New Product Design

New product design proceeds through a series of phases, each ending with a review and a go/no-go decision. This avoids spending money on an idea that cannot succeed.

 Feasibility study
        |
 Preliminary design
        |
 Detailed design & analysis
        |
 Planning for manufacture, distribution,
 use and retirement

1. Feasibility study

Purpose: to find out whether the product is worth developing.

• Is the need real? Market size, customer opinion, competitor products.
• Is it technically possible with present knowledge and materials?
• Is it economically viable (estimated cost, selling price, return on investment)?
• Is it legally and socially acceptable (safety, standards, environment)?

Output: a short feasibility report with the main concepts and the decision to proceed or stop.

2. Preliminary design

Purpose: to select the best concept and fix the overall layout.

• Alternative concepts are generated and sketched.
• Approximate calculations are done for power, size, major forces and cost.
• Concepts are compared (decision matrix) and the best one is chosen.
• Critical risks are identified and tested with simple models or mock-ups.

Output: layout drawings, main dimensions, a list of major components and materials, and cost estimate.

3. Detailed design and analysis

Purpose: to define every part completely so that it can be made.

• Stress, deflection, fatigue, wear and thermal analysis of each part; selection of standard components such as bearings, belts and fasteners.
• Material, tolerance, fit and surface finish for each part.
• Prototype building and testing; the design is modified from test results.

Output: complete working drawings, bill of materials, design calculations and test reports.

4. Later planning phases

After the detailed design the team plans manufacture (process selection, tooling, quality control), distribution and use (packaging, transport, installation, manual, service) and retirement (disposal and recycling). Considering these early keeps the design economical to produce and responsible to dispose of.

(a) Planning for manufacture

Planning for manufacture decides how the product will actually be made, so that the design is economical and of consistent quality.

• Choose the production processes (casting, forging, machining, welding, assembly) and the order of operations.
• Decide make-or-buy for each component and select standard parts where possible.
• Design for manufacture and assembly: fewer parts, simple shapes, standard sizes, easy tolerances.
• Plan jigs, fixtures, tooling, machines, inspection and quality control, and production rate and cost.

(b) Planning for distribution and use

• Distribution: packaging that protects the product, size and weight suited to transport and storage, shipping and sales channels, and installation requirements.
• Use: the product must be safe and easy to operate by the intended user; a clear instruction manual, warning labels, ease of maintenance and repair, availability of spare parts and service, and warranty. The designer considers likely misuse and the working environment (dust, humidity, temperature).

(c) Planning for retirement

Every product ends its useful life. Planning for it means:

• Designing for long life and for repair or reconditioning, so that the product is not discarded early.
• Using materials that can be recycled, marking plastics, and avoiding hazardous substances.
• Making disassembly easy so that components and materials can be reused or recycled.
• Providing for safe disposal (for example batteries, oils, refrigerants) in line with environmental rules.

The aim is to reduce waste and lifetime cost, and to protect the environment.