how to ensure your designs work
DESCRIPTION
Simple steps to ensure that Designs Works using Design Validation. Quality of a Product depends on how much time has been spent upfront at the design phase in addressing the quality objectives and validating the design for Fit, Form and Function before releasing drawingsTRANSCRIPT
How to Ensure that Your Designs Work?
EGS India
Design Validation Series ....
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Agenda
● Current Scenario
● Design Process
● Validating Design – Why & When
● Ensuring Working Design – How?
● Benefits
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Where do we stand today?
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Design Process
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Validating Design – Why & When
✔ Increases Design Confidence
✔ Improves Reliability
✔ Eliminates Errors
✔ Reduces Input Cost
✔ Assures Superior Performance
✔ Enhances Product Quality
✔ Protects Product Safety
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When to Validate a Design?
● Product Cost is Important
● Increased Profitability is a Must
● Enhanced Warranty is a Threat
● Improved Reliability is mandatory
● Green Design is in Focus to protect Environment
● Customer Satisfaction is required
● Product Development Cycle Time should be reduced
If...
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Design Validation Objectives
● Sizing
● Weight
● Cost
● Safety
● Performance (Deflection, Stresses, Vibration, Efficiency)
● Life (Warranty)
● Quality
● Sustainability
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Machine Design Validation Will any Shaft break?
What is the life expectancy of the system?
Can I meet the weight target?
Will Power consumption be more?
Will anything break under Warranty?
If I were to reduce 10% of product cost, where would I start?
Will I get vibration & noise?
Why should the customer buy my product?
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Power Train Design Validation Will my Gearing Wear out?
Will there be vibration and noise during operation?
Does the casting wall thickness need to be 22mm?
Can heat generation be kept under control?
Can I select lower sized bearings without compromising on performance?
What is the abusive load the system can handle?
Can my product be robust at the same time look sleek?
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Anti-Vibration Mounts Design Validation Can the Mount meet the
required dynamic Charateristics ?
Will the mounts meet the NVH Targets?
How does the product compare to competitive products already in market place?
Will the mount meet the tri-axial durability targets?
How to achieve the cost targets?
Will the design meet the life expectancy?
Can alternate material be used?
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Equipment Design Validation
Will my equipment pass hydro-test?
What will happen during earthquake?
Can I get pressure and velocity profiles for higher efficiency?
How can I eliminate shaft breakages?
Will my design meet ASME Code FEA requirements?
Can I achieve weight targets without compromising on safety?
Can I use alternate material?
Can I find out the load distribution?
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System Design Validation Will my system withstant burst
pressure test?
Can I reduce my BOM?
Are my pipe sizing and support adequate?
What are the possible failure modes I can expect?
Is it possible to use a smaller pump for lower power consumption?
Where are the performance bottlenecks?
Is my Design Safe?
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Machine Tool Design Validation Can Tool Vibration be
eliminated?
Can I increase tool life?
Is it possible to reduce tool change over time?
Frequent failures of tool can be prevented?
Can deflections be maintained within specified limits?
Call all forces be estimated?
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Material Handling Equipment Design Validation
Will deflections be under control?
How much material can I save?
Can I get load distribution?
Do I have acceptable Weld strength in critical locations?
What is the maximum load the structure can withstand?
Will there be vibrations during operation?
How to meet price reduction targets?
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Medical Equipment Design Validation
Will my medical device work without any stoppage?
How reliable is my product?
Will the surgeons be able to handle it without any problem?
How to keep our development costs low?
Can I avoid product recall?
Is my device safe for usage?
What is the technological edge I have over my competition?
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Pump Design Validation How efficient is my pump?
Can power consumption be reduced for the same flow characteristics?
How can we reduce product cost?
What is the MTBF for my pump?
How can I eliminate vibration problems?
How can I ensure that the bearings and seals do not fail?
How can I extend warranty without cost penalty?
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Mechanism Design Validation
Will my Design Work?
How efficient is the design?
Can I Optimize my design for least power ?
Is it possible to obtain required response time?
Where would it fail?
What is the Mean Time Between Failures?
Can my design be cost-effective?
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Corporate Social Responsibility
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Sustainability – Touching Lives
● Buy a pump that consumes more energy?● Buy an Air-conditioner that draws more current?● Live next to door to a garbage disposal centre?● Buy a washing machine that consumes more water?● Drive a noisy car?● Buy a mobile with less talk time between power
recharge?
Will anyone:
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Sustainability – Regulatory Angle
● Eco-friendly labelling of products is mandatory● Initially applicable to Refrigerators, Air-Conditioners,
Distribution Transformers, Fluorescent Lamps● Now on Electric Motors, Color TV’s, LPG Stoves have to carry
mandatory labelling
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ISO 14001:2004 – Environmental Management Systems Guidelines
An EMS meeting the requirements of ISO 14001:2004 is a management tool enabling an organization of any size or
type to:
● Identify and control the environmental impact of its activities, products or services, and to
● Improve its environmental performance continually, and to
● Implement a systematic approach to setting environmental objectives and targets, to achieving these and to demonstrating that they have been achieved.
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Environmental Impact
● Carbon Footprint
● Energy Consumed
● Air Acidification
● Water Eutrophication
Sustainability Considerations in Design
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Implementation Considerations
● Minimal Material Use● Improved Material Choices● Design for Ease of Disassembly● Product Reuse or Recycling at End of Life● Minimal Energy Consumption● Manufacture without producing Hazardous Waste● Use of Clean Technologies as a Fundamental Mindset
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Sustainability & Bottom line Profitability
Goal Benefits
Least amount of material Reduced Cost
Least amount of Energy Reduced Cost
Least amount of Resources Reduced Cost
Eco-Friendly Increased Value / USP
Smallest Carbon Footprint Incalculable Value
Recipe for Success !
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Design Validation Enables us to ...
● Innovate
● Improvise
● Indigenize
● Improve Profitability
● Give the Best to our Customers
● Be the Best Corporate Citizens
● Leave a Greener Earth for Future Generations
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