Product Development: Principles and Tools for Creating Desirable and Transferable Designs

358 Pages·2020·71.559 MB·English

by  Christopher A. Mattson, Carl D. Sorensen

Christopher A. Mattson · Carl D. Sorensen
Product
Development
Principles and Tools for Creating Desirable and
Transferable Designs
Product Development
Christopher A. Mattson • Carl D. Sorensen
Product Development
Principles and Tools for Creating Desirable
and Transferable Designs
123
ChristopherA.Mattson CarlD.Sorensen
DepartmentofMechanicalEngineering DepartmentofMechanicalEngineering
BrighamYoungUniversity BrighamYoungUniversity
Provo,UT,USA Provo,UT,USA
ISBN978-3-030-14898-0 ISBN978-3-030-14899-7 (eBook)
https://doi.org/10.1007/978-3-030-14899-7
©SpringerNatureSwitzerlandAG2020
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Preface
Inpreparingtowritethisbook,wereviewed coppersmelter. Eachoftheseprojects
morethantwohundreddesign-related requiresadesignprocessthatis
textbooks. Withalltheexistingbooks,why customizedtotheparticularproductbeing
didwedecidetowritethisbook? designed. Yettheexistingtextbooksgive
littleornoguidanceastohowaprocess
Inmorethantwentyyearsofteaching
mightbecustomized. Asexperienced
engineeringdesignclasses,coveringmore
designers,weknowhowtocustomizethe
than700industriallysponsoreddesign
process. Butourinexperiencedstudents
projectswithmorethan4,500students,
haveyettolearnhowtodothis. Therefore,
we’vecometobelievethatabookcouldbe
whenwetalkaboutthegenericdesign
writtentobettermatchtheneedsofboth
processasasetofdesignactivitiesthatwill
ourstudentteamsandpracticingdesign
applytoatypicalproduct,virtuallyevery
professionals.
teamcanclaimthattraditionalproduct
Inreviewingthedesigntextbooksthatare developmentprocessesdon’tapplytotheir
currentlyinprint,we’veidentifiedthree specificproduct.
broadclassesofcontent: (1)thedesign
Furthermore,theideaofadesignprocess
process;(2)designtools,methods,and
beingfundamentallydescribedbythe
techniques;and(3)design-relatedtopics
activitiescurrentlybeingpursuedbythe
suchaspatentlawandergonomics. The
designteamdoesn’tsquarewithour
differencesinthebooksarelargelyinthe
experienceinindustry. Whendiscussing
depthandbreadthofeachofthese
productdevelopmentprojects,team
categories,althoughtherearedifferences
membersarenotverylikelytoclassifythe
inpresentationaswell(e.g.,thenumber
productbytheiractions. Rather,theytend
anddetailoftheexamplesorcasestudies
todescribethecharacteristicsofthe
thatareusedtoteachthemaintopics).
product. Webelievethatdescribingthe
Thebooksarelargelyconsistentinfocusing
designprocessbytheevolutionofthe
theirdiscussionsofthedesignprocesson
productisclearer,moreeasilyunderstood,
theactivitiesofthedesignersduring
andmoreconsistentwiththeway
differentphasesoftheprocess.
experienceddesignersthinkabouttheir
Inourcapstoneclass,eachteamhasa work.
differentproject. Althoughallprojects
Afundamentalshiftinthisbook,then,is
requireengineeringdesign,theyvary
awayfromthefocusonprescribingthe
significantlyinscope,expectedresults,and
workofthedesignertowardafocusonthe
involvedengineeringdisciplines. For
evolutionoftheproduct. Thisshiftinfocus
example,oneyearwehadteamsdesigning
isbothchallengingandliberatingtothe
vehicles,improvingapottingprocessfor
students(andbyextension,todesign
X-raytubes,improvingthepackagingand
professionals). Thechallengecomes
distributionprocessforanutritional
becausewenolongerprescribeactions;
supplementcompany,designingthe
instead,weprescribeoutcomes. The
next-generationextensionladder,and
studentmustdeterminetheactionsthat
developingaplantopreventthereleaseof
willbestleadtothedesiredoutcome. For
visiblewatervaporfromacoolingtowerina
v
vi PREFACE
aninexperienceddesigner,thiscanbe theevolutionofthedesign. Weintroduce
hardwork,fraughtwithuncertainty. And designactivities,outcomes,andtheactivity
yet,forallitsdifficulty,thisworkisinnately mapsthatlinkthemtogether. Wedescribe
rewarding,asthestudentsuccessfully theevolutionofdesigninformationasit
wrestleswithissuesofrealimportance. appliestoallproductdevelopmentprojects.
Weshowtheimportanceofcoordinating
Theliberationinthefocusonproduct
theworkofallteammembersand
evolutioncomesfromthesamesourceas
demonstratehowanactivitymapformsthe
thechallenge: wenolongerprescribe
basisforcustomizingthedevelopment
actions. Studentsfeelnopressuretofollow
processtotheneedsoftheteamandthe
aparticularactionbecauseitispartofthe
project. Finally,wediscusssomepersonal
recommendedprocess. Instead,theyneed
characteristicsofdesignersthatwehave
onlyfocusonactionsthatareappropriate
seeninfluencesuccess.
fortheirparticulardesignproject. Forthe
industryprofessional,thisbookcanserve Wealsoincludeacasestudyofproduct
asa”fieldguide”forproductdevelopment. development. Throughshowinghowa
Itprovidesconciseguidanceaboutboth teamsuccessfullydealtwiththeunique
theactivitiesandtheoutcomesofproduct challengesoftheirassignedproduct
development. Thebookalsopresents developmentopportunities,wehopetogive
effectivedevelopmenttoolsandtechniques someconcreteguidanceandinspirationto
fortherealworld. thosewhoarestrugglingwiththeirown
project.
Havingtestedtheseprinciplesinoursenior
capstonedesignclass,wehavefoundthat PartIIofthebookisaProduct
theywork. Studentslearnbetter,work DevelopmentReference,abriefreference
better,andaccomplishmorewhenthey toproductdevelopmenttools,methods,
focusontheevolutionoftheirproduct andtechniques. TheDevelopment
ratherthananaccountingoftheiractivities. Referenceiscertainlynotexhaustive,either
Theyaremuchmorelikelytoconsider incoverageorindepth. However,wehave
instructorguidanceassuggestionstohelp attemptedtoincludeareferenceentryfor
themreachtheirdesiredproduct eachofthetools,methods,ortechniques
evolutionarystate. Furthermore,they thatismentionedelsewhereinthetext.
appeartobetterunderstandandare
Onlythefirstpartofthebook,theproduct
certainlybetterabletoarticulatethe
developmentprocess,isintendedtobe
reasonswhytheyareinvolvedina
readconsecutively. Theremainingparts
particularactivity.
canbebrowsedthroughor
Fortheindustryprofessional,thisbookcan cross-referencedfromPartI.Wehopethat
serveasa”fieldguide”forproduct thebookwillbeinvitingtoread,and
development. Itprovidesconciseguidance friendlytoreview,andthatitwillprovide
aboutboththeactivitiesandtheoutcomes insightandinspirationnotonlyduringa
ofproductdevelopment. Thebookalso classroomdesignexperience,but
presentseffectivedevelopmenttoolsand throughoutalongandsuccessfulcareerin
techniquesfortherealworld. engineeringdesign.
PartIofthisbookcoversthefundamentals WethankWHOlives.orgforallowingusto
oftheproductdevelopment(ordesign) sharethestoryoftheVillageDrill
processaswehavecometounderstandit. (human-poweredwaterwelldrill)
Weintroducefourprinciplesthatunderlie development. They’vehelpedimprovethe
productdevelopment,includingthe worldnotonlybybringingcleanwaterto
importanceofdemonstrateddesirability morethanamillionpeopleinAfricawith
andtransferabilityforproductdesigns. We theVillageDrillbutalsobyprovidingan
explainhowdesignskillsareappliedinan exampleoftheapplicationoftheprinciples
incrementalanditerativefashiontocause
PREFACE vii
inthisbooktohelpimproveproduct book. Withoutherhelp,thebookwouldbe
development. farlessreadable.
WegratefullyacknowledgeNicholeCross
forprovidingastyleguidetoachieve Provo,UT,USA ChristopherA.Mattson
consistencyinthefiguresandforher CarlD.Sorensen
capablecreationoftheillustrationsinthis August2019
Contents
Preface v
Contents viii
ListofFigures xii
ListofTables xv
I Product Development Process 1
1 GettingStarted 3
1.1 OntheShelves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 WhatThisBookOffers. . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 FourPrinciplesofProductDevelopment . . . . . . . . . . . . . . . . . 5
1.4 MovingForward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.5 Exercises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 ProductDevelopmentFundamentals 13
2.1 DesigningtheProcess. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 DesignEvolutionandtheSTEPCycle . . . . . . . . . . . . . . . . . . . 15
2.3 TheSequenceofDesignActivitiesandOutcomes . . . . . . . . . . . . 18
2.4 CoordinationofEffort . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.5 StagesofDevelopment . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.6 ApprovalatStageCompletion . . . . . . . . . . . . . . . . . . . . . . . 27
2.7 ObtainingDesignApproval . . . . . . . . . . . . . . . . . . . . . . . . 31
2.8 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.9 Exercises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3 DesignSkills 37
3.1 Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.2 Discovering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.3 Creating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.4 Representing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.5 Modeling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.6 Prototyping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.7 Experimenting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.8 Evaluating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.9 Deciding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.10 Conveying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.11 Exercises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
viii
CONTENTS ix
4 OpportunityDevelopment 49
4.1 DesignEvolutionDuringOpportunityDevelopment . . . . . . . . . . . . 49
4.2 ExampleofOpportunityDevelopment. . . . . . . . . . . . . . . . . . . 54
4.3 Top-LevelActivityMapforOpportunityDevelopment . . . . . . . . . . . 57
4.4 HowtoGatherandProcessEssentialInformation . . . . . . . . . . . . 59
4.5 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.6 Exercises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5 ConceptDevelopment 67
5.1 DesignEvolutionDuringConceptDevelopment. . . . . . . . . . . . . . 67
5.2 ExampleofConceptDevelopment . . . . . . . . . . . . . . . . . . . . 74
5.3 Top-LevelActivityMapforConceptDevelopment. . . . . . . . . . . . . 84
5.4 HowtoDevelopaStrongConcept. . . . . . . . . . . . . . . . . . . . . 84
5.5 HowtoGenerateConcepts . . . . . . . . . . . . . . . . . . . . . . . . 88
5.6 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.7 Exercises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
6 SubsystemEngineering 95
6.1 DesignEvolutionDuringSubsystemEngineering . . . . . . . . . . . . . 95
6.2 ExampleofSubsystemEngineering . . . . . . . . . . . . . . . . . . . . 101
6.3 Top-LevelActivityMapforSubsystemEngineering . . . . . . . . . . . . 103
6.4 HowtoDesignaVitalCustomComponent . . . . . . . . . . . . . . . . 111
6.5 HowtoDevelopandUseEngineeringModels . . . . . . . . . . . . . . 113
6.6 HowtoDevelopandUsePrototypes . . . . . . . . . . . . . . . . . . . 118
6.7 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
6.8 Exercises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
7 ProductRefinement 123
7.1 SystemRefinement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
7.2 ProducibilityRefinement . . . . . . . . . . . . . . . . . . . . . . . . . 129
7.3 Post-releaseRefinement . . . . . . . . . . . . . . . . . . . . . . . . . 133
7.4 HowtoReleaseaDesign . . . . . . . . . . . . . . . . . . . . . . . . . 136
7.5 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
7.6 Exercises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
8 CustomizingtheProductDevelopmentProcess 141
8.1 CreatingaCustomizedProjectPlan . . . . . . . . . . . . . . . . . . . . 141
8.2 EvaluatingtheQualityoftheProjectPlan . . . . . . . . . . . . . . . . . 145
8.3 UsingtheCustomizedProjectPlan . . . . . . . . . . . . . . . . . . . . 146
8.4 Human-PoweredDrillExample . . . . . . . . . . . . . . . . . . . . . . 148
8.5 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
8.6 Exercises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
9 SevenWaystoBecomeaBetterDesigner 157
9.1 ExpectChallenges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
9.2 BeMindfuloftheDesign . . . . . . . . . . . . . . . . . . . . . . . . . 158
9.3 BeontheTeam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
9.4 DivergeThenConverge . . . . . . . . . . . . . . . . . . . . . . . . . . 159
9.5 EmbraceMultifidelityModelsandPrototypes . . . . . . . . . . . . . . . 159
9.6 ValidateAssumptions . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
9.7 AlwaysHaveaBack-UpSolution . . . . . . . . . . . . . . . . . . . . . 160
9.8 BeyondTheseSevenSuggestions . . . . . . . . . . . . . . . . . . . . 160
10Conclusion 163
x CONTENTS
II Product Development Reference 165
11ProductDevelopmentToolsandTechniques 167
11.1 BasicDesignProcess . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
11.2 Benchmarking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
11.3 BillofMaterials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
11.4 Bio-InspiredDesign . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
11.5 Brainstorming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
11.6 CADModeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
11.7 CatalogSearch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
11.8 CodesandStandards . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
11.9 ConceptClassificationTree . . . . . . . . . . . . . . . . . . . . . . . . 184
11.10 ControlledConvergence . . . . . . . . . . . . . . . . . . . . . . . . . . 186
11.11 CostEstimation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
11.12 CostTargets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
11.13 CriticalPathAnalysis . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
11.14 Decomposition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
11.15 DelphiMethod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
11.16 DesignforAssembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
11.17 DesignforManufacturing . . . . . . . . . . . . . . . . . . . . . . . . . 200
11.18 DesignofExperiments. . . . . . . . . . . . . . . . . . . . . . . . . . . 202
11.19 DesignReview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
11.20 DesignStructureMatrix . . . . . . . . . . . . . . . . . . . . . . . . . . 206
11.21 DimensionalAnalysis . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
11.22 DrawingChecking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
11.23 Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
11.24 EngineeringChangeOrder(ECO) . . . . . . . . . . . . . . . . . . . . . 214
11.25 Ergonomics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
11.26 Experimentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
11.27 FailureModesandEffectsAnalysis . . . . . . . . . . . . . . . . . . . . 220
11.28 FaultTreeAnalysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
11.29 FinancialAnalysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
11.30 FiniteElementModeling. . . . . . . . . . . . . . . . . . . . . . . . . . 226
11.31 FocusGroups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
11.32 GoalPyramid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
11.33 InternetResearch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
11.34 Interviews . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
11.35 Method635 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
11.36 MindMaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
11.37 Multivoting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
11.38 Nucor’sCircles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
11.39 ObjectiveTree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
11.40 ObservationalStudies . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
11.41 OnePager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
11.42 Optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
11.43 PatentSearches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
11.44 PerformanceMeasures . . . . . . . . . . . . . . . . . . . . . . . . . . 254
11.45 PersonasandLocales . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
11.46 PlanDoCheckAct(ShewhartCycle) . . . . . . . . . . . . . . . . . . . 258
11.47 PlanningCanvas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
11.48 Product-FocusedRequirementStatements . . . . . . . . . . . . . . . . 262
11.49 ProjectObjectiveStatement . . . . . . . . . . . . . . . . . . . . . . . . 264
11.50 Prototyping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
11.51 QualityFunctionDeployment . . . . . . . . . . . . . . . . . . . . . . . 268