I. Lecture, Design Requirements and Objectives MED-2014-1

Design Requirements and
Objectives (DR&O)
DR&O Philosophy
Product Design Specification
(PDS) and DR&O
Examples of DR&O
Exercise to formulate DR&O
Design Requirements and Objectives
(DR&O) Philosophy:
1. A set of criteria that should be fulfilled by the

designed product.
2. A tool for formal communication between
consumers/buyers and the producers/designers.
3. To form product specification or PDS
(Product Design Specification).
4. To use as warranty to the consumers.
5. Contains realistic constraints of the designed
product without forcing the unrealistic ones.
Design Requirements and Objectives (DR&O)
Philosophy:
The Product Design Specification definition :
• PDS is a detailed listing of requirement to be
met to produce successful product.
• PDS is a document which contains all of the
facts related to the product outcome.
• PDS is used for basic reference during the
design activities.
• PDS is used as dynamic document which can
be evolved and changed with the progress of
the design.
PRIMARY ELEMENTS OF PDS:
A lot of factors should be considered during the

design process which can influence the PDS
(Product Design Specification). Some criteria
must be fulfilled by the designed product, while
other criteria are possibly fulfilled (wish
criteria). It complicates the design process if
too many criteria are enforced. The following
are the primary elements developed by the
Institution of Production Engineers of Great
Britain (1984).
1. Product performance.
2. Environment where the product operates.
3. Service life.
4. Maintenance and logistic problems.
5. Target product price.
6. Future or existing competitor.
7. Shipping method.
8. Packing.
9. Quantity of the product.
10. Manufacturing facility.
11. Dimension and weight of the product.
12. Aesthetics, appearance and finish.
13. Available materials.
14. Product life span.
15. Standard to be followed.
16. Ergonomics.
17. Quality and reliability.
18. Design schedule.
19. Testing and inspection.
20. Safety problems.
21. Company constraints.
22. Market constraints.
23. Patent problems.
24. Social and political factors.
EXAMPLE OF DR&O
Hybrid Bicycle Design
EXAMPLE OF DR&O
Hybrid Bicycle Design :

1. Must be driven by electric motor, by human
power or the combination of both (as a
consequence, it needs a one-way clutch at the
foot pedal).
2. The power of the electric motor must be less
than 250 Watt.
3. During braking the electric motor should be off
automatically.
4. The battery must be able to store electric energy
for the distance of at least 50 km.
EXAMPLE OF DR&O
Hybrid Bicycle Design :
5. Maximum target price is 400 US$.
6. Production target is 100,000 bicycles per year.
7. Attractive appearance since the target
consumers are mostly women.
8. Maximum target weight is 25 kg.
EXAMPLE OF DR&O
Automatic Hand-Brake Design :
EXAMPLE OF DR&O
1. Must function when the car stops.
2. Must not function when the car runs.
3. Must have sufficient brake pressure on the sloping
road.
4. Must be able to release the hand-brake smoothly
and once released the car must not move
backward on the sloping road.
5. Should have a spare mechanic hand-brake in case
the automatic brake fails.
EXAMPLE OF DR&O
6. Should possess high reliability.
7. The additional cost for the automatic hand-brake
system should be less than 1,000 US$ per unit.
8. Expected production is 10,000 units per year.
9. Electronic system and sensors are expected to be
developed by other companies on a sharing cost
basis.
10. Should be developed in less than 6 months.
EXAMPLE OF DR&O
Hydraulic Actuator
Design :
EXAMPLE OF DR&O
Hydraulic Actuator Design :
1. Must have a load capacity of 2 ton or 19,6 kN.
2. Must be able to sustain hydraulic pressure of 70
bar or 7 MPa.
3. Must have a maximum stroke of 190 mm.
4. Must use standard material and components.
5. Must be able to operate safely.
6. Simple and minimize production process.
7. Easy installation.
8. Target price below 600 US $.
9. Target production 1,000 pieces per year.
EXAMPLE OF DR&O Source : George E. Dieter,
Engineering Design, A
Material and Processing
Gasoline Engine Valve : Approach,
This is a high technology

design example. Valve
material must have
excellent corrosion- and
oxidation- resistance
properties in the
temperature range of 730-
925 degree C. Valve
material should have
sufficient fatigue strength
and creep resistance at high
temperature. It should have
suitable hot hardness to
resist wear and abrasion.
EXAMPLE OF DR&O
Gasoline Engine Valve :
At the areas A and C the
high temperature corrosion-
and oxidation-resistance are
most critical. Area C should
also have fatigue resistance
since its diameter reduces.
Area B(valve seat) should
resist abrasion and wear at
high temperature due to the
deposit of the fuel ash. The
stem of the valve at area D
should have sufficient wear
resistance.
EXAMPLE OF DR&O
Gasoline Engine Valve :
Wear resistance is also
needed at the end of the
stem, area E, where the
valve contacts the rocker
arm. Valve material in use
is Alloy 21-2N which has
chemical composition of
C= 0.55% , Mn=8.25%,
Cr=20.35%, and Ni=2.1 %.
Other idea is to use SAE
3140/4140 for the upper
stem connected by welding
with the lower part.
EXAMPLE OF DR&O
Exercise to create DR&O for the electric motor
housing by changing the material from gray cast iron
to aluminum casting alloy.
Source : George E. Dieter,
Engineering Design, A
Material and Processing
Approach,
Please consider the

must and the wish
criteria which should
be put in the DR &O.
EXAMPLE OF DR&O
Aluminum alloy should possess the same corrosion
and tensile strength compare to gray cast iron (see
Table). The advantage of aluminum alloy is 40%
lighter and the heat conductivity is 3 times higher than
gray cast iron. The drawback is in the compressive
strength which is lower than the gray cast iron.
Hence at the bearing support,
a steel ring insert should be
provided to minimize the
problem of the compressive
load.
EXAMPLE OF DR&O
EXAMPLE OF DR&O
Additional requirements that should be fulfilled
by electric motor housing are:
1. Vibration test.
2. Naval shock test (MIL- S-
901).
3. Salt fog test (ASTM B117-
57T).
4. Corrosion test between
aluminum alloy part and
the steel bolts.
5. Strength of the lifting lugs.
Exercise for formulating DR&O ?
Source : Aeromovel Project, Indonesia

Source :
Business Week Magazine for
most of the pictures for the
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Design Requirements and

1. A set of criteria that should be fulfilled by the

A lot of factors should be considered during the

Hybrid Bicycle Design :

This is a high technology

Please consider the

Source : Aeromovel Project, Indonesia

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