Course

Course Number:ENGRG 7520
Course Name:Design for Manufacturability (Online)
Course Description:A major portion of the costs and in turn the profitability of manufacturing organizations are affected by the quality of the design of their products. Building quality into the design will call upon engineers to systematically design a product and/or process so that it can be produced with lowest costs, rapid response time, and meet customers¿ expectations. This will require the integration of design, manufacturing, management, and economic principles. The course will address this overall integration and focus on the design for manufacturing aspects so as to provide faster time to market, productive utilization of equipment, faster delivery, improved quality, reduced cost, and effective continuous improvement. Students will be able to systematically design a product and/or process so that it can be produced with lowest costs, rapid response time, and meet customers¿ expectations. In doing so, they will be able to identify opportunity for design, address technical considerations of design & manufacturing, and make a business decision on feasibility of design.
Prerequisites:
Level:Graduate
Credits:3
Format:Online
Program:Masters of Science in Engineering
Masters of Science in Integrated Supply Chain Management
Registration Instructions

NOTE: The information below is representative of the course and is subject to change. The specific details of the course will be available in the Desire2Learn course instance for the course in which a student registers.

Additional Information

Learning Outcomes
After successfully completing the course, you should have the capability to systematically design products and/or processes to get the lowest cost, quickest response time, and best-achieved customer expectations.
Upon completion of this course, you should be able to:
    • Identify opportunities for design.
    • Address technical considerations of design and manufacturing.
    • Make business decisions concerning the feasibility of a design. 
    • Utilize DFM and Concurrent Engineering Principles on a "real life" project. 

Unit Descriptions
Unit 1: Product Design Problem Definition
In this unit, you will learn about a broad set of fundamental steps and activities needed at the beginning of a product design and development process. The sequence of processes used in this course follows the stage-gate format, which includes review and decision points before advancing to the next design or development phase. Besides the required basic engineering skills, you will learn about the importance and roles of marketing, management, and relational skills in the science and art of product development. You will also gain insight into constrains due to society regulations that govern the use of products being designed. The knowledge gained from this unit will be applied in your Term 1 project activities and submissions.
Unit 2: Concepts Generation and Selection
In this unit, you will learn about how the human mind works in conceiving creative solutions to problems, followed by a discussion on identifying barriers to creative thinking. Systematic methods for generating multiple design concepts for a product will be presented. The generated concepts need to be represented in the form of solution-neutral function structures to better understand the functional relations of components and sub-systems in terms of flow of energy, material and signals. You will also learn about the process of concept evaluation, analysis, and comparison leading to the selection of the most robust design for a product.
Unit 3: Embodiment Design
Prior to this stage, the best design concept has been selected, but the architecture or configuration has not been represented. In this unit, engineering methods for conveying the proposed physical structure in assembly, sub-systems and components and their interfaces will be discussed. The product will be tested for the 4Fs of design function, form, fit, and finishusing a full-scale prototype. How it meets the customer requirements and other important issues such as aesthetics, human-machine interaction factors, environmental impact, government regulations and business projections will be evaluated.
Unit 4: Detailed Product Design
Beyond embodiment design, the final details of dimensions and tolerances with consideration of materials and manufacturing process specifications will be carried out on all components, sub-assemblies and assemblies. We will cover aspects of material failure modes and failure stresses, as well as components protection against wear and corrosion. The manufacturability and cost effective methods of manufacturing will be fully considered in order to develop products that fulfill customer requirements at competitive market costs while meeting business objectives. Other important considerations at this stage include the impact of selected materials and processing methods on the environment, as well as their end-of-life transformations.
Unit 5: Prototype Development and Testing
Having designed the product and subjected it to various analyses, there is a need to create a prototype for testing to ensure the desired functionality of the product is realized. Where possible, a physical model is preferred. In cases in which a physical prototype is not feasible, a virtual prototype can be developed and subjected to simulations and tests using input parameters that are comparable to expected normal working conditions. Test results should be analyzed and, if necessary, used as a basis for adjustment of the product design.
Unit 6: Reflection on the Design Process
You will write a reflection on the Project Term activities analyzing the strengths and weaknesses of the design process used in your team. This is an opportunity to highlight aspects that were beneficial and what you feel was a drawback in the process.

Grading Criteria
Assignments:  
13 Quizzes
13 Homework Assignments
6 Term Projects
Grading Scale:
A     93-100
A-   90-92.9
B+   87-89.9
B     83-86.9
B-    80-82.9
C+   77-79.9
C     73-76.9
C-    70-72.9
D+   67-69.9
D     60-66.9
F       0-59.9