CHAPTER 25 THE ENGINEERING
DESIGN PROCESS PROBLEMS
INSTRUCTIONS
Part 1: Problems 25.1 and 25.2
PROBLEM 25.1 The following topics require research or
industry visitations. It is recommended that you research cur–
rent professional magazines, check websites, visit local
industries, or interview professionals in theengineering field.
Your reports should emphasize thefollowing:
■ The link between manufacturing and engineering.
■ Current technological advances.
■ The design process.
■ Team applications.
Select one or more of the following engineering fields or as
assigned by your instructor and write a 250-written and oral
report for each.
Mechanical engineering
Structural engineering
Civil engineering
Electrical engineering
Electronic engineering
HVAC and sheet metal engineering
Industrial pipe engineering
PROBLEM 25.2 The following topics are changing the way
engineering design is currently conducted. Engineering design
and industry management models are systems used by the en-
gineering world to address the constantly evolving engineering
design process.
Research, observe, visit industry or product vendors, or
search the Internet to find ways that the following applications
are allowing product development to be less expensive, faster,
and of higher quality. Your presentation should emphasize the
following:
■ process,
■ current technological advances,
■ team applications,
■ problem-solving tools, and
■ design applications for engineering.
Select one or more of the topics listed below or as assigned
by your instructor and prepare an oral presentation for each.
Top-down and bottom-up design
Kaizen event
Just-in-time (JIT)
Toyota production system (TPS)
Lean manufacturing
Six Sigma
Concurrent engineering (CE)
Life-cycle engineering
Integrated product development (IPD)
Knowledge-based engineering (KBE)
Total quality management (TQM)
Phase gate design process
Cross-functional team approach
Project portfolio management
A comparison between advanced research and existing
product research
One or more of the phase gate design process stages
Industrial design
Quality function deployment
Design specification
Functioning prototypes
Intellectual properties
Patent research and invention disclosure
Failure mode effect analysis
Computational dynamics and finite element analysis
Design documentation
Preproduction build
Regulatory approval
After full production
The end of product
Creativity and innovation in design and principles of
creativity
Change and the impact on the design process
Tracking documents
Design deliverables
DESIGN PROBLEMS
Part 2: Problems 25.3 Through 25.25
The following problems involve using elements of the engineer–
ing design process identified in this chapter to design products
from given concepts or for your own design projects. These de-
sign projects are best solved using a team approach, but they also
can be done individually, depending on your course objectives
and available participants. When using a team, identify a project
leader and the responsibility of each team member, such as in-
dustrial designers, CADD designers and drafters, prototype mak-
ers, research specialists, marketing personnel, and specification
developers. Some of the following steps may not be possible to
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accomplish because facilities, skills, or resources are not avail-
able. Confirm this with your course objectives and instructor
approval. Using the content of the engineering design process
sections found in this chapter, include the following documents
as part of the completion for each design.
Engineering Notebook Maintain a design and computation
engineering notebook to document and record all of your design
activity through the design process for your product. Your engi-
neering notebook is used to document details of the engineering
process, as an ongoing record of your project. All preliminary
and development work is recorded, including written ideas, de-
sign sketches, invention insights, observations, notes from meet-
ings and other details relating to the progression of information.
Also document and record the content from meetings with fel-
low students, industry contacts, and your instructor along with
the date, time and location for timeline verification.Your engi-
neering notebook shall be submitted to your instructor for evalu-
ation along with the set of working drawings and prototype for
your final project.
The Product Description and Business Case This is a formal
document that specifies the features, pricing, and costs of a new
product. This document communicates the customer needs to
engineering and is the guidance on which engineering acts.
Marketing gathers input from customers in the target market
and also from departments such as purchasing, engineering, and
sales.
The Project Plan This document is created by the project
leader, who issues a schedule communicating the anticipated
implementation time line for the project. The project team is
also formed at this time. Each team member is given his or her
assignment, and expectations are established. A major benefit of
this practice is to ensure that all critical tasks are identified and
accounted for. List team members’ names and identify their
specific responsibilities and estimated deadlines.
Industrial Design (ID) Team Select team members who are
possibly the most creative. These should be people who have the
ability to be creative and work within engineering, manufactur–
ing, and cost constraints. Create sketches illustrating various
layouts, features, and styling. Usually 6 to 12 idea renderings are
created in this concept design phase. Present the sketches to
marketing and engineering for their input and assistance in nar-
rowing down the concepts to one or two desired possibilities.
Concept Refinement In this step, the industrial designer be-
gins concept refinement, where final sketches and multiple
views are created. This is also usually when mockups are created.
The refined concept or concepts are then presented again to
engineering and marketing. Once everyone is in agreement on a
concept, one or more team members are selected to create CADD
models.
Customer Research Customer input can involve classmates,
friends, and family and can be established through one or more
of the following means:
■ hard copy distribution, phone surveys, or questionnaires;
■ telephone or field interviews with customers;
■ listening to and gathering customer recommendations; and
■ using a Website or other correspondence.
Create the Design Specification Establish technical specifica-
tions and performance targets. These areguidelines to the project
team and help identify what constitutes a successful design. The
design specification is a document with project requirements
such as:
■ dimensions,
■ weight,
■ materials,
■ general shape,
■ power requirements,
■ voltage requirements,
■ amperage specifications,
■ product life and durability requirements,
■ required agency approvals,
■ performance requirements,
■ included and optional accessories,
■ general and special features, and
■ environmental factors.
Product Development Construct a fully functioning prototype
model. If facilities or skills are not available for the construction
of a fully functioning prototype model, then build a model using
other materials such as paper, cardboard, or foam.
Product Bill of Materials Develop a product bill of materials to
the best of your ability and knowledge. This document is used to
establish the final product cost and to help organize the manu-
facturing process. Capital that must be spent to make parts in
production, such as tooling, die, and pattern costs, also should
be determined at this time.
Design Documentation Prepare a complete set of working
drawings for the product. This includes an assembly drawing,
parts list or bill of materials, detail drawings, and specifications.
Establish a part or drawing numbering system. The assembly
drawing can be in a 2-D or 3-D format as determined by
your course objectives. Use the content in Chapter 15, Working
Drawings, for reference.
Manufacturing If facilities and skills are available, manufac-
ture and assemble at least one of the products. Do additional
testing to determine how the first products off the production
line meet the established design specifications.
Marketing Create a marketing plan along with at least one pro-
motional flyer or brochure.
PROBLEM 25.3 Trailer hitch design
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Design a standard receiver trailer hitch for a pickup truck, light
truck, or SUV with the following requirements:
■ quick change height adjustment;
■ quick change trailer ball to accommodate at least two ball
sizes, such as 2 and 2.5 in. (50–60 mm); and
■ corrosion-resistant material or finish.
PROBLEM 25.4 Cheese cutter
Design a countertop cheese cutter with the following
requirements:
■ compact design to accommodate a typical two-pound (1 kg)
cheese block,
■ flat base to rest on any countertop or table,
■ adjustable cutting width,
■ corrosion-resistant material and finish,
■ easy cleaning, and
■ easy storage.
PROBLEM 25.5 Electronics component door
Design a door covering the controls of an electronics compo-
nent, such as a television, radio receiver, or DVD player with the
following requirements:
■ one touch opens and
■ opens slowly when door is released.
PROBLEM 25.6 Ski cycle
Design a track drive system that can replace the rear wheel on a
motorcycle, and design a ski that can replace the front wheel so
a lightweight motorcycle can be used on snow.
PROBLEM 25.7 ATV loader
Design hardware that can be mounted in a pickup truck bed that
allows one person to load and unload an ATV into the truck.
PROBLEM 25.8 Paddle-powered boat
Design a paddle-powered boat with a rudder system.
PROBLEM 25.9 Enclosed wheel lock
Design a lockable device to enclose the wheel of a boat trailer or
utility trailer to keep the wheel from being stolen.
PROBLEM 25.10 Manual can crusher
Design a manual can crusher with an ejection system. This
crusher is used to crush standard metal cans for recycling.
PROBLEM 25.11 Electric-powered can crusher
Redesign Problem 25.10 as an electric-powered can crusher with
an ejection system.
PROBLEM 25.12 Double-deck trailer
Design a double-deck trailer that can be used to load two ATVs,
one above the other.
PROBLEM 25.13 Pop-up target system
Design a pop-up target system that automatically resets itself for
target-shooting enthusiasts.
PROBLEM 25.14 Appliance dolly
Design an appliance dolly, powered or unpowered, that makes it
easier to use on stairs than a conventional dolly.
PROBLEM 25.15 Skateboard trucks
Design skateboard trucks to your own specifications in 150, 200,
or 250 mm as desired. Incorporate the following features:
■ durability and
■ noncorrosive material.
PROBLEM 25.16 Stock car roll cage
Design a stock car roll cage that enhances driver protection,
comfort, and ease of escape.
PROBLEM 25.17 Bicycle helmet
Design a bicycle helmet with the following general
characteristics:
■ lightweight and impact-resistant material;
■ three variable size groups for children, adolescents, and
adults;
■ aerodynamic; and
■ shock resistant.
PROBLEM 25.18 Bicycle seat
Design a bicycle seat with the following general characteristics:
■ wide for maximum comfort,
■ fits any standard bicycle seat shaft, and
■ absorbs shock for a smooth ride.
PROBLEM 25.19 Golf club cart
Design a golf club cart that carries a full set of golf clubs and has
the following general features:
■ separates clubs for easy access and security;
■ storage for extra balls, tees, scorecards, and other desired
compartments;
■ large tires for stability and ease of movement;
■ folding leg to stand cart upright; and
■ backpack-style and hand-carrying features.
PROBLEM 25.20 Collapsible music stand
Design a mobile collapsible music stand that has the following
general features:
■ folds into a maximum size of 8.5 3 11 in. (215 3 280 mm),
■ adjustable height from 11 in. (215 mm) to 48 in. (1200 mm),
and
■ sturdy and lightweight construction.
PROBLEM 25.21 Mobile cappuccino store
Design a mobile cappuccino store with the following general
features:
■ mobile building with trailer hookup;
■ approximate dimensions 8 3 209 (2400 3 6000 mm);
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■ preparation facilities and storage;
■ service counter and window;
■ refrigeration unit;
■ coverings over wheels, tires, and trailer tongue;
■ modern or traditional exterior architectural style as desired;
and
■ signage.
PROBLEM 25.22 Convenience store
Design a convenience store with the following general features:
■ maximum 1500 sq ft (140 m2),
■ cold cases,
■ freezer,
■ service counter,
■ restroom, and
■ modern or traditional exterior architectural style as desired.
PROBLEM 25.23 Office and warehouse combination facility
Design an office and warehouse combination facility for a small
distribution company with the following general features:
■ office area maximum 1000 sq ft (90 m2) combined with a rest-
room and employee and guest lounge,
■ warehouse area maximum 2000 sq ft (180 m2), and
■ loading dock with large door or doors.
PROBLEM 25.24 Nutcracker
Macadamia nuts are among the toughest nuts to crack. Design a
portable nutcracker for use in cracking macadamia nuts and
other nuts without damaging the nut inside the shell or harming
the operator.
PROBLEM 25.25 Creative design
Design a product of your own creation or from the ideas gathered
from a team.
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Chapter 25
The Engineering Design Process
Solutions to End-of-Chapter Problems
Part 1: Problems 25.1 and 25.2
PROBLEM 25.1 The solution to Problem 25.1 is a written report.
Design Problems
Part 2: Problems 25.3 Through 25.24
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The project plan. This document is created by the project leader, who issues a
478
Customer research. Customer input may involve classmates, friends, and family
Create the design specification. Establish technical specifications and performance
The development phase. Construct a fully functioning prototype model. If facilities
A product bill of materials. Develop a product bill of materials to the best of your
479
Design documentation. Prepare a complete set of working drawings for the product.
The pre-production build. If facilities and skills are available, manufacture and