Project Design Reviews A design review is a formal oral assessment of design work presented

Overview of Senior Challenge Design Critiques
A design evaluate is a proper oral evaluation of design work introduced by a design workforce to an viewers of its administration, its friends, and its buyer(s). Please maintain this in thoughts:
A design evaluate is just not a progress report!
As a substitute, design evaluate function milestones and have two main functions, not essentially on this order:
(1) To tell administration of achievements of milestones (since administration has the $$)
(2) To make the design higher (and thus higher fulfill the client)
It’s not the aim of design opinions to antagonize the engineers on the design workforce or make them look dangerous, nor to construct up unhealthy ranges of tension, nor to take extreme quantities of design time away from the design workforce. Good design opinions ought to save time – not waste it. Administration pledges to work with you to ensure that your design opinions fulfill the 2 functions proven above.
The important thing to having an excellent design evaluate is to USE IT as a goal date to make vital, crucial progress in your challenge. If you happen to do the work main as much as the DR, presenting the fruits of that labor is straightforward!
Orally reviewing a design is a helpful talent for engineers. One in all our most essential targets for this class is to enhance your design evaluate talents. Please take your design opinions critically and work to enhance your abilities!
The 4 Design Critiques of ME 4293 (DRI being moved to ME4383)
Recipes for every of the 4 design opinions are discovered within the subsequent part of this handbook. A quick abstract of the primary targets of the 4 opinions follows:
DR I – Conceptual Design Evaluate (Finish of Fall Semester)
Assertion of labor Engineering specs. Bulletproof idea Prepared so as to add particulars
DR II – Preliminary Design Evaluate (Week Four-6)
Detailed design Guarantee compliance with specs. Able to construct
DR III – Prototype Design Evaluate (Week 10/11)
Functioning prototype Prepared to check
DR IV – Ultimate Design Evaluate (Week 14)
Examined and modified Able to ship
We’ve not determined but if the design opinions we’re doing this semester in ME4383 will truly be DR I or DR Ia. We’ll wait to see how these come out and announce the DR schedule after we return for the spring semester.
Every workforce should submit a written report, that summarizes what’s introduced within the design evaluate. Every report ought to have 9 sections akin to the primary 9 merchandise required for the Design Evaluate (see pages 9&10), with an appendix containing everybody’s first Particular person Progress Report (see pages 17& 18)
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How one can Put together for a Design Evaluate
Listed below are some easy ideas to ensure your design evaluate presentation hits the mark.
• Be responsive!
– cowl all of the gadgets in your evaluate that we ask you to cowl!
– be sure that you just reply to each merchandise.
– in case you are requested to point out drawings or a price range, do it!
– nothing kills your evaluate quicker than being UNresponsive.
• Watch the time!
– in a 35 minute evaluate, you get 25 minutes to current your case, with 10 minutes for questions and dialogue.
– this time will fly by. Make sure you cowl every part.
• Examine the tech!
Few issues will make you look sillier than if a few of your software program or hardware malfunctions or is lacking! All the time make certain every part is current and dealing correctly earlier than your design evaluate begins:
– pc/projection methods
– digital recordsdata (on server and on detachable media – backups are good!)
– video clips embedded in your presentation
– different digital gadgets (as wanted)
– show-and-tell gadgets (hardware, fashions, and so on.)
– pointers and white board markers (for answering questions)
• See and be seen!
– use a minimal font dimension of 18 – even on graphs
– label graphs accurately and maintain them SIMPLE!
– create slides that may be coated in 60 seconds or much less
• Handouts!
– put together six copies of your slides (6 slides per web page) for school and guests.
– embody your most essential slides (drawings, price range, and so on.) within the handout bundle. – – it’s okay if you want to change some slides after you’ve got printed these handout packages – no drawback, we will take care of it!
• Apply!
– at all times commit one assembly previous to your design evaluate to preparation and observe.
– determine which workforce members will cowl which areas throughout your evaluate
– undergo a dry run of the formal a part of your design evaluate
• Showtime!
– at all times face the viewers
– preserve eye contact
– communicate to the parents on the again row
– get fired up, and present it (for those who do not, who will?)
– Act like a workforce – not only a group of engineers pressured to work on the identical challenge
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Examples of Good (high) and Dangerous (backside) Slides
What are slides for?
Keep in mind, there are actually solely two the reason why we use slides after we give talks:
(1) To assist the viewers perceive our story.
Slide High quality vs. Viewers Comprehension
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Slide High quality
Viewers Comprehension
GRAPH SHOWING THE QUALITY OF THE SLIDE VERSUS THE AUDIENCE COMPREHENSION
OF THE AUDIENCE
zero.00000000E+00
1.00000000E+01
2.00000000E+01
Three.00000000E+01
Four.00000000E+01
5.00000000E+01
6.00000000E+01
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eight.00000000E+01
9.00000000E+01
1.00000000E+02
zero 20 40 60 80 100 120
Comprehension
Hey! Good slide!
Yuk! Terrible slide!
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(2) To maintain us on observe and assist us keep in mind the factors we have to make.
All the time maintain these two issues in thoughts as you put together your slides.
While you current a graph, do the next each single time:
1. Clarify what’s being graphed. Say, “It is a graph of slide high quality versus viewers comprehension…” Then…
2. Clarify the x-axis and vary: “The x-axis exhibits slide high quality from zero to 100.” Then…
Three. Clarify the y-axis and vary: “The y-axis exhibits viewers comprehension from zero to 100.” Then…
Four. Clarify the pattern: “The graph exhibits that as the standard of the slide goes up, so does the viewers’s comprehension of that slide…”
Get within the behavior of following these 4 steps if you current graphs – you’ll be glad you probably did, and so will your viewers!
Structure and Fashion
Restrict your self to 1 or two fonts. Use a robust readable typeface – daring normally works finest.
Make titles and textual content with the identical dimension relationship all through your present. Maintain the dimensions of physique textual content to 24 factors or bigger, make headers 30 or 36 factors.
DON’T PUT LARGE AMOUNTS OF TEXT IN ALL CAPITALS (it’s annoying).
Use white or a lightweight coloration sort on a medium to darkish background. Or use black textual content on a easy white background. Keep away from “pizazz” in your presentation. Visible results similar to bullets flying in from all instructions and loopy sound results are distracting and needs to be used very sparingly.
Resolve the way you need info to be positioned in your slides and be constant all through your presentation.
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Examples of Good (high) and Dangerous (backside) Slide Formatting
Don’t do that:
SLIDE FORMATTING DO’S AND DON’TS
• As a rule of thumb, restrict your slides to 40 phrases most. Use temporary phrases, damaged into bullet factors the place acceptable. Maintain bullet factors to a most of 5 bullets or eight traces per slide.
• Profit from the “panorama” 2:Three ratio format. Organize your info to make the most effective use of the slide’s horizontal form. Use tables and charts each time potential.
• Keep away from pasting giant spreadsheets into your presentation – as an alternative condense key info from the sheet into simply understood tables.
Do that as an alternative!
Slide Formatting Do’s and Don’ts
• Lower than 40 phrases per slide!
• Use temporary, bulleted phrases
• 5 to eight bullet factors per slide
• Numerous tables and charts
• Condense giant spreadsheets into simplified tables
Slide Formatting Do’s and Don’ts
• Lower than 40 phrases per slide!
• Use temporary, bulleted phrases
• 5 to eight bullet factors per slide
• Numerous tables and charts
• Condense giant spreadsheets into simplified tables
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DR 1 – Conceptual Design Evaluate
What: The Conceptual Design Evaluate is an oral presentation by every design workforce of not more than 35 minutes.
Why: This evaluate will doc the agreements amongst your design workforce, your buyer, and administration as to: • the precise assertion of labor to be achieved, • the shoppers on your challenge and their needs, • the ideas generated and regarded, • the ultimate idea you’ve got chosen to resolve the issue, • the quantitative engineering specs and design standards that the design will fulfill and • the price range for the workforce to finish the design, fabrication, and testing of the prototype.
How: Every workforce decides for itself learn how to use the primary 25 out of 35 minutes. The school reserve the final 10 minutes: 10 for questions, and for the dialogue of “Motion Gadgets.” It’s as much as you to determine who will discuss, for the way lengthy, and on what topics. Nevertheless, every workforce member should take part within the formal oral presentation. Deadlines shall be strictly adhered to. At the least one workforce member should take detailed notes throughout the query and reply session to assist within the willpower of Motion Gadgets.
That is maybe the least formal of the Design Critiques, because the solely attendees exterior the college are (generally) the shoppers with whom the workforce has already had a number of conferences. You might costume as you’d for a daily class assembly. Every workforce is liable for its personal graphics, handouts, fashions, and so on.
When and The place: The Conceptual Design Critiques shall be held in our common classroom. Every scholar should attend ALL design opinions. Excused absences, in writing, are acceptable. Attending the opinions of different groups could be very useful for the next causes: (1) it should enable you to perceive the mechanics of the evaluate course of, (2) it’s possible you’ll get good concepts from the opposite initiatives, serving to to enhance your individual challenge, and (Three) you’ll have good concepts that may assist the workforce being reviewed. So, please be there!
Earlier than the evaluate: Every challenge is required to organize a Design Evaluate Bundle to be delivered to the school no later than 11 am the day of its design evaluate. Your bundle ought to include copies of all slides (6 slides per web page) utilized in your presentation. We notice that you could be must make last-minute adjustments to slides after delivering copies to us. That is fantastic. The copies you ship to us don’t must be etched in stone.
Grading: Every workforce shall be graded on each the content material and high quality of its presentation, in line with the connected grading sheet. Grades shall be assigned to the workforce as a complete, and individually to every particular person based mostly on the one-page progress report (“Why I shouldn’t be fired from my workforce”) which is included with the written report within the type of an appendix.
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Conceptual Design Evaluate Recipe
Numbered gadgets beneath (starting with #1) correspond to these on the grade sheet that follows. Boxed gadgets correspond to the “meat” of this specific evaluate
1. Start your design evaluate by introducing the background and motivation on your challenge.
Introduce your buyer, and succinctly describe their wants. For instance,
“Our buyer is the ACME Rubber Band Company of Tulsa. ACME is a pacesetter within the subject of high-performance rubber bands to be used in slingshots. ACME is rising, and want to develop into the profitable rubber-band powered airplane market. So as to take action, they should enhance the torsional fatigue properties of their rubber compositions.
This leads us to the Assertion of Work for our challenge:
Our workforce will design, construct, take a look at, and ship to ACME an automatic high-speed torsional fatigue testing machine, together with all hardware and management software program, able to fatigue testing all of ACME’s merchandise to be used in rubber-band powered airplane purposes.”
2. Assertion of Work: As within the instance above, it is a concise written abstract of the challenge you have been introduced with again on Challenge Night time in ME 4383. Your SOW needs to be purposeful. That’s, it ought to describe what the prototype that you just ship to your buyer will do, not the way it will do it.)
Three. Staff Duties: Arrange your workforce to make the most of the strengths of its people. A workforce chief should be agreed upon and recognized. Additionally, a security engineer should be recognized, (see Security Engineer part later in CHB). Past that, the workforce can arrange because it sees match. No matter anybody’s formal project (“testing,” or “evaluation,” or “buying,” and so on.) every workforce member should concentrate on and keen to do no matter it takes to realize the challenge’s general targets. “That’s not my job,” is just not an possibility.
Four. Prospects and Buyer Needs: Constant along with your Assertion of Work, checklist the shoppers you have to fulfill (main buyer, final shopper, authorities, and so on.) as relevant. Make bullet lists of what every sort of buyer needs from this challenge. Level out any conflicts in buyer needs.
5. Ideas Generated and Thought-about: Numerous ideas needs to be generated by the workforce and regarded for improvement. Briefly overview among the ideas generated by the workforce and never chosen. (See CHB part on “Idea Choice.”
6. Ultimate Idea Chosen: Describe the idea your workforce has chosen to perform the Assertion of Work. Sketches or drawings are crucial on this part. Fashions (foam core or speedy prototype) are generally additionally very helpful. Describe how your workforce selected this idea, versus the others that have been thought of. Together with gadgets #2 and #7, that is crucial job for this design evaluate.
7. Quantitative Engineering Specs and Design Standards: A whole checklist of all quantitative specs and different design standards needs to be introduced. Together with gadgets #1 and #7, that is crucial job for this design evaluate, because it constitutes a quantitative “contract” between you and your prospects. It’ll drive your engineering design work for the remainder of the challenge, as you guarantee prospects and administration that the design will fulfill these specs earlier than you start constructing. Additionally, your quantitative specs will dictate testing (truly measuring and evaluating towards the specs). (See CHB part on “Quantitative Engineering Specs.”)
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eight. Security: Describe the protection issues along with your idea and your plans to aggressively design and construct a secure product. Establish any security laws that should be adhered to (OSHA, FDA, UL, API, ASME, and so on.). Additionally, establish any “foreseeable misuse” points. (See CHB part on “Security.”)
9. Funds: The precise sum of money to be spent this semester needs to be clearly agreed upon between the workforce, buyer(s), and college and recognized in your price range. Quantify all prices you anticipate (vendor components, machining/fabricating prices, and so on.) even for those who anticipate that among the gadgets shall be donated. Separate your price range into two columns: (i) “Buyer Prices” – the precise dollars you’ll spend out of your buyer’s price range. (ii) “Complete challenge prices” – which can embody gadgets your buyer is not going to pay for instantly similar to student-engineering time and on-campus machining time. Estimate all prices related along with your challenge, together with engineering time, as described later within the CHB. (See “Price Estimating – Half I” and “Price Estimating – Half II” sections in CHB). Funds info is commonly troublesome to current throughout a design evaluate. At one excessive, keep away from together with a lot element that the viewers misses the “massive image” of your price range. On the different excessive, you will want sufficient element to persuade the viewers that you just perceive the price range realities of your challenge. This generally is a troublesome balancing act throughout a design evaluate. Good luck!
10. Motion Gadgets: Every workforce shall be required to jot down a listing of Motion Gadgets and a timetable for his or her completion, based mostly on the outcomes of this evaluate. On the finish of your evaluate, you’ll be requested to learn aloud your Motion Merchandise checklist. Due to this fact, at the least one workforce member should take detailed notes throughout the query and reply session, noting which gadgets must be adopted up on. Motion Gadgets will embody particulars similar to steered alternate ideas or design particulars, evaluation methods, distributors or specialists to contact, and so forth. On the finish of your evaluate, you’ll be requested to learn aloud your Motion Merchandise checklist.
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Conceptual Design Evaluate — Grading Sheet
Date: ____________
Challenge Identify: _______________________ Grader’s Identify: ______________________
Assign a rating for every portion of the presentation listed beneath. If a class is just not relevant, cross it out and don’t embody the factors for that portion within the whole.
1. Background and Intro. (_____ out of 5)
2. Assertion of Work: ( ______ out of 10)
Three. Staff Duties: ( ______ out of 5)
Four. Prospects and Buyer Needs:
( ______ out of 5)
5. Ideas Generated and Thought-about:
( ______ out of 15)
6. Ultimate Idea Description: ( ______ out of 20)
7. Quantitative Engineering Specs and Design Standards: ( ______ out of 15)
eight. Security Points Addressed? ( ______ out of 5)
9. Funds: ( ______ out of 10)
10. Response to Questions and Motion Gadgets: ( ______ out of 10)
Complete Rating:
Out of:
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Price Estimating – Half I
Prototype Prices
In design and product improvement, an engineer’s capacity to foretell prices typically makes the distinction between success and failure – of the product, the engineer, and the corporate!
It is very important be capable to predict the fee required to carry an concept into actuality, both on a prototype scale or on a manufacturing scale. The time period value estimation has quite a few implications and whole texts have been written on the subject. A non-inclusive value breakdown is introduced beneath. There are prices related to:
Producing a prototype
-engineering time
-computer, software program, evaluation time, and so on.
-prototype prices
-material
-machining
-tooling/fixturing
-instrumentation
-machinist and technician labor
-testing
Manufacturing a product
-materials
-energy
-direct and oblique labor
-machine prices
-tooling
-building prices
-the value of capital
Each of the above can have the extra burdens of oblique prices similar to
-marketing
-sales
-accounting
-clerical
-transportation
Remember that it is a simplified checklist. Particularly conditions, among the above gadgets usually are not relevant and for others, the checklist is incomplete.
With a view to predict the price of a challenge, the character of the challenge itself should be outlined. For instance, challenge targets can vary from the event of a person piece of hardware, to the mass manufacturing of things similar to cars, plane, computer systems, hand instruments, fishing reels, tennis rackets, and so on.
One of the essential facets that may have an effect on value is manufacturing quantity (whether or not 1, 100 or 106 of the gadgets are to be constructed). On this course, senior design initiatives are typically centered
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on the event of particular person prototypes. In lots of situations, these prototypes might be thought of preliminary variations of a ultimate product that might be manufactured in quantity. We’ll basically think about predicting the price of the challenge as much as and together with the design, fabrication, testing, and supply of the primary prototype to the client. Nevertheless, among the initiatives will even be required to guage quantity manufacturing prices. Estimating such manufacturing prices is roofed within the subsequent part – Half II of Price Estimating.
The aim of this part of the Handbook is to ascertain some tips for estimating challenge prices and to supply an instance. Price in these initiatives can come from quite a few sources. Some are actual (e.g., materials required to construct a prototype), others could be actual if the work have been being executed within the R&D division of an precise engineering firm (e.g., engineering wage). With a view to estimate prices on initiatives on this course, the next tough tips could also be used. Remember that a piece yr is about 2000 work-hours (50 weeks occasions 40 hours per week):
Engineering time: $70-80 per hour ($140,000 – 160,000 per yr!!)
Technician time: $45-55 per hour
Machining time: $50 per hour
Supplies: 1018 carbon metal = $1.00 per pound
304 chrome steel = $2.00 per pound
6061 – T6 aluminum = $2.00 per pound
(Observe: Anticipate to pay heaps extra for these supplies in case you are solely shopping for small portions.)
You could find these and different supplies prices on web sites similar to www.matweb.com.
The prices of different supplies similar to plastics and composites will depend on composition, fiber density, orientation, weave, alignment, processing necessities, and so on. Normally, the fabric and manufacturing method should be established and related prices recognized by means of gross sales literature or quotes from distributors. If extra correct info is offered for the supplies listed above, please use that info as an alternative.
The price of parts similar to bearings, motors, switches, gears, and so on. should be quoted from vendor info. These prices are extremely depending on the quantity required and particular person quotes are sometimes vital. Relying on obtainable sources and experience, gadgets similar to gears could also be reduce and hobbed in-house much less expensively than they are often bought from exterior sources.
The fee bases of $70-80/hr and $45-55/hr for engineering and technician time may appear considerably steep, relative to starting engineer wage ranges. Nevertheless, this value is taken into account a median estimate for starting engineers, together with overhead prices (well being care, taxes, trip, coaching, retirement, cellphone, provides, workplace house, gear, and so on.). Roughly talking, it prices an organization about two or thrice as a lot to make use of an engineer because the engineer receives in wage. Do not forget that the subsequent time you’ve got a job interview!
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EXAMPLE – Estimating Prototype Prices
A really temporary instance shall be given right here for the design and building of a rotating-bending
fatigue machine. The machine makes use of a USB motor controller and a USB air provide/regulator
with an air cylinder to use the load. The load cell offers suggestions to the air strain
controller. A schematic illustration of the system is depicted beneath adopted by a listing of
estimated challenge prices. The labor prices are on this web page and the hardware prices are on the
subsequent web page.
On this challenge, a Three-person workforce offers all of the labor.
Rotating – Bending Fatigue Machine Challenge
Prototype Price Estimation
Discover that the entire variety of hours simply exceeds that from Three college students working 9 hours per
week for 15 weeks: 3x9x15=405.
Labor
Engineering time hours Price
design 120 $9,600
Software program design 80 $6,400
Testing and evaluation 60 $Four,800
Machining Time 60 $Three,000
Technician Time
Meeting 60 $2,400
Testing 30 $1,200
Complete Labor Price 410 $27,400
bearing meeting
collet grip
motor /
coupler
air
cylinder
load cell
air provide
specimen
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Price of , Elements, Computer systems and Software program
(Bodily Prototype Price)
Supplies and PartsBase$60 metal$140 leveling pads$32 stage indicator$18Motor/Coupler$450USB Pace Controller$220Energy Provide$68Misc. Electrical$45Air provide/regulator$285Air Cylinder$68Load Cell$540Load Meeting$85Warmth Traating$60Bearing Meeting Bearings$80 Housings$240 Seals $12 Oil Ports$eight Oil Website Gauges$22Pc $1,650USB Controllers$840Information Acquisition$400Complete Materials and Elements$5,323Complete Challenge Price$32,723
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Price Estimating – Half II
Manufacturing Prices for a “Manufacturing Run”
Introduction
Estimating the manufacturing value for a brand new product is usually an essential a part of a prototype design effort. Administration will typically wish to know what it should value to provide X variety of copies of the prototype you’ve got designed and fabricated.
Many firms make use of value estimators for this objective. Generally these estimators are skilled engineers. A really giant firm, like an car producer, will make use of dozens of those professionals. Smaller firms can not afford the luxurious of a full-time workers of estimators, and should rent out the work, or else produce its personal estimates with out the help of professionals.
This temporary introduction to manufacturing value estimation is meant to assist in your efforts to estimate manufacturing prices on your senior design prototype, assuming that this is smart on your challenge. It is smart to estimate manufacturing prices for gadgets that may sometime be mass produced. It in all probability does not make sense for “one-off” sort gadgets similar to a take a look at fixture for a professor’s analysis lab.
Your challenge consists of a variety of particular person parts that you’ve assembled (or will assemble) into a complete. Beneath, we introduce a number of methods for estimating the manufacturing prices for a single part. You might discover a number of of those methods useful for the varied parts in your prototype.
You may use these tricks to estimate manufacturing prices through the use of a number of of the methods to estimate the manufacturing value, for a given manufacturing run, of every part in your prototype. In fact, with regards to mass manufacturing, not each part shall be manufactured the best way you probably did it in your prototype! For instance, you’ll have spent 11 hours machining some advanced steel half. However for those who have been going to provide 100 thousand of these components, it will definitely make sense to contemplate a steel casting course of, and even injection molding it out of plastic.
After you’ve got value estimates for every part, you possibly can use a number of of the next methods to estimate the price of assembling the parts. The price of every part, plus the price of meeting, will yield the entire estimated manufacturing value on your prototype.
How must you take care of the substantial engineering time you’ve got already sunk into your prototype? These prices are usually thought of as “overhead labor” (described underneath Technical Price Evaluation beneath) and don’t must be recovered instantly within the manufacturing value of your prototype (your organization in all probability has different sources of revenue, and your prototyping prices will be divided up amongst all these).
Price Estimating Methods
What follows are very temporary descriptions of methods you may use to estimate manufacturing prices. We hope you’ll use these (and different sources, after all) to provide a workable estimate of producing prices on your prototype – assuming this is smart on your specific challenge. Good luck!
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Supplies value x (the magic fixed) = manufacturing value
By far the quickest and dirtiest technique to estimate manufacturing prices is to multiply the supplies value for a given part by some magic fixed. Supplies value is obtained by multiplying the load of the part by the price of the fabric you’ve got specified. The magic fixed will, after all, differ with the kind of manufacturing, the dimensions of the manufacturing run, and plenty of different issues. However, typically this methodology is surprisingly correct (see instance beneath). A typical worth for the magic fixed is 2. Thus, in case your half weighs Three.zero lb. and is to be constructed of 1018 metal at a price of $zero.35 per pound, you’ve got a supplies value of $1.05 and a complete ESTIMATED manufacturing value of twice that, or $2.10.
(Half weight, lb) x (Materials value, $/lb) = Supplies Price per half, $
Manufacturing Price per half, $ = (Supplies Price per half) x 2
The massive benefit of this method is that it’s tremendous straightforward!
The massive downside is that it’s overly simplistic and thus often not very correct. It provides you an identical estimate if you’re going to manufacture 100 components or a million components (except the magic fixed for numerous manufacturing charges). It additionally doesn’t even start to take into consideration how LONG it should take to provide a component.
Materials value + store time = manufacturing value
This system improves on “materials-times-two” by bearing in mind among the affect of producing time on manufacturing value. On this methodology, the fabric value (mentioned above) is added to a second time period, which consists of the “cycle time” to make a part (machining plus welding plus meeting, for instance) multiplied by the “machine lease.” This final time period represents the price of working a given course of in a given setting, and thus takes into consideration labor prices, the price of the machine (for instance, a lathe), the price of heating the constructing, and so on.
Like materials-times-two, this methodology fails to take into consideration annual manufacturing quantity adequately. For instance, in case you have a lathe making the identical half 16 hours a day, your prices will probably be a lot lower than in case you are solely utilizing the lathe to make a couple of copies of that half on any given day (due to variations in setup time, and so on.). This methodology additionally assumes that prices shall be linear with respect to cycle time, not normally an excellent assumption.
Quotations
You possibly can at all times discover out what it will REALLY value you to fabricate a given part by acquiring manufacturing quotes from certified producers. A cellphone name adopted up by the submission of engineering drawings is all that’s required. What might be less complicated?
This methodology does have drawbacks, nevertheless. What you get with a citation is just not manufacturing value, however worth. Normally the quoted worth shall be higher than the precise manufacturing prices (due to the revenue issue). However in some circumstances, the quoted worth might even be LESS than the actual manufacturing value (the seller could also be attempting to construct up new prospects, and thus could also be keen to lose cash for awhile to achieve the profitable enterprise of your giant firm).
The opposite drawback with quotations is that you just want a brand new one each time you alter one thing. For instance, to illustrate you get a quote on 100 copies of a sure half, after which
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determine that you just want 1000 copies. You’ll have to get one other quote! A way is required that permits the engineer to play these “what if” video games and decide how numerous elements have an effect on piece value.
Technical Price Evaluation
This system for estimating manufacturing prices combines value accounting with some primary engineering ideas to permit you to individually estimate on a spreadsheet all the numerous “value parts” that go into manufacturing a part. Examples of value parts are supplies value (mentioned above), direct labor value, the price of capital (value of borrowing cash), and so on. Price parts are sometimes divided into two classes, Variable and Fastened.
Variable Price Parts
Variable value parts are these parts of piece value whose values are impartial of the variety of items produced. In different phrases, a variable value ingredient, like materials value, would be the identical, per piece, for those who make one half or a million.
Crucial variable value parts are normally:
• Supplies
• Direct Labor (similar to machining time)
• Power (utilities)
Some argue that there’s actually no such factor as a very variable value. As a lot of by now, for instance, in order for you 6 ft of metal tubing, you’ll pay much more per foot than in case you are keen to purchase 6,000 ft of the identical tubing! Nevertheless, dividing prices into variable and stuck parts offers a handy approach to consider and focus on value parts.
Fastened Price Parts
Fastened value parts are these parts of piece value which might be a operate of the annual manufacturing quantity. These prices are referred to as “mounted” as a result of they’re normally a one-time capital funding (similar to a constructing) or an annual expense (similar to engineering assist) that have a tendency to not differ with the variety of parts being manufactured. The principle parts of mounted value usually embody:
• Machine value (lathe, milling machine, welder, injection molding machine, and so on.)
• Tooling (molds, dies, and so on. Observe that these don’t final without end – thus they aren’t fully “mounted” prices)
• Overhead labor (similar to engineering time – and together with the time that went into prototype improvement!)
• Upkeep
• Constructing value
• Price of capital (the price of borrowing cash)
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Instance: Rubbermaid trash bin (made out of a plastic similar to polyethylene by the injection molding course of). The next estimates are based mostly on an annual manufacturing fee of 400,000 trash bins.
Variable Prices
Per Piece Prices, $
% of Complete Piece Price
Supplies
zero.75
55.9
Utilities (vitality)
zero.10
7.Four
Direct Labor (injection molding machine operation)
zero.14
10.9
Fastened Prices
Primary machine
zero.08
5.eight
Tooling
zero.05
Four.zero
Overhead labor
zero.06
Four.eight
Constructing
zero.02
1.Three
“different”
zero.04
2.7
Price of capital
zero.10
7.2
TOTAL PIECE COST
1.34
100.zero
For the above instance, let’s see how effectively “supplies occasions two” works:
($zero.75) x 2 = $1.50
The tough estimate ($1.50) is barely 12% above the delicate value estimate. “Supplies occasions two” works fairly effectively on this case!
A technical value evaluation spreadsheet permits the engineer to play the form of “what if” video games described above. Like the opposite strategies, nevertheless, its outcomes are solely nearly as good as the info within the mannequin. Additionally, the fashions used for this method can get extraordinarily advanced. They’ll get so sophisticated, the truth is, full-time skilled is required to take care of the fashions. Thus, the typical engineer/prototype developer could also be again to counting on the skilled with this method.
Reference: Busch, John V., Technical Price Estimating of Plastics Fabrication Processes, Ph.D. dissertation, MIT, 1987.
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Idea Choice Matrix Technique
Right here’s a fast description of a wonderful method that can be utilized, by senior design groups and others, to assist select the most effective design idea from amongst a listing of many. This methodology was first developed by Stuart Pugh, an airplane designer and engineering professor.
There are two important stipulations for utilizing this course of:
1. A suitably lengthy checklist of potential ideas. If you happen to do not ever generate that one actually nice idea, how are you ever going to choose it out from amongst a listing of simply common ones? So, brainstorm!
2. A complete checklist of analysis standards. These standards are similar to what you introduced in your first design evaluate as your “quantitative engineering specs.” It doesn’t matter what you name them, they must be measures of crucial issues that your design has to do so as to fulfill your buyer. Does your design must be cheap? In that case, then “Manufacturing value” could be in your checklist of crucial standards. Does your design must be mild? Add “Weight” to your checklist. Does it must be dependable? Add a measure of reliability to your checklist, similar to “imply time between failures.” Don’t neglect elements similar to security, look, and supply time (how lengthy it should take to construct it).
The steps outlined in 1 and a couple of above should not be rushed by means of or blown off. A awful job right here ensures failure afterward.
Having efficiently generated a wholesome checklist of competing ideas and an intensive checklist of crucial analysis standards, you are actually prepared to guage and choose the most effective idea out of your checklist. Create a matrix just like the one beneath:
Idea 1
Idea 2
Idea Three
Idea Four
Idea 5
Idea 6
Idea 7
Criterion 1
*
Criterion 2
*
Criterion Three
*
Criterion Four
*
Criterion 5
*
Criterion 6
*
Criterion 7
*
Totals
*
Subsequent, you’ll fill out this matrix utilizing a way of relative comparability, as described beneath. That is what makes the strategy so easy and helpful.
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Let’s assume we’re going to fill out the cell of the matrix the place “Idea 2” intersects “Criterion 1” (shaded above). Right here is the query it’s important to reply: Is Idea 2 higher than Idea 1 by way of Criterion 1? If the reply is sure, you set a “+” in that cell. If the reply is not any, you set a “-“. If they’re the identical, you set an “s”. And if you do not know, you set a “?”
The “?” entry deserves additional dialogue. One shortcoming of many groups with regards to these charts is an unwillingness to make use of the “?” on the chart. A “?” in your chart represents a information hole that your workforce has relating to a particular idea. If one specific idea has too many information gaps, that may be a superbly professional purpose for eliminating that idea from consideration! Some ideas must be despatched again for extra R and D earlier than they’re able to be thought of for design and advertising and marketing. This occurs often in senior initiatives, and within the “actual world” as effectively. So, be trustworthy with your self and your workforce relating to your stage of data about your ideas.
Let’s take a look at a easy instance. As an example you might be designing “a tool or method for conserving the grass in a house owner’s yard quick and neat-looking” (do not let the phrase “lawnmower” affect your brainstorming!) Let’s imagine you’ve got generated the next ideas – this checklist is clearly approach too quick:
1. A gasoline powered machine with reel blades.
2. A wire – electrical machine with rotary blades.
Three. A battery – electrical machine with rotary blades.
Four. A goat.
Now, what are the crucial standards? For the sake of the instance, let’s contemplate the next (notice: the next checklist is just too quick – and never essentially so as of significance):
1. Manufacturing value
2. Working value
Three. Security
Four. Upkeep prices
5. Garden look (common grass peak, for instance)
6. Noise air pollution
7. Air air pollution
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Our matrix may seem like this:
Gasoline
Twine-Electrical
Battery-Electrical
Goat
Manufacturing value
B
Working Price
E
Security
N
Upkeep value
C
Garden Look
H
Noise Air pollution
M
Air Air pollution
A
(non-compulsory)
Totals
R
Okay
Let’s fill out the matrix cell the place “Twine-Electrical” and “Machine Price” intersect (shaded above). To take action now we have to reply the next query:
How do the Twine-Electrical and Gasoline ideas evaluate by way of machine value?
The reply (both “+”, “-“, “S”, or “?”) is inserted into the suitable cell. Your workforce proceeds to fill out the chart in related vogue. Within the non-compulsory “Totals” row on the backside, your workforce sums up the pluses, minuses, sames, and query marks for every idea. As soon as you might be executed, you’ve got an especially highly effective doc in your possession. Utilizing it, you may see at a look how the ideas stack up to one another. Your workforce can then come to a consensus about which of the ideas are essentially the most worthy of additional consideration.
This enterprise of “coming to a consensus” deserves additional dialogue. Quantitative creatures that we’re, many engineers wish to use the “totals” on the backside of one in all these charts to make an iron-clad resolution as to which idea is the most effective. In different phrases, they need the chart to pick the most effective idea. I like to recommend towards this methodology, since I imagine that you’re a lot smarter than the chart! Use the chart to get all of the pertinent info on the desk, however then use your brains to pick the most effective idea.
There are lots of different makes use of for these charts. For instance, it’s possible you’ll discover from the chart that two ideas will be mixed into one super-concept that may blow the others out of the water (how about an electrical mower that may run off both wire or batteries?) Additionally, you should use these charts to point out your boss (or teacher) simply precisely the way it was that you just eradicated his or her favourite idea from consideration. Quite than having to say one thing actually dumb like, “We simply did not assume it will work,” you may present him the chart the place his concept is clearly and graphically outclassed by a number of different concepts by way of value, security, and so on. He could not agree with you, however he can not fail to notice how you’ve got logically and clearly made your resolution.
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These idea choice charts are a easy, highly effective design instruments that I can not advocate too extremely. I’ve checked out many conceptual-type design instruments, and that is simply the simplest one which I’ve ever seen. In different phrases, it yields essentially the most profit by way of improved design for the least period of time invested. If you’re in a gathering, battling over the lifetime of your challenge, this may be robust ammunition to assist guarantee administration that you’ve thought by means of each element, and are continuing in essentially the most goal method potential.
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Pointers for Defining Engineering Specs
A typical requirement in every design evaluate is to current the “Engineering Specs” for the challenge. It’s because the Engineering Specs are on the core of every part you’ll do on this challenge. This part defines the Engineering Specs and explains how they need to be quantified and used all through the challenge.
What are Engineering Specs?
An Engineering Design will be outlined because the engineered resolution to a particular drawback. After choosing an idea, step one in the direction of conducting a profitable Engineering Design Challenge is to ascertain the Engineering Specs. These kind a complete description of your design, defining all facets of its kind and performance. Engineering specs are additionally known as design standards, since they outline all the standards the design should fulfill.
It is very important quantify these specs early in your design challenge. In some ways, the engineering specs represent an settlement or contract between the engineer and the client or prospects.
Engineering specs are the bridge between what your prospects need – and the way you propose to ship it. The first buyer (the one who purchases and makes use of the outcomes of the challenge) is normally easy to establish, however secondary prospects will be simply as essential to the success of an engineering challenge. You’re requested to establish all of your prospects as a part of the Conceptual Design Evaluate (DR1). Secondary prospects will be inner or exterior. Inner prospects might embody the advertising and marketing or gross sales departments in your organization – or your supervisor. Exterior prospects might embody authorities businesses just like the EPA or OSHA, or skilled organizations like ASME, ANSI, or ASTM. If your organization is a subcontractor, then your main buyer could be one other firm, moderately than a person shopper. Anybody who defines any a part of your Engineering Specs might be thought of a buyer.
Quantifying Engineering Specs
Engineering specs should be particular and quantitative. Quantitative means measurable. To ensure you are paid on the finish of the challenge, you want to have the ability to present that your ultimate product meets all the specs.
To say half should be “as mild as potential” doesn’t work. Your buyer might want the half to be “as mild as potential,” but it surely turns into your job to quantify what which means! Is Four lbs. mild sufficient? Is Four lbs. achievable? “As cheap as potential” is equally non-quantitative, and much more harmful! Quantifying your specs is a crucial a part of translating what the client needs (“mild and low cost”) into what the engineer will ship (“lower than Four kilos and underneath $20 manufacturing value”).
Issues similar to weight, value, dimension, energy necessities, cycle occasions are normally simpler to quantify than gadgets associated to styling and look. Even then, effectively outlined initiatives search to quantify these standards. For instance, the exact coloration and floor end of an merchandise will be measured, as can the minimal radii of curvature for corners. It’s also potential to have focus teams of shoppers have a look at and react to the looks of mockups of designs so as to quantify their aesthetic attraction.
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After you have efficiently quantified all of your engineering specs, you have to then USE these specs. Usually, engineers spend a number of time growing their specs, after which by no means have a look at them once more till their prototype is constructed and it’s too late! This may trigger (for example) the acquisition of undersized parts (similar to electrical motors) and ultimate designs that merely don’t meet specs (or fulfill prospects).
How one can use your Engineering Specs
1. To information your evaluation: Evaluation is required to optimize designs by way of their effectivity, and to quantify security elements, working limits, and product lifetimes. Evaluation ought to happen early within the design course of. Quantitative engineering specs ought to drive these analyses! Parameters similar to tubing dimensions, motor speeds, working frequencies, temperatures, and move charges should be specified in order that the design will be in contrast with the specs. If evaluation comes too late within the design course of, there’s a good probability the design will both (a) not meet specs or (b) be over-designed.
2. To outline testing: Within the senior initiatives class, there may be typically such a push to get the hardware full that the testing part is uncared for. Every workforce ought to assign a “take a look at engineer” to start planning product testing early within the challenge. The engineering specs are the blueprint for the take a look at engineer. Checks needs to be deliberate to guarantee and quantify adherence to as most of the quantitative specs as potential. Within the senior initiatives course, it should in all probability not be sensible to check your product to failure (to fulfill, for instance, crash take a look at requirements for a automotive). Nevertheless, pressure gages can measure localized strains underneath a given load, and restrict masses could also be extrapolated from these measurements. Vital parts or joints in your design will be constructed individually and examined to failure in a load body. Working speeds, temperatures, and efficiencies (as examples) will be measured, however not with out rigorously designed testing procedures.
The desk beneath exhibits how one can join what your buyer needs along with your engineering specs and the checks you’ll run in your prototype.
Three. To judge the success of your challenge: Most engineering initiatives usually are not paid for till they’re full. A challenge is taken into account full and profitable when the ultimate prototype meets or exceeds its engineering specs. The outcomes of testing (merchandise 2 above) needs to be reported in such a approach that they supply concrete proof that each one specs are glad.
Four. To make significant suggestions for future variations of your prototype: The aim of creating a advice is to enhance the performance of the product. Because the engineering specs outline the performance, they need to be thought of strongly when making suggestions.
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Engineering Specs and Check Outcomes – Some Examples
Buyer Need
Engineering Specification
Check
Testing End result
Gentle weight
prototype weighs < 300 kilos
weigh accomplished prototype
295 lb
Low noise stage
eight hr. time-weighted avg. beneath 85dBA (OSHA CFR 1910.95)
decibel meter, per OSHA 1910.95
77 dBA (handed)
Excessive effectivity
gas economic system of 65 mpg mixed metropolis/freeway driving
5 laps of 20 mile mixed metropolis/freeway loop
66 mpg equal
Load capability
Issue of security of two.zero min on materials yield power
Pressure gage take a look at on crucial part
FS = 2.2 extrapolated to max anticipated loading
The Shifting Goal
Generally, throughout the course of a design, engineering specs should be redefined. For instance, a crucial part is unavailable, otherwise you or your buyer decide that sure desired options of the design are inconceivable to realize inside value or weight limits.
In different circumstances, prospects could develop into fickle and inform you they need a special capability for his or her machine – they might wish to change the specs or change the idea totally. Having an excellent set of engineering specs will enable you to determine whether or not or not their whims are affordable and talk along with your buyer concerning the proposed adjustments.
Often, “the actual world” could rear its ugly head when your buyer or evil administration decides to chop your price range or change different standards in the course of your challenge for no obvious purpose! Though that is unfair, it does occur – even in senior design class. One workforce noticed its price range reduce by greater than two-thirds. One other workforce had its complete drawback assertion modified with 6 weeks remaining within the semester. Each of those groups have been pressured to fully rewrite their engineering specs – and nonetheless managed to provide very good prototypes.
Every time your settlement along with your buyer adjustments, all events should conform to adjust to the revisions. For this reason the engineering specs are part of all 4 design opinions. If you’re speaking effectively along with your buyer, your specs will in all probability change barely because the challenge develops. The design opinions present a proper means to current and file all such modifications.
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Particular person Progress Report – Staff Members
or, “Why I Should not Be Fired from My Staff”
As an appendix to your workforce report, every workforce member is required to submit a person progress report. (You’ll submit one in all these after every design evaluate within the spring).
These experiences are used to find out your particular person, versus workforce, grade for every design evaluate. Years in the past, some college students began calling these experiences “Why I Should not be Fired from my Staff,” and the identify caught. Really, that is a reasonably good description of the aim of those progress experiences! These progress experiences are much like what a lot of you’ll in all probability be required to do in business sometime – you’ll have already executed this in case you have a number of intern expertise. The concept is to let administration know particularly what you’ve got contributed to your workforce’s general effort main as much as the design evaluate.
These experiences are restricted to TWO PAGES MAX – doubled-spaced. The concept is to not see how a lot of your time we will waste. With a bit observe, it is possible for you to to jot down one in all these experiences in a short time.
Do’s and Don’ts for Particular person Progress Stories
• Use a bullet checklist to file your accomplishments. The principle factor we are going to search for in every bullet is, (1) What you probably did, and (2) What have been the outcomes of that motion.
 Checklist gadgets in previous tense: We’re not fascinated by what you might be “going to do.” As a substitute, inform us particularly (1) What you probably did, and (2) What have been the outcomes of that motion.
• Deal with actual accomplishments: Keep away from itemizing a number of minor “accomplishments” similar to: “Attended all conferences.” That is anticipated of everybody.
• Be particular: Examples:
 DON’T say: “Researched distributors on the web.”
o DO say: “Recognized ACME Rubber Band Corp (acme.com) as a provider for our ¾ hp flubber motor. Confirmed worth of $199 plus delivery, and supply time of two weeks from date of buy.”
 DON’T say: “I ready for Design Evaluate 1.”
o DO say: (for instance), “I developed a price range and schedule for Design Evaluate 1…” and embody the small print.
• Deal with what you’ve got executed, not on what you might be planning on doing. There needs to be no future tense in these experiences. It is easy to make guarantees, however they’ll get you no factors! We’re on the lookout for accomplishments.
• Keep away from passive verbs:
 “attended,” “participated,” “helped.”
• Make use of energetic verbs:
 “designed,” “analyzed,” and “constructed.”
• Deal with technical challenge work: “Scanned paperwork” could also be time-consuming, and any individual does must do it, however we don’t want to rent an engineer to do this. Checklist all
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your accomplishments, however focus in your engineering, enterprise, and technical accomplishments.
• Watch out describing collaborative work: If you happen to shared the work on a sure job, that is fantastic – it is a workforce challenge! “Redesigned engine mount with Dan” is suitable. However attempt to focus in your particular person contributions to collaborative work: “Dan made the sketches, then I transformed them to SolidWorks…”
• Put your self in your boss’s sneakers: Consider your IPR, as you write it, from the boss’s perspective. If you happen to have been on the lookout for the reason why (or why not) to “fireplace” somebody, what would you wish to see?

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