In this module, we will learn the importance of designing products that are reliable, portable, modular, configurable, manageable, extensible, maintainable and scalable.
Reliability is the ability of a product to consistently perform its intended or required function, on demand, and without degradation or failure - as long as the product is used under specified conditions, and used for the purpose it is intended to serve. A reliable, trouble-free product continues to satisfy its customers for a long period of time. Product reliability is quantified by two metrics: MTBF and MTTR. Mean-Time-Between-Failures (MTBF) measures the average time elapsed between a failure of the product and the next time a failure occurs. That is, MTBF is an indicator of how frequently or infrequently the product fails. Mean-Time-To-Repair (MTTR) measures the average time required to troubleshoot and repair a failed product. That is, MTTR is an indicator of how long it takes to fix a broken product.
1. A washing machine that doesn't work as expected is not a reliable product
2. A car that breaks down frequently in the middle of the road is unreliable
Example 1: Suppose you buy a brand new washing machine for your home, but within a few weeks of using it, you encounter problems with it. The machine doesn't start sometimes, or occasionally stops midway through washing, or the liquid soap oozes out of its door at times. If these issues happen frequently, would you consider the washing machine to a reliable product?
Example 2: Suppose your car breaks down frequently and you have to get it towed to the garage every time to have it fixed. Either the car has a manufacturing defect, has not been repaired properly earlier, or has developed a new problem. Whatever may be the case, a car that breaks down frequently is not a reliable product. If the car breaks down, say, 3 times in 3 months, then it's MTBF is 90 days / 3 = 30 days. If it takes a total of 6 hours to repair 3 breakdowns, then MTTR = 6 hours / 3 breakdowns = 2 hours.
Tip: Reliability of a product is an inherent expectation of any user. Build a reliable product, and half your battle is won.
Work Chair Case Study:
Reliable operation of the product is an inherent expectation of any user. As such, it is very important to design a work chair that works reliably every time it is used. The key factor that controls the reliability of a work chair is the spring-mechanism mounted within the vertical tubular structure between the seat and the legs. The spring allows the height of the seat to be controlled. When the spring is stretched, it increases the height of the chair, but when the spring is compressed, it reduces the height of the chair. If the spring loses its tension, the height of the chair cannot be adjusted easily. We can design the work chair to be reliable by making use of high-quality and sturdy metal spring that has high tension. This way, it can work reliably even after multiple uses.
Exercise 9:
Consider the bicycle shown on the left. The bicycle has a chain that couples the pedal with the rear wheel. The chain is mounted on a gear mechanism on both its ends. When the user pedals the bicycle, it makes the chain move forward, and in turn the rear wheel. This is how a bicycle works. However, if you happen to pedal the bicycle backward, the chain may fall off from the gear mechanism. When this happens, one cannot ride the bicycle any more. And, it is quite messy to put the chain back in place. How can we re-design a better and more reliable bicycle?
See answer to Exercise 9:
Re-design the bicycle by doing away with the chain mechanism and attach the pedal directly to the axel of the front wheel. See: http://www.getchainless.com for more details.
Re-design the bicycle by doing away with the chain mechanism and make use of meshed gears that couple the pedal with the rear wheel. See https://www.designboom.com/technology/ceramicspeed-chainless-bike-07-10-2018/ for more details.
Portability is the ability of a product to be easily and safely carried around, or moved from place to place and be used in a variety of situations and locations without increasing the user's effort and workload. In other words, portability is the flexibility with which a product can work anywhere without requiring any changes or needing significant setup time. Product portability greatly enhances user experience as it improves flexibility in product usage.
1. Portable gadget can be carried around easily
5. Portable software works on multiple Operating Systems ->
2. A portable wheel chair can be moved around
3. Mobile No. portability - same mobile number can be used even if we switch mobile operators
4. Large sized products can be disassembled and re-assembled are portable during transportation
Example 1: A mobile phone is considered a portable gadget as it can be carried around and used anywhere. It owes its portability to its small size, light weight and battery power. It also works on a wireless network. Contrast this with the refrigerator in your home that is large is size, quite heavy and requires AC mains power supply to operate, rendering it much less portable than a mobile phone.
Example 2: A wheel chair is considered a portable product as it has wheels, enabling it to be moved around easily compared to a regular chair that has no wheels.
Example 3: A mobile number is considered portable if a customer can switch from one mobile service provider to another while continuing to use the same mobile number. For e.g., when I switch my mobile service provider from Airtel to Vodafone, I can retain the same mobile number as before. This is called mobile number portability.
Example 4: A furniture such as a big sofa that can be disassembled during transportation and re-assembled at the installation site can also be considered as portable.
Example 5: A software program that can be readily transferred from one computer (running operating system "A") to another computer (running operating system "B") is considered portable (for e.g., Java, Python, HTML, etc. programs) in contrast to those software programs that require modification before they can be run on computers with different operating systems.
Tip: A portable product provides flexibility and convenience to users over products that aren't portable. Consider how your product can be built with portability in mind.
Work Chair Case Study:
Very often, the work chair needs to be moved in and out of works spaces, cubicles and meeting rooms. As the chair is heavy, it is difficult to lift it and move around. We need a mechanism that makes it easy to move the chair around. We can design the work chair to be portable (that is its ability to be moved around easily) by adding wheels to it's legs.
Exercise 10:
Consider the almirah shown on the left. It is quite heavy and difficult to move easily. How can you re-design the almirah to be portable so that it can be easily moved from one room to another within a home?
See answer to Exercise 10:
Re-design the almirah with four wheels attached to its bottom. Let the wheels have locking mechanism to prevent the almirah from accidentally moving.
Product modularity is a method of designing products by sub-dividing the product functionality into several smaller functional blocks or modules. Each block or module has a distinct functionality. When these blocks are combined / integrated with each other, they give rise to the overall product. Modular product design provides several benefits to product designers as well as to end-users:
Modular design helps product designers handle complexity by breaking down the product's functionality into various less-complex modules or blocks, each with its own sub-functionality.
By designing each block with well-defined interfaces, product designers can easily integrate various blocks with each other. This gives rise to plug-n-play product architecture.
Modular architecture makes repair and maintenance of the product easier. A block that is faulty can be repaired or replaced with another block without impacting the rest of the product.
Modular product blocks can be used independently or combined with different blocks to give rise to different product functionality or features. This gives greater flexibility and convenience to users who would like to use different functionality of the product at different times and for different needs.
By combining multiple 'similar' blocks together, it is possible to scale up / down the product capacity to handle increased / decreased load.
If designed with the right intent, it is possible to integrate one or more third-party blocks with the product, thereby extending the functionality of the product.
A modular vacuum cleaner with different attachments, brushes and nozzles for performing different types of cleaning jobs
Example: Consider a home vacuum cleaner. Most of the modern vacuum cleaners come with multiple attachments such as brushes, hose pipes and nozzles. There are various types of brushes provided for cleaning floor, cleaning carpets, cleaning furniture, cleaning fabric, cleaning windows, etc. By attaching one hose pipe to another, one can extend the overall reach of the vacuum cleaner to clean ceiling, wall corners, floor corners, stairs, etc. using different sized nozzles.
Imagine for a moment if you had to buy different vacuum cleaners for each of the above jobs. That would have been a nightmare !! By making the vacuum cleaner design highly modular, it becomes possible for the user to buy one vacuum cleaner with multiple attachments, and use different attachments for different cleaning jobs. In case any of the attachments break, the user can just replace the particular attachment instead of buying an entirely new vacuum cleaner!
Tip: Modular products can bring significant flexibility and convenience to end-users, repair technicians and also to product designers & manufacturers.
Work Chair Case Study:
While a basic work chair has a seat, a back rest, and comes with wheels, it is often not enough. Some users prefer to rest their head and arms on the chair as well. So, we need to provide some support for these users. We can have a modular design of the work chair by providing a head-rest and two arm-rests. The head rest and arm-rests can be attached to, or detached from the chair-frame depending on the convenience and comfort of its user.
Exercise 11:
Consider the sofa shown on the left. How can you re-design the sofa to be modular so that users can arrange each module according to their needs, convenience and space available in their living room?
See answer to Exercise 11:
Re-design the wide & monolithic sofa into multiple smaller, but modular sofa blocks. Each sofa block can be arranged according to the needs and convenience of the user. See https://www.article.com/product/13934/corvos-whisper-gray-modular-sofa for more details.
Configurability defines the ability of a product to be dynamically modified, adjusted, re-arranged or extended while it is operational. Configurability involves changing a certain part, component, aspect or parameter of a product so that the variation alters the operation or performance of the product. Configurability allows the product designer to design a generic product which can then be configured to serve the needs of different types of users or customers. Without the ability to configure, a product needs to be customized to every customer's requirement. In summary, configurability brings flexibility to the product operation by allowing the product to: (a) be used in different operating environments & conditions, (b) meet different user needs - without having to be re-designed or re-built for each configuration.
1. Configure WiFi settings on laptop or phone
2. Configure or tune car's engine parameters
3. Configure WiFi hotspot on phone
Example 1: Laptops and mobile phones provide users with the ability to connect to WiFi network of their choice by allowing users to configure the WiFi network's credentials (SSID and password) on it.
Example 2: Car manufacturers design an engine and make many of its parameters configurable. This makes it possible for them to tune the engine to meet the requirements of different markets without re-designing the engine for each market. In addition, by allowing the engine parameters to be tunable, it becomes possible for service technicians to tune the performance, fuel-efficiency, or emission levels of the car to desired levels.
Example 3: Most modern smartphones allow users to configure a WiFi hotspot on the fly, making it possible for other devices to connect to the hotspot using the hotspot's credentials (SSID, password and security type).
Without the ability to configure, a product would remain set to factory default settings and would not be usable in different user environments or operate at the desired performance levels.
Tip: People love to configure and re-configure products to accommodate their changing needs and requirements. Designing products that are configurable allows product designers to build a product once and offer it to multiple customers, who can then configure it to their individual needs.
Work Chair Case Study:
While providing a head-rest and arm-rest to the chair will make it convenient for many users, it may not be enough. Users need a way to adjust the height of the head-rest and arm-rests as per their comfort and convenience. We can design the work chair to be configurable by providing a sliding and locking mechanism to the head-rest and arm-rests. This way, users can adjust the height of the head-rest and arm-rests as per their convenience and lock them into position.
Exercise 12:
Consider the headphone shown on the left. It has fixed dimensions and can fit the heads of children easily. However, adults find it difficult to use this headphone since their head size is bigger. How can you re-design the headphone to be configurable so that it can fit people's heads of different sizes - both children as well as adults?
See answer to Exercise 12:
Re-design the headphone such that the head-band can be stretched or contracted depending on the head size of the wearer.
Manageability is the ease, speed, and competence with which a product can be configured, modified, installed, controlled, metered and supervised. A product that is manageable allows itself to be maintained and operated easily over time and minimizes the chances of the product breaking down or malfunctioning (thereby improving its overall availability and reliability). A product may be self-managed, managed externally from external systems, or by users themselves. When a product is managed externally, it can be managed locally or remotely. A locally-managed product requires another system or user to be available at the location where the product is deployed in order to be managed. A remotely-managed product allows itself to be managed by external systems or users from a distance using communication networks.
1. Managing App updates on smartphones
2. Managing Amazon Echo device using Alexa app
3. Managing networked computers remotely
4. Managing a laser printer
Example 1: Today's smartphones have several apps installed on them. These apps need to be updated from time-to-time to take advantage of the latest features made available by its developers. Smartphones allow you to either "auto-update" the apps or "manually update" the apps. If you choose the auto-update option, your apps get automatically updated on your phone as and when new updates are available for the apps on the App Store. This is an example of a self-managed product. Alternatively, you can disable the auto-update option and choose to update your apps selectively by yourself. This is an example of manually managed product.
Example 2: Alexa app can be used to locally setup and manage Amazon's Echo voice assistant device in your home. This is an example of local manageability where both the mobile phone running Alexa app and the Echo device are connected to the same WiFi network.
Example 3: A remote computer can be used to remotely login to the computer network in your school or office in order to install software tools, configure network settings, setup anti-virus software and user accounts, etc. This is an example of remote manageability.
Example 4: A laser printer can be managed locally by its user for loading paper, configuring print settings, etc., or remotely managed or metered by an external system over the network.
Tip: Design your product to be manageable, either locally or remotely. A product that is not manageable makes life inconvenient or even complicated for the end-user as well as for the company which sells the product.
Work Chair Case Study:
When we order a work chair, it is usually shipped from the warehouse to the customer's site in a dismantled position to save space during transportation. The chair needs to be assembled / installed at the customer's site before it can be used. We can design the work chair to be self-manageable by making it simple and easy for the user to assemble and install the chair by themselves without needing the help of a professional. As part of self-manageability, we can provide assembly-tools (such as a screw-driver, nuts and bolts) and an instruction manual (with step-by-step instructions) for assembling and installing the chair.
Exercise 13:
Consider the street lights shown on the left. They need to be turned on at sunset and turned off eat sunrise everyday. If the maintenance staff delay in turning on the street lights at sunset, the streets will be dark and unsafe for vehicular and pedestrian movement. If the maintenance staff delay in turning off the street lights at sunrise, it will lead to wastage of electricity. How can you re-design the street lights to be self-manageable?
See answer to Exercise 13:
Re-design the street light with a photo-voltaic circuit that senses the sunlight. If the sunlight is dim, it turns on the street light automatically. If the sunlight is bright, it turns off the street light automatically. This way, the street light becomes self-manageable.
Extensibility is a measure of: 1) the ability to extend a product's functionality beyond what it was initially built for, and 2) the level of effort required to implement the extension. Extensibility provides for future growth of the product through addition of new functionality without impairing existing functionality. Depending on the design of the product, it may be possible to extend the product functionality by product designers, by end-users, or by both. In addition, some products may have built-in extensions that can be made use of by users on need basis.
1. Extending a car's ability to carry extra luggage
2. Extending a train by coupling coaches to each other
3. Moto Mods - Modular extensions to Motorola smartphones
4. A sofa that can be extended into a bed
Example 1: Take the case of a luggage-carrier that can be fitted on top of a car. This is an extension that can be added to the car to enhance its ability to carry luggage on its roof.
Example 2: Railway coaches are designed and built keeping extensibility in mind. A train's capacity to carry additional people or goods can be dynamically extended by adding additional coaches using inter-coach coupling mechanisms.
Example 3: Moto Mods are extensions that can be attached to Motorola smartphones to extend the functionality of the phone. The extension Mods include zoom lens, speaker, power bank, projector, wireless charger, vehicle mount, etc. These Mods can be snapped onto the phone using magnetic contacts.
Example 4: Consider a sofa with built-in extension that allows it to be converted into a bed. During day time, the extension is folded-in, allowing users to sit on the sofa. At night times, the bed extension can be pulled out allowing users to sleep on it.
Tip: Never limit your product design to only today's needs and requirements. Future-proof your product by designing with extensibility in mind.
Work Chair Case Study:
Some users prefer additional features in the product that add greater value to them. We can make the work chair extensible by providing a mechanism to attach a "Leg-rest" to the chair frame. When the leg-rest is attached, users can stretch their legs while being seated on the chair. The leg-rest can be purchased separately (if needed) and attached to the chair on need basis. The leg-rest can either be folded-down or removed from the chair when not in use.
Exercise 14:
Consider the bicycle shown on the left. It has one seat for the rider to ride the bicycle. How can you extend the bicycle design to carry a child in addition to the rider?
See answer to Exercise 14:
Re-design the bicycle such that a child seat can be attached on top of the metal rod between the handle and the main seat of the bicycle.
Maintainability is the degree to which a product allows safe, quick and easy mechanism to identify & correct defects or their causes, repair or replace faulty or worn-out components without having to replace still working parts, prevent unexpected working condition, improve product performance by tuning configuration settings, maximize a product's useful life and maximize product's efficiency, reliability & safety. Typically, service engineers or technicians are involved in maintaining a product. At times, a customer or end-user may also perform maintenance jobs if it is simple.
Most product maintenance jobs are conducted at the site where the product is deployed, though smart connected products allow service engineers to remotely perform maintenance operations on the product via the Internet. Maintainability is a very important aspect of product design to ensure that the product runs at its optimal capacity and performance without breaking down or malfunctioning. If adequate maintainability capabilities are not built into the product at the time of design, it will make it harder to undertake repair or maintenance jobs. This can result in high product maintenance costs, long out-of service times and possible injuries to maintenance engineers.
1. Manholes allow for maintenance of clogged sewage pipes
2. OBD port in car is used to perform maintenance operations
3. Remote Desktop Apps allow remote maintenance of computers
Example 1: Haven't you noticed manholes on street corners? They are used to carry out inspection, cleaning and removing obstruction in the sewer line. Manholes have a removable lid that can be opened by municipal staff for maintenance operations. Without a manhole designed as part of the sewer network, it would be very difficult to carry out maintenance operations.
Example 2: Modern cars have a connector called "OBD Port" in them. It is usually found underneath the car's dashboard or below the glove compartment. The OBD port facilitates maintenance activities by service engineers. Service engineers connect a computer to the OBD port through a cable in order to diagnose the car's emission levels, mileage, speed and tune the car's engine performance. Without the OBD port, it would be difficult to diagnose or tune the engine. The OBD port makes the maintenance job easier.
Example 3: Today, most computer manufacturers offer remote assistance service to buyers of laptops or desktop computers. In case you have any trouble with your computer, you can call the service center, and a service engineer will remotely login to your computer and fix it. This is an example of remote maintenance. If your computer didn't have remote access capability built-in, you would have to physically carry your computer to the service center to have it fixed.
Tip: Design your product to be maintenable, either locally or remotely. A product that is not maintenable makes life inconvenient or even complicated for the end-user as well as for the company which sells the product.
Work Chair Case Study:
The work chair gathers dust and dirt over a period of time. It requires to be cleaned regularly to maintain it in good shape. We can design the work chair to be easily maintainable by making use of fabric and materials for the chair that lend themselves to easy and effective cleaning - by wiping with a dry or damp cloth, by scrubbing with a brush, or by cleaning with a furniture vacuum cleaner. In addition, we can design the chair such that seat cover and back-rest cover can be added to or removed from the chair easily.
Exercise 15:
Consider the ceiling fan shown on the left. The blades of the ceiling fan often collect dust, especially the upper surface of the blades. It is often difficult to clean the blades since they are at a sufficiently high level and are unreachable for most people standing on the ground. This results in poor maintainability of the ceiling fan. How can you re-design the ceiling fan for better maintainability?
See answer to Exercise 15:
Re-design the ceiling fan such that it's blades can be bent downwards when they needs to be cleaned.
Scalability describes the ability of a product to grow in its capacity to handle increased demand over time. A scalable product is advantageous because it is more adaptable to the changing needs or demands of its users or customers. Scalability of a product can be improved by scaling up (vertically) or scaling out (horizontally). Vertical scaling involves adding higher capacity resources to the product to improve its ability to handle more load in a given time. For example, by employing a bigger capacity refrigerator in a cold-storage unit, you can increase the number of items that can be refrigerated. Horizontal scaling involves adding multiple product resources, each of which can individually handle part of the job and together contribute to the overall ability of the product to manage higher load. For e.g., you can set up several small refrigerator units to increase the total number of items that can be refrigerated in a cold-storage unit.
1. Use a big bus or multiple cars to scale
2. Horizontal & vertical scaling of computing resources
3. Scaling up/down a table to seat more/less people around it
4. Scaling up a train to carry more passengers
Example 1: What if you need to transport 40 people from point A to point B. Either you use of a big bus which can accommodate 40 people (vertical scaling), or press into service several buses or cars to do the same job (horizontal scaling). Either way, you can handle the increase in load (people to be transported) by scaling up vertically or horizontally.
Example 2: Suppose you have a software application running on a computer and there is a spurt in the number of users using your software application. How do you handle the increased load on your software? You can either put in place a bigger computer (with greater processing power, memory and storage) to run your software application (vertical scaling), or add several small computers that run in parallel to share the increase in load.
Example 3: An extensible dining table can be scaled up / down to seat more / less people around it.
Example 4: A train can be scaled out (horizontally) to carry more passengers by adding several coaches to it, or scaled up (vertically) to carry more passengers by having a small number of double-decker coaches, that each carry more people.
Tip: Products don't remain stagnant while in use. As users and customers see value in using a product, they wish to get more out of the product. This can increase the load on the product. A product that can't handle additional load will fail sooner or later. Design your product with future scalability in mind.
Work Chair Case Study:
The work chair can be used by a variety of people - some with slim waist and some with wide waist. As such, it is important to design the chair keeping in mind different types of users. We can design a scalable work chair whose arm rests on both sides can be pulled side ways (on need basis) to allow a person with wide waist to sit on the chair.
Exercise 16:
Consider the refrigerator shown on the left. It has a limit on the number of items that can be refrigerated. What if we need to refrigerate many more items? How can you scale up the refrigerator to store more items in it?
See answer to Exercise 16:
You can increase the size of the existing refrigerator to store more items (called vertical scaling), or add many more smaller refrigerators (called horizontal scaling) to the cold-storage unit to store more items.
You made some progress in refining the Water Wheel product yesterday. However, design is an iterative process that requires successive rounds of refinement to build a good product. So, please go through a third round of refinement today and further improve the design of the Water Wheel using the knowledge of 8 additional product quality attributes learnt today.
Watch the video of Water Wheel product. Design an improved version of the Water Wheel by incorporating at least 4 product quality attributes learnt today (over and above the improved design you came up with yesterday).
To know more about Wello Water Wheel, please click here.
Tips: Enhance the Water Wheel design such that:
It does not malfunction or break down when in motion (reliability)
It can be detached, transported over long distances or stored in small spaces easily (portability)
It's components can be attached or detached depending on need (modularity)
It can be configured with additional attachments to serve the needs of village women during day or night, under different weather conditions, with or without a baby, and ensures the personal safety & security of village women moving in a group or alone (configurability)
It can be installed, assembled for use or disassembled after use easily without the need for professional help (manageability)
It has in-built mechanisms allowing it to be extended beyond its core capabilities to serve the additional needs of village women (say, with baby) (extensibility)
It can be repaired by a village women on her own without needing professional help (maintainability)
It allows more than 5 gallons of water to be transported in one trip from the lake to home (scalability)
This activity is a real test of your creative & critical thinking abilities. Please think through in depth and determine how you can incorporate the product quality attributes into the design of the water wheel.
Sketch your design on paper or create a 3D design using TinkerCAD 3D Designer or TinkerCAD CodeBlocks tool.
Create multiple sketches or 3D designs to show how you have incorporated the various product quality attributes in the design.
Preferably, sketch with 3D perspective.
Incorporate any 4 product quality attributes learnt today to a product of your choice. Sketch the product design on paper - showing how you have incorporated the attributes.
Designing products that are Secure
Designing products that are Highly Available
Designing products that are Personalizable
Designing products that are Smart
Designing products that are Compatible
Designing products that are Interoperable
Designing products that are Standards Compliant
Designing products that are Regulatory Compliant