Think to design

Often when discussing product or industrial design, it’s not simply a matter of a few product or mechanical engineers recording requirements and transforming them into a 3D model and prototype. The design thinking process involves numerous critical stages that may not be immediately apparent to outsiders, but are essential for arriving at the final design. To illustrate this, the following chart depicts the process flow.

PRODUCT REQUIREMENT STUDY

Product requirements are usually rolled out by product managers and market analysis teams based on the market need. The PRS document briefly contains the product functionalities, compliance, working boundary conditions, and accuracy of the results.

For instance, let’s look at this example. Design and develop an outdoor device that measures air temperature, CO2, and relative air humidity. The product name suggested is FX01. Here are the high-level Product Requirement Specs (PRS) for the FX01 product.

• The device has to be IP68 rated.
• The device uses 2 AAA batteries for powering the electronics and the battery should last for a minimum period of 6 months.
• The device should have one RGB LED visible from the outside to indicate the status of the device.
• The device needs to be mounted to a round GI/steel pole that has a dia of 2” or 3”.
• The annual sales projection expected is 10000 units. The cost of the device has to be as low as possible.

MARKET ANALYSIS

The market analysis is carried out mainly to check if any products already exist in the market and if so, what are the limitations of a particular product that can be identified as an opportunity. How our product stands out as a unique product in the market with enhanced features.

Initially, we have to go through a market survey of existing products to analyze the missing features and functionalities and then overcome them with our own new design. Now let’s look at the outcome of the market survey,

• Most of the devices are bulky in size and difficult to install on different surfaces. Thus, the scope of compact form factor and aesthetical improvisation is noted.
• The devices have mostly external connectors for the sensors.

KEY DESIGN INPUTS

After thorough market analysis and study of product requirements, key design inputs are noted down which will be the deciding factors for the product development in further stages. For instance, factors like product size, cost, less number of child parts, ease of serviceability, usability, etc.

CONCEPT DESIGN

In order to generate different concepts, several supporting methods were used, individually and in combination, to help the designers to think outside the box and enhance creativity. Some of these methods are mind mapping, brainstorming, build to Think.

MIND MAPPING

Mind mapping is a way to remember, organize, process, and combine the information in a creative and effective way. Each thought is recorded in one or two representational keywords. Relationships amongst keywords are shown by diagramming.

Symbols are used to add visual variety and increase memorability. Different colors are used to represent different groups of ideas. It starts by writing a keyword that represents the problem in the center of the page and circling it.

This technique was used to create an overview of which problems are needed to be solved, how they relate to each other, and method to visualize and compile all uncertainties regarding the development of the product.

BRAINSTORMING

The purpose of the brainstorming method is to generate as many ideas as possible. It does not matter whether the ideas are big or small, possible to implement, or useful. The method was developed for groups, but it is also useful for individual engineers. If the brainstorming is performed individually, the person can easily fixate himself or her selves on one type of solution.

BUILD TO THINK

This is a method for physically visualizing ideas where simple models were built out of office material such as paper, tape, etc. These low-fidelity prototypes are made to hold and see the concepts and in this way more easily interact with the ideas than with sketches. Prototypes are a good way to encourage reflection on design aspects. Low-fidelity prototypes, such as paper models, are often cheap, fast, and easy and are therefore well suited early in the design process.

DESIGN DRAFTING

Once the concept generation process is done. The discussed ideas are poured into concept design by drafting which solves the puzzle of combining all the input into one single piece. How the electronics fit together with the mechanical parts and the assembly structure of the product.

CONCEPT DESIGN EVALUATION

Even though multiple concepts are generated only one design can be filtered. This is carried out by evaluating the concepts and the solutions with a decision matrix and then merging the solutions with the most potential into overall concepts.

All the solutions and concepts generated during the previous phase were evaluated using a decision-making matrix to choose which solutions to continue with and use in further development. This is a simple and effective method for comparing different alternatives. In essence, the concepts are scored relative to each other in their ability to meet the criteria.

Decision Matrix

FINAL DESIGN

After evaluating all the concepts, the one with the highest score is chosen for further design detailing, prototyping, and testing phases.

CONCLUSION

By embracing crucial thought processes, including the utilization of proper technical data, a creative approach, and the accumulation of the best ideas, one can attain a comprehensive design process.