6 Product Design - Concept Generation
6 Product Design - Concept Generation
6.Concept Generation
7.Concept Selection 8. Concept Testing 9.Product Architecture 10. Industrial Design 11.Design for Manufacturing 12.Prototyping 13.Product Development Economics
Perform Economic Analysis Benchmark Competitive Products Build and Test Models and Prototypes
Case Study
The president of a tool manufacturing company commissioned a team to develop a new hand-held nailer for the high-end consumer market. One of the several currently available pneumatic tools for the professional market is shown in Figure 1. The mission of the team was to consider broadly alternative product concepts, assuming only that the tool would employ conventional nails as the basic fastening technology. After identifying a set of customer needs and establishing target product specification, the team faced the following questions:
Power Nailer
What existing solution concepts, if any, could be successfully adapted for ` this application? What new concepts might satisfy the established needs and specifications? What methods can be used to facilitate the concept generation process? A product concept is an approximate description of the technology, working principle, and form of the product. It is concise description of how the product will satisfy the customer needs. A concept is usually expressed as a sketch or as a rough 3- dimensional model and is often accompanied by a brief textual description. The underlying goal of concept generation is to develop as many ideas as possible.
2. Search Externally Lead Users Experts Patents Literature Benchmarking Existing Concepts
4. Explore Systematically Classification Tree Integrated Solutions 5. Reflect on the Solutions and the Process Constructive Feedback
New Concepts
Based on the assumptions, the team had identified the customer needs for a hand-held nailer. These include: The nailer insert nails in rapid succession. The nailer is lightweight.
These basic needs were subsequently translated into target product specifications. The target specifications included the following: Nail lengths from 50 millimeters to 75millimeters. Maximum nailing energy of 80 joules per nail. Nailing forces of up to 2000 newtons. Peak nailing rate of one nail per second. Average nailing rate of four nails per minute. Ability to inert nails between standard stud/joists (368 millimeter opening). Tool mass less than 4 kilograms. Maximum trigger delay of 0.25 seconds.
Material (nails)
Signal (tool "trip")
Hand-held nailer
Signal (?)
The next step in functional decomposition is to divide the single black box into sub functions to create a more specific description of what the elements of the product might do. This is done in order to implement the overall function of the product. Each sub function can generally be further divided into even simpler sub functions. The division process is repeated until the team members agree that each sub function is simple enough to work with. The end result is shown below
Energy
Store or Accept External energy Store nails Convert Energy to Translation energy Isolate nails Apply Translational Energy to nail
Nails
Driven nail
Trip of tool
Sense trip
Trigger tool
Functional decomposition is only one of several possible ways to divide a problem into simpler sub problems. Two other approaches are described bellow:
2. Decomposition by sequence of user action For example, the nailer problem might be broken down into three user action: Moving the tool to the gross nailing position Positioning the tool precisely Triggering the tool. This approach is often useful for products with very simple technical functions involving a lot of user interaction. 3. Decomposition by key customer needs For the nailer, this decomposition might include the following sub problem: Free nails in rapid succession Fits in tight places Has a large nail capacity This approach is often useful for products in which form, and not working principles or technology, is the primary problem. Examples of such products include toothbrushes (assuming the basic brush concept is retained) and storage containers.
Concept classification tree is used to systematic exploration of concept solutions. The classification tree helps the team divide the possible solutions into independent categories.
Concept Classification Tree The concept classification tree is used to divide the entire space of possible solutions into several distinct classes which will facilitate comparison and pruning. An example of a tree for the nailer example is shown in the Figure. The branches of this tree correspond to different energy sources. The classification tree provides following important benefits:
1. Pruning of less promising branches If by studying the classification tree the team is able to identify a solution approach that does not appear to have much merit, then this approach be pruned and the team can focus its attention on the more promising branches of the tree. 2. Identification of independent approaches to the problem Each branch of the tree can be considered a different approach to solving the overall problem. Some of these approaches may be almost completely independent of each other. In these cases, the team can cleanly divide its efforts among two or more individuals or task forces. 3. Exposure of inappropriate emphasis on certain branches Once the tree is constructed, the team is able to reflect quickly on whether the effort applied to each branch has been appropriately allocated.