Unit 8 Assessment Booklet

BTEC National Diploma in Engineering

Level 3

Unit 8

Engineering Design

Student Name:

Assessor Name: Paul Mulder

Document Revision & Date: Rev 1 (30/7/12)

Students to initial the box in the “Submitted” row below to show that an assignment is being submitted for assessment.

Learner Declaration:By initialling the submission box below, I confirm that the work submitted to complete the given tasks is my own. I have indicated where research and other sources have been used to confirm the conclusions reached within the submission and have listed those sources in a bibliography.

Outcome P1 P2 P3 P4 P5 P6 P7 M1 M2 M3 D1 D2

Submitted

Achieved

Referred

Resubmitted

Unit 8 – BTEC Level 3 - Eng. Design Page 1

Outcome Assignment Task Task No. EvidenceAchievement

DateAssessor Signature

P1Describe the operation of the design process in an engineering company

1Written

Assignment

P2Interpret the requirements of a given customer and produce a product design specification

2Written

Assignment

P3

Describe the appropriate legislation and standards which apply to the design of two different products

3Written

Assignment

P4

Describe the environmental, sustainability and manufacturing constraints which influence the design of a given product

4Written

Assignment

P5Produce design proposals which meet the requirements of a given PDS

5Sketches and

notes

P6

Extract reference information from component manufacturers’ catalogues and materials and design databases

6Written

Assignment

P7

Use a range of techniques to present a final design solution which meets the requirements of a given PDS and relevant legislation and design standards

7

CAD generated

drawings and screen shots

M1

Explain the possible impact of a poor customer design process on customer relationships and requirements

8Written

Assignment

M2

Explain the importance of using a range of accurate design reference materials when developing design proposals

9Written

Assignment

M3

Explain the issues which influence whether a design proposal should be developed into a final solution suitable for manufacture

10Written

Assignment

D1

Evaluate the impact of legislation and standards on the design process in relation to the profitability of the business

11Written

Assignment

D2

Evaluate a final design solution against customer requirements and a PDS, and suggest improvements

12Written

Assignment


Task(s) 1

Assignment Deadline

Outcome P1Assignment Brief Describe the operation of the design process in an engineering companyEvidence Written Assignment

Assignment Guidance

All engineering companies are different in the procedure they use when designing a new product. However, some basic steps should always applied to ensure a successful outcome. Describe the various stages of the design process which may take place within an engineering organisation including those listed below. Include in your assignment Finite Element Analysis (FEA), rapid prototyping, the approval process, packaging, etc.


Task Requirement Task completed to the required standard?

YES NOAs a minimum your assignment should describe the points listed below:Design idea/concept.Design brief.Market research.Create a specification.Design ideas.Development, including the use of FEA where appropriate.Prototyping.Design evaluation.Finalise design.Production.

Assessor Feedback: Achieved?

YES/NO

Task(s) 2

Assignment Deadline

Outcome P2

Assignment BriefInterpret the requirements of a given customer and produce a product design specification

Evidence Written Assignment

Assignment Guidance

Produce a PDS (product design specification) that will be used for the design and development of a new electronic, digital, mobile music system. Your design brief should be original and include features note readily available at present.

Task Requirement Task completed to the required standard?YES NO

As a minimum your PDS should consider and include the points listed below:Overall sizeScreen and button sizesStyle, colour and finishPosition of headphone socketSwitching, including power on/off, volume control, track selection, locking the buttons while the device is being carried, connectivity for loading tunes.Battery life, recharging and accessing battery.BrandingPackagingTarget market, which will be effected by sales price.


YES/NO


Task(s) 3

Assignment Deadline

Outcome P3

Assignment BriefDescribe the appropriate legislation and standards which apply to the design of two different products


Assignment Guidance

Describe the appropriate legislation and standards which apply to the design of two different products, in this case your assignment should focus on an electric kettle and the games console and handset as described in the PDS used for P5.


Ensure that your assignment describes each of the areas listed below:Investigate, list and briefly describe the standards which are specifically required for a kettle. It may be plastic, metal or both.Investigate, list and briefly describe the standards which are specifically required for a games console.Investigate, list and briefly describe the standards which are generically required for electrical products connected to the UK mains electricity supply such as 13A plug regulations, earthing requirements, CE marking and complying with the WEEE directive, etc.


YES/NO


Task(s) 4

Assignment Deadline

Outcome P4

Assignment BriefDescribe the environmental, sustainability and manufacturing constraints which influence the design of a given product.


Assignment Guidance

Describe how constraints outside of your control might influence the design of an electric kettle. Consider environmental, sustainability and manufacturing constraints and describe ways in which a designer may overcome these restrictions.


Ensure that your assignment describes each of the areas listed below:Environmental constraints such as:

The power used to boil water The carbon footprint Recycling the kettle at the end of it’s working life.

Sustainability constraints such as: The materials being used for all the components of the

kettle. Where the materials come from including where they are

made and air miles to get them to the assembly line. Do parts come from renewable or recycled sources?

Manufacturing constraints such as: Manufacturing cost, how this effects market price and

therefore sales of the kettle Serviceability. Is it even necessary? Meeting British Standards, European standards and

recyclability targets. Detail what the standards are. Achieving a good energy rating.


YES/NO


Task(s) 5

Assignment Deadline

Outcome P5Assignment Brief Produce design proposals which meet the requirements of a given PDSEvidence Sketches and notes

Assignment Guidance

Produce a series of free-hand isometric and orthographic sketches that will show your design proposals for the games console and controller as specified in the PDS. A written explanation should accompany each sketch along with details of proposals for materials to be used. Include detailed views, where necessary, showing close ups of certain features or fixings. The PDS is enclosed on the next 6 pages of this document.


Ensure that your assignment meets each of the areas listed below:All generic design ideas with a short explanation of why they were rejected or progressed onwards.A series of free-hand sketches showing the development of your design ideas including colours and finishes where appropriate.An indication as to where each pre-set part from the PDS will be fitted, including close-up auxiliary views where necessary.Notes about how parts will be fixed together, such as screws, clips, etc.


YES/NO


Product Design Specification

(PDS)

Product:

Game Station Hand Controller

Contents:

1. Focus

2. Planning

3. Specification

4. Packaging


1. Focus

1.1 Our market research team has identified a number of features that the game station hand controllers currently on the market either don’t have, or need to be improved. For this reason Canterbury College has decided to design, manufacture and market our own gaming station hand controller. Main design focus areas will include:

Ergonomics, to reduce the risk of repetitive strain injury (RSI). New technology, with features not currently marketed.

1.2 Customer satisfaction is our top priority. Therefore, essential market research has been carried out and will continue to be carried out on an ongoing basis, focussing on the following data:

What do customers like and dislike about current game stations hand controllers? Which game stations hand controllers do they currently use, and why? What image do customers have of our business and products? What concerns would customers have about buying from Canterbury College? How can we make their gaming experience more enjoyable? Using sales data to identify the products that sell well and which are in decline. Using sales data to identify regional and seasonal trends. Identifying target age group and gender of main customer base.

2. Planning

2.1 A project team will manage the design process.

Specific, quantified design objectives will be set out in section 3 of this document. While no specific manufacturing cost target has yet been set, good engineering

practice should be used at all times to constrain manufacturing costs to a minimum, but without compromising quality.

Milestones for this project should be carefully recorded and managed. The target completion date for the completed design portfolio is 14 June 2012. This document will contain design constraints and considerations and must be

adhered to, as set out in section 3. The design should allow for all parts to be manufactured in a cost effective manner

and comply with legal and health and safety requirements. This product is primarily to be designed for the UK market, although alterations or

enhancements will be considered for worldwide markets at a later date.


2.2 From design to manufacture to market.

The product launch date is set for 1st November 2013 and sufficient units need to be manufactured, assembled and tested prior to this date to ensure take-up demands are met. Further details of initial quantities will follow.

Specific parts used in the building of this product such as the wireless transceiver, the volume control switch and the vibrate control on/off switch will be sourced from existing manufacturers. The make or buy decision for other parts will be made on a cost effectiveness basis. See 3.2 for a full list.

All parts will be assembled and tested in the UK. It is reasonable to expect that the cost of manufacturing component parts should be

kept to a minimum. Standard components and tools should be used across a range of as many parts as

possible, such as screws, rather than more expensive custom-made items. Any additional design ideas to improve this product may be used provided the design

requirements are met and approval is granted.

2.3 Intellectual property.

Protecting the intellectual property of this product is paramount throughout this project. Therefore, all employees who are involved in any way with this project must sign a Canterbury College confidentiality agreement prior to any information being disseminated to them from any source, written or verbal.

This action is being taken to prevent competitors from copying the unique design features which this product will have. In so doing, the following points must be adhered to:

If additional expertise is required from third parties, they must sign a Canterbury College confidentiality agreement prior to being given any information on this product, however small.

No information must be imparted to third parties, including family members and friends, outside of Canterbury College without the written consent from the department manager and the individual signing of the afore mentioned confidentiality agreement.

Patent protection for new and innovative products will be applied for wherever possible.

Design registration to protect the shape, appearance and function of this product will be applied for.

Registered trade-marks which distinguish this product from the competition will be applied for including marketing names, logo’s, etc.


3. Specification

Different types of design present different opportunities and problems. The following is a list of design features that are required as a minimum. However, extra value added ideas maybe incorporated into the design subject to approval.

3.1 The key features and functions of the hand controller design are as follows:

The handset will be used for many hours and must be durable in design. The handset will be designed using ergonomic principles to ensure that it is

comfortable to use. The handsets will be wireless. The handset will incorporate the following control options:

2 gaming joysticks 10 gaming buttons

Each button on the hand controller will be identified by a symbol or alpha-numeric character which will be logical to understand.

The handset will incorporate an LED battery life indicator. The handset will contain 2 x 1.5V AA rechargeable batteries which should be

accessible for changing/upgrading if necessary. The hand controller will contain a cavity to house the PCB. The circuit board may be any shape but will be 1.5mm thick and have a surface are

of 3000mm² ±10%. You will also need to allow a minimum of 5mm on the top of the circuit board for surface mounted components.

The hand controller will of a minimum weight and be as light as it is practically possible to make it.

3.2 Preset design features for hand controller.

The following parts are pre-determined and a digital file will be provided for each part to the designer. The designer will ensure that the hand controller and base unit incorporates appropriate apertures and fixing points to ensure that these parts fit correctly.

Hand controller LED battery life indicator 1.5V AA Battery


3.3 The visual appearance:

The hand controller will be designed to look aesthetically pleasing in a domestic environment, in both colour and style.

The colour of the hand controller will be determined by the designer.

3.5 Quality standards must be used and stated in the project portfolio

All parts must conform to the relevant British Standard.

4. Packaging

The packaging should be made from materials which can easily be recycled and the graphics should include recycling information.

4.1 The hand controller will be packaged as a single unit.

The hand controller will be packaged in such a way as to withstand transportation vibration, a drop test from 1.5m and stacking as part of transportation and storage.


Task(s) 6

Assignment Deadline

Outcome P6

Assignment BriefExtract reference information from component manufacturers’ catalogues and materials and design databases


Assignment Guidance

All materials and fixings for your games console and hand controller should be sourced from both electronics catalogues and the internet, as well as paper catalogues. Ensure that you reference correctly the source including date, suppliers name, web address or catalogue issue and any other relevant information.


Your assignment must include the data listed below according to whether the part is referenced from a paper or online source. The items that you must source are shown in the table at the bottom of this page.

For paper based catalogue information the following details should be included in the assignment:

A copy of the page(s) referenced with the appropriate item being highlighted.The name of the supplerThe date that the catalogue was published or it’s period of validityThe price for the item(s) required including break prices where appropriate

For web based supplier information the following details should be included in the assignment:A print out of the page(s) referenced with the appropriate item being highlighted.The name of the supplierThe exact I.P address (webpage link) for the online catalogue being referencedThe date the webpage was accessed and data recordedThe price for the item(s) required including break prices where appropriate

Finally, write a conclusion about your experience of sourcing these parts comparing the 2 methods, listing the advantages and disadvantages of each.Assessor Feedback: Achieved?

YES/NO

Paper based items to source: Online items to source:Fan 120mm 240V 94CFM Pozi Csk. Self-Tapping Screws No.4 x 6.5mmGreen diffused LED 25mA 5mm 5mm 5v Green LEDPozi Csk. Self-Tapping Screws No.6 13mm (½”) SKF 6009-2RS1 1 row radial ball bearing 45mm IDSingle row radial ball bearing,25mm ID Black rubber mains plug,13ABlack re-wireable straight plug,10A 250Vac Fan 120mm 240V 94CFMM4 x 30 Socket Cap Head Screw Zinc Plated M4 x 12mm stainless steel grub screw (socket set

screw)


Task(s) 7

Assignment Deadline

Outcome P7

Assignment BriefUse a range of techniques to present a final design solution which meets the requirements of a given PDS and relevant legislation and design standards

Evidence CAD generated drawings, screen shots and written assignment

Assignment Guidance

Produce a 3D CAD model of a games controller as specified in the PDS. The digital files as well as prints of each part from at least 4 views must be submitted including screen shots and engineering drawings of the assembly. A written explanation of the materials to be used, their specification data. The submission must also include a written assignment justifying your design, the material(s) used. Also explain why your design is suitable for manufacturing and how your design conforms to the required standards, including what those standards are.


Ensure that your assignment submission contains each of the items listed below:A series of 3D SolidWorks generated parts which are assembled to make the games controllerDoes the design include all of the pre-set parts?A document containing screen shots of the completed designA 3rd angle orthographic drawing showing a minimum of 3 views of your design with the width, depth and height dimensions shown and including an isometric view.Your written assignment should include the following:

Justification for your design Justification, explanation and specification of the materials used The suitability of your design for manufacture The standards your design conforms to and why it conforms.


YES/NO


Task(s) 8

Assignment Deadline

Outcome M1

Assignment BriefExplain the possible impact of a poor customer design process on customer relationships and requirements


Assignment Guidance

In general terms explain the possible impact of a poor design process on customer relationships and requirements. Also, specifically focus on the recall of the early PS2’s, in September 2005 as an example and explain why and how this poor design affected customer relationships including the impact it may have had on consumer confidence.


Your assignment should include the following elements:An explanation of the impact or poor design as it effects each of the following areas:Customer returnsThe cost of repairing or replacing faulty goodsThe cost of sending replacement partsHow this effects the profitability of a companyConsumer confidence and future sales

Specifically concerning the problems with the PS2’s, include the following areas:Scale of the problemInjury to customers and damage to their propertyWhat choices did customers have?Did this problem effect Playstation’s market position?

Don’t forget to include a conclusion


YES/NO


Task(s) 9

Assignment Deadline

Outcome M2

Assignment BriefExplain the importance of using a range of accurate design reference materials when developing design proposals


Assignment Guidance

Describe the process of designing using accurate design reference materials when developing a design for a roof, the beams of which need to have certain load bearing properties and as such are defined as “mission critical”. Describe the documented reference sources that could and should be used in such circumstances. Describe how dimensions and material specification are vital in this scenario.


Your assignment should include a description of the following factors as a minimum:Identify and explain the different types of roof design commonly used, include pictures to aid this and reference the source.Define the term mission critical as it applies to a roof structure.Define what constitutes a “live load” and why it is important to factor it in?Define what constitutes “dead or passive loads” and why it is important to factor it in?How do climatic conditions play a part in the design process?Describe the need for accurate design calculations when calculating the load bearing of a roofExplain why the use of tables would be an advantage when designing a roof.Explain how/if CAD would be an advantage when designing a roof.What British Standards are commonly applied to roof design and why?


YES/NO


Task(s) 10

Assignment Deadline

Outcome M3

Assignment BriefExplain the issues which influence whether a design proposal should be developed into a final solution suitable for manufacture


Assignment Guidance

On the basis that you need to work around the constraints mentioned in P4, explain the issues which influence whether a design proposal should be developed into a final solution suitable for manufacture such as manufacturing cost, market demand, competitors products and life cycle.


Your assignment should include an explanation of the following points as a minimum:Whether a design should be developed or not based on environmental considerations, not only for manufacturing, but end of life recycling also.Whether a design should be developed or not based on material sustainability considerations, which also needs consider end of life recycling.Whether a design should be developed or not based on manufacturing constraints such as legislation and standards, both current and likely forthcoming changes.Whether a design should be developed or not based on manufacturing costs, which may include geographical considerationsWhether a design should be developed or not based on market demand and competitors productsWhether a design should be developed or not based on anticipated life cycle


YES/NO


Task(s) 11

Assignment Deadline

Outcome D1

Assignment BriefEvaluate the impact of legislation and standards on the design process in relation to the profitability of the business


Assignment Guidance

Using the example of the games controller designed in conjunction with P3 (task 3) the PDS in P5 (task 5) and P7 (task 7), identify and evaluate the impact of the legislation and standards which apply to the design process of the games controller, the materials used and the effects in relation to the profitability of the business.


Your assignment should include the identification and evaluation of the following elements as a minimum:Have the legislations and standards been identified and described?Has the effect on the design of each of these legislations and standards been identified and described?Has the legislations and standards and how they apply to each of the game controllers materials and components been identified and described?Has the legislations and standards and how they impact the profitability of the business in terms of profit and added cost been identified and described?Has the legislations and standards and how they safeguard the profitability of the business in terms been identified and described?


YES/NO


Task(s) 12

Assignment Deadline

Outcome D2

Assignment BriefEvaluate a final design solution against customer requirements and a PDS, and suggest improvements


Assignment Guidance

Students will be paired up to assess how the games controller design of the other student meets the PDS. Produce a written report evaluating the design of another students’ game console and controller against the PDS. The report should be objective and consider good and bad areas of the design including choice of materials and colours. The report should make recommendations for improvements where appropriate. The report needs to be objective and honest.


Your assignment should include the evaluation of the following elements as a minimum:Has the assessment form on the next page been completed in full?Does the assignment consider how the evaluated design meets, or does not meet, each area of assessment?Is the assignment objective and honest?Does the assignment make recommendations for improvements?Does the assignment have a conclusion?


YES/NO


Product Design Specification (PDS) Assessment for Gaming Controller

Designer:- Assessor:-

Key features and functions of Game ControllerVery Poor

Poor Satisfactory Good Excellent

The handset will be used for many hours and must be durable in design

1 2 3 4 5

The handset will be designed using ergonomic principles to ensure that it is comfortable to use

1 2 3 4 5

The handsets will be wireless 1 2 3 4 5

The handset will incorporate 2 gaming joysticks 1 2 3 4 5

The handset will incorporate 8 gaming buttons 1 2 3 4 5

Each button on the hand controller will be identified by a symbol or alpha-numeric character which will be logical to understand

1 2 3 4 5

The handset will incorporate an LED battery life indicator

1 2 3 4 5

The handset will contain 2 x 1.5V AA rechargeable batteries which should be accessible for changing/upgrading if necessary

1 2 3 4 5

The hand controller will house the PCB with at least 5mm above the surface of the board and the board will be of approx. 3000mm² ±10%

1 2 3 4 5

The hand controller will of a minimum weight and be as light as it is practically possible to make it

1 2 3 4 5

Both the base unit and the hand controller will be designed to look aesthetically pleasing in a domestic environment, in both colour and style

1 2 3 4 5

The colour of the hand controller and the base unit are to be determined by the designer

1 2 3 4 5

SCORE: Column total:

Overall score:

Signed (Assessor): Signed (Verifier):


Documents

Unit 8 Assessment Booklet