Preamble:

Product Development and

Manufacturing Cycles
K.P. Karunakaran

Indian Institute of Technology Bombay

Outline
Preambles

Three Industrial Revolutions

Three Influencing Factors of This Era
Three Types of Businesses

Essentials of Good Product Development

Product Development and Manufacturing Cycles

Three Industrial Revolutions

Ind.
Rev.
I
II
III

Effect

Enablers

Mechanization
(1760-1840)

Water wheel and wind mill

Steam engine, IC engine
Electricity, pneumatics and hydraulics

Automation
(1870-1914)
Integration
(1950-till date)

Hard automation
NC, CNC, Robotics, PCs &
CAD/CAM/CAE/PLM/ERP systems
Network & Internet,
3D scanning and 3D Printing

Digital (ease of copying, modification and transmission), virtual (high speed; less
expensive and risky), mobile (anywhere, any time), personal (done by self good
control, confidentiality).

Three Influencing Factors of This Era

3rd Ind. Revolution driven by Internet, AM, Bio, Nano, AM,
1. Information
The most powerful
weapon today.
Data, knowledge,
inference, information,
intuition
Software tools help in
managing the vast
information (relational
databases Oracle; data
mining Google, Yahoo,
Wikipedia etc.). Therefore
IT is synonymous with
software that manage
these data.

2. Communication

3. Transportation

Transfer of information.

Transfer of physical things

One way: Radio, TV

By road, rail, water, air,

Both ways: (sync/ async): Speed is the bottleneck;

Post, telephone, fax,
of late, with the rising
Intranet, Internet, Email terror attacks, safety too is
a concern.

Convertibility between information and

physical things (similar to mass and energy,
currencies )?
(See the science fiction movie The Fly)
Manage with video conferences

Three Types of Businesses

Type of Business
Production
Service

Profit

Trading

Remarks
Due to the higher profit margins, there is
a tendency for producers to shift to
service and trading. However, these
three functions need to be balanced;
when this balance is disturbed, it leads to
economic recession. The other reason
for recession is complacence. There are
external factors too such as rise in oil
price that have spiralling effect.

Examples:
Plastic spectacle frame Rs. 30 is the price manufacturer gets
whereas it is sold at > Rs. 300 at the shop. There are many traders
between the producer and customer.
OptiLOM 50% for the trader, 25% each for the two developers.

Essentials for Good Product Development

1. Design iterations
A design is rarely right first time. So no escape from iterations.
Number of design iterations is not necessarily a reflection of your
inability to look ahead.
Design iterations improve the quality of design (which is different
from the standard definition of quality which actually refers to
quality of manufacture, viz., conformance to design).
Iterations cost in time and money too! So, use quicker and cheaper
tools such as sketches, virtual CAE tools etc.

Essentials for Good Product Development

2. Do lot of sketching
Ideas come at high speed (Vayu
vegam Mano vegam). Existing
CAD cannot capture all. So, grasp
them quickly through sketches.
(Analogy: Lord Ganesh helping Ved
Vyas for recording Maha Bharat).
Your sketch need not be beautiful or neat; but when you look at
them, you will be able to recall most of the thinking of that time.
Therefore, the sketches make more sense to the designer who
sketched them than to the others.

Essentials for Good Product Development

3. Do not evaluate ideas while generating them
This is one place where we favor serial activities.
Evaluating the idea as it is suggested will (i) block further flow of
ideas and (ii) inhibit the participant in the brainstorming session.

Essentials for Good Product Development

4. Do not fall in love with your ideas or its manifestations
This is too will inhibit further generation of ideas.

Essentials for Good Product Development

5. Do not be lazy to iterate
This is too will inhibit further generation of ideas.

Essentials for Good Product Development

6. Appropriate manpower
Manpower: Skilled & Dedicated & Passionate & Loyal & Teamspirited.
High attrition rate is the single most challenging problem today;
not funds or equipment any more.
Man behind the machine is important. Organizations excel not
because of their infrastructure but because of their people.

Essentials for Good Product Development

Constraints:
Conventional and
CAD design on the
same table.
Adjustable
inclination with
ease
Ease of shifting
between manual
drafting and CAD
Limited space

[Courtesy: Shrishail and Parth, Alumni of VJTI]

Illustration: Design iterations of a drawing table

Essentials for Good Product Development

Survey of some tables available in the market.

[Courtesy: Shrishail and Parth, Alumni of VJTI]

Illustration: Design iterations of a drawing table

Essentials for Good Product Development

Sketching new options
Importance of rough sketching in design process
Table layout options
Monitor mechanisms

[Courtesy: Shrishail and Parth, Alumni of VJTI]

Illustration: Design iterations of a drawing table

Essentials for Good Product Development

Design to meet the basic requirements
Frame and wedge design to achieve
variable angle for the drafting board

Board lifted and kept behind while

using monitor
Swivelling mechanism for monitor

Base Design

[Courtesy: Shrishail and Parth, Alumni of VJTI]

Illustration: Design iterations of a drawing table

Essentials for Good Product Development

Board had to be lifted every time you
have to use the computer
Glass surface used

The base was removed to incorporate

new monitor mechanism
The base side of the frame made
circular for better support
Fillet provided at the base of the
wedges for a surface contact instead
of line contact

Iteration 2:

[Courtesy: Shrishail and Parth, Alumni of VJTI]

Illustration: Design iterations of a drawing table

Essentials for Good Product Development

Angle cannot be reduced below 45
degrees
The dimensions of the frame has to be
modified to improve the range
Frame made in two parts
Two bolts on each arm
Height of the frame is adjustable
Very low angles possible
Angles below 30 degrees not possible

Iteration 3:

[Courtesy: Shrishail and Parth, Alumni of VJTI]

Illustration: Design iterations of a drawing table

Essentials for Good Product Development

The bolts must be adjusted every time
Design iterations for various possible
solutions

Clip mechanism introduced

Importance of sketching in the
configurational design stage
Design improved by providing wedges
on both the links
Entire frame can be removed
Even 0 degrees possible

Iteration 4:

[Courtesy: Shrishail and Parth, Alumni of VJTI]

Illustration: Design iterations of a drawing table

Essentials for Good Product Development

The bolts must be adjusted every time
Design iterations for various possible
solutions

Clip mechanism introduced

Importance of sketching in the
configurational design stage
Design improved by providing wedges
on both the links
Entire frame can be removed
Even 0 degrees possible

Iteration 4:

[Courtesy: Shrishail and Parth, Alumni of VJTI]

Illustration: Design iterations of a drawing table

Essentials for Good Product Development

All previous mechanisms give discrete
variation in the angle
Use of a handle for continuous
variation
Use of bevel gears and stud to convert
rotary motion to linear motion
Different iterations to determine the
best position of joints
Problem at lower angles
Cost increases

Iteration 5:

[Courtesy: Shrishail and Parth, Alumni of VJTI]

Illustration: Design iterations of a drawing table

Essentials for Good Product Development

FINAL
DRAFTING AND
PROTOTYPING

[Courtesy: Shrishail and Parth, Alumni of VJTI]

Illustration: Design iterations of a drawing table

Essentials for Good Product Development

Illustration: Design iterations of the rotor of a MAV

Product Development and Manufacturing

Cycles
Product & Its classification

Product Cycle

Product
A product is a commodity that serves certain functions.
It could be physical or virtual (say, a software). However,
we shall be mostly concerned with the physical ones.

Product Cycle

The activities are actually arranged in a cycle.

All need not take constant and equal duration.

They have precedence relationships among them;

parallelism and slack also exist.

They may occur at different geographic locations too.

These are handled by Marketing, Design and

Manufacturing departments.

Product Cycle

Product Cycle
Two phases of product cycle

i. Product Development Cycle

The phase from identifying the need for the product, conception of the product
through its development, proving through a series of prototypes till productionizing.

ii. Product Life Cycle

The phase from the manufacture of the product batch after batch, sales, service till
finally disposal of the product after it has finished its useful life.

Product Cycle
Four phases of product cycle

i. Product Identification
ii. Design
iii. Manufacture

iv. Sales & Service

Product Cycle
Shigleys Six stages of product development cycle

1. Recognition of need

4. Analysis and Optimization

2. Specification of the product

5. Evaluation

3. Synthesis

6. Presentation

Product Cycle
Product identification

- Market Survey
-Analysis of Customer Requirements & Feedback
-Watch the competitor

Product identification
Need

It starts with a need. Identification of this need is the responsibility of

the marketing department. Extensive market research (data
collection from customers, retailers etc. and analysis) will be required
to identify the need. Often watching the competitors is enough!
(industrial espionage! Reverse Engineering!!)

Product identification
Product types
The need could be met by
products arising out of radically
new ideas or a modification of an
existing product.
Sometimes, a technology may
lead to innovative new products
for which a market may not exist
readily. In such a case, marketing
department has to excite the
customers and generate interest
in it through advertising/ demos.

Project types

Q: Identify the group for cell phone with camera and radio, European
car for India, an automotive company starting an IT division, annual
release

Product identification
Importance of correct identification and undistorted communication

Marketing, Design and

Manufacturing are the
three main groups
responsible for the product.
It is essential that they
communicate among
themselves the need for
and specifications of the
product without distortion.
If the company
understands the need
correctly and launches a
product in time that meets
this need, it flourishes.

Design
Design is the creative activity of developing a new product that meets
the needs. Design involves a series of decisions which form an
inverted tree. It is often an iterative process.

Design
Three stages of design

1. Conceptual design
2. Configurational design
3. Detailed design

Design
Three stages of design
The 3 important phases of design are [Fisher]:
i. Conceptual design
Generation of numerous ideas to meet the need
Evaluation of these ideas and choosing the best one
Arriving at an abstract design

ii. Configurational design

Modularization
Decide interface among the modules & design collaborations

iii. Detailed design

The work is distributed to the functional groups are
distributed
Geometric modeling, Determination of material etc.
Analysis, synthesis and optimization.

The possibilities of automation increases in these phases creative

to mundane!

Design
Conceptual design

- Product Definition, i.e., Specifications.

-Synthesis of Ideas (leading to the principle of
operation of the product)

Design
Configurational design

- Modularization
- Establishing Design Collaborations

Design
Detailed design : Modeling

Detailed Design: Modeling

- Geometric Modeling CAD

- Digitizing
- Drafting

Design
Detailed design : Analysis, synthesis & optimization

Detailed Design: Engg Analysis & Synthesis

CAE (a misnomer)
- Structural Analysis
- Heat & Fluid Flow Analysis
- Kinematic Analysis
- Dynamic Analysis
- Design for Xability (DFX) Analysis
(X = Manufacture, Assembly, Disassembly, Repair, EcoFriendliness, Mass Customization etc.),
- Optimization

Design
Detailed design : Virtual Prototyping

- Mathematical Modeling
- Virtual Reality, Interference Check
- Virtual Testing

Manufacture
Manufacture is the physical realization of a design specification.
Manufacturing strategies are different for prototypes and regular
product. Furthermore, it also depends on other factors such as
volume, quality of labor etc.

Manufacture
Types

Types of Manufacture

Types of Activities

1.
2.

1.
2.

Prototype manufacture
Regular production

Managerial activities
Shop floor activities

Manufacture
Physical Prototyping

Physical Prototyping:
- Physical Models (scaled/full, actual/ Alternate material) by conventional manufacture or by Rapid
Prototyping
- Working Prototypes. One has to do manufacturing activities such as Process Planning, Tool Design,
NC Programming etc. specific to these prototypes
- Physical Testing

Manufacture
Physical Prototyping
- Make/ Buy Decision
- Vendor Development
- Resource Planning (facilities etc. : BPR or
MRP III)
- Selection of Site

- Scheduling
- Machine loading
- Line balancing
- Man power deployment
- Salary
- Purchase
-Resource planning (MRP I & II)
-Supply Chain Management
-Product Lifecycle Management

- Regular manufacture (casting, forging, forming,

machining & Joining)
- Assembly
- Inspection & QC
- Warehousing
- Shipping

- Product Design (Value Engineering,

Aesthetics and Ergonomics)
- Freezing Design and Release of Design
Documents
- Process Planning
- Tool Design & Manufacture
- NC Programming
- Group Technology
- Plant Layout

Sales & Service

- Advertising
- Maintenance

Sales & service is the responsibility of Marketing Department. As this

department is directly in touch with the consumer, they are also responsible for
identifying the need for a product.

Summary So Far
Activities of the product form cycles.
Each may have different and non-constant periods with
precedence relations. Hence parallelism and slacks are possible.

Mostly they are stochastic rather than deterministic.

Various classifications were presented.
Use of computers helps in better efficiency and integration.

Thank You!
K.P. Karunakaran
Professor
Department of Mechanical Engineering
Indian Institute of Technology Bombay
Powai, Mumbai-400076, INDIA
Tel.: 022-25767530/ 9869541570
karuna@iitb.ac.in
www.me.iitb.ac.in/~karuna