. A. Cottel and the
Institution of Mechanical Enginers.) 232
37. Typical cracks in rotating shafts. (By courtesy of G. A. Cottel
and the Institution of Mechanical Enginers.) 23
38. Fatigue failure in the section of a keyed shaft. (By courtesy of
R. Cazaud and the Institution of Mechanical Enginers.) 235
39. Fatigue cracks revealed by dye penetrant method. (By courtesy
of R. Cazaud and the Institution of Mechanical Enginers.) 235
LIST OF TABLES, PLATES AND ILLUSTRATIONS XI
40. Fatigue by peeling in a key way. (By courtesy of R. Cazaud and
the Institution of Mechanical Enginers.) 236
41. Failure in crankshaft initiated at oil hole. (By courtesy of R.
Cazaud and the Institution of Mechanical Enginers.) 236
42. Fatigue crack in forward steering arm of a car. (By courtesy of
G. A. Cotel and the Institution of Mechanical Enginers.) 237
43. Crack due to badly cut thread on stud. (By courtesy of G. A.
Cotel and the Institution of Mechanical Enginers.) 237
44. Torsional fatigue fracture at the fillet radius of a crankshaft.
(By courtesy of R. Cazaud and the Institution of Mechanical
Enginers.) 238
45. Typical corrosion fatigue cracks. (By courtesy of G. A. Cottel
and the Institution of Mechanical Enginers.) 238
46-61. Steel micrographs. (By courtesy of J. T. Greaves and Chapman
& Hal.) 241
62. Finishing the outside of a plaster model. (By courtesy of R. R.
Knoblaugh and McGraw-Hil.) 252
63. Vertical lines being added to the plaster model. (By courtesy of
R. R. Knoblaugh and McGraw-Hil.) 252
64. Gouging out a cavity in plaster. (By courtesy of R. R. Knob-
laugh and McGraw-Hil.) 253
I L L U S T R A T I O N S
1. The organisation chart of a smal or medium enginering firm. 6
2. A chart of a horizontally integrated mixed production organisa-
tion with an enginering division. 6/7
3. Company performance chart. (By courtesy of P. R. Marvin
and Machine Design.) 1
4. Graph as basis for company development policy. (By courtesy
of L. A. Williams, R. J. Finlayson and the Institution of Mechani-
cal Enginers.) 13
5. Product survey. (Based on E. L. G. Robbins and Industrial
Administration Ltd.) 19
6. Marketing research. (By courtesy of E. L. G. Robbins and
Industrial Administration Ltd.) 20
7. Market evaluation and kWh disposal graph. (By courtesy of
L. A. Williams, R. J. Finlayson and the Institute of Mechanical
Enginers.) 23
8. Research expenditure and growth of industries chart. (By
courtesy of C. Freman and Economic Review.) 29
9. Law of expenditure graph. 31
10. Development activity and functional relationships diagram.
(Based on Torward product planning' by courtesy of E. L. G.
Robins and The Production Enginer.) 36
X U L I S T O F T A B L E S , P L A T E S A N D I L L U S T R A T I O N S
11. Product development, initial phase—Feasibility study and speci-
fication chart. (Based on E. L. G. Robbins and Industrial Ad-
ministration Ltd.) 37
12. Project proposal form. (By courtesy of J. Hodge and the Insti-
tution of Mechanical Engineers.) 40
13. Budgeting form. (By courtesy of J. Hodge and the Institution of
Mechanical Engineers.) 42/43
14. Generalised model of an engineering project. (By courtesy of
P. J. Booker and the Engineering Designer.) 44
15. Feasibility study—duct restraint unit. (By courtesy of P. J.
Booker and the Engineering Designer.) 48
16. Final product. Frusto-conical restraint unit. (By courtesy of
P. J. Booker and the Engineering Designer.) 49
17. Product profitability and variety reduction graph. (By courtesy
of E. L. G. Robbins and Industrial Administration Ltd.) 51
18. Manufacturing costs and variety reduction graph. (By courtesy
of E. L. G. Robbins and Industrial Administration Ltd.) 51
19. Functional relationship of R. & D. (By courtesy of P. R.
Marvin and Machine Design.) 53
20. Product development programme bar graph. (By courtesy of
E. L. G. Robbins and Industrial Administration Ltd.) 56
21. C.P.M. diagram with bar graph. (By courtesy of H. Berman and
The Constructor and Building Research Fiation, D.S.I.R.) 60
22. M.O.S.T. Management Operation System. (Based on A. L.
Iannone and the Chart. Mech. Engineer.) 62
23. P.E.R.T. network and printouts. (By courtesy of International
Computors and Tabulators.) 62/63
24. Slip inserter history tree. (By courtesy of P. J. Booker, J.
Prince and the Engineering Designer.) 71
25. Slip inserter. Completed project. (By courtesy of P. J. Booker,
J. Prince and the Engineering Designer.) 72
26. Symmetry of units. (By courtesy of A.E.I. (Manchester) Ltd.) 99
27. Symmetry of controls (By courtesy of A.E.I. (Manchester)
Ltd.) 100
28. Unity in functional interdependence. (By courtesy of A.E.I.
(Manchester) Ltd.) 100
29. House symbol (By courtesy of A.E.I. (Manchester) Ltd.) 107
30. Machine tool control panel. (By courtesy of R. S. M. Kay
and A.E.I. (Manchester) Ltd.) 112
31. Electronic circuit control panel. (By courtesy of A.E.I. (Man-
chester) Ltd.) 113
32. Design task: provision of a rotating net platform. (By
courtesy of R. Bauerfeind and Maschinenbau Technik.) 125
33. Effects of torsion and shear on frusto-conical bellow restraint
unit. (By courtesy of P. J. Booker and the Engineering De-
signer.) 126
34. Compression spring design. Load-length curves. (By courtesy
of F. A. Votta and Machine Design.) 130
LIST OF T A B L E S , P L A T E S A N D I L L U S T R A T I O N S xiii
35. Compression spring design. Effect of wire diameter on final stress,
all other factors remaining constant. (By courtesy of F. A. Votta
and Machine Design.) 131
36. Compression spring design. Allowable stress curves super-
imposed on actual working stress curves. (By courtesy of F. A.
Votta and Machine Design.) 131
37. Screw jack design. Variations and combinations. (By courtesy
of R. Bauerfeind and Maschinenbau Technik.) 132
38. Family of Gildermeister piano-millers. (By courtesy of the
makers.) 133
39. Compression spring design. Comparison. (By courtesy of F. A.
Votta and Machine Design.) 134
40. Absolute and percentage costs for a turned component in
aluminium alloy. (By courtesy of V.D.i.-Verlag G.m.b.H.,
Düsseldorf, Germany.) 145
41. Percentage cost distribution for a wagon and precision wrist
watch. (By courtesy of V.D.I.-Verlag G.m.b.H., Düsseldorf,
Germany.) 146
42. Percentage cost distribution for prototypes of a small automatic
switch. (By courtesy of V.D.I.-Verlag G.m.b.H., Düsseldorf,
Germany.) 147
43. Percentage of material costs by product. (By courtesy of V.D.I.-
Verlag G.m.b.H., Düsseldorf, Germany.) 147/8
44. Engineering value of three successive designs. (By courtesy of
V.D.I.-Verlag G.m.b.H., Düsseldorf, Germany.) 148
45. Schematic version of an early prototype. (By courtesy of P. J.
Booker, J. Prince and the Engineering Designer.) 149
46. Principal design concept. Cantilever type inserter. (By courtesy
of P. J. Booker, J. Prince and the Engineering Designer.) 150
47. Principal design concepts of duct restraint units. (By courtesy of
P. J. Booker and the Engineering Designer.) 151
48. Principal problem of fishing net platform and design concepts.
(By courtesy of R. Bauerfeind and Maschinenbau Technik.) 152
49. Design concepts for net platform problem and principal solu-
tions of element 'a'—runner. (By courtesy of R. Bauerfeind and
Maschinenbau Technik.) 153
50. Design concepts for net platform problem and solutions of
element *b'—height adjustment of strut. (By courtesy of R.
Bauerfeind and Maschinenbau Technik.) 154
51. Design concepts for a net platform and solutions of element *c'
—strut anchorage. (By courtesy of R. Bauerfeind and Maschin-
enbau Technik.) 155
52. Roller support proposal for a net platform problem. (By
courtesy of R. Bauerfeind and Maschinenbau Technik.) 156
53. Design scheme tree for a fishing net platform. 157
54. Sub-problem analysis for a kinematic scheme of a pushrod cup
cam. Slip inserter. (By courtesy of P. J. Booker, J. Prince and
the Engineering Designer.) 158
X i v LIST O F T A B L E S , P L A T E S A N D I L L U S T R A T I O N S
55. Cycle of operations of grippers. Slip inserter. (By courtesy of
P. J. Boker, J. Prince and the Enginering Designer.) 163
56. Gripper unit of slip inserter. (By courtesy of P. J. Booker,
J. Prince and the Enginering Designer.) 164
57. The significance of lack of new product development. (By
courtesy of P. R. Marvin and Machine Design.) 181
58. Newcomen's steam engine. Sample specification. (By courtesy of
R. Bauerfeind and Maschinenbau Technik.) 186
59. Alternatives to avoid infringement. (By courtesy of G. V.
Wodling and Machine Design.) 18
60. Design realisation. (By courtesy of E. L. G. Robbins and In-
dustrial Administration Ltd.) 196
61. Soderberg-Godman diagram. 26
62. Stres concentration nomograph. 234
63. Prototype completion and acceptance. (Based on E. L. G.
Robins and Industrial Administration Ltd.) 254
64. Lock design simplification. (By courtesy of E. L. G. Robbins
and Industrial Administration Ltd.) 260
65. Pulley and fan cost reduction. (By courtesy of E. L. G. Robbins
and Industrial Administration Ltd.) 260
66. Oil pump improvements. (By courtesy of E. L. G. Robbins and
Industrial Administration Ltd.) 261
67. Manufacturing functions. (By courtesy of E. L. G. Robbins and
Industrial Administration Ltd.) 263
68. Launching of Product. (Based on E. L. G. Robbins and In-
dustrial Administration Ltd.) 264
69. Tooling and production costs. (Based on E. L. G. Robbins and
Industrial Administration Ltd.) 265
70. The effect of increasing size of batch on process time. (By
courtesy of K. J. Shone and Time & Motion Study.) 271
71. Variation of process time with reciprocal of batch size. (By
courtesy of K. J. Shone and Time & Motion Study.) 272
PREFACE
TH E prosperity of a commercial concern depends to a large extent
on its ability to introduce new products, or at least revised designs
of the same products as required. The success of these products,
and thus the growth of the company, will depend mainly on their
function, cost and appearance, in other words, their design com-
petence. Too often in industry the progress of an idea for a new
product to its ultimate production is haphazard and wasteful. To
ensure successful operation in a competitive environment, a
thorough investigation of the whole development process is essen-
tial. Successful design as generally practised today is still a largely
creative, intuitive process growing up around a central theme or
an original idea and ranging in execution from the bare, func-
tional solution to the purely artistic, depending on the type of
product. In order to obtain maximum financial return, project
evaluation is essential before and during development. Attempts
have been made to rationalise this process, but the literature so far
available does not cover the whole field, nor have many of the
aspects of the problem been discussed in this context. Although
reference to the bibliographies in each chapter might indicate
how some aspects of design can be tackled, it is felt that a broader,
more independent approach is required, rather than a synthesis of
the various opinions expressed so far.
The book sets out to provide the uninitiated with details of
engineering project development in any industry which produces
or uses engineering plant of any kind. Management is frequently
unaware of actual progress and is therefore unable to give the
necessary guidance, or take vital decisions. Communications be-
tween factories, or even departments involved, are often non-
existent or tenuous, and the result is wasteful duplication or
XV