Product Design Process Research Articles

Research on harmonious design of chairs based on the Kano model and analytic hierarchy process

To meet the functional and emotional needs of users for outdoor leisure chairs, the three-level theory of harmonious design was applied. A product design process was put together based on the Kano model and analytic hierarchy process (AHP). The Kano model obtained demand attributes and influence coefficients, while the AHP obtained total weights. The target products were designed and evaluated based on the three-level theory of harmonious design to improve the user experience and satisfaction of outdoor leisure chairs. The attribute categories of harmonious demand were obtained based on the Kano model, and the harmonious demands were ranked by importance. The design analysis and design practice were conducted with the goal of harmonious design. The AHP was used to analyze the comprehensive weights of the index factors, evaluate the user satisfaction of the three design schemes, and conduct consistency test and feasibility verification of the design schemes. The optimal design scheme was selected based on the total weight mean of three design schemes. The design and analysis method based on the Kano-AHP model can focus on user demand. It can objectively and efficiently analyze design pain spots, and effectively guide the harmonious design practice, which improves user satisfaction and market transformation efficiency of creative products.

Enhancing multi-facility manufacturing resilience through integrated product and supply chain network design

This paper presents an integrated approach for joint decision-making in reliable product design and resilient supply chain network design within a two-echelon capacitated network. Our methodology simultaneously addresses two crucial decisions faced by manufacturing industry by integrating the design processes of modular products and their supply chain networks, allowing for multiple production facilities and product variants. Through redundancy allocation, we optimize product reliability within production facilities while considering component sourcing from multiple suppliers. Our approach employs three resilience strategies—multi-sourcing, supplier fortification, and backup supplier contracting—to enhance supply chain resilience against disruptions. A case study solved using a genetic algorithm demonstrates the effectiveness of different resilience strategy combinations in achieving various levels of production resilience. This research offers insights into integrated decision-making for enhancing product reliability and supply chain resilience, thereby providing valuable guidance for industry practitioners. Furthermore, the sensitivity analysis highlights the framework’s capability to minimize total costs by prioritizing resilient designs and strategically investing in resilience strategies as costs of production shortage increase. This analysis underscores the interconnected nature of product and supply chain network design decisions in mitigating disruptions and enhancing production resilience.

Analysis of Value Stream Mapping (VSM) in the Application of Lean Manufacturing to Minimize Waste at PT. Karya Indah Medika

Achievements to minimize waste can be done by adopting a Lean manufacturing approach. Lean manufacturing is a concept that can design production processes to be better, faster, and cheaper with minimal space, small inventory, small labor hours, and avoid waste. This research takes the case study of PT Karya Indah Medika which is a company engaged in manufacturing to produce medical devices, medical device service services, and medical device installation. In the company there is still waste, especially in unnecessary movements and product defects. This study aims to identify waste that occurs in the company and provide recommendations for improvements in order to minimize waste and obtain optimal production time. Value stream mapping is used to describe all processes in the company. The results showed that the initial production time of 17 hours 18 minutes could be reduced to 1 hour 55 minutes. Based on the Failure Mode and Effect Analysis (FMEA) it is known that the root cause of the problem in the highest waste is workers in a hurry so they are not thorough in working with a Risk Priority Number (RPN) score of 294, lack of materials needed for production, placement of tools that are not in accordance with production needs and a warehouse area that is less extensive by 216.

3D Vase Design Based on Interactive Genetic Algorithm and Enhanced XGBoost Model

The human–computer interaction attribute of the interactive genetic algorithm (IGA) allows users to participate in the product design process for which the product needs to be evaluated, and requiring a large number of evaluations would lead to user fatigue. To address this issue, this paper utilizes an XGBoost proxy model modified by particle swarm optimization and the graphical interaction mechanism (GIM) to construct an improved interactive genetic algorithm (PXG-IGA), and then the PXG-IGA is applied to 3D vase design. Firstly, the 3D vase shape has been designed by using a bicubic Bézier surface, and the individual genetic code is binary and includes three parts: the vase control points, the vase height, and the texture picture. Secondly, the XGBoost evaluation of the proxy model has been constructed by collecting user online evaluation data, and the particle swarm optimization algorithm has been used to optimize the hyperparameters of XGBoost. Finally, the GIM has been introduced after several generations, allowing users to change product styles independently to better meet users’ expectations. Based on the PXG-IGA, an online 3D vase design platform has been developed and compared to the traditional IGA, KD tree, random forest, and standard XGBoost proxy models. Compared with the traditional IGA, the number of evaluations has been reduced by 58.3% and the evaluation time has been reduced by 46.4%. Compared with other proxy models, the accuracy of predictions has been improved up from 1.3% to 20.2%. To a certain extent, the PXG-IGA reduces users’ operation fatigue and provides new ideas for improving user experience and product design efficiency.

Process Design for Direct Production of Battery Grade Nickel Sulfate

The clean energy transition has increased the global demand of nickel sulfate used in the Li-ion batteries. A short-term solution is to refine the nickel sulfate product from nickel intermediates. In the long-term, new direct nickel sulfate production technologies are needed. This research focused on the modeling-based concept development of a novel direct hydrometallurgical nickel sulfate process consisting of chemical leaching, impurity removal by precipitation, solvent extraction, and crystallization as an alternative to the conventional nickel sulfate production route via a nickel matte intermediate. The conventional process route with the studied nickel concentrate had lower chemical consumption and waste production compared to direct hydrometallurgical process where approximately 60% of iron was leached consuming oxygen, and the following iron precipitation step consuming calcium carbonate resulted in a high amount of iron precipitate together with gypsum. However, hydrometallurgical alternatives are often suitable for lower ore grades or volumes and can recover copper as by-product metal. The biggest impacts on carbon footprint from chemical consumption in the direct hydrometallurgical process were generated in iron precipitation and oxygen use in leaching. With the studied nickel concentrate, pyrrhotite played a key role in both oxygen use and iron precipitation. In the leaching step, 68% of total oxygen consumption was related to pyrrhotite leaching, while in iron removal 73% of total iron originated from pyrrhotite. Thus, especially pyrrhotite removal prior to leaching needs to be developed to reduce the carbon dioxide footprint, when the pyrrhotite content in the material is high.Graphical

Development and Improvement of a Production Company (and their Product) Based on the Value Stream Mapping of Business Processes

Abstract Value stream mapping is one of the basic tools used in the processes improvement or design – in accordance with the Lean concept. This paper presents a model of designing production processes and introducing new products to the market based on the analysis of the value streams flow in the production process. Particular attention was paid to the importance of input data necessary to plan a properly functioning production process, which results in a high-value product (from the customer’s point of view). In the paper also the list of all the most important tools supporting all stages of designing new production processes or improving existing processes has been presented. Also the advantages of big pictures analysis using was highlighted. In this case value stream mapping and big picture analysis were oriented on quality in the product development process and contribute to: creating value (based on customer requirements) while maintaining timely deliveries and constant costs (Value Stream Mapping), sustainable use of tangible and intangible resources (removing waste at the design stage). However, from the company point of view, and particular in the cost level, the product can gain value because a lower input is required for its production. After improvement, the process lead time has been shortened in an area where value was not added, but the consequence of implementing the change is an increase in the production volume while maintaining the process transition time – therefore, unit costs of production will change.

Elderly clothing upgrading in product-service system design using extended Kansei Engineering methodology

PurposeThis study aims to integrate fall-protection function into the elderly clothing to meet both the daily life and fall-protection needs of the elderly people, thereby upgrading the performance of elderly clothing.Design/methodology/approachThis study identified the design strategies of elderly clothing using an Extended Kansei Engineering methodology. Extended Kansei Engineering methodology is a new design framework developed from the traditional Kansei Engineering methodology to meet the design requirements of the product-service system. This study focuses on the product section of product-service system design. According to the product design process of the Extended Kansei Engineering methodology, this study first collected and organized the design elements and Kansei words of elderly clothing. Then a questionnaire was designed using Semantic Differential Scale. Finally, the questionnaire survey was conducted and the collected data was analysed to understand the consumption preferences of elderly people. A total of 399 elderly people aged 65 and older provided valuable design insights for this survey.FindingsThe research findings include the product design strategies for the development of elderly clothing, as well as a product prototype canvas and a product prototype elderly clothing developed based on the design strategies.Practical implicationsThe research findings can provide competitive design strategies for the development of elderly clothing, thereby upgrading the performance of elderly clothing.Social implicationsThis elderly clothing integrates fall-protection function to reduce the risk of injury for elderly people due to falls, thereby helping society alleviate the medical and healthcare pressure caused by falls for elderly people.Originality/valueThe research findings can provide competitive design strategies for the development of elderly clothing. Furthermore, the Extended Kansei Engineering methodology introduced in this study can provide product and service designers with design methods that are more in line with the development trend of modern product-service system business models.

Simulation and conceptual design of a dl-methionine production process by the chemical synthesis route

Methionine is one of the two sulfur-containing amino acids demanded in the diet of humans, other mammals and avian species, while most of the produced methionine is consumed as an animal feed additive, especially in livestock production and the poultry market. In this paper, the techno-economic assessment and conceptual design of an industrial scale, feed grade dl-methionine production process was carried out using SuperPro Designer simulator. The plant was designed to produce 109 tons of dl-methionine per year through the chemical synthesis route. The total capital investment and annual operating cost of the proposed plant were USD $ 8.282 million and USD $ 1.323 million, respectively, while the net present value, the internal rate of return and payback time of the project were USD $ 4.436 million, 20.33 % and 4.74 years, respectively. The findings indicated that the proposed production process is feasible and profitable for a dl-methionine selling price of USD $ 35/kg. The innovative simulation model obtained in this work could be used for further optimization studies, as well as to increase the productivity and profitability of the proposed plant.

Process Design and Economic Assessment of Biomass-Based Hydrogen Production Processes

Process Design and Economic Assessment of Biomass-Based Hydrogen Production Processes

Designer's log in planning the development of comics with socioscientific issues content: Case studies

The development of learning media research evolves rapidly in design-based research (DBR). However, most of the research in this area concentrated on media implementation and media format. In this paper, we explain one side rarely discussed: the process of designing media pre-implementation. This research uses the designer’s log as core data that notes the essential things during the discussion between media designers and practitioners. This study depicts two case studies when researchers (as media designers) and teachers (as practitiones) were developing comics with socioscientific issues (SSI) content. This research employed a case studies approach, using the designer’s log in three meetings with teachers. The data analysis of the designer’s log focused on three criteria: analysis, comics-building, and teaching activities development. The main themes identified as results in this study were the student experience in comics, previous content related to SSI, comics form, SSI content in comics, and classroom activities. This study also presented designer log examples highlighting our discussion with teachers to explain teachers’ consideration in designing comics with SSI content. From this study, we offer recommendations, especially regarding DBR. Firstly, future researchers need to be aware not only of the final DBR product but also of the product design process; secondly, in preparing media (in this paper, comics), determining content needs to be considered together between designers and teachers from student conditions, culture, and school background.

Developing a product design process via a deeper understanding of user experience UX and collaborative design.

Developing a product design process via a deeper understanding of user experience UX and collaborative design.

Implementasi Metode Agile Scrum Dalam Perancangan UI/UX Design Command Control Map Service Di PT. Len Industri (Persero)

Implementasi Metode Agile Scrum Dalam Perancangan UI/UX Design Command Control Map Service Di PT. Len Industri (Persero)

A patent retrieval method and system based on double classification

As one of the most prominent carriers of knowledge, patents can provide masses of cross-domain knowledge to support the innovative design process of products. However, there is a major problem faced by most patent-aided innovation design systems, that is, identifying and providing patents related to design requirements from a multitude of cross-domain patents. To address this problem, a patent retrieval method based on double classification is proposed in this study, and a corresponding patent-aided innovative design prototype system is also developed. Firstly, the functional attributes are extracted from design requirements and expanded to different fields based on functional bases, by which the primary patent sets are constructed via classifying cross-domain patents. Secondly, technical features are mined from the primary patent sets with the topic model, which is used to classify the primary patent sets in turn and construct the secondary patent sets, hence, corresponding patents can be obtained to solve the design problems. Finally, a patent-aided prototype system is developed based on the proposed method. On the basis of the system, the hole plug of irradiated samples of nuclear reactor pressure vessel has undergone innovative design, which verifies the feasibility and practicability of both the method and system.

Impulsive Control Discrete Fractional Neural Networks in Product Form Design: Practical Mittag-Leffler Stability Criteria

The planning, regulation and effectiveness of the product design process depend on various characteristics. Recently, bio-inspired collective intelligence approaches have been applied in this process in order to create more appealing product forms and optimize the design process. In fact, the use of neural network models in product form design analysis is a complex process, in which the type of network has to be determined, as well as the structure of the network layers and the neurons in them; the connection coefficients, inputs and outputs have to be explored; and the data have to be collected. In this paper, an impulsive discrete fractional neural network modeling approach is introduced for product design analysis. The proposed model extends and complements several existing integer-order neural network models to the generalized impulsive discrete fractional-order setting, which is a more flexible mechanism to study product form design. Since control and stability methods are fundamental in the construction and practical significance of a neural network model, appropriate impulsive controllers are designed, and practical Mittag-Leffler stability criteria are proposed. The Lyapunov function strategy is applied in providing the stability criteria and their efficiency is demonstrated via examples and a discussion. The established examples also illustrate the role of impulsive controllers in stabilizing the behavior of the neuronal states. The proposed modeling approach and the stability results are applicable to numerous industrial design tasks in which multi-agent systems are implemented.

Polarizability matters in enantio-selection

The prevalence of chirality, or, handedness in biological world is a fundamental phenomenon and a characteristic hallmark of life. Thus, understanding the origin of enantio-selection, i.e., the sense and magnitude of asymmetric induction, has been a long-pursued goal in asymmetric catalysis. Herein, we demonstrated a polarizability-derived electronic effect that was shown to be capable of rationalizing a broad range of stereochemical observations made in the field of asymmetric catalysis. This effect provided a consistent enantio-control model for the prediction of major enantiomers formed in a ruthenium-catalyzed asymmetric transfer hydrogenations of ketones. Direct and quantitative linear free energy relationships between substrates’ local polarizabilities and observed enantio-selectivity were also revealed in three widely known asymmetric catalytic systems covering both reductions and oxidations. This broadly applicable polarizability-based electronic effect, in conjunction with conventional wisdom mainly leveraging on steric effect considerations, should aid rational design of enantio-selective processes for better production of chiral substances.

Online prediction of the enzymatic hydrolysis efficiency of crop straw

The extent of removal of lignin and hemicellulose are crucial indicators for evaluating the efficiency of enzymatic hydrolysis of crop straw. Numerous factors influence these two indices. Establishing a quantitative model that correlates these factors with hydrolysis efficiency is essential, as it can guide efficient hydrolysis. In this study, a predictive method for enzymatic hydrolysis efficiency in crop straw was proposed using Grey relational analysis (GRA), Kernel principal component analysis (KPCA), and a least squares support vector machine (LSSVM). The authors collected a dataset from actual production data and developed an efficiency predictive model using GRA for variable selection, KPCA for dimensionality reduction, and LSSVM for model training. This model allows for the direct estimation of the final enzymatic hydrolysis efficiency based on production condition variables, which can include enzyme amount, temperatures, pH, time, agitation, and straw dimensions. Extensive experimental testing validated the effectiveness of the proposed method, resulting in minimal errors, a high degree of fit, and exceptional performance. The methodology described in this study can serve as a foundation for optimising the design of efficient enzymatic hydrolysis production processes for crop straw. Additionally, it offers valuable soft measurements to support efficient control of the enzymatic hydrolysis process.

Bio-Based Plastics in Product Design: The State of the Art and Challenges to Overcome

Replacing fossil-based feedstock with renewable alternatives is a crucial step towards a circular economy. The bio-based plastics currently on the market are predominantly used in single-use applications, with remarkably limited uptake in durable products. This study explores the current state of the art of bio-based plastic use in durable consumer products and the opportunities and barriers encountered by product developers in adopting these materials. A design analysis of 60 durable products containing bio-based plastics, and 12 company interviews, identified the pursuit of sustainability goals and targets as the primary driver for adopting bio-based plastics, despite uncertainties regarding their reduced environmental impact. The lack of knowledge of bio-based plastics and their properties contributes to the slow adoption of these materials. Furthermore, the lack of recycling infrastructure, the limited availability of the plastics, and higher costs compared to fossil-based alternatives, are significant barriers to adoption. Product developers face significant challenges in designing with bio-based plastics, but opportunities exist; for example, for the use of dedicated bio-based plastics with unique properties. When designing with bio-based plastics, product developers must think beyond the physical product and consider sourcing and recovery, which are not typically part of the conventional product design process.

Comparison of CAD Software for Designing Cellular Structures for Additive Manufacturing

Additive manufacturing (AM) technologies provide significant design freedom, which is highly desirable in today’s fast-paced product design processes. However, most of the parametric CAD software tools used today do not fully utilize this potential for freedom of form and design. Design mechanisms, such as topology optimization (TO), generative design (GD), and lattice structures, are available on the market to help designers minimize weight and material cost while maximizing the stiffness and flexibility of planned designs. This paper proposes a benchmarking approach for designers and engineers to select a suitable software tool for lattice structure generation for their specific applications. The approach includes preselecting software tools based on a weighted point evaluation of seven significant criteria. The tools are then evaluated based on key metrics such as computing time and file size of exported structures, as well as the following six distinctive attributes: usability, reliability, availability, performance, support, and cost. The evaluation process considers a total of 32 defined features. The investigation produced clear recommendations regarding overall performance, reliability, and user experience. The findings indicate that the option of a comprehensive support offering, as well as the initial and operational costs, are significant drivers in the decision-making process.

Optimizing Industrial Effluent Flue Gas as Source of Energy for Charcoal Production

This research suggests a unique way to produce charcoal utilizing industrial flue gas as an energy source. The process entails gathering, cleaning, and transporting the flue gas to a pyrolysis reactor where it is used to carbonize and heat biomass. The paper outlined the design of various components, such as the heat exchanger, pyrolysis reactor, and flue gas filter. It specified that the flue gas temperatures in the glass, pulp and paper, and alcohol industries typically range from 400-500°C, 200-500°C, and 150-300°C, respectively. Furthermore, the chemical compositions of these industries were analyzed at the factory. The study emphasized the importance of these design considerations and temperature ranges for efficient operation and optimal performance in the respective industries. The resultant charcoal has several uses and is a sustainable and renewable fuel. In addition, the technique lessens greenhouse gas and flue gas emissions into the atmosphere, protecting the environment and slowing down climate change. The average chemical composition of flue gas from three industries was ascertained, together with the temperature range necessary for pyrolysis and the mechanical layout of the system used to produce charcoal. Upon determining the characteristics of industrial flue gas, the mechanical design of the charcoal production process was incorporated essential components. These include a temporary storage tank, a pyrolysis reactor, and a flue gas filter. This comprehensive design aims to ensure the production of quality charcoal while addressing environmental concerns related to pollution from flue gas treatment. The integration of these components is crucial for optimizing the production process and enhancing environmental sustainability by mitigating the impact of flue gas emissions on the environment. The project report emphasizes the significance of these design considerations in achieving efficient and environmentally friendly charcoal production. The paper also discusses the environmental and economic benefits of using flue gas as an energy source for charcoal production. The paper concludes that this method is a feasible and promising solution for efficient resource utilization and sustainable development.

Aesthetic Improvement: Innovating the Design and Development Framework for Engineering Products

One of the primary issues with many product design and development processes today is to have a good balance between the elements of form and function. While all products must be able to perform their intended functions, considerations of aesthetic features are also necessary for them to be accepted as a good quality design. However, most available design and development processes of engineering products have been more focused on achieving the functional aspects and tend to treat the aesthetic aspects as less crucial features. This approach has led to many failed functional products in the market as their physical design lacks appealing factors to the targeted customers. To improve the situation, a new product design and development framework is proposed in this study to better facilitate designers or engineers in creating an all-rounded quality product design. This new method is developed based on the findings from a conducted survey among engineering students, who are future product design engineers, to identify and resolve issues with current methods that they use for their design tasks. All in all, the new proposed method is essentially tailored to offer a comprehensive guide for developing beautiful and useful products based on a semantics design approach.