About this previous year paper
PRODUCT DEVELOPMENT & DESIGN (NME022)
Section-wise Solved Answers & Notes
SECTION – A (10 × 2 = 20 Marks)
Very short & precise answers
(a) Product plan
A product plan is a systematic outline that defines product objectives, target market, features, cost, and development schedule.
(b) Productivity
Productivity is the ratio of output to input, showing how efficiently resources are used.
Productivity=OutputInput\text{Productivity} = \frac{\text{Output}}{\text{Input}}Productivity=InputOutput
(c) Technology-based developments
Improvements in products achieved using new technologies, such as automation, CAD/CAM, AI, and advanced materials.
(d) Economic feasibility
Economic feasibility evaluates whether a product is financially viable, considering cost, profit, and return on investment.
(e) Importance of aesthetics
Aesthetics improve visual appeal, customer attraction, brand value, and market acceptance of a product.
(f) Morphology
Morphology is the study of structure, form, and configuration of a product to generate design alternatives.
(g) Utility index
Utility index is a numerical value representing how well a design satisfies customer needs compared to alternatives.
(h) Reliability
Reliability is the probability that a product performs its intended function without failure for a specified time.
(i) MTBF
MTBF (Mean Time Between Failures) is the average time interval between consecutive failures of a repairable system.
(j) Use of Bathtub curve
The bathtub curve shows failure rate vs time, identifying:
Early failures Useful life Wear-out failures
SECTION – B (Any 5 × 10 = 50 Marks)
(a) Influence of product design on manufacturing process
Product design directly affects manufacturing by: Selecting suitable materials
Deciding manufacturing method Reducing production cost
Improving quality and productivity Simplifying assembly
Good design leads to easy manufacturing and low defects.
(b) Requirements of a good design A good design should be:
Functional Economical
Reliable Safe
Easy to manufacture Easy to maintain
Aesthetically pleasing Ergonomic
(c) Consequences of not using ergonomics
Ignoring ergonomics may cause: Operator fatigue
Health problems Reduced productivity
Increased accidents Poor product usability
(d) Brainstorming
Brainstorming is a creative group technique used to generate a large number of ideas without criticism.
Steps: Define problem
Generate ideas freely No judgment during idea generation
Evaluate ideas later
(e) Break-even point (BEP) calculation Break-even point is where total cost equals total revenue.
BEP (units)=Fixed CostSelling Price – Variable Cost\text{BEP (units)} = \frac{\text{Fixed Cost}}{\text{Selling Price – Variable Cost}}BEP (units)=Selling Price – Variable CostFixed Cost
It helps in deciding minimum production quantity.
(f) Procedure for assessing design reliability
Steps: Identify failure modes
Collect failure data Calculate reliability indices (MTBF, failure rate)
Use reliability models Improve weak components
(g) Three stages of creative design route
Problem definition – identify need Conceptual design – generate solutions
Detail design – finalize materials, dimensions Example: Designing a new electric kettle.
(h) Analysis of need statement
“Community needs water” This statement is too broad.
Improved need statement: Quantity of water
Quality requirement Source of water
Cost and availability Purpose (drinking, irrigation, sanitation)
SECTION – C (Any 2 × 15 = 30 Marks)
Q3. New methods of design (with examples)
New design methods include:
CAD (Computer Aided Design) – faster & accurate design
CAE (Computer Aided Engineering) – simulation & analysis
DFMA (Design for Manufacturing & Assembly) – cost reduction
Concurrent engineering – parallel product development
Example: Automotive design using CAD & CAE tools.
Q4. Automatic floor washer – Function matrix
Main function:
Clean floor
| Sub-functions | Options |
|---|---|
| Scrub | Rotary brush |
| Rinse | Water spray |
| Dry | Air blower |
| Move | Wheels / motor |
Most promising solution: Rotary brush + water spray + hot air blower.
(Function matrix diagram should be drawn in exam)
Q5. Techniques of decision making
Decision-making techniques include: Weighted ranking method
Decision matrix method Cost-benefit analysis
Utility theory Decision matrix method:
List alternatives Assign weights
Score each alternative Select highest score design