Process

Here, an engineering layout is developed, working with the engineers for general packaging, line and proportion, being sure to work to scale.

Sketches put concept ideas forward quickly. This allows further discussion and thought.

Details of dashboard component mount.

Here a fender assembly is clay modeled on a grid plate base for dimensional accuracy to the vehicle coordination system.

Sketching design concepts alongside the engineers, brainstorming the design control criteria and generating solutions for their review, comment and evolution is a rewarding challenge. Mixing your experience and ideas with their constraints and design objectives can be done in good humor for heightened creativity to find solutions for often difficult problems. Successfully conquering these without just jumping to the first easy solution path, results in a superior product. The number of coexisting design constraints and objectives is both fascinating and challenging; function, cost, durability, reliability, use of common parts, tooling implications, materials, serviceability, manufacturability, design simplicity, customer perception, and more. This highlights the benefit of working close with a broad team experience and resource approach.

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Design Process

This outline of photos and text on the creative process utilized by Integrated Vision is intended to provide the uninitiated, or the student, a view of the engineering and design world of agricultural and industrial equipment. The process here is similar to the process utilized in the automotive sector and shares use of state-of-the-art technology. A unique difference to the usual corporate automotive studios, or programs, is the fact that "much has to be done by few, in little time and less budget". Hence, the automotive industry could pick-up clues toward program innovation by observing some tricks of the agricultural and industrial sector. However, with larger budgets and staff, they have wonderful expanded capabilities of their own. We hope this is enlightening and inspiring for the student interested in an engineering and design career.

~~READ~~

Be around people doing things differently. Be curious. Read publications, pull out products that inspire the team and put up for team discussion.

Climb on equipment

Clay modeling provides styling study. Here it also functions as a full scale model for casting prototype molds, and then parts from these.

STUDY, BE CURIOUS AND AWARE

Study the competition

CONCEPTUALIZE

Sketches, art renderings, CAD rough-in, doodle ideas

ACCUMULATE BACKGROUND INFORMATION AND SPECS.

Initial customer clinic and focus group reviews of competitive products and your proposed path, is a solid foundation for your design specifications and goals.

DISCUSSION & BRAINSTORM

Clay and foam mock-ups are used to quickly study the packaging and appearance on a steering and instument panel console.

MODELING

Work out engineering and assembly and review with experienced team-members. This should be occuring at all stages of concept development.

Evaluation of model refinement at the shop of Fibeco.

Prototyping- Fiberglass prototype parts made from epoxy cast molds off of models are refined to represent components and component assemblies.

Model Study- CAD surfacing is used to cut CNC models. These are then evaluated for styling concerns or evolution. Changes can be made to the model, which can then be digitized in the area of the change for capturing back into the CAD engineering surfaces.

Rough models and clay models are digitized and coordinated with engineer's latest CAD design. Amazing capabilities are available in the latest advanced surfacing software. The proper CAD software should be used for the particular task, and should not handicap the engineer from achieving the sophistication of the original intent.

The computer model is constructed with definition of engineered components and assemblies. This is done in concert with accomplishing styling definition by the varied methods of shop modeling, ergonomics studies and CAD surfacing.

ENGINEERING & CAD DEVELOPMENT

DETAIL DEVELOPMENT FOR MANUFACTURE, ASSEMBLY, & TOOLING

TEAM REVIEW OF STANDING PROTOTYPE

With a completed prototype, customer clinics can be effectively used to evaluate achievement of marketing goals and customer needs. This, again, is the real drive.

SITUATIONS - BE CAREFUL FOR LOSS OF DESIGN DETAILS

PRODUCTION INTENT LEVEL MODELS

General concepts are advanced onto the base layout.

There is nothing that beats constructing design solutions directly on the machine when the project allows. Real visualization of the problems, assembly, use, and serviceability is possible. This also allows other experienced personnel to stop by during the process and quickly provide his, or her, ideas with a fuller comprehension of what your constraints and objectives are. It is the solution that is important, not whether or not the model is crude or beautiful.

Cube model review and quick tape line study of visual impact of style line changes. The cube model here is CNC cut REN material for a durable tooling proof and review of surfaces. This will be used to create the mold for the prototype part, allow changes as areas of concern are identified. "Cube" means the model is constructed on a referenced base and the components are CNC cut separate and dowel pinned together for a study of exact fit.

Be cautious and aware of risks of losing design detail and intent on the path to production.

...... If the customer doesn't get it, then it really doesn't matter what great styling thoughts were going on in your head at the time, or what great contribution to art you were hoping to make. Make those statements on another product where the customer will be happy with it. Remember......Customer....feel it,..... feel it.....

Russ Strong's experience has shown that studied modification of what is generally considered the "management styling review" process can result in significant program gains. This step should be an exciting driver in the design process. It has been observed in many cases, however, that the approach of the industry norm can lead to an inappropriate sense of executive power. This can have the undesired result of removing ownership from the creative team and losing critical momentum. When this occurs, the resulting program dynamics actually run counterproductive to the team effort and the true corporate objectives.

Experience suggests that executives ask themselves: Shouldn't I be supportively involved in the early stages with encouragement and guiding energy? This is best accomplished by the management team personally passing through the design team and studio from time to time to review progress and challenges that the team is facing. This provides a general pulse on the program with abilities to assess and utilize the talent level that has been assembled. Then, provision of support, guidance, and resources where needed is optimized, allowing any necessary corrective moves early rather than late. This process of ongoing awareness, selection and use of best talent, with then encouraging, supporting, and trusting this assembled team is the great enabler. A smooth running team will follow customer and market objectives, providing the most cost effective path towards your goals. Success here significantly reduces the need for the heavy emphasis on management styling review later.

What you are wanting to avoid is the confusion that results from a flurry of management's personal opinions at a late stage. We can trust what many of us have seen from observing management and personality dynamics in many program situations. Getting it right, on the way through the program, is far lower cost than correcting the results later. Many of us can recall a situation of late corrections in a struggling program and the impact of the resulting expensive schedule delays and modifying or scrapping of production tooling. The goal is to get in the game, bring the game up front smoothly and rapidly.

STYLING AND EMPOWERMENT MANAGEMENT

ACHIEVE GREAT STYLING, BUT BE HONEST TO YOUR CUSTOMER NEEDS

FOLLOW-UP THROUGH PRODUCTION TOOLING

An example is shown here of steel tooling being cut on a 5-axis CNC machine at Delta Tooling Co. In high cost tools, your design wants to be right. Here is where design that has been limited by a designer's CAD software capabilties or an engineer's "That is good enough, it looks okay to me" attitude starts to look foolish. The tool will open and close the same for thousands of parts, whether a beautiful part shape or a mediocre part shape, for the same cost. The company and customer lives with the result. Changes now are expensive. With $200,000 to $300,000 for a larger tool, here is where the pressure comes to get it right, and the reward comes when it is right. With this stage of a program running smoothly, great program leadership pays off.

Cross Sections, component iso-views and exploded views aid advancing the design by exploring solutions to difficult areas.

Details of a hood assembly