Design of Electromechanical and Combination Products: An Agile and Systems Approach

✍ Scribed by Ali Jamnia

• Publisher: CRC Press
• Year: 2023
• Tongue: English
• Leaves: 461
• Edition: 2
• Category: Library

✦ Synopsis

The second edition of this work, now with the expanded title of Design of Electromechanical and Combination Products, covers the design and development of electromechanical products, updated throughout to focus not only on an Agile Systems approach but also its application to disposables and consumables.

Providing a practical set of guidelines and thorough examination of best practices, this book focuses on cutting-edge research on sustainability of electromechanical and combination products.

Key Features

• Presents the design, development, and life cycle management of electromechanical and combination products

• Provides a practical set of guidelines and best practices for world-class design

• Explains the role of costing and pricing in product design

• Covers Design for X and its role in product life-cycle management

• Examines the dynamics of cross-functional design and product development teams

• Develops DHF and DMR as tools and inherent components of configuration management

• Includes numerous real-world examples of electromechanical and combination product designs

This book is intended for scientists, engineers, designers, and technical managers, and provides a gateway to developing a product’s design history file (DHF) and device master record (DMR). These tools enable the design team to communicate a product’s design, manufacturability, and service procedures with various cross-functional teams.

✦ Table of Contents

Cover
Half Title
Title
Copyright
Dedication
Contents
Preface
Acknowledgments
Author
Section I Front End: Product Development Lifecycle Management and Roadmap
Chapter 1 Product Lifecycle Management Models
Introduction
Product Development Models
The V-Model for Lifecycle Management
Engineering and Scientific Activities
Quality by Design
DMADV
DMIAC
V-Model, Agile and Product Development
Co-Relationship between V-Model and Agile
Traditional vs Agile Development Cycle Times
Engineering/Scientific Roadmap
Combination Products
Section II Requirements and Their Cascade
Chapter 2 Systems and Requirements
Introduction
Systems Definition
Voice of Customer and Voice of Stakeholders
Agile Personas
Developing a Persona
Common Pitfalls
Example of Personas
Document Collection and Control
Design Documents
Subsystem Design Document
Subsystem Architecture Document
Assembly Design Document
Chapter 3 Developing a Product’s Requirements
Introduction
Defining the Product to Be Developed
Measuring What Customers Need
Stories, Epics and Personas
Minimal Viable Product
Brainstorming Guidelines
Affinity Diagram
Ranking High-Level Needs
Analytical Hierarchy Process
Product Requirements Development
Translation from Needs to Requirements
Product Requirements Document
Chapter 4 Concept Development and Selection
Introduction
Quality Function Deployment
Using QFD in Product Development
Developing System Architecture and Function Diagram
Boundary and Function Diagram
Assign Functions to Subsystems
High-Level Design and Concept Selection
Pugh Matrix (A Rational Decision-Making Model)
Theory of Inventive Problem Solving (Also Known as TRIZ)
An Understanding of Function within TRIZ
Morphological Analysis
Selected Concept
Customer Alignment
Chapter 5 Initial DFMEA and Product Risk Assessment
Introduction
Initial Concept Failure Modes and Effects Analysis
Preparing for the Detailed Design
Product Risk Assessment
Hazard, Hazardous Situation, and Harm
Chapter 6 Transfer Functions
Introduction
A Closer Look at the Transfer Function
Design of Experiments
Coded Space
Chemical Reagent Case Study
Section III The Nuts and Bolts of the Design
Chapter 7 The Virtual Product
Introduction
Requirements Decomposition
Interface Issues and Functional Tolerance Concerns
Functional Tolerance Analysis
Monte Carlo Technique
Signal Response Variations
Polymer Disposables and Chemical Consumables
Stack Up Tolerance Analysis
Theory of Operation, Manufacturing Approaches, and Selection
Theory of Operation
Choosing Manufacturing Approaches
Mechanical Components
Electronics Printed Circuit Board and PCBA Production
Electromechanical Component Productions
Polymers and Chemical Consumables
Make versus Buy Decisions
Standard Parts, Reuse, and Naming Convention
File Storage and Change Control
Numerical Simulation
What-If Scenarios
Failure Analysis
Reversible Failures
Irreversible Failures
Sudden Failures
Progressive Failures
Single Point Solutions versus Distributions
Prototyping and Human Factors
Assembly or Subsystem Verification Testing
Chapter 8 Engineering Drawings and Other Design Details
Introduction
The What and How of Detailed Design
Format of a Detailed Engineering Drawing
Information Block
Tables in Engineering Drawings
Revision Table
BOM Table
Statement of Proprietary and Confidential Rights
Status Notes
Drawing Practices
ASME Standards
The Need for Standards and Its Relationship with Interchangeability
A Common Engineering Language
Case Study
Principles of Geometric Dimensioning and Tolerancing
Features
Feature Control
Datums
Requirements and Critical Design Outputs
Sources for Tolerances Specifications
Function Requirements
Assembly Requirements
Manufacturing Capability
Measurement Systems
Functional Gages
File Storage and Change Control
Emerging Concepts and MIL-STD-31000A
Chapter 9 Design for X (DfX)
Introduction
Design for Manufacturability
A Few Case Studies
Materials and Processes
DfA and Serviceability
A Few Case Studies
Case Study # 1
Case Study # 2
Case Study # 3
Case Study # 4
Printed Circuit Board Assemblies
Mistake-Proofing (Poka-Yoke)
A Few Guidelines
Standardization
Principle of Self-Help and Component Design
Ergonomics for Assembly and Service
DfM/A/S in the Design Process
Design for Reliability
Product Use Profile
Failure Modes and Mechanisms
Corrosion
Migration
Polymer Failures
Life Expectancy, Design Life, Reliability, and Failure Rate
Product Reliability Modeling
Theoretical Modeling
Reliability Testing
Reliability Allocation
Other Aspects of Reliability
Reliability Planning and Execution in Design Process
Design for Robustness
Robustness vs. Reliability
Chemical Stability and Shelf Life Studies
Section IV Preparation for Product Launch
Chapter 10 Cost Requirements Cascade and Purchasing
Introduction
Cost, Price, and Revenues
Cost of Manufacture and Its Structure
Cost Estimates
Three Case Studies
Surgical Tool Handle Costs Savings
Lessons Learned
Machining Versus Stamping
Ultrasonic Dental Scaler
Purchasing
Best Practices
Supplier Selection Process Map
Acceptable Supplier Exits
Acceptable Supplier Does Not Exist
Chapter 11 Detailed DFMEA, PFMEA, and Control Plans
Introduction
xFMEA and Design Process
Detailed DFMEA Study
Parameter Diagram
A Case Study: Ultrasonic Air-In-Line Sensor
DFMEA Team and Prework
Performing DFMEA
Item Function or Requirement
Potential Failure Modes
Potential Failure Effects
Severity
Classification
Potential Failure Causes or Mechanism
Occurrence
Prevention
Detection
Risk Priority Number
Recommended Actions
Responsibility and Target Completion Date
Actions Taken
Final RPN
Process Failure Mode and Effect Analysis
PFMEA Team and Prework
Performing PFMEA
Item Stage Process Requirement
Potential Failure Modes
Potential Failure Effects
Severity
Classification
Potential Failure Causes
Occurrence
Prevention
Detection
Risk Priority Number
Recommended Actions
Responsibility and Target Completion Date
Actions Taken
Final RPN
Control Plan
Example
Chapter 12 Design Verification, Product Validation, and Design Transfer
Introduction
Design Transfer in Product Development Model
A Successful Design Transfer Activity
Design Transfer Process
Design Verification and Product Validation
Traceability to Requirements
Verification or Validation Process
Section V More on Agile
Chapter 13 Market and Customer Changing Needs
Introduction
V-Model and Agile
Managing Market Change
Product Upgrades
Creating Product Feature Backlog
Feature Score Card
Agile Teams and Task Completion
Section VI Sustaining a Marketed Product
Chapter 14 Configuration and Change Management
Introduction
Configuration Management
CM Process
Management and Planning
Configuration Identification
Specification Identification
Change Control Forms
Details of Project Baseline
Document Control
Configuration Control
Configuration Status Accounting
Configuration Verification and Audit
CM P-Diagram
CM and CMII
Change Management and Control
Change Control Process
Chapter 15 Product Retirement and End of Life
Introduction
End of Life Assessment and Planning
Impact Assessment
Business (Marketing, Branding, and Finance)
Logistics and Distribution Channels
Operations and Design Team
End of Life Planning
Obsoleting a Product
Business Aspects
Technical Aspects
Design Team
Manufacturing
Supply Chain Management
Service
Section VII Best Practices and Guidelines
Chapter 16 Tolerance Specification and Analysis
Introduction
Tolerance Design in the V-Model
Tolerance Specifications
Example
Process Capability
Example
In a Nutshell
Tolerance Analysis
Worst Case Analysis
Electrical Circuits
Nonlinear WCA
RSS Method
Sensitivity Analysis
Example
Monte Carlo Analysis
Unintended Consequences of Tolerance Specifications
Cost-Based Tolerance Analysis
Case Study 1
Case Study 2
Case Study 3
Quality Loss Function
Example
Chapter 17 Data, Measurements, Tests and Experiments
Introduction
Noise Factors and Variations
Level of Measurement and Basic Statistics
Categorical Data
Quantitative Data
Histogram
Measures of Central Tendency
Measures of Dispersion
Population versus Sample
Measurements
Dealing with Variation in Data
Confidence Level and Power of the Test
Confidence Intervals
Sample Size
Sample Size Calculations
Comparing Two Data Sets
Measurement System Analysis
Accuracy, Precision, and Bias
Gage Repeatability and Reproducibility
A Few More Words on Variations
Tests, Experiments and Elements of a Robust Plan
Experiments
Chapter 18 Failure Analysis and Product Improvements
Introduction
Investigation Process
Failure Observation and Determination
Failure Isolation and Scope Determination
Failure Verification
Failure Analysis and Root Cause Determination
Root Causes
Corrective Actions and Verification
Effectiveness and Control
Investigation Tools and Tips
Keys to a Successful Investigation
Data Collection and Retention
Core Team
Chapter 19 Technical Reviews and Checklists
Introduction
Guidelines
Design Evaluation Checklists
Elements of a Checklist
Example 1—Developing A Checklist for PCBA Layouts
Example 2—A Checklist for Plastic Component Designs
Example 3—A Checklist for Developing Engineering Drawings
Example 4—A Checklist for Program Gate Review
Chapter 20 Technical Writing and Communication Skills
Introduction
Features of Technical Communications
Language
Purpose
Structure
Data, Information and Decision Making
Example
Technical Reports
A Few More Words on Writing
A Few Words on Presentations
Working with the Team
Draft Document
Feedback and Revision
Finalization and Approval
Closing Remarks
Appendix A What Is Agile?
Introduction
A Brief History
Agile Manifesto: Values and Principles
Agile Process: Plan-Do-Review
Roadmap and Backlog
Agile Roles and Responsibilities
Scrum and Kanban
Scrum
Kanban
Agile Project Management
Reported Metrics
Agile Leadership
Corporate Culture and Agile
Appendix B A Case Study for Employing Agile Methodology
Introduction
Nuances of Hardware Development
Hardware vs. Software Development
Team Makeup, Scrum, and Integration
Reliability Testing Using Agile Mindset
Lessons Learned
References
Index