Index
Note: Page numbers followed by f indicate figures, t indicate tables, and p indicate plates.
A
Accuracy 182
engineers and organizations 402
six-point plan 403
Attention to detail 12
B
minimum safety factor 265–266
procedure, analyst/designer 266–269
roof beam loading regime 265
sectional view, intended 268f
Blue Angel certification 388
classic 150–156
imaginary 157–158
deforestation 352
environmental impact, industrial activity 352
Brazil 352
China 353–354
India 353
Russia 352
net cost-benefit argument, longevity/reparability 381–382
C
CAF See Computer-aided failure (CAF)
emissions, waste, environmental quality 347
guidelines and codes 347
quality, natural environment 347
Cantilever lifting device 292
advantages and disadvantages 362
burden shifting 361
description 361
goods and services, climate change 361
initiatives 361–362
life cycle assessment 361
types, organizations 361
Carbon Reduction Label 389
China, BRICS Nations 353–354
bed lifting device 154–155
definition 152
free thinking 150–151
generated solutions, phases 155–156
topic and ground rules 153
drawing 213
individual 221
large institutions 220–221
medium-sized 221
presentation, designs 223
project requirements 222–223
requirements 221
styles, methods and presentation 223
Combined Heat and Power Act (KWKG) 350
description 236
design flaws 237
pressurized cabin 236–237
drawing 213
general 215–216
instructions, drawing 213
materials 216
oft-repeated convention 214
parts lists 216
remarks, drawings 213–214
title block and border 213
academic publishing 194
description 181
designers 181
drawing application 200–220
graphics 194–200
manufacturing 181
project/technical reports 187–194
tools 181
written 182–187
aerodynamics 8
description 259
red-colored areas, maximum air disruption 259
wind tunnel tests 259
strength and weight, component/structure 234
complex calculations 256
novice engineers 256
supermarket (Mall) roof 256
client 53
function and performance 52
and PDS 54
advantages 51
classic brainstorming 45
decomposition 43–44
heuristic redefinition 44–45
imaginary brainstorming 45
“inventor syndrome” 43
least commitment 43
“mental blocks” 44
synectics 46–47
TILMAG 45
word-picture associations and analogies 45
technical informations 54
visual representation 52
benchmarking, competitive products 129
design specification 125
“development iteration” 125
economic analysis 129
identification, customer needs 125–126
modeling and prototyping 129–130
project planning 129
testing 129
Consumer benefit 404–405
D
“Biggest Pie in the World” 279
cooker, designed 248
designers 279–282
loading regime 279
one single column within fabrication 281
structure 279
advantages, structural analysis 299
aircraft 24
application 144–150
artisans 21–22
attention to detail 12
bolt-together system 292
CAD modeling and simulation software 24
cantilever lifting device 292
Colt factory 22
creativity, tools 143
critical path 174
decision-making process 30
definition 143–150
drafting methods 23
dummy activities 174
elements 33
kinetic energy storage device project 33–34
high-priority/low-priority activities 172
industrial device 292–293
innovative process methods 295
lifting device 292–293
“light-bulb moment” 21
assembly direction minimization 307
car-parking device 306–307
design parts, fabrication and assembly 304–305
fastening systems 305–306
handling minimization 307
industry, 20th century 22
minimization, parts 303
modular designs 303
multifunctional parts 303
multiuse design parts 304
modularization 300–302
NASA 143–144
optimization strategy 294–295
passenger vehicle body 296
PDS 32–33
PERT 174–175
practical product See (Practical product, design approach)
product creation process 291
prototypes 63
quality, manufactured goods 23
recycling infrastructure 310
reduction 310
refurbishment 310
requirements and tools, product 25
reuse 310
single-unit production 299
sustainable design function 310–311
time allocation 173–174
tools 144
uniformly stressed beams 299
engineering purchaser 322
manufacturing engineer 322
marketing and sales 322
multidisciplinary design team 321
product designer 322
production costs 321
value engineer 321–322
constructive discontent 29
creative attitudes 28–29
flywheel kinetic energy storage system 28
knowledge and skills 25–28
magnetic levitation bearings 28
processes 25–28
solutions 29
Digital analytical prediction 296
assembly and subassembly drawings 200
detail/manufacturing drawings 199–200
subassemblies 200
description 197–198
digitization 198
Filter Tilter 199
tools 198
allocation, drawing numbers 216–219
center lines 211
checklist and errors 213–214
size 207–208
strategy 209–210
hidden detail 207
information clarity 201–202
material specification 211
orthographic projection 202–206
text and formal lettering 212
title block 211–212
tolerances and surface finish 210–211
views and sections 206–207
E
description 362
environmental impact and carbon footprint (CO2) scores 362
LCA programs 363
catalytic converter 360–361
concept, NRE 358–360
“country of origin” 360
mining form 360–361
recycling issues and “hidden flow” 360
RS factor 360
World Summit on Sustainable development (WSSD) 358–360
defined 228
diverse sources 230
GN/m2 units 228
“predicted” stresses 228
resistance, shock load 229
stress calculation 228
tensile tests 229
EMIT consortium 364–365
designer’s role 342
recycle 341–342
reduction 339–340
reuse, floor panels 342
reuse/refurbish 340–341
description 101
disposal techniques 76
EnEg See Energy Conservation Act (EnEg)
Energy Conservation Act (EnEg) 350
Energy Savings Trust 401
actuation systems 6–7
brand-new product 1
CFD 8
computer databases 8
3-D computer-aided design (CAD) 7
definitive process 2
description 1
electric motor options 7
elements 8
environmental impact and sustainability 16–18
evolutionary process 7–9
factory environment 7
first product 7
“information is the currency of design” 5–6
inventions 1
lubrication delivery systems 12
modern 3-D systems 12
modern vehicles 8
new product 1
packages, CAD software 10
people and society 16
process, new designs 12
profit 16
qualities 10–12
suppliers and manufacturers 7
tools 9
Engineering plastics 337–338
carbon emission reductions 358
decision makers 358
description 358
“fit-and-forget” approach 358
EOL See End-of-life (EOL)
Directive 2008/98/EC 348
framework directives, national law 349
impacts, environment 347
pollution issues 347
product groups, working plan 348
regulations 348
sustainable and renewable energy generation 348
F
The Comet, First Jet Airliner 236
description 235
cracks 239
materials 239
variations 239
welds 239
S-N Curves 240–245
welded joints 239
elimination 368
high investment cost 368
machine tools 368
packaging improvements 368–369
redesign/substitution 368
selection, materials 368
standardized reusable transport crates 369
G
General beam theory 297
design 122
drawings 122
geometry, materials and tolerances 122
material components 122–124
planning 120–122
production system 124–125
prototype testing and refinement 124
B2B sales 350
KWKG and EnEg in 2008 350
nonrecyclable packaging materials 350
packaging 350
priorities 350
producer 350
responsibility, federal government 349
sustainability strategy 349
Goodman Curves See S-N Curves
academic users, private companies and corporations 363
CAD software programs 364
CES Selector 364
EMIT consortium 364–365
issues across life cycle stages 363–364
LCA systems 363
“material intelligence” design aid tool 363
2D modeling 199–200
3D modeling 197–199
low-to high-level precision 195
H
Happy Planet Index (HPI) 400
HDPE See High-density polythene (HDPE)
Heat transfer, Denby Dale pie 282–283
Heuristic redefinition 143–150
containers 401
milk bottle 401
HPI See Happy Planet Index (HPI)
I
mini cement mixer 157–158
tool 157
India, BRICS Nations 353
Industrial device 292–293
ISO 9000 series 393
ISO 14000 series 387
J
Basic Environment Plan 354
control, pollution levels 354
disaster at Fukushima 354
hybrid and electric vehicles 354
2010 OECD review, Japanese policy 354
role, guardian 354
K
KWKG See Combined Heat and Power Act (KWKG)
L
BRICS Nations See (BRICS Nations)
Canada 347
description 345
financial 368–369
social 365–367
Europe 347–349
Germany 349–351
Chinese government 356
empirical evidence 356
European Environment Agency (EEA) 355
“fit-and-forget” approach 355
issues 355
lawyers and lawmakers 356
positive and preventative approach 357
“race-to-the-bottom” argument 356
UK DEFRA 355–356
Japan 354
labor cost 345–346
marketers 345
nonlegislative measurement and guidance tools See (Nonlegislative measurements)
recycling 346
The United Kingdom 349
The United States 346
LG Electronics 391–392
carbon footprint and embodied energy 323–324
designer’s duty 326–327
natural energy 323–324
steel fabrications 323
M
Market-driving sustainability 398–399
calculation 375
financial performance 377
GDP 376
index system 375
social responsibility 376
Modular design 312–313
N
carbon footprint 361–362
development, “eco” tools 357
EAI and IDEA abacus 357
Eco-Rucksack tool 358–361
energy-based and carbon-based models 357
Granta research 363–365
models, databases and algorithms 358
nonsustainable energy 357–358
pollution emissions 357
research and educational institutions 357
tool concept, ECO-IT 362–363
O
Old-style chassis design 296
Organisation Environmental Footprint (OEF) 384
convention 205–206
P
accounting 220
contents 220
manufacturing 220
planning department 220
purchasing department 219
advanced computational analytical techniques 249
basic electronic calculation tools 249
bearings and seals suppliers 247
CAF See (Computer-aided failure (CAF))
categories 225
CFD analysis, wind tunnel model See (Computational fluid dynamics (CFD))
design iteration, computer-aided analysis See (Computer-aided analysis)
3D picture development, stresses 233
engineers 233
standard beam calculations 233
3D CAD system 252–253
engineering analysis 225
fatigue strength prediction See (Fatigue strength prediction)
first bottom line 260
Formula One racing car engine 225
by guesswork/sheer experience 225
engineers, industrial revolution 226
mathematicians and engineers 226
analytical techniques 226
elastic region 227
fracture point 228
UTS 228
yield point 228
mathematical techniques 225
accurate material strengths, experimental data 230
designers 231
factors 230
footbridge 230–231
multiple safety factor 231
pivot points, “Car Stacker” 232
second bottom line 260–261
stages 247
stainless steel pipeline junction 257–258
third bottom line 262
vibration isolation vendors 247
analysis 60–61
3-D software package 58
Producers benefit 383–384
cost and sustainability 40
description 35
competition 38–39
patents 39
duty 41–42
economic and manufacturing 42
environmental 42
sustainability 42
metrics 43
progression 35–36
requirements and constraints 43
brainstorming See (Brainstorming)
concept See (Concept development)
decision making 117
development 114
project and team 114–115
function 113–114
generic See (Generic product development process)
imaginary brainstorming 157–158
investment 117
manufacturing 114
marketing 113
morphological box 167–169
function allegiances 118
inadequate resources 118
lack of team responsibility 118
minimal cross functional expertise 118
planning and methods, designs See (Design approach)
coordination 119
management 119
opportunities 120
physical 118
planning 119
quality assurance 119
screws 117
systematic approach See (Systematic approach, design development)
technologies 117
TILMAG 163–167
time pressure 117
trade-offs 117
word-picture See (Word-picture associations and analogies)
Product Environmental Footprint (PEF) 384
Programme evaluation and review technique (PERT) 174–175
appendix 191
bibliography 191
body of text 190
contents page 188
cover sheet 188
description 187
effective introduction 189–190
elements 187–188
executive summary/abstract 189
language 187
grammar and spelling 194
logical progression 192
margins 193
pictures, diagrams and tables 194
single page, text 192
recommendations 190
title 188
R
description 17p
digital 80–81
reductions, methods 78
virtual factories 80
ball bearing 94
clamp leg 94
gripper bar 95
machinery and equipment 91
Pivot pin 94
seals and bearings 92
self-lube plastic bearing 94
Stahel’s concept 91
“alarming”, urban and industrial areas 352
environmental specialists 352
sovereign guarantees, environmental loans 353
S
SDV See Sustainable disposal value (SDV)
SGBV See Sustainable giveback value (SGBV)
SLV See Sustainable life value (SLV)
Smart Factory See Renault Tangiers Smart Factory
SMaV See Sustainable maintenance value (SMaV)
EN 8 (080M46) 242
calculation, diameter 244
diameter 244
infinite number, stress reversals 244
maximum bending moment 244
parameters 244
working stress σw, 100 MN/m2 245
stress concentrations See (Stress concentration factors)
carbon emission reduction 365
consumer product suppliers 365
description 365
direct emission reductions 367
German activism and legislation 365
public awareness, energy savings 365
savings, projects 367
stringent Stage IIIB/Tier 4i emissions 367
TerraChoice 365
bicycle relative components 274f
design engineers, project requirements 271–275
dynamics, powering a bicycle 247
parameters 271
pedal-wheel relationship 272f
calibration within software 258
reader’s attention 258
analysis 245–247
bending moment 263
bending stress 263
d/D ratio 264
σmax determination 265
determination, gear-mounted shaft 262–264
elements, shoulders/undercuts 245
find reactions 262
maximum level 247
maximum stress, shaft 265
nominal stress σnom 265
r/D ratio 264
second moment, area 263
“S-N” curve 245
aircraft structures 102
architects and builders 69
blogs and public rating systems 390–391
Blue Angel/Blauer Engel 388
Brundtland Commission Report 65
carbon neutral 387–388
Carbon Reduction Label 389
closed loop material cycle 67
coal-and oil-powered power stations 68
design, manufacture 77–81
D to AAA rating system 387
Earth’s ecosystem 68
Eco-rucksack and Envirowise 100
Energy Saving Trust Recommended scheme 389–390
energy star label 388
engineering designers and design 104
EOL rotor 101
EU Ecolabel 389
giveback technique 96–97
“Holy Grail” 66
human infestation 67–68
IMechE 105
labels and quality management systems 393
LG Electronics 391–392
market communications 392–393
carbon dioxide 98
energy as parameter 99
mechanical engineering 69
open-loop cycle 66
recycling 71
4Rs 66
sourcing/ecosourcing 73–76
Taguchi approach 72
TerraChoice organization 391
US-based research 385
vehicle manufacturers 71
web-based criticism 390
application 288
design and manufacture process 287–288
embedded energy 287
recycled materials 289–290
reduction, haulage dependence 290–291
sourcing 288–289
stages 288
benefit to buyers 380–383
measurement and certification industry 384–393
3P approach See (Triple bottom line (TBL))
producers benefit 383–384
EOL disposal techniques 88
4R components 88
recycling 89
reduction 96
repair and refurbish 89–91
reuse and refurbish 91–95
Sustainable engineering design (SED) 72–73
Sustainable giveback value (SGBV) 97
measurement method 105
gaskets 87
internal combustion engines 83–84
lubrication 87–88
manufacturers 83
PTFE 87
description 77
safe product, minimal embodied energy value 299
smart factory 77–81
designers’ duty 76
managed sources 75
material flow systems 76
recycle 76
techniques 75
transportation 73–74
design optimization 81–82
energy storage 82–83
incorporate equipment 82
natural energy 82
reducing energy 82
SUV See Sustainable use value (SUV)
analysis 137–138
design 133
customer needs statement 140–141
designer 130
evaluation 134–137
evolution 140
invention and lateral thinking 143
“primary need” product 130
secondary needs 141
concept design specification 130–131
elements 131–132
product design specification 130
technique 130
synthesis 132–133
T
quality manufacturing 72
SED 72–73
TBL See Triple bottom line (TBL)
bed lifting device 165
operation technique 164
solution generation technique 163
behavioral analysis 247
design engineers, project requirements 269–271
parameters 269
design function 291–311
assembly direction minimization 319
assembly methods 318
design constraints and team formation 320–322
design parts, fabrication 314–315
fastening systems 318–319
handling minimization 320
maximization, compliance 319–320
minimizing number of parts 312
modular design 312–313
multifunctional parts 313
multiuse parts 313
product creation process 311
reevaluation, welds 315–318
EOL disposal 338–342
lifetime usage 323–327
accessibility, ease of component removal 329
component life prediction 328
detail design, quick-and-easy maintenance 330–331
downtime 329–330
engineering plastics 337–338
life, product 327–328
location 331–332
lubrication and lubricant delivery 334–335
modular build 333
simplicity, components and standardization 329
water-well rock drill 332–333
manufacturing 311–322
stages, product’s development 287
sustainability umbrella model 285–286
Cascade Engineering Inc. 378
company’s financial performance 374
description 373
“elastic tool” 379
financial health and profitability 374
manufacturing companies, TBL 377–378
measurement systems 375–377
people/society 373
planet/environment 373
profit 373
public attitudes 373–374
public decision-making 379
“sketchy” set 379
society’s emerging trends 374
sustainability performance 379–380
U
UDL See Uniformly distributed load (UDL)
Ultimate tensile strength (UTS) 228
Uniformly distributed load (UDL) 297–298
DEFRA, waste hierarchy 349
description 349
Waste and Emissions Trading Act 2003 349
academics and engineering bodies 346
environmental protection 346
“gas guzzler tax”, vehicles 346
UK’s BREEAM and LEED certification systems 346
water pollution and resources development 346
UTS See Ultimate tensile strength (UTS)
V
behavioral analysis 247
deflection 278
engine mount arrangement, large diesel engine 277
isolation efficiency graph 277–279
load, each isolator 278
spring stiffness 279
Virtual material (VM) 360
W
bed lifting device 160–161
complications 161
description 160
picture associations 161
team stimulation 161–163
tools 160
word associations 161
memory 158
random words 159–160
team stimulation 161–163
word associations 161
World Summit on Sustainable development (WSSD) 358–360
accuracy 182
avoidance 185
brevity and clarity 184
crafting 183
graphics 184
guidelines 183
intended audience 184–185
logs and notebooks 186
memoranda, business letters and e-mail 186–187
planning 183
presentation 182
report structure 183
research 182
revising, editing and proofreading 185–186
rewriting and proofreading 185
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