Product design and development questions and answers PDF

DEPARTMENT OF MECHANICAL ENGINEERING

QUESTION BANK

V SEMESTER

OMF 551 / PRODUCT DESIGN AND DEVELOPEMENT

Regulation – 2017

Academic Year 2019 – 20

Prepared by

Mr.R – AP (Sr) / Mechanical

DEPARTMENT OF MECHANICAL ENGINEERING QUESTION BANK SUBJECT: OMF 551/ PRODUCT DESIGN AND DEVELOPEMENT SEM / YEAR: V / III

UNIT I

INTRODUCTION

Need for IPPD-Strategic importance of Product development - integration of customer, designer, material supplier and process planner, Competitor and customer - behavior analysis. Understanding customer- promoting customer understanding-involve customer in development and managing requirements - Organization process management and improvement. Plan and establish product specifications.

PART – A 2 Marks

Q Questions BT Level Competence 1. List the need for IPPD. BTL1 Remembering 2. Explain the importance of Product development. BTL2 Understanding 3. Define customer focus. BTL1 Remembering 4. Explain briefly concurrent development of product and process. BTL1 Remembering 5. Define product strategy. BTL2 Understanding 6. Describe the importance of product strategy. BTL1 Remembering 7. Explain briefly the elements involved in product strategy. BTL2 Understanding 8. Draw the basic process flow chart for IPPD. BTL2 Understanding 9. Summarize the steps involved in customer involvement. BTL2 Understanding 10. Define supplier integration. BTL1 Understanding 11. Interpret the life cycle plant. BTL2 Applying 12. Infer supplier assessments. BTL5 Applying 13. List the basic steps in supplier assessments. BTL1 Applying 14. Define Product ideas. BTL1 Remembering 15. Demonstrate Behavior analysis. BTL3 Understanding 16. Illustrate down basic planning methods in IPPD. BTL3 Applying 17. State the benefits of IPPD. BTL1 Understanding

1. Explain the Needs of organization process management. BTL4 Evaluating
2. Define ram-up. BTL1 Applying
3. Select the best training method in IPPD. BTL4 Creating

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1. Judge the importance of producing recyclable products in an eco- friendly production system.

BTL-4 Analyzing

1. Analyze a type of development process suitable for successful residential air-conditioning units.

BTL-4 Analyzing

1. Create a product-technology roadmap illustrating the availability of technologies for a class of products you understand well, such as personal computers.

BTL-4 Analyzing

UNIT II CONCEPT GENERATION, SELECTION AND TESTING

Task - Structured approaches - clarification – search externally and internally-Explore systematically - reflect on the solutions and processes - concept selection -methodology-- benefits.

PART-A 2 Marks

1 Prepare the road map for concept generation process. BTL-1 Remembering

2 Prepare the flow chart for concept generation. BTL-1 Remembering 3 Give the basic methods involved in concept Generation. BTL-2 Understanding 4 Explain the clarification of problems. BTL-4 Understanding 5 Describe the external approach in concept generation. BTL2 Understanding 6 Infer the internal approach in concept generation. BTL2 Understanding

7 Explain the problems that can be explored in concept generation process. BTL-2 Understanding

8 List different methods in explore technique. BTL-1 Remembering 9 Define Bench mark. BTL-1 Remembering 10 Define Team work. BTL-1 Remembering 11 Summarize the concept classification tree approach. BTL-2 Understanding 12 Summarize the concept classification table approach. BTL- 4 Applying 13 Define concept selection. BTL-1 Remembering 14 Draw the flowchart for concept selection. BTL-2 Understanding 15 Give the basic methods of concept selection. BTL-2 Understanding 16 Tabulate the measurement technique involved in concept selection. BTL-2 Understanding 17 Discuss survey formats in testing. BTL-1 Remembering 18 Define concept scoring. BTL-1 Remembering 19 Interpret the product performance in concept testing BTL-5 Analyzing 20 Explain concept testing briefly. BTL-1 Remembering

PART -B 13 Marks

1. (i) Describe the activity of concept generation in a cordless electric roofing nailer. (08) (ii) Explain the relative advantages and disadvantages of involving

Remembering

understanding

Telephone

Electronic Mail

Postal Mail Internet

Face-to- Face Verbal descriptionSketch • •• •• •• •• Photo or renderingStoryboard •• •• •• •• VideoSimulation •• •• Interactive multimediaPhysical appearance model • •• Working prototype •

Enumerate the significance of above table, for concept communication of a SUV. (13)

BTL-2 Understanding

1. Roughly estimate assumptions N for the following products. List your

(i) A sleeping pillow for air travelers. (7) (ii) An electronic weather station (monitoring temperature, humidity, etc.) for homes. (6)

BTL-6 Evaluating

PART–C 15 Marks

Compose the problem of designing a barbecue grill. Try a functional decomposition as well as a decomposition based on the user interactions with the product.

Understanding

Prepare an external - search plan for the problem of permanently applying serial numbers to plastic products.

Evaluating

When might it not be advantageous to communicate the product concept to potential customers using a working prototype? Under what circumstances is it better to use some other format?

Analyzing

4 Explain how should a company align the concept generation, selection and testing process, when a CNC job is outsourced to a design consultancy.

Evaluating

UNIT-III PRODUCT ARCHITECTURE

Implications - Product change - variety - component standardization - product performance - manufacturability -Product development management - establishing the architecture - creation - clustering - geometric layout development - Fundamental and incidental interactions - related system level design issues - secondary systems -architecture of the chunks - creating detailed interface specifications.

PART A 2Marks

1. Define product architecture. BTL-1 Remembering
2. Write short notes on chunks. BTL-1 Remembering
3. Interpret Modularity in product architecture. BTL-2 Understanding
4. Give a few illustrations for chunks. BTL-2 Understanding
5. List the types of modularity. BTL-1 Remembering
6. Illustrate slot modular architecture. BTL-2 Understanding
7. Interpret the bus modular architecture. BTL-2 Understanding
8. Describe the section modularity briefly. BTL-2 Understanding
9. List the need for interfacing chunkss. BTL-1 Remembering 10 Define product variety. BTL-1 Remembering 11 Express the Product changes. BTL-2 Understanding 12 Define Manufacturability. BTL-1 Remembering 13 List out the need for component standardization. BTL-1 Remembering 14 Express the need for Product development management. BTL-2 Applying 15 Define add-on. BTL-1 Remembering 16 Define upgrade. BTL-1 Remembering 17 Explain the steps involved in establishing product architecture. BTL-1 Remembering 18 Explain the two categories of integration process. BTL-1 Remembering 19 Enumerate the secondary system. BTL-5 Applying 20 Assess the design issues in PA. BTL-5 Applying

12 Compare differentiation plan and commonality plan, for a CNC milling machine. (13) BTL-3 Comparing 13 Give short notes on, (i)Functionality of Chunks (07) (ii) Platform Planning (06)

Remembering

Remembering

14 Give short notes on, (i)Manufacturability and DFM issues (07) (ii) Schematic of a product. (06)

Remembering

Remembering

PART C 15 Marks

1 Plan a schematic for a wrist watch, using only functional elements. (without assuming any particular physical working principles or components).

BTL-5 Analyzing

Draw a schematic of a small electromechanical product including the essential functional elements Formulate a schematic including the essential functional elements. Identify two or three possible clustering’s of these elements into chunks.

Analyzing

3 Judge - A firm cannot achieve high product variety without a modular product architecture.

BTL-5 Analyzing

Explain how product architecture will differ for a product (bicycle) developed for an economically lower segment of market vis-a-vis the same product (bicycle) developed for upper segment of market.

Analyzing

Compare the slot modular architecture, bus modular architecture and section Modular architecture. (13)

BTL-3 Comparing

11 Component standardization affects the degree of product variety - Analyze the statement and give justification. (13)

BTL-5 Analyzing

UNIT IV INDUSTRIAL DESIGN

Integrate process design - Managing costs - Robust design - Integrating CAE, CAD, CAM tools – Simulating product performance and manufacturing processes electronically - Need for industrial design- impact – design process - investigation of customer needs - conceptualization- refinement - management of the industrial design process - technology driven products - user - driven products - assessing the quality of industrial design.

PART A 2 Marks

1 Define industrial design. BTL-1 Remembering 2 List the steps involved in integrated process design. BTL-1 Remembering 3 List out the need for customer focus. BTL-1 Remembering 4 Express the function of cost management. BTL-1 Remembering 5 Define robust design. BTL-1 Remembering 6 Interpret the use of integrating CAE/CAD/CAM. BTL-4 Analyzing 7 Explain briefly the need for industrial design. BTL-1 Remembering 8 List the investigation methods used to infer customer needs. BTL-2 Understanding 9 Define customer satisfaction. BTL-1 Remembering 10 Express the block diagram for Managing cost. BTL-1 Remembering 11 Illustrate product differentiation. BTL-2 Understanding 12 Infer the importance of management in industrial design process.

BTL-6 Creating

13 Summarize the different driven technique used in management design.

BTL-1 Remembering

14 Explain briefly technology driven products. BTL-2 Understanding 15 List out few user driven products. BTL-2 Understanding 16 Define conceptualization. BTL-5 Evaluating 17 Analyze the role of an user in Industrial design. BTL-5 Analyzing 18 What is the need for assessment of quality in industrial design? BTL-5 Evaluating 19 Generalize the product refinement process. BTL-6 Creating 20 List the steps in AQID. BTL-6 Creating

Explain the role of Investigation of customer needs and conceptualization in evolution of the RAZR concept. (13) BTL-3 Comparing

9 Give short notes on, (i)Refinement and Final Concept Selection (06)

(ii) The Impact of Computer-Based Tools on ID Process. (07)

Remembering Remembering 10 Compare technology-driven products and user- driven products. Also list out the corresponding merits and demerits. (13)

BTL-3 Comparing

11 Coordination with EngineeriVendors are essential for ID. ng, Manufacturing, and External - Analyze the statement and give justification. (13)

BTL-5 Analyzing

12 Compare the assessment of Industrial Design quality with continuous quality control systems. (13)

BTL-3 Comparing

Give short notes on,

(i) Quality of the User Interface (07)

(ii) Emotional appeal (06)

Remembering Remembering

14

Give short notes on, (i)Appropriate use of resources. (07) (ii) Product differentiation. (06)

Remembering Remembering

PART C (15 Marks)

List some firms that you feel have a strong corporate identity. What aspects of their products helped to develop this identity? BTL-4 Analyzing

2

Design the product form both "from the inside out” and "from the outside in" for a simple product such as stapler, a telephone and decide.

Evaluating

-3 The term visual equity is sometimes used to refer to the value of the distinctive appearance of a firm’s products. How is such equity obtained? Can it be “purchased” over a short time period, or does it accrue slowly?

BTL-4 Analyzing

By what cause-and-effect mechanism does ID affect a product’s manufacturing cost? Under what conditions would ID increase or decrease manufacturing cost?

Evaluating

UNIT V DESIGN FOR MANUFACTURING AND PRODUCT

DEVELOPMENT

Definition - Estimation of Manufacturing cost-reducing the component costs and assembly costs – Minimize system complexity - Prototype basics - Principles of prototyping - Planning for prototypes - Economic Analysis

• Understanding and representing tasks-baseline project planning - accelerating the project-project execution.

PART A 2 Marks

1 Define DFM. BTL-1 Remembering 2 List the steps in DFM process. BTL-1 Remembering 3 Give the main categories involved in DFM. BTL-1 Remembering 4 List the steps to reduce manufacturing cost. BTL-2 Understanding 5 Explain assembly cost briefly. BTL-1 Remembering 6 Define component cost. BTL-1 Remembering 7 List out the impact of overhead cost. BTL-2 Understanding 8 Define fixed cost. BTL-1 Remembering 9 List the steps involved in reducing assembly cost. BTL-2 Understanding 10 Discuss the economic analysis. BTL-2 Understanding 11 Explain industrial prototyping. BTL-2 Understanding 12 List out the different prototype techniques. BTL-2 Understanding 13 Summarize the benefits of complexity minimization. BTL-2 Understanding 14 List the estimation methods used in manufacturing cost. BTL-2 Understanding 15 Interpret the steps involved in prototype design. BTL-4 Analyzing 16 Illustrate the basic principle of base line project planning. BTL-4 Analyzing 17 Infer the planning steps involved in task representation. BTL-2 understanding 18 Assess the different types of economic analysis. BTL-4 Analyzing 19 Assess the quantitative analysis in quality control. BTL-4 Analyzing 20 Define project execution. BTL-1 Remembering

PART B 13 Marks

1 Consider the following 5 “design rules” for electromechanical products. Do these seem like reasonable guidelines? Under what circumstances could one rule conflict with another one? How should such a trade-off be settled? a) Minimize parts count. b) Use modular assembly.

BTL-4 Analyzing

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8 Can you think of successful products that never would have been developed if their creators had relied exclusively on a quantitative financial model to justify their efforts? Do these products share any characteristics? (13 )

BTL-4 Analyzing

One model of the impact of a delay in product introduction is that sales are simply shifted later in time. Another model is that some of the sales are pushed beyond the “window of opportunity” and are lost forever. Can you suggest other models for the implications of an extension of product development time? Is such an extension ever beneficial? (13)

Applying

Explain the following, (i) Methods for accelerating the projects. (06) (ii) Need for quantitative analysis. (07)

Understanding Understanding

11

What would you expect to be some of the characteristics of individuals who successfully lead project teams? Explain them in detail. (13)

Remembering

Explain the following, (i) Economic analysis. (06) (ii) Project execution (07)

Understanding Understanding

13

Under what conditions might efforts to accelerate a product development project also lead to increased product quality and/or decreased product manufacturing costs? Under what conditions might these attributes of the product deteriorate when the proj- ect is accelerated? (13)

BTL-4 Analyzing

14 When a task on the critical path (e., the fabrication of a mold) is delayed, the completion of the entire project is delayed, even though the total amount of work required to complete the project may remain the same. How would you expect such a delay to impact the total cost of the project? (13)

BTL-3 Applying

PART C 15 Marks

Evaluate the production cost for a simple product you may have purchased such as pen or a baby's toy of 10 no. The upper bound for the estimation including overhead can be taken as the wholesale rate is 50% to 70% of retail. BTL- Analyzing

Compose some potential cost-reducing modifications you could make to improve the product cost for simple product such as pen or baby’s toy. Compute the DFA index before and after these changes.

Evaluating

Summarize the reasons why reducing the number of parts in a product might reduce production costs. Also explain some reasons why costs might increase.

Analyzing

4 A furniture manufacturer is considering a line of seating products to be fabricated by cutting and bending a recycled plastic material available in large sheets. Create a prototype of at least one possible chair design by cutting and bending a sheet of paper or cardboard. (You may wish to design the chair with a sketch first, or just start working with the sheet directly.) What can you learn about the chair design from your prototype? What can’t you learn about the chair design from such a prototype?

BTL-1 Remembering

What are the 5 elements of product design?

What are product design questions?

How do you prepare for product design questions?

What three questions should you ask if you are designing a new product?