SRM VALLIAMMAI ENGINEERING COLLEGE

SRM Nagar, Kattankulathur – 603203

DEPARTMENT OF MECHANICAL ENGINEERING

QUESTION BANK

V SEMESTER

OMF 551 / PRODUCT DESIGN AND DEVELOPEMENT

Regulation – 2017

Academic Year 2019 – 20

Prepared by

Mr.R.Ashok – AP (Sr.g) / Mechanical

 SRM VALLIAMMAI ENGINEERING COLLEGE
SRM Nagar, Kattankulathur – 603 203.

DEPARTMENT OF MECHANICAL ENGINEERING

QUESTION BANK
SUBJECT: OMF 551/ PRODUCT DESIGN AND DEVELOPEMENT
SEM / YEAR: V / III

UNIT I
INTRODUCTION
Need for IPPD-Strategic importance of Product development - integration of customer, designer, material
supplier and process planner, Competitor and customer - behavior analysis. Understanding customer- promoting
customer understanding-involve customer in development and managing requirements - Organization process
management and improvement. Plan and establish product specifications.

PART – A 2 Marks
Q.No Questions BT Level Competence
1. List the need for IPPD. BTL1 Remembering
2. Explain the importance of Product development. BTL2 Understanding
3. Define customer focus. BTL1 Remembering
Explain briefly concurrent development of product and process. BTL1 Remembering
4.
5. Define product strategy. BTL2 Understanding
6. Describe the importance of product strategy. BTL1 Remembering

7. Explain briefly the elements involved in product strategy. BTL2 Understanding

8. Draw the basic process flow chart for IPPD. BTL2 Understanding
Summarize the steps involved in customer involvement.
9. BTL2 Understanding
10. Define supplier integration. BTL1 Understanding

11. Interpret the life cycle plant. BTL2 Applying

12. Infer supplier assessments. BTL5 Applying

13. List the basic steps in supplier assessments. BTL1 Applying

14. Define Product ideas. BTL1 Remembering

15. Demonstrate Behavior analysis. BTL3 Understanding

16. Illustrate down basic planning methods in IPPD. BTL3 Applying

17. State the benefits of IPPD. BTL1 Understanding

18. Explain the Needs of organization process management. BTL4 Evaluating

19. Define ram-up. BTL1 Applying
20. Select the best training method in IPPD. BTL4 Creating
 PART -B 13 Marks
1. Write briefly on the following
i) Characteristics of successful product development. (7) BTL1 Remembering
ii) Challenges in new product development. (6) BTL1 Remembering
2. i) Describe the concept of behavior analysis. (7) BTL1 Remembering
ii) Explain the importance of behavior analysis in PLC. (6) BTL 2 Understanding

Describe the input methods for obtaining information from customer, BTL1 Remembering
3.
using suitable illustrations. (13)
i) Discuss the methodology used in new product development. (7) BTL1 Remembering
4.
ii) Explain the role of competitive bench marking in planning. (6) BTL1
Remembering
Explain the various factors that promote innovation and continuous
5. BTL-2 Understanding
improvement in an organization. (13)
Briefly explain the organizational policies for product planning,
6. BTL-1 Remembering
process management and improvement of product. (13)

7. List out the mission statements for a screw driver project including
BTL1 Remembering
the description and proposition. (13)
i) Briefly explain strategic importance of product development.(6) BTL1 Remembering
8.
ii) List out the preparation method for metric formulation of a
bicycle suspension. (7) BTL1 Remembering
9. Describe about ideal and marginally acceptable target values in product BTL-4 Applying
specifications. (13)

10. Generalize the concept of managing requirements with suitable BTL-4 Applying
example from concurrent development. (13)
Explain the phases of generic product development process and point BTL-2
11. Understanding
out the tasks and responsibilities of the organization. (13)
Explain the ways of involving customer in development of a new BTL-2 Understanding
12.
product. (13)
Write briefly on the following,
13. Remembering
i) Steps to obtain target specifications. (7) BTL1
ii) Steps to obtain final specifications. (6) BTL1 Remembering
Explain the need for integration of customer, designer, material
14. Analyzing
supplier and process planner. (13) BTL-3

PART - C 15 Marks
Evaluate the analogy between working of a hospital and a product
1. BTL-5 Applying
development organization. Illustrate by suitable flow charts.
 Judge the importance of producing recyclable products in an eco- Analyzing
2. BTL-4
friendly production system.

3. Analyze a type of development process suitable for successful BTL-4 Analyzing

residential air-conditioning units.

Create a product-technology roadmap illustrating the availability of

4. BTL-4 Analyzing
technologies for a class of products you understand well, such as
personal computers.
 UNIT II CONCEPT GENERATION, SELECTION AND TESTING

Task - Structured approaches - clarification – search externally and internally-Explore systematically - reflect on
the solutions and processes - concept selection -methodology-- benefits.

PART-A 2 Marks

1 Prepare the road map for concept generation process. BTL-1 Remembering

Prepare the flow chart for concept generation. BTL-1 Remembering

2

3 Give the basic methods involved in concept Generation. BTL-2 Understanding

4 Explain the clarification of problems. BTL-4 Understanding

5 Describe the external approach in concept generation. BTL2 Understanding

6 Infer the internal approach in concept generation. BTL2 Understanding

Explain the problems that can be explored in concept generation

7 BTL-2 Understanding
process.

8 List different methods in explore technique. BTL-1 Remembering

9 Define Bench mark. BTL-1 Remembering

10 Define Team work. BTL-1 Remembering
Summarize the concept classification tree approach. BTL-2 Understanding
11
Summarize the concept classification table approach. BTL- 4
12 Applying
13 Define concept selection. BTL-1 Remembering
14 Draw the flowchart for concept selection. BTL-2 Understanding
15 Give the basic methods of concept selection. BTL-2 Understanding
Tabulate the measurement technique involved in concept selection. BTL-2 Understanding
16
17 Discuss survey formats in testing. BTL-1 Remembering
18 Define concept scoring. BTL-1 Remembering
19 Interpret the product performance in concept testing BTL-5 Analyzing
20 Explain concept testing briefly. BTL-1 Remembering

PART -B 13 Marks
1. (i) Describe the activity of concept generation in a cordless electric BTL1 Remembering
roofing nailer. (08)
(ii) Explain the relative advantages and disadvantages of involving BTL 2 understanding
 actual customers in the concept generation process. (05)

2. Consider the task of generating new concepts for the problem of

BTL-6 Evaluating
dealing with leaves on a lawn. How would a plastic-bag
manufacturer’s assumptions and problem decom-position differ
from those of a manufacturer of lawn tools and equipment and
from those of a company responsible for maintaining golf courses
around the world? Should the context of the firm dictate the way
concept generation is approached? (13)

3. Generate 20 concepts for the sub problem “prevent fraying of end

BTL-6 Evaluating
of rope” as part of a system for cutting lengths of nylon rope from
a spool. (13)
4. (i) Explain the problem clarification for concept generation. (07) BTL-1 Remembering

(ii) Explain the measurement technique in Concept selection. (06) BTL-1 Remembering

5. (i) Explain the problem search internally in CG. (07) BTL-1 Remembering
(ii) Explain the nature of sample to be used as lead users. (06) BTL-1 Remembering
6. How can the concept selection methods be used to benchmark
BTL-6 Evaluating
existing products. Perform such an evaluation for five automobile
you might consider purchasing. (13)
7. (i) Describe the concept screening process for a microprocessor
selection in traffic signal. (07) BTL-1 Remembering
(ii) Explain the concept scoring with a suitable illustration. (06) BTL-1 Remembering
8. How can concept selection method be used to decide whether to offer a Remembering
BTL-1
single product to the market place or to offer several different product
options. (13)
9. (i) Explain the methods for choosing survey population. (06) BTL-1 Remembering
(ii) Elaborate the various survey formats. (07) BTL-1 Remembering
10. (i) Describe the methods used for concept communication. (06) BTL-1 Remembering

(ii) Explain the steps to measure customer response. (07) BTL-1 Remembering
11. Propose a set of selection criteria and testing method for the choice
BTL-5 Analyzing
of a battery technology in an electric vehicle. (13)
12. List the some different ways you could communicate a concept for a
BTL-5 Analyzing
new user interface for an automotive audio system. (13)
13. Electronic Postal Face-to-
BTL-2 Understanding
Telephone Mail Mail Internet Face
Verbal description • • • • •
Sketch • • • •
Photo or rendering • • • •
Storyboard • • • •
Video • •
Simulation • •
Interactive multimedia • •
Physical appearance model •
Working prototype •

Enumerate the significance of above table, for concept

communication of a SUV. (13)
Roughly estimate N for the following products. List your
14. BTL-6
assumptions Evaluating

(i) A sleeping pillow for air travelers. (7)

(ii) An electronic weather station (monitoring temperature,
humidity, etc.) for homes. (6)

PART–C 15 Marks

Compose the problem of designing a barbecue grill. Try a functional

1. BTL-1 Understanding
decomposition as well as a decomposition based on the user
interactions with the product.

Prepare an external - search plan for the problem of permanently

2. BTL-6 Evaluating
applying serial numbers to plastic products.

When might it not be advantageous to communicate the product

3. BTL-5 Analyzing
concept to potential customers using a working prototype? Under
what circumstances is it better to use some other format?

4 Explain how should a company align the concept generation, selection BTL-6 Evaluating
and testing process, when a CNC job is outsourced to a design
consultancy.
 UNIT-III PRODUCT ARCHITECTURE

Implications - Product change - variety - component standardization - product performance -

manufacturability -Product development management - establishing the architecture - creation -
clustering - geometric layout development - Fundamental and incidental interactions - related system level
design issues - secondary systems -architecture of the chunks - creating detailed interface specifications.

PART A 2Marks
1. Define product architecture. BTL-1 Remembering

2. Write short notes on chunks. BTL-1 Remembering

3. Interpret Modularity in product architecture. BTL-2 Understanding

4. Give a few illustrations for chunks. BTL-2 Understanding
5. List the types of modularity. BTL-1 Remembering

6. Illustrate slot modular architecture. BTL-2 Understanding

7. Interpret the bus modular architecture. BTL-2 Understanding

8. Describe the section modularity briefly. BTL-2 Understanding

List the need for interfacing chunkss. Remembering

9. BTL-1
10 Define product variety. BTL-1 Remembering

11 Express the Product changes. BTL-2 Understanding

12 Define Manufacturability. BTL-1 Remembering

13 List out the need for component standardization.

BTL-1 Remembering
Express the need for Product development management. Applying
14 BTL-2
15 Define add-on. BTL-1 Remembering

16 Define upgrade. BTL-1 Remembering

Explain the steps involved in establishing product architecture. BTL-1 Remembering
17
18 BTL-1 Remembering
Explain the two categories of integration process.
19 Enumerate the secondary system. BTL-5 Applying
20 Assess the design issues in PA. BTL-5 Applying
 PART -B 13 Marks
1 (i) Describe the need for chunks in product architecture. (07)
BTL-1 Remembering
(ii) Explain the types of modularity with example. (06)
BTL-1 Remembering

2 Explain the modularity involved in the bicycle chunk mentioned BTL-2 Understanding

below, (13)

3 (i) Describe the implications of architecture in product BTL-1 Remembering

development. (07)

(ii) Explain the importance of component standardization. (06) BTL-1 Remembering

4 i) Explain product performance using Swatch as a case study BTL-1 Remembering

and illustrate the same. (07)

(ii) Explain the Product development management related to BTL-1 Remembering

Modular and integral architectures. (06)

(i) Express the way by which the product will be created and BTL-2
5 Understanding
clustered in architecture. (07)
(ii) Explain fundamental and incidental interaction with
BTL-2
examples. (06) Understanding

Explain secondary Systems like safety systems, power systems, BTL-1 Remembering
6
and structural supports in detail. (13)

Summarize the design issues that make an impact in related BTL-2 Understanding
7
system of product architecture. (13)
Number SOHO (Small Office,
8 Chunks of Types Family Student BTL-3 Comparing
Home Office)

Tabulate a commonality plan for a printer in the format

mentioned above. (13)

9 Describe the four-step method to structure the decision process, BTL-1 Remembering
using the deskjet printer, with a geometric layout. (13)
 Compare the slot modular architecture, bus modular
BTL-3 Comparing
10 architecture and section Modular architecture. (13)

Component standardization affects the degree of product variety BTL-5 Analyzing

11
– Analyze the statement and give justification. (13)
12 Compare differentiation plan and commonality plan, for a CNC
BTL-3 Comparing
milling machine. (13)
13 Give short notes on,
(i)Functionality of Chunks (07) BTL-1 Remembering

(ii) Platform Planning (06)

BTL-1 Remembering

14 Give short notes on,

(i)Manufacturability and DFM issues (07) BTL-1 Remembering

(ii) Schematic of a product. (06)

BTL-1 Remembering

PART C 15 Marks
Plan a schematic for a wrist watch, using only functional
1 BTL-5 Analyzing
elements. (without assuming any particular physical
working principles or components).
Draw a schematic of a small electromechanical product
2 including the essential functional elements Formulate a BTL-5 Analyzing
schematic including the essential functional elements.
Identify two or three possible clustering’s of these elements
into chunks.
Judge - A firm cannot achieve high product variety without a
3 BTL-5 Analyzing
modular product architecture.
Explain how product architecture will differ for a product
4 (bicycle) developed for an economically lower segment of market
vis-a-vis the same product (bicycle) developed for upper segment BTL-5 Analyzing
of market.
 UNIT IV INDUSTRIAL DESIGN

Integrate process design - Managing costs - Robust design - Integrating CAE, CAD, CAM tools –
Simulating product performance and manufacturing processes electronically - Need for industrial design-
impact – design process - investigation of customer needs - conceptualization- refinement - management of
the industrial design process - technology driven products - user - driven products - assessing the quality of
industrial design.
PART A 2 Marks
1 Define industrial design. BTL-1 Remembering

2 List the steps involved in integrated process design. BTL-1 Remembering

3 List out the need for customer focus. BTL-1 Remembering

4 Express the function of cost management. BTL-1 Remembering

5 Define robust design. BTL-1 Remembering

6 Interpret the use of integrating CAE/CAD/CAM. BTL-4 Analyzing

7 Explain briefly the need for industrial design. BTL-1 Remembering

8 List the investigation methods used to infer customer needs. BTL-2 Understanding
9 Define customer satisfaction. BTL-1 Remembering

10 Express the block diagram for Managing cost. BTL-1 Remembering

11 Illustrate product differentiation. BTL-2 Understanding

12 Infer the importance of management in industrial design Creating

BTL-6
process.

13 Summarize the different driven technique used in management BTL-1 Remembering

design.

14 Explain briefly technology driven products. BTL-2 Understanding

15 List out few user driven products. BTL-2 Understanding

16 Define conceptualization. BTL-5 Evaluating
17 Analyze the role of an user in Industrial design.
BTL-5 Analyzing
18 What is the need for assessment of quality in industrial design? BTL-5 Evaluating

19 Generalize the product refinement process. BTL-6 Creating

20 List the steps in AQID. BTL-6 Creating
 PART B 13 Marks
1
(i) Briefly explain Control drawings or model used in ID. (07)
BTL-1 Remembering
(ii) How industrial design establishes a corporate identity for
BTL-1 Remembering
market needs? (06)

Explain the industrial design history of the following product BTL-2 Understanding
2
given below, (13)

(i)Describe the need for assessing Industrial Design. (07) BTL-1 Remembering
3
(ii) Assess the importance of industrial design for Motorola’s
RAZR mobile phone. (06) BTL-1 Remembering

Is Industrial Design Worth the Investment? Explain with BTL-1 Remembering

4
respect to, singular architecture and integral architecture. (13)

5 (i) Compare ergonomic needs and aesthetic needs. (07)

BTL-3 Comparing
(ii)Compare total Expenditures on Industrial Design and
percentage spent on ID. (06)
Give short notes on,
6
(i)Robust design (07) BTL-1 Remembering

(ii) Simulation of product performance (06) Remembering

BTL-1

Explain the need for CAE/CAD/CAM in Industrial design, BTL-2 Understanding

7
using suitable illustrations. (13)
 Explain the role of Investigation of customer needs and
8 BTL-3 Comparing
conceptualization in evolution of the RAZR concept. (13)

Give short notes on,

9
(i)Refinement and Final Concept Selection (06) BTL-1
Remembering

(ii) The Impact of Computer-Based Tools on ID Process. (07) BTL-1 Remembering

10 Compare technology-driven products and user- driven products.

BTL-3 Comparing
Also list out the corresponding merits and demerits. (13)
Coordination with Engineering, Manufacturing, and External
11 BTL-5 Analyzing
Vendors are essential for ID.
– Analyze the statement and give justification. (13)

12 Compare the assessment of Industrial Design quality with BTL-3 Comparing

continuous quality control systems. (13)

Give short notes on,

13
(i) Quality of the User Interface (07) BTL-1 Remembering
(ii) Emotional appeal (06) BTL-1 Remembering

Give short notes on,

14
(i)Appropriate use of resources. (07) BTL-1 Remembering
BTL-1 Remembering
(ii) Product differentiation. (06)

PART C (15 Marks)

List some firms that you feel have a strong corporate identity.
1 BTL-4 Analyzing
What aspects of their products helped to develop this identity?

Design the product form both "from the inside out” and "from
2
the outside in" for a simple product such as stapler, a telephone BTL-5 Evaluating
and decide.

The term visual equity is sometimes used to refer to the value

-3 BTL-4 Analyzing
of the distinctive appearance of a firm’s products. How is such
equity obtained? Can it be “purchased” over a short time
period, or does it accrue slowly?
By what cause-and-effect mechanism does ID affect a
4 BTL-5 Evaluating
product’s manufacturing cost? Under what conditions would ID
increase or decrease manufacturing cost?
 UNIT V DESIGN FOR MANUFACTURING AND PRODUCT
DEVELOPMENT

Definition - Estimation of Manufacturing cost-reducing the component costs and assembly costs – Minimize
system complexity - Prototype basics - Principles of prototyping - Planning for prototypes - Economic Analysis
- Understanding and representing tasks-baseline project planning - accelerating the project-project execution.

PART A 2 Marks
1 Define DFM. BTL-1 Remembering
2 List the steps in DFM process. BTL-1 Remembering
3 Give the main categories involved in DFM. BTL-1 Remembering
4 List the steps to reduce manufacturing cost. BTL-2 Understanding
5 Explain assembly cost briefly. BTL-1 Remembering
6 Define component cost. BTL-1 Remembering
7 List out the impact of overhead cost. BTL-2 Understanding
8 Define fixed cost. BTL-1 Remembering

List the steps involved in reducing assembly cost. BTL-2 Understanding

9
10 Discuss the economic analysis. BTL-2 Understanding
11 Explain industrial prototyping. BTL-2 Understanding
12 List out the different prototype techniques. BTL-2 Understanding
13 Summarize the benefits of complexity minimization. BTL-2 Understanding
List the estimation methods used in manufacturing cost. BTL-2 Understanding
14
15 Interpret the steps involved in prototype design.
BTL-4 Analyzing
16 Illustrate the basic principle of base line project planning. BTL-4 Analyzing

17 Infer the planning steps involved in task representation. BTL-2 understanding

18 Assess the different types of economic analysis. BTL-4 Analyzing

19 Assess the quantitative analysis in quality control. BTL-4 Analyzing

20 Define project execution. BTL-1 Remembering
PART B 13 Marks
1 Consider the following 5 “design rules” for electromechanical BTL-4 Analyzing
products. Do these seem like reasonable guidelines? Under what
circumstances could one rule conflict with another one? How
should such a trade-off be settled?
a) Minimize parts count.

b) Use modular assembly.

 c) Stack assemblies.

d) Eliminate adjustments.

e) Eliminate cables. (13)

2 Can you propose a set of metrics that would be useful for the BTL-4 Analyzing
team to predict changes in the actual costs of supporting
production? To be effective, these metrics must be sensitive to
changes in the design that affect indirect costs experienced by the
firm. What are some of the barriers to the introduction of such
techniques in practice? (13)

3 (i) Is it practical to design a product with 100 percent Understanding

BTL-3
assembly efficiency (DFA index = 1.0)? What conditions would
have to be met? Can you think of any products with very high
(greater than 75 percent) assembly efficiency? (9)

(ii) Explain the steps in estimation of manufacturing cost. (4)

Explain the following,
4
(i) Basic Principles used in prototype design. (06) BTL-2 Understanding

(ii) Prototyping technologies. (07) BTL-2 Understanding

5 Many product development teams separate the “looks-like” BTL-4 Analyzing

prototype from the “works-like” prototype. They do this because

integrating both function and form is difficult in the early phases
of development. What are the strengths and weaknesses of this
approach? For what types of products might this approach be
dangerous? (13)
(i) Describe in detail the DFM process,with suitable example. (7) BTL-2 Understanding
6
(ii) Explain the steps to reduce component and assembly cost. (6) BTL-2 Understanding
7 Today there are several technologies able to create physical parts BTL-4 Analyzing

directly from 3D CAD files (e.g., stereolithography and selective

laser sintering). How might a team use such rapid prototyping
technologies during the concept development phase of the
product development process? Might these technologies
facilitate identifying customer needs, establishing
specifications, generating product concepts, selecting product
concepts, and/or testing product concepts? (13)
 Can you think of successful products that never would have BTL-4 Analyzing
8
been developed if their creators had relied exclusively on a
quantitative financial model to justify their efforts? Do these
products share any characteristics? (13)
One model of the impact of a delay in product introduction is BTL-1
9 Applying
that sales are simply shifted later in time. Another model is that
some of the sales are pushed beyond the “window of
opportunity” and are lost forever. Can you suggest other models
for the implications of an extension of product development
time? Is such an extension ever beneficial? (13)
Explain the following,
10
(i) Methods for accelerating the projects. (06) BTL-2 Understanding

(ii) Need for quantitative analysis. (07) BTL-2 Understanding

What would you expect to be some of the characteristics of
11 individuals who successfully lead project teams? Explain them in BTL-1
Remembering
detail. (13)
Explain the following,
12
(i) Economic analysis. (06) BTL-2 Understanding

(ii) Project execution (07) BTL-2 Understanding

Under what conditions might efforts to accelerate a product BTL-4 Analyzing
13 development project also lead to increased product quality and/or
decreased product manufacturing costs? Under what conditions
might these attributes of the product deteriorate when the proj- ect is
accelerated? (13)

14 When a task on the critical path (e.g., the fabrication of a mold) BTL-3 Applying
is delayed, the completion of the entire project is delayed, even
though the total amount of work required to complete the project
may remain the same. How would you expect such a delay to
impact the total cost of the project? (13)
PART C 15 Marks

Evaluate the production cost for a simple product you may have
purchased such as pen or a baby's toy of 10 no.s. The upper
1 bound for the estimation including overhead can be taken as the
wholesale rate is 50% to 70% of retail. BTL-4 Analyzing
 Compose some potential cost-reducing modifications you could
2 make to improve the product cost for simple product such as BTL-5 Evaluating
pen or baby’s toy. Compute the DFA index before and after
these changes.

Summarize the reasons why reducing the number of parts in a

3 product might reduce production costs. Also explain some BTL-4 Analyzing
reasons why costs might increase.

A furniture manufacturer is considering a line of seating products to Remembering

4 BTL-1
be fabricated by cutting and bending a recycled plastic material
available in large sheets. Create a prototype of at least one possible
chair design by cutting and bending a sheet of paper or cardboard.
(You may wish to design the chair with a sketch first, or just start
working with the sheet directly.) What can you learn about the chair
design from your prototype? What can’t you learn about the chair
design from such a prototype?