Design 1

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CONFIDENTIAL

Document No : UniKL MFI SD AC41 Revision No: 02

Effective Date: 01 December 2014

SET A

UNIVERSITI KUALA LUMPUR Malaysia France Institute

FINAL EXAMINATION SEPTEMBER 2014 SESSION

SUBJECT CODE : NMB22203 SUBJECT TITLE : DESIGN 1

LEVEL : BACHELOR

TIME / DURATION : 9.00 AM – 11.00 AM ( 2 HOURS )

DATE : 6 JANUARY 2015

INSTRUCTIONS TO CANDIDATES

1. Please read the instructions given in the question paper CAREFULLY.

2. This question paper is printed on both sides of the paper.

3. Please write your answers on the answer booklet provided.

4. Answer should be written in blue or black ink except for sketching, graphic and illustration.

5. This question paper consists of TWO (2) sections - Section A and B. Answer ALL questions in Section A. For Section B, answer THREE (3) questions only.

6. Answer all questions in English.

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SEPTEMBER 2014 CONFIDENTIAL

SECTION A (Total: 40 marks)

INSTRUCTION: Answer ALL questions.

Please use the answer booklet provided.

QUESTION 1

(a) What are the characteristics in order to be creative? What is the difference between creativity and innovation?

(7 marks)

(b) State four categories that are considered for the product to be a good design. What are the concepts regarding total life cycle design for recycling?

(7 marks)

(c) What are the THREE (3) fundamental questions that need to be answer by an engineer or designer in identifying customer needs activities?

(6 marks)

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QUESTION 2

Quality Function Deployment is a technique to “translate” user requirements in product requirements. The graphical tool used to apply this technique is called “House of Quality” as the shape resembles a house. The drawing shows a number of elements normally contained in the tool.

(a) Are all the elements (rooms) present in the drawing? If not, produce a drawing containing all elements (rooms)?

(3 marks) (b) Place the letter indicating the House of Quality elements below in the correct location

in the figure.

A Customer requirement

B Engineering Characteristics C Correlation matrix

D Relationship matrix

E Importance Ranking

F Customer Assessment (Benchmark)

G Technical Assessment

H Target Values

(8 marks)

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SECTION B (Total: 60 marks)

INSTRUCTION: Answer THREE (3) questions ONLY.

Please use the answer booklet provided.

QUESTION 3

a) What kind of mistake proofing (POKA–YOKE) devices or assembly method would you suggest using the following situations?

i. A check that the required number of bolts are available for assembling a product ii. A count that the proper number of holes has been drilled in a plate

iii. Insurance that three wires are connected to the proper terminals

iv. A simple method to ensure that a product identification label has not been glued upside down

v. A simple method to ensure that a plug is inserted in the proper orientation in an electrical plug

(10 marks)

b) What are the ‘human error’ mistakes in the manufacturing environment? How can this human mistake be rectified?

(10 marks)

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QUESTION 4

Assume that a focus group of UNIKL students convened to show the public an innovative new product development of a prototype motorcycle and to ask what characteristics they wanted to have. The comments were as follows:

The motorcycle must be able to start engine quickly It can support the rider comfortably

The motorcycle can be a fast transport It must be easy to steer the motorcycle

The motorcycle must be able to absorb rock shocks

Translate these customer requirements into engineering characteristics of the product and unit dimensions.

(20 marks)

Question 5

The marketing department made the following estimates about four different product designs. Use benefit cost analysis to determine which design to pursue.

Design Unit Manufacturing cost

Sales Price Estimate Annual Sales

A $12.50 $25.00 $250,000

B $22.00 $40.00 $200,000

C $15.00 $25.00 $250,000

D $15.00 $20.00 $300,000

(20 marks)

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Question 6

In the search for more environmentally friendly design, paper cups have replaced Styrofoam cups in most fast food restaurants. These cups are less effective insulators, and the paper cups are often too hot for the hands. A design team is in search of a better disposable coffee cup. The designs to be evaluated are (a) a standard Styrofoam cup (b) a rigid injection molded cup with a handle (c) a paper cup with cellular wall. These design concepts are to be evaluated with Styrofoam as the datum.

The engineering characteristics on which cups are evaluated are : Temperature in the hand

Temperature of the outside of the cup Material environmental impact

Indenting force of cup wall Porosity of cup wall Manufacturing complexity Ease of stacking the cups Ease of use by customer

Temperature loss of coffee over time

Estimate cost for manufacturing the cup in large quantities

Using your knowledge of fast food coffee cups, use Pugh concept of selection method to select the most promising design.

(20 marks)

END OF QUESTION