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Produc_Design_CIE2 (1)

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1. What is product architecture? Explain the types of modular architecture.

Ans: Product architecture refers to the scheme by which the functional elements of a product
are organized into physical chunks and how these chunks interact with each other [T3]. It plays a
crucial role in determining how a product is designed, developed, and manufactured.

Modular architecture is a key concept in product architecture and can be classified into different
types based on how the chunks are structured and interact with each other. Here are the types
of modular architecture as explained in the book:

(i) Slot-Modular Architecture: This is the most common type of modular architecture. In
slot-modular architecture, each chunk requires a unique interface to accommodate
specific interactions with the rest of the product. This type is suitable for products where
different chunks have distinct interactions with the overall system.
(ii) Bus-Modular Architecture: In a bus-modular architecture, chunks interact with each
other in standard ways, allowing for a wide variation in the overall product configuration.
This type is beneficial when all the chunks can use the same type of power, fluid
connection, structural attachment, or signal exchanges.

(iii) Sectional-Modular Architecture: In sectional-modular architecture, all interfaces are


of the same type, but there is no single element to which all the other chunks attach.
The assembly is built up by connecting the chunks to each other via identical interfaces.
This type is commonly found in piping systems, sectional sofas, office partitions, and
some computer systems.

Each type of modular architecture has its own advantages and is chosen based on the
specific requirements of the product being developed. The goal of modular architecture is to
allow for design changes to be made to one chunk without necessitating changes to other
chunks, thus enhancing flexibility and ease of product development.

2. What is prototyping? Identify the different types of prototypes.

Ans: Prototyping is the process of creating a preliminary version of a product to test and validate
design concepts, functionalities, and features before full-scale production. It allows designers
and engineers to gather feedback, identify potential issues, and make necessary improvements
early in the development process, ultimately reducing risks and costs associated with product
development 310.

There are different types of prototypes that can be used in the product development process.
These prototypes can be classified based on their physical or analytical nature:

1. Physical Prototypes: Physical prototypes are tangible artifacts that closely resemble the final
product. They are built to test and evaluate aspects of the product that require a physical
representation. Examples of physical prototypes include models that look and feel like the
product, proof-of-concept prototypes used for quick testing, and experimental hardware to
validate product functionality 310.

2. Analytical Prototypes: Analytical prototypes represent the product in a non-tangible


manner, often using mathematical models or simulations. These prototypes are used to
analyze specific aspects of the product without physically building it. Examples of analytical
prototypes include computer simulations, mathematical models encoded in spreadsheets,
and computer-generated models of three-dimensional geometry 310.

By utilizing both physical and analytical prototypes, product development teams can gain
valuable insights into the design, functionality, and performance of the product, leading to more
informed decision-making and successful product outcomes.

3. Illustrate PERT charts with a neat sketch.

Ans: A PERT chart is a graphical representation of a project schedule that shows the sequence of
tasks, their dependencies, and the estimated time required to complete each task. Here is a
description of a simple PERT chart:

1. Nodes: Tasks are represented by nodes or circles in the chart. Each node corresponds to a
specific task in the project.

2. Arrows: Arrows are used to connect the nodes and show the dependencies between tasks. The
direction of the arrows indicates the sequence in which tasks need to be completed.

3. Task Duration: Each node is labeled with the task name and the estimated duration required to
complete that task.

4. Critical Path: The critical path, which is the longest sequence of dependent tasks that must be
completed on time for the project to finish as scheduled, is often highlighted in the PERT chart.

5. Parallel Tasks: Tasks that can be completed simultaneously are shown as parallel paths in the
chart, indicating that they do not have dependencies on each other.

6. Loops: PERT charts typically do not show loops or feedback loops, as they focus on the
sequential flow of tasks in the project.

By visually representing the tasks, dependencies, and timelines in a project, PERT charts help
project managers and teams understand the project's timeline, identify critical tasks, and
optimize the project schedule for efficiency and success.
4. Illustrate briefly the set of guidelines for accelerating product development projects.

Ans: Accelerating product development projects is crucial for meeting tight deadlines and gaining
a competitive edge in the market. Here is a brief overview of a set of guidelines for accelerating
product development projects as outlined in the book:

(i) Start the Project Early: Initiating the project ahead of schedule can significantly impact the
overall timeline. Beginning the project early allows for more flexibility in handling
unexpected delays and ensures a smoother development process.

(ii) Manage Project Scope: Avoid scope creep by sticking to the original project requirements
and objectives. Additional features or changes can lead to delays and increased complexity.
Focus on delivering the core product efficiently.

(iii) Facilitate Information Exchange: Establish effective communication channels within the
project team to ensure rapid and frequent information exchange. Utilize collaboration tools
and structured communication methods to streamline information flow.

(iv) Develop Contingency Plans: Identify potential risks and develop contingency plans to
address unforeseen challenges that may arise during the project. Having backup strategies in
place can help mitigate delays and keep the project on track.

(v) Compress the Schedule: Explore opportunities to compress the project schedule without
compromising quality. Identify critical tasks on the project's critical path and focus on
reducing the time required to complete these tasks to accelerate the overall project timeline.

By following these guidelines and implementing strategies to streamline the product


development process, teams can effectively accelerate projects, meet deadlines, and deliver
high-quality products to the market in a timely manner.

5. Illustrate the design for manufacturing (DFM) process with block diagram.

Ans.

(i) Estimate Manufacturing Costs: The DFM process begins with estimating the manufacturing
costs of the proposed design. This step helps identify which aspects of the design, such as
components, assembly, or support, are most costly.

(ii) Reduce Costs of Components: The next step involves focusing on reducing the costs
associated with individual components of the product. This may include simplifying designs,
selecting cost-effective materials, or optimizing component manufacturing processes.

(iii) Reduce Costs of Assembly: The DFM process then addresses ways to minimize assembly
costs by optimizing the assembly process, reducing the number of assembly steps, or
designing for ease of assembly.

(iv) Reduce Costs of Supporting Production: This step involves identifying opportunities to
reduce costs related to supporting production activities, such as tooling, testing, quality
control, and logistics.
(v) Consider Impact on Other Factors: Throughout the DFM process, it is essential to consider
the impact of design decisions on other factors such as product performance, reliability,
sustainability, and manufacturability.

(vi) Recompute Manufacturing Costs: After implementing design improvements based on the
previous steps, the manufacturing costs are recomputed to assess the impact of the
changes and ensure that the design modifications align with cost-saving objectives.

The DFM process is iterative, and multiple iterations may be required to optimize the design for
manufacturing efficiency and cost-effectiveness. By following these steps and continuously
refining the design based on manufacturing considerations, product development teams can
create products that are not only well-designed but also optimized for efficient and cost-effective
manufacturing processes.
6. Discuss the concept of design for safety and environmental considerations in product
design.

Ans: Design for safety and environmental considerations in product design involves integrating
principles and practices that prioritize the safety of users, minimize environmental impact, and
promote sustainability throughout the product development process. Here are key aspects of
incorporating safety and environmental considerations into product design:

(i) Safety Design Principles:

o Risk Assessment: Conducting thorough risk assessments to identify potential


hazards associated with product use and implementing design features to mitigate
risks.

o User-Friendly Design: Designing products with user safety in mind, including


ergonomic considerations, clear instructions, and intuitive interfaces to reduce the
likelihood of accidents.

o Compliance with Regulations: Ensuring that the product design complies with
relevant safety standards, regulations, and certifications to guarantee its safe use
and distribution in the market.

(ii) Environmental Design Principles:

o Life Cycle Assessment: Conducting a life cycle assessment to evaluate the


environmental impact of the product from raw material extraction to disposal and
identifying opportunities to reduce environmental footprint.

o Material Selection: Choosing environmentally friendly materials, such as recyclable


or biodegradable materials, and minimizing the use of hazardous substances to
promote sustainability.

o Energy Efficiency: Designing products to be energy-efficient during use, reducing


energy consumption, and incorporating renewable energy sources where possible.

o End-of-Life Considerations: Designing products for ease of disassembly, recycling, or


repurposing at the end of their life cycle to minimize waste and promote circular
economy principles.

(iii) Integration of Safety and Environmental Considerations:

o Cross-Functional Collaboration: Involving experts in safety engineering,


environmental science, and regulatory compliance throughout the product
development process to address safety and environmental concerns effectively.

o Design Trade-Offs: Balancing safety, environmental impact, cost, and performance


considerations to make informed design decisions that prioritize both safety and
sustainability.

o Continuous Improvement: Implementing feedback mechanisms, post-market


surveillance, and product updates to address safety issues, improve environmental
performance, and adapt to changing regulations and standards.
By incorporating design for safety and environmental considerations into product development,
companies can create products that not only meet user needs and regulatory requirements but
also contribute to a safer, more sustainable future.

7. Discuss briefly the concurrent design approach for product design.

Ans: Concurrent design, also known as concurrent engineering or simultaneous engineering, is


an approach to product design that emphasizes parallel and collaborative work among cross-
functional teams throughout the product development process. Here is a brief overview of the
concurrent design approach:

(i) Simultaneous Activities: In concurrent design, different stages of the product development
process, such as concept generation, design, prototyping, testing, and manufacturing
planning, are carried out simultaneously rather than sequentially. This parallel execution of
activities helps reduce overall project lead time.

(ii) Cross-Functional Teams: Cross-functional teams consisting of members from various


disciplines, such as design, engineering, manufacturing, marketing, and quality assurance,
work together from the early stages of product development. This collaboration ensures that
different perspectives and expertise are integrated into the design process.

(iii) Early Integration of Stakeholder Input: Concurrent design involves engaging stakeholders,
including end-users, suppliers, and other relevant parties, early in the design process to
gather feedback, requirements, and constraints. This early integration helps align design
decisions with user needs and market demands.

(iv) Iterative Design Process: The concurrent design approach emphasizes an iterative design
process where feedback from different team members and stakeholders is incorporated
continuously. This iterative cycle allows for rapid prototyping, testing, and refinement of
design concepts to address issues early in the development process.

(v) Risk Management: By identifying and addressing potential risks, conflicts, and dependencies
across different functional areas early on, concurrent design helps mitigate project delays,
cost overruns, and quality issues. Risk management strategies are integrated into the design
process to proactively address challenges.

(vi) Communication and Information Sharing: Effective communication and information sharing
among team members are essential in concurrent design. Collaborative tools, project
management software, and regular meetings facilitate real-time sharing of updates,
progress, and decisions to ensure alignment and coordination among team members.

(vii) Focus on Time-to-Market: One of the primary goals of concurrent design is to reduce time-
to-market by streamlining the product development process, minimizing design iterations,
and accelerating decision-making. This focus on efficiency and speed helps companies stay
competitive in rapidly evolving markets.

By adopting a concurrent design approach, organizations can enhance collaboration, innovation,


and efficiency in product development, leading to the creation of high-quality products that
meet customer needs and market demands effectively.

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