Engineering design and production principles

Engineering Design Principles

The engineering design process involves problem identification, research, brainstorming possible solutions, selecting the optimal solution, prototyping, testing, iterating, and finalising the design.
A crucial part of the engineering design process is the identification and understanding of user needs and requirements.
Brainstorming and idea generation methods could include techniques like SCAMPER (Substitute, Combine, Adapt, Modify, Put to another use, Eliminate, Rearrange).
Design models, such as the Double Diamond Model, highlight the importance of exploring multiple ideas in the design process before narrowing down (divergent thinking followed by convergent thinking).

Environmental considerations in engineering design include the use of sustainable materials, energy-efficient manufacturing processes, and end-of-life disposal or recyclability.
Economic influences involve considering the cost-efficiency of the design, including materials, manufacturing, and operational costs.
Social impacts encompass how the design indirectly affects the society in terms of employment, new markets, and potential shifts in lifestyles.
Ethical aspects refer to ensuring the product design doesn’t harm users, society, or the environment, and respects intellectual property rights.

Additive manufacturing, such as 3D-printing, involves adding material layer by layer to create the desired product.
Subtractive manufacturing, such as milling or turning, involves removing material from a workpiece to shape the product.
Formative manufacturing, such as forging or bending, deforms the workpiece into the desired shape without adding or removing material.

Quality control involves checking products during the manufacturing process to ensure they meet predetermined specifications.
Maintaining quality control reduces the number of defective products produced and thus minimises wastage and retains customer satisfaction.
Various inspection methods can be employed, including visual inspection, testing, and measuring with instruments like callipers or micrometers.

Ensuring the safety of workers during the manufacturing process is a crucial aspect to consider during production planning.
Risk assessments help identify potential hazards in the production process and establish mitigation strategies.
Working environments must adhere to health and safety regulations, and regular training should be conducted for all staff.

The automotive industry uses a variety of manufacturing processes: forming for body panels, subtractive for engine components, and additive for prototyping unique parts.
Quality control in the automotive sector is vital; defects could result in failure leading to accidents, recalls, and a negative brand reputation.
The automotive industry must also consider environmental, social, and ethical aspects, such as emission standards, working conditions, and sourcing of raw materials.