4.

SUCCESSFUL AND APPRECIABLE DESIGN

The design of a product and its production require a number of activities.

The following steps have often been suggested:-

1. Create product ideas by searching for consumer needs and screening the various
alternatives.
2. Select the product on the basis of various considerations, including data from market and
economic analysis and make a general feasibility study.
3. Prepare a preliminary design by evaluating various alternatives, taking into consideration
reliability, quality, and maintenance requirements.
4. Reach a final decision by developing, testing and simulating the processes to see if they
work.
5. Decide whether the enterprises current facilities are adequate or if new or modified
facilities are required.
6. Select the process for producing the product; consider the technology and method
available.
7. After the product is designed, prepare the layout of the facilities to be used. Plan the
system of production, and schedule the various things that must be done.

SELECTION OF BEST DESIGN

A. A product designed for proper functioning is essential aspect. Each element in the
product is to function properly as required and in co-ordination with other element. In
modern design practice certain strategies used by product designers for engineering
products are :-
1. Biasing: - Biasing comprises presenting members of machine parts at no load in such
a way that when actual external loads are imposed during working, the resultant stress
in the member becomes zero. For example: - the spokes of a bicycle wheel are put in
tension and the air pressure introduces hoop tension in the walls of tube and tyre.
Under actual loading, which is compressive in nature, the resultant stresses in the
spokes and tube walls tend to zero or very small in magnitude. (Students are to seek
more examples of biasing)
2. Cascading or Stage formation: - Use the multiple blades of fans, multiple stages in
pump and compressors are examples, where use of multiple elements results in
greater output from the machine.
3. Regeneration:-Regeneration is based on the principle, Never waste anything of
value. Examples of effective regeneration are use of exhaust gases for preheating the
incoming fuel, application of waste heat in heat exchangers for preheating incoming
fluidetc.
 4. Avoiding Redundancy: - Designers employ the kinematic design principle of
avoiding redundancy. This is particularly useful in designing structures and
mechanisms. In a structure, the number of members should be exactly the same as the
number of members essential for fulfilling the functional requirement. For example: -
A three legged stool is very stable because three points of support are provided,
which completely define a unique plane surface. Such a stool is stable even on a
rough plane. A four legged stool can be stable only on a perfectly flat surface.
5. Compatibility and matching considerations in product design: - Many design systems
include a power developing device a motor, an engine or a human being. At the
load end, are seen a power absorbing device, a pump, a propeller,etc. it is essential
to determine an operating point for a design system for which both the power
developing device and the power absorbing device will work. If a unique is not
obtained, the system will fail to function and is deemed to be incompatible. A
designers role is to determine the correct operating point. For this purpose,
characteristic curves of power developing and power absorbing devices should be
known or modeled.
Example: - Bicycle rider and bicycle the force that can be comfortably produced by
the rider at the rear wheel when in slop, steep climb, bad road. Or the power of the
motor, the speed of the motor, the rotation of the lead screw, the rotation of the shaft
need to be compatible for proper screw cutting process.

B. Aesthetics
The appearance of a product is the total visual effect produced by structure, form,
material, dimension and surface finish including color. Form refers to the profile of the
product. Appearance can only be judged subjectively and there is no yardstick for
expressing it subjectively. Beauty and ugly are two words to express aesthetic validity. A
discordant, shoddy, incomplete product can be immediately labeled as ugly. Unity and
order are most essential for a product to be classed as aesthetic.
1. Unity: - A product must appear as a finished, complete unit, and its separate elements
and details harmonized in a logical way. There must be no elements that appear as if
they are
Superfluous and cause surprise. It will also offend the eye if the product has some
part missing.
2. Order: - Order refers to repetition of patterns with a suitable break of monotony.
3. Psychology: - The eye is used to perceive vertical and horizontal as the main visual
directions, and it is natural to think in terms of these directions. Any two lines other
than those at right angles offend the eye. Examples: - House wiring, Flag post.
4. Ease of production: - Faces right angles to each other are easy for production.
Products with basic forms are easy to digest. Examples: - Square, Rectangle,
Cylindricaletc.
 5. Balance: - The idea of group formation is fundamental to our visual perception. If we
study a number of elements in a group, we see that they interact with each other apart
from just appearing to be together. It will be felt that the elements are visually in
balance. A visual balance may be achieved by symmetry. ( examples :- arranging bath
room tiles, windows of the car to match with the shape of the car)
6. Elegance and rhythm: - Rhythm based on varying the direction of distinct angle of the
element can also be a powerful tool in providing a dynamic effect on the product. The
shape of windows and doors in a car gives rise to the system of lines which they form.
The arrangement, shape and angle of the lines together form a pleasing and aesthetic
rhythm which varies for different cars.
7. Proportion: - One of the most important parameter that conveys the overall
impression is the proportion of the object. Proportion and beauty go hand in hand.
Proportions such as 2:3, 3:5 and 6:8 are applied in many areas. Examples are: - Text
books, Houses, Mandala.
8. Joints exposed may be pleasing or unpleasing :- (a) the elements are so designed that
the joint on the whole is unnoticed. (b) The joint is emphasized and deliberately used
as part of the form characteristic of the product.
9. Product message :- (a) Lightness: - Change the form to make product lighter and
attractive. Examples: - Mobile Phone or computer. (b) Stability and Weight The
means that can be expressed as stability and weight through the form aim at placing
the center of gravity in the lowest feasible position. Heavy curves are useful to
convey such an effect.

C. Appropriateness of Technology used in design

To judge the appropriateness the following points must be put into question on designed
product
1. Design establishes and defines solutions to and pertain structures for problems not
solved before, or new solutions to problems which have previously been solved in a
different way.
2. The design included both science and art.
3. The design and the product are produced to satisfy a need that someone has. It is
something that has not always existed; instead it is created expressly to satisfy a need.
4. Is the product robust and reliable?
5. The product must have high utility value, utility is a good measure of economic
worthiness of a product.
6. Is the product as safe as they can possible be; safe, according to industry-wise
standards; safe, if used in the manner and situations specified in the instructions; safe,
for a child who may behave impulsively.
 7. Is the product (design) a defect-free or fail-safe design that will not lead to
accidents, in case of functional failure. Examples are in power steering system in
automobile even it fails the vehicle can be handled manually. Or if electric supply is
interrupted there is stand- by generator to operate in cable car.
8. Is the design compact? Compact design conserves material, reduces storage and
transportation costs and is user friendly.
9. Is the product environmental friendly while in use and after retirement. Does not
pollute air, water and soil? What is the percent of elements in the product as bio-
degradable, non-bio-degradable and recyclable?
10. Is the product designed in such a way as to prevent hazardous use in an unintended
but foreseeable manner?
D. Ergonomics
Ergonomic design complements the human face. The products human interfaces should
be safe, easy to use, and intuitive. Each feature should be shaped so that it communicates
its function to the user.
The following are the ergonomic needs for a product:-
1. Ease of use: - Important both for frequently used product such as office photocopier
or for infrequently used product such as fire extinguisher. Ease of use is more
challenging if the product has multiple features and/ or modes of operation which
may confuse or frustrate the user. For example: Lorry cranking to start the engine
during winter. Self-starter with preheating system eased the starting problem.
2. Ease of maintenance: - If the product needs to be serviced or repaired frequently,
then ease of maintenance is crucial. The question to be asked is that if the product
communicates maintenance / repair procedures to the user. It is desirable to eliminate
the need for maintenance entirely. Example: a user should be able to clear a paper jam
in a printer or photocopier easily.
3. The number of user interaction required for the products functions: - The
minimum is desirable. Example: A door knob requires only one interaction and a
portable computer may require a dozen or more and in this case each interaction may
require a different design approach and / or additional research.
4. Novel user interface: A more novel user interface may require substantial research
and feasibility studies.
5. Safety issues: The safety concerns in the design of a childs toy are much more
prominent than those for new computer mouse.
E. Innovation

Following a scientific discovery, a new body of technical knowledge develops rapidly;

the proper use of this discovery may result in an almost complete deviation from past
practice. Every skill, which the designer or the design team can muster in analysis and
synthesis, is instrumental in a totally novel design. The following questions are answered.
1. Is the design and product development according to Product Development Process?
Under which category the innovation is designed?
(a) Generic (Market pull) products: - designers begin with a market opportunity and
selects appropriate technologies to meet customer needs. Examples: - sporting
goods, furniture, tools.
(b) Technology push products: - The team begins with a new technology, then finds
an appropriate market. Example: - Chip - stick.
(c) Platform products: - The design team assumes that the new product will be built
around an established technological sub-system such as consumer electronic build
up for computers and printers.
(d) Process intensive products: - The characteristics of the product are highly
constrained by the production process. Examples are snack foods, breakfast
cereals, chemicals.
(e) Customized products: - New products are slight variations of existing
configurations. Examples are motors of various capacities for different power
input. Containers of different shapes, capacities and sealing systems
(f) High risk products: - these products face high risks of failure due to technical and
market uncertainties. Examples are pharmaceuticals, space systems.
(g) Quick- build products: - Rapid modeling and prototyping technology enabled
many designs progress very fast in design build test cycles to final production
stage. Examples are software, cellular phones.
(h) Complex systems: - For complete product production system, subsystems for
required components are created to bring to final product. Examples are airplanes,
jet engines, automobiles.

2. Is the design and product development according to Industrial Design Process?

(a) Technology driven products: - The primary characteristic is that its core benefit is
based on its technology, or its ability to accomplish a specific technical task.
While such a product may still have important aesthetic or ergonomic
requirements, consumer will most likely purchase a product primarily for its
technical performance. Example: - hard disc drive for a computer.
(b) User driven products: - The core benefit of a user driven product is derived from
the functionality of its interface and / or its aesthetic appeal. Typically there is a
 high degree of its user interaction for these products. Accordingly the user
interface must be safe, easy to use, and easy to maintain. The products external
appearance is often important to differentiate the product and to create pride of
ownership. Example: - Office chair.

Examples of products that can be categorized from user driven products to technology driven products are:

1. Office Chair FROM User driven Products

2. Coffee maker

3. Wrist watch

4. Camera (Justify this ranking with reasons.)

5. Automobile

6. Lap top computer

7. Cellular phone

8. Hard disc drive

9. Super Computer TO Technology driven Products.

Questions

1. Explain all the three principal and inter-related elements to be considered for a complete
product design. Why is it important?
2. Explain the necessities about the factors mentioned below for to make the product
excellent :-
(a) Avoiding redundancy
(b) Compatibility and matching considerations
(c) Balance for aesthetics
(d) Fail safe design
(e) Biasing
(f) Ease of use and maintenance
3. Compare and explain with suitable examples for the following :-
(a) Technology driven and user driven products.
(b) Aesthetics and ergonomics aspects for product design
(c) Compatibility and matching considerations in product design.
4. Examples, problems and case studies on the topic.