Classification and choice in product design

Life is full of difficult choices. Everyone has their own way of dealing with these, some effective, some not. The problem is particularly acute in engineering design because of the vast amount of information designers have to process. This paper deals with a subset of this set of problems: the subset of selecting materials and processes, and their links to the design of products. Even these, though, present many of the generic problems of choice, and the challenges in creating tools to assist the designer in making them. The key elements are those of classification, of indexing, of reaching decisions using incomplete data in many different formats, and of devising effective strategies for selection. This final element - that of selection strategies - poses particular challenges. Product design, as an example, is an intricate blend of the technical and (for want of a better word) the aesthetic. To meet these needs, a tool that allows selection by analysis, by analogy, by association and simply by 'browsing' is necessary. An example of such a tool, its successes and remaining challenges, will be described.

The technical potential for reducing metal requirements through lightweight product design

Metal production consumes around 10% of all global energy, so is a significant driver of climate change and other concerns about sustainability. Demand for metal is rising and forecast to double by 2050 through a combination of growing total demand from developing countries, and ongoing replacement demand in developed economies. Metal production is already extremely efficient, so the major opportunities for emissions abatement in the sector are likely to arise from material efficiency - using less new metal to meet demand for services. Therefore this paper examines the opportunity to reduce requirements for steel and aluminium by lightweight design. A set of general principles for lightweight design are proposed by way of a simple analytical example, and are then applied to five case study products which cumulatively account for 30% of global steel product output. It is shown that exploiting lightweight design opportunities for these five products alone could reduce global steel requirements by 5%, and similar savings in aluminium products could reduce global aluminium requirements by 7%. If similar savings to those in the design case studies were possible in all steel and aluminium products, total material requirements could be reduced by 25-30%. However, many of these light-weighting measures are, at present, economically unattractive, and may take many years to implement. © 2011 Elsevier B.V. All rights reserved.

Buyer-supplier partnerships during product design and development in the global automotive sector: Who invests, in what and when?

This paper explores the concept of partnerships between buyers and suppliers in the global automotive sector during product design and development. Partnerships are often the goal in a shift away from adversarial arms-length relationships. The objective of this research is to provide empirical evidence to explain the levels of mutual investment expected and achieved in partnerships from both buyer and supplier perspectives. During this research, 25 employees from 12 global supplier organisations who were in partnership with a specific vehicle manufacturer (VM) were interviewed. Twelve employees from this VM were also interviewed. The research showed the differences between partnerships and non-partnerships and the disparities in the expectations of investment from each partner. For suppliers and buyers to get the most out of partnerships, clear expectations and investments needed over time should be understood and agreed early in the relationship. © 2009 Elsevier B.V.All rights reserved.

UbiDM: A new paradigm for product design and manufacturing via ubiquitous computing technology

Since ubiquitous technology was introduced in the early 1980s, it has rapidly developed, and been applied to various domains mainly for the improvement of human life. In this article, the authors propose that ubiquitous computing technology can be effectively used for the design and manufacturing of a product by proposing a new paradigm, called UbiDM (Design and Manufacture via Ubiquitous Computing Technology). The key aspect of UbiDM is the utilisation of the entire product lifecycle information obtained via ubiquitous computing technology for the design and manufacture of the product. The new paradigm can solve many of the problems that have not been properly handled by previous manufacturing paradigms. Specifically, it will address the concept of UbiDM by the following aspects: (1) why there is a need for UbiDM; (2) the essence of UbiDM; (3) enabling technologies; (4) application area; (5) worldwide RD status; and (6) the societal impacts of UbiDM.

Using an Outdoor Learning Space to Teach Sustainability and Material Processes in HE product Design.

The world is facing environmental changes that are increasingly affecting how we think about manufacturing, the consumption of products and use of resources. Within the HE product design community, thinking and designing sustainability’ has evolved to become a natural part of the curriculum. Paradoxical as the rise in awareness of sustainability increases there is growing concern within HE product design of the loss of workshop facilities and as a consequence a demise in teaching traditional object-making skills and material experimentation. We suggest the loss of workshops and tangible ‘learning by making skills’ also creates a lost opportunity for a rich learning resource to address sustainable thinking, design and manufacture ‘praxis’ within HE design education. Furthermore, as learning spaces are frequently discussed in design research, there seems to be little focus on how the use of an outdoor environment might influence learning outcomes particularly with regard to material teaching and sustainability. This 'case study' of two jewellery workshops, used outdoor learning spaces to explore both its impact on learning outcomes and to introduce some key principles of sustainable working methodologies and practices. Academics and students mainly from Norway and Scotland collaborated on this international research project. Participants made models from disposable packaging materials, which were cast in tin, in the sand on a local beach, using found timber to create a heat source for melting the metal. This approach of using traditional making skills, materials and nature was found to be a relevant contribution to a sustainable discourse.

An industrial implementation of a methodology for the optimisation of product design tolerances

Today, the key to commercial success in manufacturing is the timely development of new products that are not only functionally fit for purpose but offer high performance and quality throughout their entire lifecycle. In principle, this demands the introduction of a fully developed and optimised product from the outset. To accomplish this, manufacturing companies must leverage existing knowledge in their current technical, manufacturing and service capabilities. This is especially true in the field of tolerance selection and application, the subject area of this research. Tolerance knowledge must be readily available and deployed as an integral part of the product development process. This paper describes a methodology and framework,currently under development in a UK manufacturer, to achieve this objective.