TECH 101 Product Design and Manufacturing. TECH 1012 System Life-Cycle Engineering 2 Major phases in almost all products and in many cases services –Acquisition.

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Product Design and Manufacturing

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System Life-Cycle Engineering

• 2 Major phases in almost all products and in many cases services– Acquisition phase

• Need identification• Conceptual design• Detail design• Production or construction

– Utilization phase• Usage, maintenance, phase out, & disposal.

Figures 2.1 & 2.2

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Steps in Product or Service Development

• Identification of Needs

• Accomplishment of Feasibility Study

• Advance System Planning

• System Requirements Analysis

• Technical Performance Measures (TPMs)

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Steps in Product or Service Development continued . . .

• Functional Analysis and Allocation

• Synthesis, Analysis and allocation

• Synthesis, Analysis and Evaluation

• System Specification

• Conceptual Design Review

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Identification of Need

• Identification of need is the 1st. Step in the conceptual design.– The need or want or desire may be for a new

or improvement of a product or a process. It is based on a real or perceived deficiency. Examples: cost, speed, availability, quality, reliability. The deficiency must be well defined.

• Biases and political factors

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Feasibility Analysis

• After the needs are identified, alternatives for achieving the objectives must be developed and evaluated for technological, economical, and financial feasibility. Major decisions are made at this early stage.

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Advance System Planning

• Given the need and a feasible system to fulfill it, the advance planning commences. Figs. 3.1-3.2. In preparing the specifications, it must be stated in terms of “whats and not “hows” unless necessary.

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Systems Requirements Analysis

• Definition of Operational Requirements

• Operational distribution or deployment - includes geographical distribution & schedule of deployment Fig. 3.3

• Mission profile or scenario - identification of primary mission, and its secondary or alternative mission, etc. Fig. 3.4

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Systems Requirements Analysis continued

• Performance and related parameters - definition of basic requirements, speed, altitude, range, accuracy, throughput, capacity, etc.

• Utilization requirements - how often and how much the system is used per shift, per period, for its life cycle.

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Systems Requirements Analysis continued

• Effectiveness requirements - MTBF, MTBM, MTTR, , and MDT

• Operational life cycle (horizon)

• Environment - definition of the environment where the system will be used. In short, answer the following:

• What function(s), & when will be per-formed, where will it be used, and how will it accomplish its objectives

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Maintenance and Support Requirements

• The performance of the mission is the most important.

• Maintenance and its major levels are also important. Fig. 3.5

• Levels of maintenance - on what part of the system and where the repair is performed

• Sys. maintenance & repair policy

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Maintenance and Support Requirements continued

• Organizational responsibilities - who is responsible for the maintenance?

• Logistic support elements - includes spare parts, test equipment, personnel, moving & transportation equipment, etc.

• Effectiveness requirements - support capability

• Environment - temperature, humidity, dust, vibration, arctic or tropical, etc.

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Functional Analysis & Allocation

• Functional analysis is the process of translating systems requirements into detailed design criteria. The steps are:– Abstraction of the needs of the customer– Translate the above to hardware, software,

facilities, etc.

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Functional Analysis & Allocation continued

• In the analysis phase, “what” customer’s needs are specified and not how they are going to be achieved.

• Functional analysis is iterative. It breaks down the requirements and allocates it to subsystems at various hierarchy. The result is a definition of the system in functional terms, design function, production function, etc.

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Functional Analysis & Allocation continued

• Functional Flow Block Diagram can be used for system functional breakdown.

• Functional allocation is used to group similar functions into some logical subdivision.

• Coordination and Integration of activities must initiated at an early stage.

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Synthesis, Analysis, & Evaluation

• Trade-off in designs, technologies, materials, packaging, make or buy, etc., are made during the life cycle of the project.

• The trade-off analysis leads synthesis, i.e., combining components that gives a feasible system configuration. In each step of the way, evaluation

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Systems Specification

• The technical requirements & elements have to be documented. The content of the specification document for type A (top level) system is shown in Fig. 3.16.

• Type A( Systems Specification): Technical, performance, operational, & support characteristics of the overall system.

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Systems Specification continued

• Type B ( Development spec.): Development spec., it includes the requirements for any subsystem level. R&D , equipment, & processes are specified along with their performance, effectiveness, etc.

• Type C ( Product spec.): The same as above, except they are available or can easily be procured.

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Systems Specification continued

• Type D(Process Spec.): This includes any service or process that must be performed on any component of the system, such as machining, welding, heat treating, etc.

• Type E (Material Spec.): Tech. Requirements for the raw material, paints, chemicals, etc.

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Conceptual Design Review

• It is a formalized check

• Provides a baseline for all project personnel

• Provides a forum for concurrent engineering

• Interface problems are addressed

• Provides a formalized record of design decisions & helps the design to mature