Product design : techniques in reverse engineering and new product development / Kevin N. Otto, Kristin L. Wood.

by Otto, Kevin NLooking glass; Wood, Kristin LLooking glass.

Publisher: Upper Saddle River, N.J. : Prentice Hall, 2001.Description: xxi,1071 pages : illustrations ; 25cm.ISBN: 0130212717.Subject(s): Industrial designLooking glass | New productsLooking glass | Product managementLooking glassNote: Includes bibliographical references and index.
Item type Home library Collection Class number Status Date due Barcode Item reservations
Long loan Central Saint Martins
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Enhanced descriptions from Syndetics:

Product Design presents an in-depth study of structured designed processes and methods. KEY TOPICS: Fundamental approach is that reverse engineering and teardowns offer a new better paradigm for design instruction, permitting a modern learning cycle of experience, hypothesis, understanding, and then execution. MARKET: For practicing engineers interested in learning about mechanical design.

Includes bibliographical references and index.

Table of contents provided by Syndetics

  • Foreword (p. xxi)
  • Preface (p. xxiii)
  • Chapter 1 Journeys in Product Development (p. 1)
  • 1.1 Chapter Roadmap (p. 3)
  • 1.2 An Introduction to Product Design (p. 3)
  • Thoughts for the Reader and Student of Product Design (p. 3)
  • Product Development versus Design (p. 5)
  • Types of Design and Redesign (p. 7)
  • What is Engineering Design? (p. 9)
  • 1.3 Modern Product Development (p. 12)
  • A Modern Product Development Process (p. 13)
  • A Reverse Engineering and Redesign Product Development Process (p. 21)
  • 1.4 Examples of Product Development Processes (p. 27)
  • Systems: Xerox Corporation (p. 27)
  • Industrial Design: Design EDGE, Austin TX Product Design Firm (p. 30)
  • Rapid: Microsoft Corporation (p. 32)
  • Research Intensive: Raychem Corporation (p. 35)
  • Complex: Ford Motor Company (p. 38)
  • Technical: Raytheon Corporation (p. 40)
  • 1.5 Theories and Methodologies in Design (p. 41)
  • 1.6 Summary and "Golden Nuggets" (p. 48)
  • References (p. 48)
  • Chapter 2 Product Development Process Tools (p. 51)
  • 2.1 Chapter Roadmap (p. 53)
  • 2.2 Product Development Teams (p. 54)
  • The Basics of Teams (p. 55)
  • Team Composition: Seeking Synergy, Unity, Competence, and Consensus (p. 56)
  • Strategies: Team Structures (p. 62)
  • Team Building (Basic Activities) (p. 65)
  • Team Evaluation (p. 71)
  • Closing: Product Development Teams (p. 74)
  • 2.3 Product Development Planning (p. 74)
  • Planning Process (p. 75)
  • Basic Planning and Scheduling Tools (p. 77)
  • 2.4 Summary and "Golden Nuggets" (p. 79)
  • References (p. 81)
  • Chapter 3 Scoping Product Developments: Technical and Business Concerns (p. 83)
  • 3.1 Chapter Roadmap (p. 85)
  • 3.2 Determining What to Develop (p. 86)
  • S-Curves (p. 86)
  • S-Curves and New Product Development (p. 88)
  • Comments on S-curves and Technology Forecasting (p. 91)
  • 3.3 Basic Method: Mission Statement and Technical Questioning (p. 93)
  • Technical Questioning (p. 93)
  • Mission Statements (p. 94)
  • Finger Nail Clipper: Clarification and Mission Statement (p. 95)
  • 3.4 Advanced Method: Business Case Analysis (p. 97)
  • Harvard Business Case Methodology: Product Evolution (p. 98)
  • Product Development Economic Analysis (p. 99)
  • 3.5 Advanced Method: Design Drivers (p. 104)
  • Design Drivers (p. 104)
  • Example: Finger Nail Clipper (p. 108)
  • 3.6 Summary and "Golden Nuggets" (p. 110)
  • References (p. 110)
  • Chapter 4 Understanding Customer Needs (p. 111)
  • 4.1 Chapter Roadmap (p. 112)
  • 4.2 Customer Satisfaction (p. 112)
  • Voice of the Customer (p. 112)
  • Customer Populations (p. 115)
  • Types of Customer Needs (p. 116)
  • Customer Need Models (p. 117)
  • 4.3 Gathering Customer Needs (p. 118)
  • Need Gathering Methods (p. 118)
  • Conducting Interviews: Like/Dislike Method (p. 120)
  • Conducting Interviews: Articulated-Use Method (p. 123)
  • Customer Interviews: Product Feel and Industrial Design (p. 129)
  • 4.4 Organizing and Prioritizing Customer Needs (p. 130)
  • Grouping Interpreted Needs (p. 130)
  • Grouping the Needs--Affinity Diagram Method (p. 130)
  • Determining Need Importance (p. 133)
  • Customer Use Patterns (p. 141)
  • Customer Needs Documentation (p. 144)
  • 4.5 Summary and "Golden Nuggets" (p. 145)
  • References (p. 145)
  • Chapter 5 Establishing Product Function (p. 147)
  • 5.1 Chapter Roadmap (p. 148)
  • 5.2 Why Functional Decomposition? (p. 148)
  • Motivation (p. 148)
  • Function Modeling Basics (p. 151)
  • Functions and Constraints (p. 152)
  • 5.3 Modeling Process (p. 153)
  • 5.4 A Simple Approach: Function Trees (p. 154)
  • The FAST Method (p. 154)
  • The Subtract and Operate Procedure (p. 159)
  • 5.5 Establishing System Functionality: Creating a Function Structure (p. 162)
  • The Basics of Function Structures: Black Box and Definitions (p. 162)
  • The Function Structure Modeling Process (p. 167)
  • Phase 1 Develop Process Descriptions as Activity Diagrams (p. 167)
  • Phase 2 Formulate Subfunctions Through Task Listing (p. 168)
  • Phase 3 Aggregate Subfunctions into a Refined Function Structure (p. 174)
  • Phase 4 Validate the Functional Decomposition (p. 174)
  • Phase 5 Establish and Identify Product Architecture and Assemblies (p. 176)
  • 5.6 Augmentation: From Simple Function Trees to Complete Models (p. 177)
  • An Example of Hierarchical Function Structure Decomposition (p. 179)
  • Bringing Flows into the Functional Hierarchical Decomposition (p. 180)
  • 5.7 Aggregation Revisited: Simplicity of Shooting Darts (p. 181)
  • 5.8 A Functional Common Basis (p. 187)
  • The Common Basis (p. 188)
  • Transforming Functional Models (p. 189)
  • Uses of a Common Basis (p. 190)
  • Aggregate Function Study (p. 191)
  • 5.9 Critique of Functional Modeling Methods (p. 192)
  • 5.10 Summary and "Golden Nuggets" (p. 194)
  • References (p. 194)
  • Chapter 6 Product Teardown and Experimentation (p. 197)
  • 6.1 Chapter Roadmap (p. 198)
  • 6.2 Teardown Process (p. 200)
  • Overview (p. 200)
  • Step 1. List the Design Issues (p. 201)
  • Step 2. Prepare for Product Tear Downs (p. 202)
  • Step 3. Examine the Distribution and Installation (p. 202)
  • Step 4. Disassemble, Measure, and Analyze Data by Assemblies (p. 203)
  • Step 5. Form a Bill of Materials (p. 203)
  • 6.3 Teardown Methods (p. 204)
  • Subtract and Operate Procedure (p. 204)
  • SOP Examples (p. 206)
  • Force Flow (Energy Flow Field) Diagrams (p. 212)
  • Measurement and Experimentation (p. 220)
  • 6.4 Post Teardown Reporting (p. 234)
  • Disassembly Plan and BOM (p. 234)
  • Exploded Views with Highlighted Features (p. 236)
  • Actual Product Function Structure (Network) (p. 236)
  • 6.5 Applications of Product Teardown (p. 238)
  • Application: Slide-Out Auxiliary Visor (p. 239)
  • Case Study of an Automatic Iced Tea Maker (p. 249)
  • 6.6 Summary and "Golden Nuggets" (p. 256)
  • References (p. 256)
  • Chapter 7 Benchmarking and Establishing Engineering Specifications (p. 259)
  • 7.1 Chapter Roadmap (p. 260)
  • 7.2 Background: Know Your Enemy to Know Yourself (p. 260)
  • 7.3 A Benchmarking Approach (p. 262)
  • Step 1 Form a List of Design Issues (p. 262)
  • Step 2 Form a List of Competitive or Related Products (p. 263)
  • Step 3 Conduct an Information Search (p. 263)
  • Step 4 Teardown Multiple Products in Class (p. 268)
  • Step 5 Benchmark by Function (p. 268)
  • Step 6 Establish Best in Class Competitors by Function (p. 268)
  • Step 7 Plot Industry Trends (p. 269)
  • Benchmarking Example: Coffee Mills (p. 270)
  • 7.4 Support Tools for the Benchmarking Process (p. 274)
  • Indented Assembly Cost Analysis (p. 274)
  • Function--Form Diagrams (p. 275)
  • Trend Analysis (p. 278)
  • Proposal on Opportunities for Re-design (p. 279)
  • Thoughts on Benchmarking the Competition (p. 280)
  • 7.5 Setting Product Specifications (p. 283)
  • Specification Process (p. 284)
  • Basic Method: The House of Quality (p. 289)
  • Advanced Method: Value Analysis (p. 297)
  • 7.6 Summary and "Golden Nuggets" (p. 302)
  • References (p. 302)
  • Chapter 8 Product Portfolios and Portfolio Architecture (p. 303)
  • 8.1 Chapter Roadmap (p. 304)
  • 8.2 Product Portfolio Architecture (p. 304)
  • Background (p. 304)
  • Portfolio Architecture Types (p. 306)
  • 8.3 Choosing an Architecture Type (p. 315)
  • Theory (p. 316)
  • Market Basis for Architecture Decisions (p. 318)
  • 8.4 Platform Architecture (p. 331)
  • Negotiating a Modular Family Platform (p. 332)
  • Basic Method: Charts (p. 334)
  • Advanced Method: Functional Architecting (p. 339)
  • Advanced Method: Optimization Selection (p. 345)
  • 8.5 Summary and "Golden Nuggets" (p. 354)
  • References (p. 355)
  • Chapter 9 Architecture (p. 357)
  • 9.1 Chapter Roadmap (p. 358)
  • 9.2 Product Architectures (p. 359)
  • Introduction (p. 359)
  • Architecture Types (p. 360)
  • Architecture Examples (p. 361)
  • 9.3 Product Modularity: Background (p. 362)
  • Types of Modularity (p. 363)
  • 9.4 Modular Design: Basic Clustering Method (p. 370)
  • Step 1 Create a Function Structure of the Product (p. 370)
  • Step 2 Cluster the Elements into Module Chunks (p. 371)
  • Step 3 Create a Rough Geometric Layout(s) (p. 374)
  • Step 4 Define Interactions and Detail Performance Characteristics (p. 376)
  • 9.5 Modular Design: An Advanced Functional Method (p. 378)
  • Function Dependencies (p. 378)
  • Module Heuristics (p. 379)
  • Process: Application of the Module Heuristics (p. 391)
  • Summary (p. 398)
  • 9.6 Architecture-Based Development Teams (p. 399)
  • A Method of Forming Module Based Development Teams (p. 400)
  • Application of Module-Based Development Teams (p. 401)
  • Summary of the Development Team Method (p. 408)
  • 9.7 Summary and "Golden Nuggets" (p. 408)
  • References (p. 409)
  • Chapter 10 Generating Concepts (p. 411)
  • 10.1 Chapter Roadmap (p. 413)
  • 10.2 Concept Generation Process (p. 414)
  • 10.3 Basic Methods: Information Gathering and Brainstorming (p. 416)
  • Information Gathering: Conventional Aids (p. 417)
  • Traditional Brainstorming (p. 419)
  • Brain-Ball (p. 424)
  • C-Sketch/6-3-5 Method (p. 425)
  • Idea Generators for Intuitive Techniques (p. 432)
  • 10.4 Advanced Methods: Directed Search (p. 433)
  • Systematic Search with Physical Principles (p. 433)
  • Systematic Search with Classifying Schemes (p. 435)
  • Theory of Inventive Problem Solving (p. 443)
  • 10.5 Morphological Analysis (p. 454)
  • Develop Concepts for Each Product Function (p. 455)
  • 10.6 Combining Solution Principles (Concept Variants) (p. 456)
  • Digression/Caution: Function Sharing (p. 459)
  • Product Application: Fingernail Clipper (p. 460)
  • Product Application: Bilge Water Removal Product (p. 461)
  • Product Application: Smart Spoon to Assist Persons with Disabilities (p. 464)
  • 10.7 Summary and "Golden Nuggets" (p. 475)
  • References (p. 476)
  • Chapter 11 Concept Selection (p. 477)
  • 11.1 Chapter Roadmap (p. 478)
  • 11.2 Introduction (p. 478)
  • Factors that Determine Effective Decision Making (p. 479)
  • Design Evaluations (p. 480)
  • Information Quality (p. 480)
  • 11.3 Estimating Technical Feasibility (p. 482)
  • Estimation (p. 483)
  • Example: Air Conditioning for an Electric Vehicle (p. 484)
  • Estimating Hints (p. 486)
  • 11.4 A Concept Selection Process (p. 487)
  • Forming Consensus on the Criteria (p. 489)
  • Forming Consensus on the Alternatives (p. 491)
  • Ranking (p. 492)
  • Assessment (p. 492)
  • Attacking the Negatives (p. 493)
  • 11.5 A Basic Method: Pugh Concept Selection Charts (p. 493)
  • Establish the Criteria and Alternatives (p. 494)
  • Select a Datum (p. 494)
  • Ranking and Assessment (p. 495)
  • Alternative Rank Ordering (p. 496)
  • Attacking the Negatives (p. 496)
  • Iteration and Solution (p. 497)
  • Example: Coffee Mill (p. 497)
  • 11.6 Advanced Discussion: Measurement Theory (p. 500)
  • Set Structure of Evaluation (p. 500)
  • Ordinal Scales (p. 501)
  • Interval Scales (p. 506)
  • Ratio Scales (p. 511)
  • Extensively Measurable Scales (p. 513)
  • 11.7 Advanced Method: Numerical Concept Scoring (p. 513)
  • Scoring with Interval Scales (p. 513)
  • Selection Error Analysis (p. 517)
  • Concept Selection with Error Analysis: Design of a Cat Litter Box Product (p. 527)
  • 11.8 A Critique of Design Evaluation Schemes (p. 532)
  • 11.9 Chapter Summary and "Golden Nuggets" (p. 533)
  • References (p. 533)
  • Chapter 12 Concept Embodiment (p. 535)
  • 12.1 Chapter Roadmap (p. 536)
  • 12.2 Overview and Context (p. 537)
  • 12.3 Basic Methods: Refining Geometry and Layout (p. 542)
  • General Process of Product Embodiment (p. 543)
  • Embodiment Checklist (p. 546)
  • 12.4 Advanced Methods: Systems Modeling (p. 550)
  • Systems Modeling (p. 550)
  • Mechanical Embodiment Principles (p. 555)
  • FMEA Method: Linking Fault States to Systems Modeling (p. 565)
  • 12.5 Case Study: Computer Monitor Stand for a Docking Station (p. 571)
  • Summary (p. 595)
  • 12.6 Summary and "Golden Nuggets" (p. 596)
  • References (p. 600)
  • Chapter 13 Modeling of Product Metrics (p. 603)
  • 13.1 Chapter Roadmap (p. 604)
  • 13.2 Introduction: Model Selection by Performance Specifications (p. 604)
  • Model Preparation and Selection Method (p. 606)
  • Product Application: Model Preparation and Selection (p. 607)
  • 13.3 Mathematical Modeling versus Physical Prototyping (p. 610)
  • Example (p. 610)
  • 13.4 Advanced Topic: What is a Product Model? (p. 614)
  • Informal Models (p. 614)
  • Formal Models (p. 615)
  • 13.5 Constructing Product Models: basic Method (p. 622)
  • A Basic Modeling Approach (p. 623)
  • A Product Application in Constructing Basic Models: Iced Tea Maker (p. 632)
  • 13.6 Constructing Product Models: Advanced Method (p. 644)
  • Approach (p. 645)
  • Method (p. 645)
  • 13.7 Product Models: Cases (p. 648)
  • Electric Wok Product (p. 648)
  • Handle Temperature (p. 654)
  • Other Metrics to Integrate a Complete Model (p. 658)
  • Comments on Design Model Validation (p. 660)
  • 13.8 Summary and "Golden Nuggets" (p. 661)
  • References (p. 662)
  • Chapter 14 Design for Manufacture and Assembly (p. 663)
  • 14.1 Chapter Roadmap (p. 664)
  • 14.2 Overview and Motivation (p. 665)
  • 14.3 Basic Method: Design Guidelines (p. 666)
  • Design for Assembly (p. 667)
  • Design for Piece Part Production (p. 675)
  • 14.4 Advanced Method: Manufacturing Cost Analysis (p. 685)
  • Cost Driver Modeling (p. 686)
  • Manufacturing Cost Analysis (p. 690)
  • 14.5 Critique of Design for Assembly Methods (p. 709)
  • 14.6 Chapter Summary and Golden Nuggets (p. 716)
  • References (p. 716)
  • Chapter 15 Design for the Environment (p. 719)
  • 15.1 Chapter Roadmap (p. 721)
  • 15.2 Why DFE? (p. 722)
  • 15.3 Environmental Objectives (p. 722)
  • Global Issues (p. 723)
  • Regional and Local Issues (p. 724)
  • 15.4 Basic DFE Methods: Design Guidelines (p. 725)
  • Application: Paper Carrier Design (p. 725)
  • 15.5 Life Cycle Assessment (p. 733)
  • Overview (p. 733)
  • Basic Method: ATandT's Environmentally Responsible Product Assessment (p. 738)
  • Weighted Sum Assessment Method (p. 744)
  • Life Cycle Assessment Method (p. 752)
  • 15.6 Techniques to Reduce Environmental Impact (p. 753)
  • Design to Minimize Material Usage (p. 754)
  • Design for Disassembly (p. 756)
  • Design for Recyclability (p. 764)
  • Design for Remanufacturing (p. 767)
  • Design for High-Impact Material Reduction (p. 769)
  • Design for Energy Efficiency (p. 771)
  • Design to Regulations and Standards (p. 771)
  • 15.7 Chapter Summary and "Golden Nuggets" (p. 777)
  • References (p. 778)
  • Chapter 16 Analytical and Numerical Model Solutions (p. 781)
  • 16.1 Chapter Roadmap (p. 782)
  • 16.2 Overview and Strategy (p. 783)
  • Solution Definition (p. 786)
  • Pareto Optimality (p. 787)
  • 16.3 Basic Method: Spreadsheet Search (p. 789)
  • Product Application: Spreadsheet Search for a Toy Rocket Product (p. 792)
  • Summary (p. 800)
  • 16.4 Fundamental Concepts in Optimization (p. 801)
  • Constraints (p. 801)
  • Objective Functions (p. 803)
  • Standard Null Form (p. 803)
  • 16.5 Advanced Topic: A Discussion of Analytical Formulations (p. 805)
  • Unconstrained Problems (p. 805)
  • Lagrangians (p. 806)
  • 16.6 Practical Optimization (p. 811)
  • Numerical Search (p. 812)
  • Stopping Criteria (p. 813)
  • Sensitivity Analysis (p. 814)
  • Global Optimality (p. 815)
  • Solution Method: Matlab (p. 815)
  • Solution Method: Spreadsheet Solvers (p. 817)
  • 16.7 Product Applications (p. 822)
  • Application: Redesign of a TOMY "Push-n-Go" Train (p. 822)
  • Application: Electric Wok Product (p. 828)
  • 16.8 Summary and "Golden Nuggets" (p. 830)
  • References (p. 831)
  • Chapter 17 Physical Prototypes (p. 833)
  • 17.1 Chapter Roadmap (p. 834)
  • 17.2 Prototyping Essentials (p. 836)
  • What Are Physical Models/Prototypes (p. 838)
  • 17.3 Types of Prototypes (p. 839)
  • Prototypes Goals (p. 845)
  • 17.4 Uses of Prototypes (p. 846)
  • Mock-up Materials and Processes (p. 848)
  • Prototyping Processes (p. 852)
  • 17.5 Rapid Prototyping Techniques (p. 854)
  • Rapid Prototyping: A Historical Prespective (p. 856)
  • Commercial Rapid Prototyping Processes (p. 858)
  • Choosing Rapid Prototyping for a Product? (p. 864)
  • 17.6 Scale, Dimensional Analysis, and Similitude (p. 866)
  • Buckingham II Theorem and Scaled Testing (p. 866)
  • Buckle Design Example (p. 868)
  • 17.7 Basic Method: Physical Prototype Design and Planning (p. 871)
  • Guidelines for Prototype Design (p. 872)
  • Sample Prototype Application (p. 873)
  • 17.8 Summary and "Golden Nuggets" (p. 887)
  • References (p. 887)
  • Chapter 18 Physical Models and Experimentation (p. 891)
  • 18.1 Chapter Roadmap (p. 892)
  • 18.2 Design of Experiments (p. 893)
  • Basics of Designed Experiments (p. 894)
  • Basic Method: Two Factorial Experiments (p. 901)
  • Extended Method: Interactions (p. 916)
  • A Basic Product Application: Redesign of a Toy Solar Car (p. 922)
  • 18.3 Design of Experiments: Reduced Tests and Fractional Experiments (p. 929)
  • Full Factorial Inefficiencies (p. 929)
  • Orthogonality (p. 933)
  • Base Design Method (p. 934)
  • Higher Dimensions Fractional Factorial Designs (p. 936)
  • 18.4 Statistical Analysis of Experiments (p. 938)
  • Degrees of Freedom (p. 938)
  • Correlation Coefficient (p. 939)
  • Standard Error of the Residual (p. 940)
  • t-Test (p. 940)
  • ANOVA: F-ratio Test (p. 942)
  • Other Indicators: Residual Plots (p. 949)
  • Summary: Advanced DOE Method for Product Testing (p. 949)
  • 18.5 Product Applications of Physical Modeling and DOE (p. 950)
  • Product Application I: Nerf Missilestorm (Norrell, 1995) (p. 950)
  • Blender Panel Display Evaluation (p. 959)
  • Coffee Grinder Experimental Optimization (p. 965)
  • 18.5 Summary and "Golden Nuggets" (p. 977)
  • References (p. 977)
  • Chapter 19 Physical Models and Experimentation (p. 979)
  • 19.1 Chapter Roadmpa (p. 980)
  • 19.2 Quality Design Theory (p. 980)
  • General Robust Design Model (p. 981)
  • Robust Design Model Construction (p. 983)
  • 19.3 Basic Method: Taguchi's Method (p. 987)
  • Noise Variable Matrix (p. 987)
  • Design Variable Matrix (p. 989)
  • Experimental Matrix (p. 989)
  • Signal to Noise Ratios (p. 991)
  • Selection of a Target Design (p. 994)
  • Parameter Design and the Taguchi Philosophy (p. 994)
  • 19.4 Advanced Analysis: Probability Theory (p. 1001)
  • Sizing the Variation (p. 1002)
  • General Robust Design Problem Formulation (p. 1004)
  • 19.5 Chapter Summary and "Golden Nuggets" (p. 1008)
  • Robust Design as a Design Philosophy (p. 1008)
  • Golden Nuggets (p. 1010)
  • References (p. 1010)
  • Appendix A Function Structure Definition (p. 1011)
  • A.1 Flow Definitions (p. 1011)
  • Material (p. 1012)
  • Energy (p. 1012)
  • Signal (p. 1016)
  • A.2 Function Definitions (p. 1017)
  • Channel (p. 1017)
  • Support (p. 1018)
  • Connect (p. 1018)
  • Branch (p. 1019)
  • Provide (p. 1020)
  • Control Magnitude (p. 1020)
  • Convert (p. 1020)
  • Signal (p. 1021)
  • A.3 Function Structures for Example Products (p. 1021)
  • Appendix B DOE Tables (p. 1033)
  • B.1 Base Design Tables (p. 1033)
  • B.2 L-Array Tables (p. 1036)
  • Appendix C TRIZ Relationship Table (p. 1039)
  • Appendix D Eco-Indicator Environment Assessment (p. 1043)
  • Index (p. 1051)

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