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CALTECH E 105 - Syllabus

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ME/E105 Product DesignFirst Term 2004 (3,0,6)Tuesday, Thursday 2:30 to 3:55, Thomas 08Guest SpeakersWe will also hear some guest speakers who will discuss how these principles apply in their industries. There will be a parallel speaker Series which will present additional materials related to building products for a sustainable world. Attendance at these Talks though not, mandatory, can enrich your understanding and lead to a better final product result.TimetableThe TA and I are available continuously for counseling on this assignment. Please feel free to call on us.GradesAuditingLecture: Tools to design products robust against unintended uses as well as against flaws that can cause early failure.Financial ConsiderationsME/E105 Product DesignProfessor Ken Pickar, TA: tbaFirst Term 2004 (3,0,6)Tuesday, Thursday 2:30 to 3:55, Thomas 08 Office: Thomas 101Office hours: please e-mail or call ahead to scheduleE-mail: [email protected], Phone: X4185 (Pickar)Website: http://www.its.caltech.edu/~kpickar/Course Objectives:- To study the business and social context for developing products.- To study how product development is accomplished and to actually design a product through the early design stages- To learn team and communications skillsNote: For 2004, for students interested in the subject of “design of appropriate products in developing countries”, we will explore the social context required to develop successful products in general and in developing countries in particular. In addition there will be a parallel module, with a speakers' series to cover this subject in more detail. We expect students from Art Center and Occidental College to join us. Other projects, not related to this subject are, of course, also considered.The purpose of this course will be to expose students to the complete spectrum of productdevelopment activities from market research to production and after-market support. The course will give insight to products developed using a variety of technologies in a number of industry segments. The context will include issues peculiar to new start-up companies as well as to mature ones. DFXFor all students, industry-standard good practices will be presented. Design will be presented as a process whose cost, performance, timing, and quality can itself be measured. Integral with this approach is the adoption of a series of anticipatory design practices which form the core of this course. (These are sometimes referred to as DFX or Design For “X” methodologies.) For example, researched customer desires are taken intoaccount to assure that the product will have a market. Another concept covered is producteconomic return, including the practice of design to a specified cost. An important issue is reliability where we address the question of making products that are robust against use (or misuse) and predictably survive for greater than a specified period. Manufacturability will be covered where the design enables products to be made in the most cost-effective, reproducible fashion. We emphasize the effect on the environment through all phases of the life cycle of a product. This includes manufacture, use and disposal, all considered during the design stage to minimize unhappy surprises. The human interface is another important consideration. In addition to ease of use, this subject also addresses health and safety concerns. Sustainability in a resource-limited world will also be emphasized thisquarter through the medium of products that are appropriate in non-technological societies. For developed societies we also will consider the issue of the effect of our products on our limited natural resources. Ethical discussions, using case methodologies, will cover occasions when engineers are faced with choices that conflict with personal values. We will present methodologies for addressing these dilemmas, which arise in the life of every engineer. We consider also that products are made in a social and political context. It is particularly important for engineers to be aware in the design phase of regulatory issues, IP protection, legal restrictions, misuse and other government and socialconstraints. To study these methodologies, there will be a student term project where a student-chosenproduct concept is developed by a 3-person team. Each of the good practices will be applied to each of the selected projects. In addition to the design of products appropriate in developing countries, we consider other ideas as well. These may involve the development of a good user interface, (such as a future application of a PDA or cell-phone technology). They may also involve the application of a Caltech technology to a new product in a new market. There will be an opportunity for rapid prototyping to help in the design concept. It is not expected that a complete ready-to-manufacture design will be completed in the limited time available. However, design studies and drawings will be made and perhaps early prototypes could bedeveloped.MentorsTo assist you, experienced mentors with industry or developing country experience will beassigned to each product team.Designs Appropriate for the Developing WorldIn addition to lectures, we will employ real-life studies, using guest speakers to explore several examples of the application of these principles. As mentioned above, for the subject of products for developing countries, there will be a parallel speaker series which will emphasize the special issues associated with this subject. For these projects, we intendto have a fourth team member from the developing country, working under the guidance of an in-country mentor. Because of their higher organizational complexity we will have these teams in place and the subjects vetted prior to the start of class. This sequence is being developed in collaboration with the Caltech Chapter of Engineers for Sustainable Development (www.its.caltech.edu/~esw) and Design that Matters, an MIT-related organization (www.designthatmatters.org) and the Enhanced Energy Foundation (www.eefnow.org).ME 71Some lectures will be held jointly for students in Professor Burdick’s class, ME 71. These are indicated by an asterisk in the 2004 Class Schedule listed below.FactoryThere will be one field trip. The objective is to see how the ideas learned in class are applied in real industrial settings. In particular, how product design and manufacturing are made congruent. TeamsTo increase the team diversity


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