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2019 | Buch

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Design Principles and Methodologies

From Conceptualization to First Prototyping with Examples and Case Studies

verfasst von: Prof. Dr. Alessandro Freddi, Dipl.-Ing. Mario Salmon

Verlag: Springer International Publishing

Buchreihe : Springer Tracts in Mechanical Engineering

Enthalten in: Springer Professional "Wirtschaft+Technik" , Springer Professional "Technik" , Springer Professional "Wirtschaft"

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Über dieses Buch

This book introduces readers to the core principles and methodologies of product development, and highlights the interactions between engineering design and industrial design. It shows to what extent the two cultures can be reconciled, and conversely what makes each of them unique. Although the semantic aspect is fundamental in industrial design, while the functional aspect is essential for the industrial product, the interaction between the two worlds is strategically vital. Design is also a strategic problem-solving process that drives innovation, builds business success and leads to better quality of life through innovative products, systems, services and experiences. The book connects product development with the concepts and strategies of innovation, recognizing that product design is a complex process in which invention, consumers’ role, industrial technologies, economics and the social sciences converge. After presenting several examples of artifacts developed up to the conceptual phase or built as prototypes, the book provides a case study on a packaging machine, showcasing the principles that should underlie all design activities, and the methods that must be employed to successfully establish a design process. The book is primarily targeted at professionals in the industry, design engineers and industrial designers, as well as researchers and students in design schools, though it will also benefit any reader interested in product design.

Inhaltsverzeichnis

Frontmatter

Methods

Frontmatter

Chapter 1. Engineering Design and Industrial Design

Abstract

Engineering designers and industrial designers are the main actors called to collaborate, within their jurisdiction, in the design of products/service through creative choices that define functions, structures and forms together with manufacturing processes. In spite of different cultures and practical approaches of the two categories of professionals, design accomplishes a common goal: development of new products and services. Each design process runs from a conceptualization phase and moves towards an embodiment phase, trying to meet the customers’ real needs, and at the same time to satisfy business requirements, in respect of health-, safety- and environmental constraints [32]. Obviously, it is necessary to distinguish between the end user and the industrial customer that have requirements that must be met differently.

Alessandro Freddi, Mario Salmon

Chapter 2. Design Methods

Abstract

It is customary to refer the expression cognitive science, since the end of the seventies, to all the disciplines that relate to the interdisciplinary scientific study of the mind and its processes. Cognitive science focuses on how information is represented, processed, and transformed (in faculties such as perception, language, memory, attention, reasoning, and emotion) in human and animal minds and machines. Let’s apply these concepts to the analysis of the methods that are developed in the design process. The cognitive theory emphasizes the relationship between design thinking and memory. The tools for memory management are writing and drawing actions necessary to transfer experiences and mental processes to new subjects involved in the design process. Basically, we can say that design is a technical but also a humanistic process because it is related to a human problem solving process. Design in its most effective form is a process, an action, more than an object. It is a protocol for solving problems and discovering new opportunities. Every design process has common elements. Over the last fifty years, methods for understanding the nature of design have been discussed and proposed. While the design processes are distinctive in specific ways depending on the different fields (mechanical, precision engineering, electronic and software engineering, etc.), a common cognitive base of different methods exists.

Alessandro Freddi, Mario Salmon

Chapter 3. Requirements and Specifications

Abstract

Subjects involved in the design and production of goods have to build their decisions on market data. Collecting and organizing information is then the preliminary activity, necessary in understanding the complexity of the customer needs, often not “clear and distinct”, but on the contrary, expressed in a confused and interrelated way. Users can play an active role that must be taken into account: user-driven design versus user-centered design is a controversial position that it is worth analyzing. The design process starts by the identification of the needs of potential customers and proceeds with conceptual design, then embodiment and finally detail design, and the knowledge and satisfaction of user real needs is crucial in any phase. The tools developed for acquiring this knowledge are far from being formalized (i.e. mathematically formulated) but, nevertheless, are consistent and based on principles of logic, cognitive sciences and on the human experience of all the subjects that collaborate in the design process. This great work of interpretation and translation leads, at the end of the conceptual design, to fundamental documents which are called “product (or service) specifications” and which are the starting points for all the following design phases.

Alessandro Freddi, Mario Salmon

Chapter 4. Invention and Innovation

Abstract

Up to this point we met design methods with a predominantly technical approach, according to which the design process is developed as a sequence of actions related to the invention of solution principles. Through the previous approach we learned how to perform certain functions, i.e. with the invention of functional variants and also in certain cases, the construction of prototypes. However, especially design guidelines and the ISO 9001 standards now open up a broader scenario, in which a technical design is oriented to an industrial mass production. In this case, the problem-solving choices are no longer only a problem of technical invention. Mass-production requires the study of another coordinate of the problem: the design development within an industrial company. It concerns the “innovation concept” that is the core value played primarily within company strategies.

Alessandro Freddi, Mario Salmon

Special Topics

Frontmatter

Chapter 5. Safety Assessment

Abstract

Planning is a process which leads from acquired knowledge to new knowledge. Unknown materials, models, environments etc. can generate abnormal operating conditions with the risk of damage. Designers have a number of tools to protect themselves from this eventuality. The first concept that was introduced to guarantee the safety of a project is the safety factor. In general terms, a system has a safety factor when the collapse is expected with conditions markedly more rigorous than those provided as design requirements. However, in a vision closer to reality, the most correct way of addressing the problem consists in recognizing the probabilistic nature of each process in use of a product, involving not only artificial, but also human actions. Every product/service is naturally subjected to failures, but more than failure in itself, are the effects of a failure that give significance to the failure. Then not only the nominal functions (with no failures) but also the functions consequently to a failure must be considered as possible system’s operating conditions. In an initial presentation there will be set forth some basic concepts of system reliability as the probability of no failures, along with the tools most commonly used, such as FMEA which, by virtue of their semi-scientific content, take into account variables not necessarily “measurable” but, nevertheless, lead to a significant reduction of the risk associated with a “failure”.

Alessandro Freddi, Mario Salmon

Chapter 6. Design of Experiment

Abstract

In the case of lack of theoretical knowledge of the relationships between input and outputs variables of a system, we have a second possibility: the experimental reconstruction of these relationships. In the case of theoretical knowledge, the system is represented by linear or nonlinear equations between input and output variables, while in the absence of them an experiment must be planned to reach a certain level of knowledge of the system: the Design of experiment (DOE). This tool is general enough to be applied to different types of variables (e.g. categorical variables). Given the introductory character of this chapter, the presentation is limited to basic aspects.

Alessandro Freddi, Mario Salmon

Chapter 7. Introduction to the Taguchi Method

Abstract

We now introduce a further powerful engineering tool: the Robustness concept. It is inextricably linked to the name of Genichi Taguchi, a Japanese engineer. Although his approach is based on what was outlined in the previous chapter on Design of Experiment, it contains strong innovation of those concepts. Significant improvements are proposed for three design phases: system design, parameters design and tolerance design. It is not possible to draw a comprehensive picture of the method here. Only the main concepts are introduced, leaving any more complex treatment of the method to specialized books. This method is a real improvement of the application of statistical methods to design applications. This chapter describes the basic concepts, among which the Quality Loss Function that better than other interpretations clarifies the term, often ambiguous, of quality. In this way, the link between robustness, reliability and design of quality becomes obvious. We tried to give emphasis to ideas more than to technicality, but a limited mathematical formalism is necessary.

Alessandro Freddi, Mario Salmon

Case Studies

Frontmatter

Chapter 8. One-Off Product Design

Abstract

In the seminal conceptual idea that things derive from other things, in this chapter we will show examples of design that have been developed at the level of useful prototypes. They remained at this level, since they were designed as single units and it was considered not suitable at that time to transform them into large batch products. Only later, did some of them become first models of others, but outside the responsibility of the authors. Nevertheless, these prototypes have received confirmation of their usefulness in special environments, (as equipment in national laboratories and private companies’ research centers).

Alessandro Freddi, Mario Salmon

Chapter 9. Design of a Packaging Machine: General Description and Conceptualization

Abstract

This Chapter is devoted to the description of the conceptual design of an industrial product, the SASIB ALFA Packer (Sasib S.p.a., Bologna, now part of the COESIA Group, Italy), an automatic machine for the packaging industry, developed in the eighties, under the direction of one of the authors. The Dante Alighieri motto “It is true that, as a form is frequently discordant with the intention of an art, because its matter in response is deaf”, reminds us that in any human activity a gap always exists between theory and practical implementation. Design of artifacts shows a deep gap between conceptual phase and realization inside a business oriented organization. While theory gives guidelines for the design of a product, industrial practice is product oriented, i.e. its goal is to “develop a new product” taking into account any related activity “from cradle to grave”; while theory takes into account essentially “physical” constraints, a real mass production must consider human and social constraints such as time, expenditure, human resources, customers, and stakeholders, psychology, etc.

Alessandro Freddi, Mario Salmon

Chapter 10. Embodiment Design of the Packaging Machine: Prototype Development

Abstract

This chapter is devoted essentially to the embodiment design of the SASIB ALFA Packer Prototype, following the topic dealt with in the previous chapter. The embodiment design is the part of the design process in which, starting from the main decisions made in conceptual design, the product plan is concretely developed, dealing with technical and economic criteria. This step moves from logical to physical solutions, to define shape and size. In the example shown, the embodiment design is essentially an illustration of the main constructive solutions adopted. However, unlike conceptual design, embodiment design requires many corrective actions in which analysis and synthesis alternate. It is a less systematic process that gives rise to many reviews. In any case, we do not deal with the detailed design phase.

Alessandro Freddi, Mario Salmon

Backmatter

Titel: Design Principles and Methodologies
verfasst von: Prof. Dr. Alessandro Freddi
Dipl.-Ing. Mario Salmon
Verlag: Springer International Publishing
Electronic ISBN: 978-3-319-95342-7
Print ISBN: 978-3-319-95341-0
DOI: https://doi.org/10.1007/978-3-319-95342-7

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