Product Dissection Course Materials

Course Description
This interdisciplinary course examines the way in which products and machines work: their physical operation, the manner in which they are constructed, and the design and societal considerations that determine the difference between success and failure in the marketplace. Students from a variety of engineering majors work in teams to dissect several common industrial and consumer products. In the process, they decipher the internal functions in terms of basic physical principles, and examine issues of design, manufacturing, materials selection, ethics and green design. This course relies on problem-based learning and hands-on laboratory experience closely coupled to classroom lectures. Heavy emphasis is placed on the development of mental visualization skills and the development of team and communication skills.

This course is intended for freshman or sophomore level students of all engineering majors. It is a required course in the Product Realization Minor. It was developed by the Manufacturing Engineering Education Partnership, a coalition of Penn State, The University of Puerto-Rico Mayaguez, the University of Washington and Sandia National Labs. Funding was provided by the Technology Reinvestment Program.

The course materials consist of modules in electronic form (Microsoft Powerpoint and Word) for easy dissemination and modification. In order to view these files, you will need to install MS powerpoint (or powerpoint viewer) and MS Word as helper applications for your Web browser. Alternatively, you may exit Netscape and directly open the files contained on this CD with the appropriate application.

Table of Contents

Read this first
Introduction
 Course Information intro.doc
Introductory Lecture intro.ppt
Shop Rules shoprule.doc
Sample Syllabus syllabus.doc
Skills Matrix matrix.doc

Team Building
Team Building Slides Part 1 team1.ppt
Team Building Slides Part 2 team2.ppt
Team Building Slides Part 3 team3.ppt

Dissection Modules

  • Bicycle Dissection - Used bicycles (typically 10 speed versions) are dissected and refurbished. Students explore engineering principles such as work, energy, power transmission, materials, biomechanics – things they never thought of before when they rode their bike.
    Bicycle Dissection Instructions bicycle.doc
    Bicycle Lecture Slides Part 1 bike1.ppt (Introduction)
    Bicycle Lecture Slides Part 2 bike2.ppt (Bicycle History)
    Bicycle Lecture Slides Part 3 bike3.ppt (Biomechanics)
    Bicycle Lecture Slides Part 4 bike4.ppt (Design Issues)
    Bicycle Power Calculator

  • Power Drill Dissection - Electric hand drills from a variety of manufacturers are dissected and reassembled in working order. Students explore electrical and mechanical drive hardware, such as motors, bearings, gears. Drills from different manufacturers are compared for their design, ease of manufacture and cost.

    Hand Drill Dissection Instructions drill.doc
    Hand Drill Lecture Slides Part 1 drill1.ppt
    Hand Drill Lecture Slides Part 2 drill2.ppt
    Hand Drill Lecture Slides Part 3 drill3.ppt
    Hand Drill Lecture Slides Part 4 drill4.ppt
    Hand Drill Lecture Slides Part 5 drill5.ppt
    Animation of permanent magnet DC motor motor.ppt

  • Single Use Camera Dissection - The single use camera, first invented by Kodak, is an example of a high volume, low cost product which is designed to have a high content of re-used parts and recycled materials. Students dissect two consecutive versions and identify product improvements. Issues of injection molding, design for manufacture, and design for recycling are examined.

    Funsaver Camera Dissection Instructions camera.doc
    Reference article on design for Recyclability - Kodak's Single Use Camera kodak.htm

  • Lawnmower Engine Dissection - Virtually every aspect of mechanical engineering can be found in an internal combustion engine, and most students are instantly attracted to them. Students dissect, reassemble and troubleshoot a lawnmower engine. In the process, they learn about combustion, carburetors, cooling, ignition systems, lubrication, materials and proper use of tools.

    Engine Dissection Instructions engine.doc
    Engine Lecture Slides engine.ppt

  • Telephone Dissection - Students dissect rotary dial telephones, as well as modern electronic versions. The rotary dial telephone, while now obsolete, is an excellent example of an electro-mechanical device. The ringing mechanism, the rotary dial governor, and the carbon microphone are extremely clever devices. They provide an opportunity to discuss the invention and history of the telephone. By comparing with modern telephones, the students also can see the evolution of a product, from electro-mechanical, to computer-integrated.

    Telephone Dissection Instructions phone.doc
    Telephone Lecture Slides Part 1 phone1.ppt
    Telephone Lecture Slides Part 2 phone2.ppt

  • Product Benchmarking - Benchmarking and competitive analysis are important tools for product design, whereby design and manufacturing information is gleaned from existing products. Students benchmark the performance of kitchen mixers from a variety of manufacturers. The results of the benchmarking are used to conceptually design the “ultimate” hand mixer.

    Benchmarking Lecture Part 1 bench1.ppt
    Benchmarking Lecture Part 2 bench2.ppt
    Benchmarking Lecture Part 3 bench3.ppt
    Hand Held Mixer Benchmarking Exercise mixer.doc

    Other Materials


    Recent publications about this course:
    Course Authors:
    John Lamancusa - Penn State (jsl3@psu.edu)
    Miguel Torres - University of Puerto Rico, Mayaguez (mtorres@exodo.upr.clu.edu)
    Vipin Kumar - University of Washington (vkumar@me.washington.edu)
    Jens Jorgensen - University of Washington (jorgen@u.washington.edu)
    Jim Fridley - University of Washington
    Product Dissection at Other Universities:
    Stanford
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    20 August 1999