ENME472: Integrated Product and Process Development

• To experience many aspects of the design process and demonstrate competence in the skills required to participate successfully in this team process
• To develop a comprehensive understanding of how to use the design and analysis methods and tools acquired throughout the Mechanical Engineering curriculum (e.g., CAD drawing, costing, manufacturing knowledge).
• To produce a working, functional prototype of the product’s key mechanical system(s) and demonstrate how it satisfies all aspects of functionality while meeting identified customer requirements.
• To produce a complete description of the final design project, including detailed analysis and plans for production of CTQ systems; an estimate of the life cycle cost; and set of engineering drawings.
• To record details of the reasoning applied to arrive at the final product in sufficient detail so that a subsequent team could continue the process.
• To refine personal design philosophy, including preferences in technical, social, and ethical matters) to guide future practice.

The mechanical design process is the articulation of a physical artifact to satisfy a particular need. The product realization activities include determining customer (user) requirements and product characteristics necessary for satisfaction, quality, reliability, manufacturing methods and material selection, assembly, cost, environmental concerns, and safety regulations, and more. Successful product development requires formulating the design challenge correctly and generating an initial design specification before focusing on creating solutions. After the problem is defined, the method requires that possible solutions are first generated and then evaluated against a selection of quantifiable attributes based on the users' requirements and other criteria. The team selects from a set of candidate embodiments one that will best satisfy the objectives and constraints. Lastly, a detailed plan is developed that clearly shows how the design will be produced and how the methods chosen to produce it will insure a product that meets the users' requirements and makes a profit for the company. This requires continuous focus on the functionality and features that assure engineering performance and customer satisfaction. Topics covered include:

• Engineering design and PDP
• Market analysis and problem identification
• Setting design parameters; PDS
• Concept generation
• Human factors design and evaluation
• Design documentation
• Embodiment, configuration, and parametric design
• Detail design
• Materials selection and manufacturing processes
• Concept selection – Pugh analysis; Analytical Hierarchy Process
• Failure Modes and Effects Analysis
• Machine element design
• DFM, DFA, DFX, Design for Reliability
• Cost analysis
• Ethics
• Intellectual property