THEORY EXAMINATION (SEM–VI) 2016-17 PRODUCT DEVELOMENT & DESIGN

PRODUCT DEVELOPMENT & DESIGN (NME022)

Section-wise Solved Answers & Notes

SECTION – A (10 × 2 = 20 Marks)

Very short & precise answers

(a) Product plan

A product plan is a systematic outline that defines product objectives, target market, features, cost, and development schedule.

(b) Productivity

Productivity is the ratio of output to input, showing how efficiently resources are used.

Productivity=OutputInput\text{Productivity} = \frac{\text{Output}}{\text{Input}}Productivity=InputOutput​ 

(c) Technology-based developments

Improvements in products achieved using new technologies, such as automation, CAD/CAM, AI, and advanced materials.

(d) Economic feasibility

Economic feasibility evaluates whether a product is financially viable, considering cost, profit, and return on investment.

(e) Importance of aesthetics

Aesthetics improve visual appeal, customer attraction, brand value, and market acceptance of a product.

(f) Morphology

Morphology is the study of structure, form, and configuration of a product to generate design alternatives.

(g) Utility index

Utility index is a numerical value representing how well a design satisfies customer needs compared to alternatives.

(h) Reliability

Reliability is the probability that a product performs its intended function without failure for a specified time.

(i) MTBF

MTBF (Mean Time Between Failures) is the average time interval between consecutive failures of a repairable system.

(j) Use of Bathtub curve

The bathtub curve shows failure rate vs time, identifying:

Early failures                      Useful life                           Wear-out failures

SECTION – B (Any 5 × 10 = 50 Marks)

(a) Influence of product design on manufacturing process

Product design directly affects manufacturing by:        Selecting suitable materials

Deciding manufacturing method                                  Reducing production cost

Improving quality and productivity                               Simplifying assembly

Good design leads to easy manufacturing and low defects.

(b) Requirements of a good design                             A good design should be:

Functional                                                                    Economical

Reliable                                                                        Safe

Easy to manufacture                                                    Easy to maintain

Aesthetically pleasing                                                  Ergonomic

(c) Consequences of not using ergonomics

Ignoring ergonomics may cause:                                Operator fatigue

Health problems                                                          Reduced productivity

Increased accidents                                                      Poor product usability

(d) Brainstorming

Brainstorming is a creative group technique used to generate a large number of ideas without criticism.

Steps:                                                                         Define problem

Generate ideas freely                                                  No judgment during idea generation

Evaluate ideas later

(e) Break-even point (BEP) calculation           Break-even point is where total cost equals total revenue.

BEP (units)=Fixed CostSelling Price – Variable Cost\text{BEP (units)} = \frac{\text{Fixed Cost}}{\text{Selling Price – Variable Cost}}BEP (units)=Selling Price – Variable CostFixed Cost​

It helps in deciding minimum production quantity.

(f) Procedure for assessing design reliability

Steps:                                                                            Identify failure modes

Collect failure data                                                       Calculate reliability indices (MTBF, failure rate)

Use reliability models                                                   Improve weak components

(g) Three stages of creative design route

Problem definition – identify need                            Conceptual design – generate solutions

Detail design – finalize materials, dimensions            Example: Designing a new electric kettle.

(h) Analysis of need statement

“Community needs water”                                          This statement is too broad.

Improved need statement:                                          Quantity of water

Quality requirement                                                    Source of water

Cost and availability                                                    Purpose (drinking, irrigation, sanitation)

SECTION – C (Any 2 × 15 = 30 Marks)

Q3. New methods of design (with examples)

New design methods include:

CAD (Computer Aided Design) – faster & accurate design

CAE (Computer Aided Engineering) – simulation & analysis

DFMA (Design for Manufacturing & Assembly) – cost reduction

Concurrent engineering – parallel product development

Example: Automotive design using CAD & CAE tools.

Q4. Automatic floor washer – Function matrix

Main function:

Clean floor

Most promising solution:                                  Rotary brush + water spray + hot air blower.

(Function matrix diagram should be drawn in exam)

Q5. Techniques of decision making

Decision-making techniques include:                  Weighted ranking method

Decision matrix method                                    Cost-benefit analysis

Utility theory                                                      Decision matrix method:

List alternatives                                                     Assign weights

Score each alternative                                           Select highest score design