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ENGINEERING DESIGN
BMCD 2573

Product Development Process

By
Syahibudil Ikhwan Abdul Kudus
Department of Design & Innovation
Faculty of Mechanical Engineering
 Revision - Design Process
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 Introduction to Product Development
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Process
• Engineering design/design process of a product is
vital part of this process, but
• Product development involves much more than
design.
• Development undertaken by company to make a
profit for its shareholders.
• Thus, the influence of business considerations, in
addition to engineering performance, is seen in the
structure of the PDP.
 Product Development Process (PDP)
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• The six phases of PDP diagram below proposed by

Asimow – generic PDP.
• This symbolizes the “gate" or review that the project
must successfully pass through before moving on
to the next stage or phase of the process
• The amount of money to develop a project
increases exponentially from Phase 0 to Phase 5
 Phase 0 - Planning
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 determine the possible markets and whether the

product is in alignment with the corporate strategic plan.
 determine technical and manufacturing feasibility.
 marketing analysis that involves market segmentation to
identify the target market, the product positioning, and
the product benefits.
 critical part of the business case is the financial analysis
 lf the decision is to proceed, then a multifunctional
team with a designated leader is established
 Phase 0 – Planning – Gantt Chart
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PROJECT SCHEDULE

2010 2011 2010

Project Activities J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D
1.Literature review and Patent search   

2. Modeling and Simulation of the Human

Walking Kinematics and Dynamics     
as well as controller design by
simulation

3. Development of portable gait analysis

system and magnetorheological          
damper design

4. Development of active prosthetic leg

and controller implementation      

5. Performance evaluation
  
6. Report Writing
    
 Phase 1 - Concept Development
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 process of determining the needs

of the customer is more detailed
than the initial market survey done
in Phase 0 to develop product
design specification (PDS)
 considers the different ways the
product and each subsystem can
be designed
 Produce a set of feasible concepts
that meet PDS, the best concept
suited for development into a
product must be determined using
selection methods
 Phase 2, System-Level Design
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 functions of the product are examined,

leading to the division of the product
into various subsystems.
 The interfaces between subsystems
are identified and studied
 Selections are made for materials
and manufacturing processes, and
the configuration and dimensions of
parts are established.
 Those parts whose function is critical to
quality are identified and given
special analysis to ensure design
robustness
 Phase 2, System-Level Design cont’
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 Careful consideration is given to the

product-human interface
(ergonomics)
 final touches will be made to the
styling introduced by the industrial
designers
 critical parts may be built with rapid
prototyping methods and physically
tested
 At this stage of development,
marketing will most likely have
enough information to set a price
target for the product and legal will
worked out any patent licensing
issues
 Phase 3, Detail Design
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 output of the detail design phase

is the control documentation for
the product.
 This takes the form of CAD files
for the product assembly and
for each part and its tooling.
 It also involves detailed plans
for production and quality
assurance, as well as many
legal documents in the form of
contracts and documents
protecting intellectual property
 Phase 4, Testing and Refinement
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 It is concerned with making and testing many preproduction

versions of the product
 The first (alpha) prototypes - the same dimensions and using
the same materials as the production version but not necessarily
made with the actual processes and tooling
 Know whether the product will actually work as designed.
 Phase 4, Testing and Refinement cont’
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 The beta tests are made on products made from parts

made by the actual production processes and tooling.
 The purpose of these tests is to satisfy any doubts about
the performance and reliability of the product, and to
make the necessary engineering changes before the
product is released to the general market
 At the end of Phase 4 a major review is carried out to
determine whether the work has been done in a quality
way and whether the developed product is consistent
with the original intent.
 Phase 5, Production Ramp-up
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 In this phase, manufacturing operation

begins to make and assemble the
product using the intended production
system
 Most likely they will go through a
learning curve as they work out any
production yield, quality problems
 Early products produced during ramp-
up often are supplied to preferred
customers studied carefully to find
any defects
 Production usually increases
gradually until full production is
reached and the product is launched
and made available for general
distribution.
 Factor of success
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 In commercial markets, the cost to purchase a product is

importance.
 Cost – materials, components, manufacturing, assembly,
labour and etc.
 Cost relates to product price.
Profit = product price – product cost
 Keys to determine the success of a product in market
place:
a) Quality, performance and price
b) Cost to manufacture the product over its life cycle
c) Cost to product development
d) Time needed to bring the product to the market.
 Factor of success
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 Factor of success
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 Variations on the generic PDP
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 The PDP described in this topic was based on assumption

that the product is being developed in response to an
identified market need – a market pull.
 The situation where the company stars with a new
proprietary technology and looks for a market – technology
push.
 Platform product – built around a pre-existing technological
subsystem.
 Process intensive product – manufacturing process places
strict constraints on the properties of the product, which the
product can’t be separated from the design of production
process. i.e: automotive sheet steel.
 Customized product – variations in configuration and content
are created in response to a specific order of a customer.
 On next lecture…
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2.1 Product Cycles and

Organization
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END OF SLIDES

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