pd paper 2

5 stages of six sigma

Define, Measure, Analyse, Improve, Control

Accuracy

Level of conformity of a measurement to the required value

Advancements in CAD/CAM: 3D printing

Rapid prototyping

Advancements in CAD/CAM: cloud based cad/cam software packages

Software accessibility improves productivity- facilitates growth of mass customisation

Advancements in CAD/CAM: extensible markup language

Improved file compatibility with a range of software

Advancements in CAD/CAM: FEA and CFD

Simulate impact of decisions made at a design stage to facilitate improvements

Advancements in CAD/CAM: Standardised file formats

Connect CAD/CAM processes for software and hardware

Advancements in CAD/CAM: Virtual reality systems

Realistic appraisal of virtual designs in their environment

Batch production

Machines often set up to do specific tasks.
Job rotation between machinery would be used

BSI

Devises standard procedures.
Shows a standard has been met.

Council Of Industrial Design (COID) define

post-second world war British organisation. To improve design standards and competitiveness.

CPA

Critical Path Analysis.
Helps plan production.

Critical path analysis (CPA)

Management method used to schedule efficient completion stages in process.

• Sequential order of tasks.
• Unnecessary waiting times identified.
• Parallel process opportunities used to ensure maximum efficiency.

Datum

Reference surface or edge from which measurements are taken to improve accuracy.

Define 3rd party feedback

Independent view of products which is objective and unbiased.

Define a datum edge

reference surface or edge from which measurements are taken to improve accuracy.
Generated by laser levels.

Define biological nutrients

Organic non-toxic materials.
Can safely re-enter ecosystems without harming them.

Define carbon footprint

Total amount of CO2 released into atmosphere as a result of activities of individual, community, organisation.

Define circular economy

Approach that anticipates and designs biological and technical nutrients to be continuously reused at same quality. - reduces dependency on sourcing new materials.

• Delivers a more competitive UK economy.
• Works against unsustainable 'take, make, dispose' culture.

Define critical analysis

in-depth, objective study of elements of a design.

Define demographic group

a specific category of the population.

Define evaluation

Report on how effectively design meets its original specification.

Define microelectronics

small electronic devices and systems facilitated by the development of integrated circuits.

Define non-renewable resources

Oil, coal, natural gas

Define primary carbon footprint

Measures DIRECT emissions of CO2- from fossil fuels
Includes transport and domestic energy consumption

Define product recall

Removal of a product from sale and return of products to the manufacturer to rectify any faults/ errors.
I.e. recalls from current limiters in Mercedes Benz cars due to fire risk

Define profile projectors

Measure fine details such as threads to an accuracy of 0.015mm

Define renewable resources

Wind, hydro, solar, wave, geothermal, biomass

Define secondary carbon footprint

Measures indirect emissions of CO2 from the products that we use

Define technical nutrients

Man-made materials, i.e. polymers
Designed to be used continuously at high quality and with no adverse environmental effects

Define the internet of things (IoT)

Networking of multiple microelectronic devices using WiFi and the internet
E.g. smart fridges using cameras and radio frequency identification to order products as they are used

Describe the following designer: Dieter Rams.

Who was he?
What specific product did he make? Evaluate this product in terms of its good and bad features.
Who was he? German designer during post WW2, developed 10 principles of good design, simple and honest functional designs.

Product: Braun SK4 radio record player.
Innovative incorporation of thermoplastics and electronics (Good).
Highly functional (Good).
No superfluous features (no unnecessary features) (Modernism style).
Followed many iterations (Good - product tested through various prototypes to achieve an enhanced final product).

Describe the following designer: James Dyson

Who was he?
What specific product did he make? Evaluate this product in terms of its good and bad features.
Who was he? - British ´serial inventor´, technology innovator, made 1000s prototypes (fans, hair dryers, hand dryers…)

What specific product did he make? DC01 vacuum cleaner.
Bagless dual cyclone cleaning system (removes dust and dirt from main airstream into clear canister allowing for 100% suction power all the time).
Colour scheme aids use (Good, aids customers to be able to use product easier).
No suction loss (Good, improves the vacuuming of product as a whole).
Injection moulded ABS (Good, thermoplastic that is durable, can also be recycled).

Describe the following designer: Marc Newson

Who was he?
What specific product did he make? Evaluate this product in terms of its good and bad features.
Who was he? - Australian designer, designed cat walk pieces, FORM PRIORITISED, some designs influenced by origami, collaborated on Apple Watch.

Product: Lockheed lounge
Aircraft style rivit construction (metal material uncomfortable for long periods of time, bad).
Statement piece rather than functional (postmodernism) (can be good or bad).
Needed to be "more comfortable than a bus stop".
Styled off a blob of mercury.

Describe the following designer: Margret Calvert.

Who was she?
What specific product did he make? Evaluate this product in terms of its good and bad features.
Who was she? Graphic designer, developed transport and other fonts, UPDATED ROAD SIGNAGE.

Product: ´Men at work´ road sign.
Stylised pictogram (Catchy and easy to spot - Good).
SImple and clear communication of information (Good).
Modernist style.
Replaced old fashioned road signs that used text (Good, easier and more efficient).

Describe the following designer: Marianne Brandt.

Who was she?
What specific product did she make? Evaluate this product in terms of its good and bad features.
Who was she? - Bauhaus student, head of metalwork department in 1928, developed geometrically pure kitchenware, products commercially successful.

Product: Tea infuser MT49.
Typical Bauhaus design (geometrical form).
Offset lid, prevent drips (Good, functionality).
Ebony handle postioned for ease of pouring (Good, ergonomically feature).

Describe the following designer: Phillip Stark.

Who was he?
What specific product did he make? Evaluate this product in terms of its good and bad features.
Phillip Stark - French designer, post modern ideas, designer for Alessi, used modern materials and manufacture.

Product - Juicy Salic Lemon Squeezer.
Sculptural aesthetics
Leg angle stops juice running (good)
Oranges don't fit well (bad, limited use)
Pip collection not perfect (Bad)
Cost of 50 pounds (Bad - expensive for a lemon squeezer)

Describe the following designers: Charles and Ray Eames.

Who were they?
What specific product did they make? Evaluate this product in terms of its good and bad features.
Who were they? Husband and wife, creative design partnership, ideas evolved from laminated plywood leg splints, experimented with a wide range of materials.

Product: Lounge chair 670.
Combines industrial production with hand craftsmanship (Idea of movements combined).
Moulded plywood shell (standardised product, allows for quality checks).
Comfortable (Ergonomics, good).
Leather upholstery (Natural materials).

Developments in tech: Fibre injection moulding

Injection moulding - uses pellets of glass and carbon fibre filled polymers.
Parts produced are strong, stiff, lightweight - sustainable by reusing carbon fibre waste.
Aerospace parts, sports and medical equipment.

Developments in tech: Glulam

Layered timber.
Eliminates defects, good strength to weight ratio, sustainable.
Buildings, bridges, and other structures.

Developments in tech: graphene

2D microscopic carbon particles.
Rolled into thin hollow tubes, good tensile strength, hardness, heat resistance, not recyclable.
Nanoelectronic devices, battery manufacture.

Developments in tech: Kevlar

Fibre (often combined with resins).
High toughness and tensile strength, lightweight.
Bullet proof vests, aircraft construction.

Developments in tech: laser beam welding

Laser beam heat joins multiple pieces of metal together.
Faster than MIG, TIG, deep welds possible, no finishing needed, welds thin sheets.
Ship building, construction, railway equipment.

Developments in tech: physical vapour deposition

Base material vaporised and deposits a thin layer.
Durable, abrasion resistant, uniform deposition, can utilise a wide range of materials.
Food packaging, machine tool tips, decorative products.

Developments in tech: precious metal clay

Microscopic particles of metals bound together in a pliable medium.
Easily hand shaped before fired in an oven 700 degrees.
Jewellery and decorative items.

Dieter Rams 10 principles of good design (I U A U U H L D M )

Innovative
Useful
Aesthetic
Understandable
Unobtrusive
Honest
Longevity
Detail
Minimalist

Digital measuring devices

Digital vernier calipers and micrometers provide dimension readouts.
Facilitate dimensional accuracy checks in a range of situations.
Digital vernier = +-0.02mm accuracy
Digital micrometer = +-0.001mm accuracy

Forest stewardship council logo (FSC)

Timber products sourced from managed forests.
Insists use of local, fairly paid, fully trained workers in a safe environment.

Trees that are harvested must be replanted to reduce deforestation.

Idea generation method: define SCAMPER

Substitute
Combine
Adapt
Modify
Put to other use
Eliminate
Reverse

Improving accuracy

Use of datum points and edges

International organisation for standardisation ISO

Consists of 150 national standards bodies.
Facilitates products into an international market.
i.e. CE mark means product conforms to all relevant EU standards.

Iterative design

Product constantly evaluated during design process (usually by user feedback) before it is finally made as a product.

Large-scale production

(mass production of glass/ polymer bottles).

• Facilitates ' right first time and every time'.

• Machine tool maintenance, replacement, alignment procedures required.

• Mould replacement cycle used due to wear on moulds.

• Regular checks on weight and measures legislation.

• Need for high levels of skill is LOWER due to reliance on machines.

mass production

Use of automation where possible - CNC machinery.
Doesn't require highly skilled workers for product manufacture.

Medium-scale production

(Batch production of aircraft or prestige vehicles).

• Used of JIGS and fixtures.
• Use of high skill levels and measuring devices (laser micrometres).
• Facilitates 'right first time and every time'.
• CNC machinery usually used.

Non-destructive testing

1 - ultrasonic. Sound waves pulsed and different sounds indicate faults.

2 - xray. Beam passes through material and image made. Allows for checks on tiny defects such as hairline cracks in material.

On-off production

Labour intensive- primarily the domain of skilled craftsmen and manufacturers

Outline the art deco movement

When was it?
What was it mainly influenced from?
Key features/ aspects?
Artists?
When was it? Early 1900´s France

Influenced by DISCOVERY OF TUTUNKHAMUNS TOMB (1920) AND THE 1925 PARIS EXHIBITION - symbol of modernity.

Features: Symmetry, sunburst motifs, geometric shapes, ziggurat (pyramid steps - Chrysler building is a great example), repetition of shapes.

Artists:
Walter Dorwin
Clarice Cliff

Outline the arts and crafts movement

When was it?
What was it mainly influenced from?
Key features/ aspects?
Artists?
When was it? Late 19th century

Influenced by DAMAGING EFFECTS OF INDUSTRIALISATION and the appreciation of the beauty of materials, rebellion of the use of machines in manufacturing - concern that the division of Labour caused by this would end craftsmanship.

Features: Raw materials, no ornament of natural materials, hand processing, nature, gothic and medieval design.

Artists:
William Morris (textiles)

Outline the modernism Bauhaus movement

When was it?
What was it mainly influenced from?
Key features/ aspects?
Artists?
Influences from TOPOGRAPHY (Forms and land surfaces), Art Deco, concept if uniting art and industrial design, and ART NAUVEOU (inspired by nature), this was implemented quickly as much of Europe needed to be rebuilt after the war.

Features: Geometric shapes, no ornament, simplicity, clean lines, standardised materials (concrete and steel), primary colours. FORM FOLLOWS FUNCTION (focus on the function not aesthetic).

• EMBRACING THE MACHINE AGE - Mas production (everyday products for everyday people).

Artists:
Walter Gropius (Founder of Bauhaus school) - Bauhaus chairs etc…
Marcel Breuer

Outline the post-modernism Memphis movement

When was it?
What was it mainly influenced from?
Key features/ aspects?
Artists?
When was it? 1980 -87

Influenced by ART DECO AND POP ART STYLES, and was a response to the modernism movement (break away from mainstream style art).

Features: Juxtapostion of geometric shapes, bold and colourful designs (conflicting colours), challenging sculptural forms. Focus was on aesthetics rather than functionality, non traditional materials.

Artists:
Ettore Sottsass

Primary investigative techniques

First hand research:

• Market research (questionnaires, surveys)
• Interviews
• Human factors: empathetic research
• Focus groups
• Product analysis: disassembly

Production prototype

Representation of how mass-produced product would look and function - would still potentially use off the shelf components to assemble.

Proof of concept prototype

Shows key functionality + main technical aspects of design.

Quality assurance

Procedures, policies which ensure products meet spec criteria.

Quality assurance policies

• Materials and components ISO 9001.
• Checking temps correct for effective cavity filing in moulding procedures.
• Pre-production CAD modelling to check fit and assembly.
• FINITE ELEMENT ANALYSIS (FEA).
• MOULD FLOW ANALYSIS (MFA).

Quality assurance topics

Policies.
Project management systems (Total quality management, Scrum, Six Sigma, Critical path analysis).

Quality control

Monitoring, checking, testing procedures used DURING production.

Quality control measures: go/no go gauge

Check single measurement for tolerance range (pass/ fail reading).
Quicker then vernier caliper or micrometer.
No adjustment and calibration needed.

Quality control measures: Laser/ probe scanning & measuring

Coordinate measuring machinery.

• Probe scanners check pre-defined measurements of finished components.
• Accurate due to comparison with 3D CAD model.
  Non-contact lasers are non-invasive, take 1000s readings/ sec.

Quality control topics

Monitoring, checking, testing.
Tolerance.
QC methods.
Digital measuring devices.
Non-destructive testing.

Rationing

Limitation of availability of certain goods - typically in response to crisis', war…

Restriction of Hazardous Substances directive (RoHS)

Introduced in 2006.
Restricts hazardous materials: lead, mercury, cadmium in electrical products.

This is to reduce damage to human health and environment.

Scrum

Working in team to reach goals quickly.
Team goals specified and individuals feedback progress daily via feedback meetings.

Secondary investigative techniques

Online/ book research:

• Style influences: design movements
• Material, component research
• Anthropometric data

Six sigma

System to reduce defects
Monitors, assesses, improves each stage of design

Small-scale production

Crafts people making bespoke furniture

• Inaccuracies due to bespoke nature.
• High skill levels needed due to dimensional accuracy being key.
• Calipers and gauges used.
• Templates and traditional tools used (jack planes…)

Socio-economics

How society and the economy interact to create particular circumstances

Socio-economics: post 1st world war

Bauhaus design school - Marcel Breuer.
Large-scale wartime adoption of metal tubing as replacement for wood.
Tubular steel doesn't have grain issue that wood has.
Traditional handcrafting skills ignored due to machinery.

Socio-economics: 2nd world war

utility schemes targeted footwear, clothing.
Scheme led by Gordon Russel:
Furniture fulfilled basic requirements.
Designs strong, simple, fit for purpose.
Typical vernacular methods used. LOGO was CC41.

Tolerance

Acceptable upper and lower limits of accuracy of a measurement

Total quality management

Remove waste and make products right first time by continuous improvement
Workforces views, teamwork, communication prioritised
Harnesses workforces expertise

Types of measuring aids

JIGS (guide tools)
Fixtures
Templates
Gauges
Laser micrometres
CNC machines

User centred design (UCD)

Designing product to enhance user experience at its core.
I.e. ergonomics, anthropometrics, focus groups.

Most products made this way follow an iterative design process.

Utility products

post-second world war basic products that were often rationed

Visual prototype

Sample/model that shows overall shape and size of product- does not usually have any working parts

Waste from Electrical and Electronic Equipment directive (WEEE)

Introduced in 2006.
Covers end of life of electronic equipment.

[crossed out wheelie bin shows compliance].

What are the main 3 components into sustainability

• Economic
• Social
• Environmental

What did Council Of Industrial Design give way to in 1972?

Gave way to the Design Council.

• Act as govs advisory body for design
• Focus on products, user experience, and the product in the built environment.

What did Council Of Industrial Design set out to improve?
What 2 exhibitions did it hold.

Due to the drabness of utility furniture people sought exciting, fashionable, decoratively designed furniture
COID set out to improve:

• Standards in design (training)

Held:

• 1946 Britain Can Make it exhibition
• 1951 Festival of Britain

What did Marcel Breuer contribute to furniture during the Bauhaus period (post WW1 - socioeconomics)

B3 chair - paved way for industrial furniture making techniques.

What did the council of design impose from post 1972?

• Development of polymer based products = range of colours, shapes (i.e. Robin Days PP chair)
• Development of transistor saw electronic product demand rise (i.e. small radios, record players)
• Development of formed plywood furniture IKEA Lovet table, Billy bookcase.

What impact have microelectronics has on designing and manufacturing?

Use of CAD, the internet, use of CNC machines JiT Systems, 3D printing have allowed us to design and manufacture much more efficiently than before.

The use of automated scanning, digital imaging, and probe measuring allows for even more accuracy in quality control testing.

What is the iterative (cyclic) process?

Usually used in large scale manufacture.
Designs modified via refinements and evaluations being made.
(usually done through focus groups and individual feedback).
Allows for technological innovations to be made.

What types of technical developments were there for music players

Compact cassettes
CD
Laser
To music streaming

What types of technological developments were there for products (early 19th century - 2017)

Early 19th century saw electrical batteries and circuits.
Moved to transistors (portable radios)
Then Microelectronics (highly portable devices)
Large scale Integrated circuits (laptops and mobile phones)

2017: 10 trillion + transistor integrated circuits (super computers and ability for more powerful mobile devices)

When evaluating a product, why is BSI kitemarks important?

Indicates that products have certification so have achieved certain standards.