UNIVERSITI TEKNIKAL MALAYSIA MELAKA DEVELOPMENT OF AN AUTOMATED KEROPOK LEKOR CUTTING MACHINE USING PNEUMATIC SYSTEM This report submitted in accordance with requirement of the Universiti Teknikal Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering (Robotic and Automation) with Honours.
by
MOHD ADIB BIN TUKIRAN
FACULTY OF MANUFACTURING ENGINEERING 2009
DECLARATION
I, hereby, declared this report entitled “Development of an automated keropok lekor cutting machine using pneumatic system” is the result of my own research except as cited references.
Signature
: ……………………………………………..
Author’s Name
: MOHD ADIB BIN TUKIRAN
Date
: 7 MEI 2009
APPROVAL
This report is submitted to the Faculty of Manufacturing Engineering of UTeM as partial fulfillments for the degree of Bachelor of Manufacturing Engineering (Robotic and Automation) with Honours. The member of supervisory committee is as follow:
……………………………………………….. (ISMAIL BIN ABU SHAH) Main Supervisor Faculty of Manufacturing Engineering
ABSTRACT
Keropok lekor is a famous snack food, originated from East-Coast of Malaysia which is made from the composition of fish, sago flour, pandan leaves, salt, and water. The purpose of this study was to develop a keropok lekor cutting machine using pneumatic concept. This study focused on engineering concept and application of this invention in order to help keropok lekor entrepreneur to increase their production volume. Generally, this prototype involved cutting and feeding mechanism. Firstly, the keropok lekor will be moved by feeding mechanism and the cutting blade will reciprocally move upward and downward to implement cutting process. The study started with define specification such as identify customer requirement and function of the machine. Then the process continued with concept generation which a few designs and concepts of the machine. Once decision has been made via critical and systematical analysis, detail design has been made using SolidWork as a 3D modeling of the machine. After completion of 3D modeling, the design has been analyzed using COSMOXPress to optimize the design. When the prototype development completed, product testing have been done. From the result of this prototype, suggestions and recommendation for improvement have been persuaded as a continuous improvement of the machine. Upon completion of the study, it can be applied by the entrepreneurs who seriously involved in the keropok lekor manufacturing industry. As a consequence, volume production can be done and fulfill market requirement all over the country.
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ABSTRAK
Keropok lekor merupakan makanan ringan yang berasal dari Pantai Timur Semenanjung Malaysia. Oleh kerana permintaan yang tinggi di pasaran, usahawan keropok lekor perlu meningkatkan jumlah pengeluaran mereka. Namun demikian. mereka tidak mampu memenuhi permintaan pasaran yang semakin meningkat kerana kebanyakan proses pengeluaran masih menggunakan konsep manual kerana ketiadaan mesin yang sesuai. Penyelidikan ini dijalankan adalah betujuan untuk membangunkan mesin pemotong keropok lekor. Penyelidikan ini menggabungkan konsep dan aplikasi kejuruteraan dalam membantu usahawan keropok lekor dalam meningkatkan kuantiti pngeuaran mereka. Prototaip mesin pemotong keropok lekor ini mempunyai 2 mekanisma utama iaitu mekanisma pergerakan dan mekanisma pemotongan. Penyelidikan ini dimulakan dengan mengenalpasti kehendak dan keperluan pengguna iaitu para usahawan keropok lekor bagi memastikan mesin yang dihasilkan daripada prrojek penyelidikan ini dapat membantu mereka. Seterusnya, proses pembangunan melibatkan penjanaan idea bagi memenuhi kehendak pengguna. Apabila keputusan tentang konsep mesin yang bakal dibangunkan telah dibuat melalui analisis yang sistematik, lukisan kejuruteraan telah dihasilkan menggunakan perisian SolidWork sebagai model 3 dimensi. Kemudian lukisan tersebut telah dioptimumkan menggunakan perisian COSMOXpress. Apabila prototaip mesin telah disiapkan, mesin telah diuji bagi memastikan samada ia dapat berfungsi sepertiyang dikehendaki atu tidak. Berdasarkan kepada prestasi mesin ini, beberapa cadangan untuk penambahbaikan telah dicadangkan. Sebaik pembangunan mesin ini selesai, para usahawan keropok lekor dapat menggunakannya bagi meningkatkan kuantiti pengeluaran mereka. Hasilnya, produk keropok lekor bukan sahaja dapat memenuhi permintaan domesrik, malah boleh dieksport ke luar negara.
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DEDICATION
For my beloved parents: Hj. Tukiran @ Maskuri bin Hj. Nor @ Md. Ali Hjh. Jumirah @ Fauziah binti Hj. Yassin
For my cherish brothers and sisters: Mohd Latif bin Tukiran M. Tusidan bin Tukiran Hj. Mohd Rohimi bin Tukiran Siti Katiah binti Tukiran Siti Norisnaini binti Tukiran
For my beloved fiancée Rabiatul Adawiyah binti Hj. Ismail
And my treasured friends Thanks for everything. The work and success will never come true without all of you.
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ACKNOWLEDGEMENT
In The Name of Allah; the Most Gracious and the Most Merciful, Be Upon His Messenger Prophet Muhammad S.A.W and His Companions.
Assalamualaikum W.B.T.,
First of all, thanks to Allah for his divine inspirational guidance, this helped me to accomplish this project. I would like to convey my sincere thanks to project supervisor, Mr. Ismail bin Abu Shah for his constructive guidance and patience in fulfilling our inspiration in completing this project.
Besides, special thanks to the Microzas Sdn. Bhd. and Mr. Hazreen Azeez bin Abdul Rahman for their explanation, demonstration, and providing facilities in order to develop the machine prototype. Finally, I would like to express greatest gratitude to my family and friends for their valuable encouragement and continuous support until the completion of this study.
Last but not least, I would like to convey special thanks to those person who had contributed to my final year project, whether directly or indirectly.
Sincerely, M. Adib Tukiran
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TABLE OF CONTENT
Abstract
i
Abstrak
ii
Dedication
iii
Acknowledgement
iv
Table of Content
v
List of Tables
ix
List of Figures
x
List Abbreviations
xii
1.0
INTRODUCTION
1
2.0
Project Background
1
2.1.1
Keropok Lekor
2
2.1.2
Cutting Mechanism
2
2.2
Problem Statement
3
2.3
Objectives
4
2.4
Scope
4
2.5
Benefit of The Project
5
2.6
Project Planning
5
3.0
LITERATURE REVIEW
9
3.1
Design
9
3.1.1
Engineering Design
10
3.1.2
Conceptual Design
12
3.1.3
Detail Design
13
3.2
Development
13
3.3
Automated
15
3.3.1
Manual-Work Systems
15
3.3.2
Worker Machine System
16
v
3.3.3
Automated System
17
3.4
Keropok Lekor Properties
19
3.5
Cutting Mechanism
20
3.5.1
Important Criteria of Cutting Mechanism
22
3.6
Electric Motor
25
3.6.1
AC Motors
27
3.6.2
DC Motors
29
3.6.3
Stepper Motors
30
2.7
Relay Logic
31
2.7.1
Basic Format for Relay Logic Diagram
33
2.8
Pneumatic System
34
2.8.1
Advantages of Pneumatic Systems
35
2.8.2
Pneumatic Components
36
2.8.2.1 Actuator
36
2.8.2.2 Air Compressor
38
2.8.2.3 Air Filter
38
2.9
Software
38
2.9.1
SolidWorks
39
2.9.2
CosmoXpress
40
2.9.3
Automation Studio
41
2.10
House of Quality
41
2.11
Pugh Method
44
2.11.1 Steps to Develop Pugh Method
45
2.12
Push Pull Gauge
46
4.0
METHODOLOGY
48
4.1
Stages of The Project
48
4.1.1
Project Understanding and Planning
49
4.1.2
Define Specification
51
4.1.3
Literature Review
51
vi
4.1.3.1 Books
52
4.1.3.2 Journals, Articles, and Paper
52
4.1.3.3 Catalogues
52
4.1.3.4 Internet Resources
52
4.1.4
Conceptual Design
53
4.1.5
Detail Design and 3D Modeling
54
4.1.6
Design Optimization
55
4.1.7
Fabrication and Assembly
56
4.1.8
Testing
57
4.1.9
Discussion
58
4.1.10 Conclusion
58
4.1.11 Presentation and Evaluation
58
4.0
RESULT AND ANALYSIS
59
4.1
Identification of Customer Requirement
60
4.2
Define Product Specification
64
4.2.1
Experimental Analysis
65
4.3
Design Concept Generation
68
4.3.1
Concept 1: Cam-Follower Mechanism
69
4.3.2
Concept 2: Pneumatic System
70
4.3.3
Concept 3: Worm Gear Concept
71
4.3.4
Concept 4: Rack and Pinion Mechanism
72
4.4
Design Concept Selection
73
4.5
Further Design Improvement
75
4.5.1
Cylinder Bore Size
76
4.5.1.1 Specification of Pneumatic Cylinder
77
4.5.2
Ideal Speed for Feeding Mechanism
79
4.6
Detail Design
82
4.6.1
3D Modeling
85
4.6.1.1 Cutting Mechanism
87
4.6.1.2 Feeding Mechanism
88
4.6.1.3 Overall Machine
90
vii
4.6.2
Drive and Driven System
91
4.6.3
System Operation
92
4.6.4
Design Optimization
95
4.6.4.1 Cutter Blade
96
4.7
Fabrication
97
4.7.1
Bending
97
4.7.2
Welding
98
4.7.3
Turning
99
4.7.4
Milling
100
4.8
Machine testing
101
4.8.1
Testing result
101
5.0
DISCUSSION
104
5.1
Normal Cutting Process
105
5.2
Main Factor of Machine Performance
108
5.3
Degree of Freedom in Keropok Lekor Cutting Process
107
5.4
Techniques to Implement Cutting Process
112
5.5
Proposal of Machine Improvement
120
6.0
CONCLUSION AND SUGGESTIONS
123
6.1
Conclusion
123
6.2
Suggestions
124
REFERENCES
126
viii
LIST OF TABLES
1.1.1 Gantt Chart for PSM 1
7
1.1.2
Gantt Chart for PSM 2
8
4.1
Evaluation of conceptual design using Pugh method
74
4.2:
BOM of keropok lekor cutting machine (parts and components)
84
4.3:
BOM of keropok lekor cutting machine (fastener)
85
5.1:
Manual Cutting of Keropok Lekor in Ambient Temperature
114
5.2
Manual Cutting of Keropok Lekor (After Stored In A Fridge)
117
ix
LIST OF FIGURES
2.1
The Seven Stages of Engineering Design
11
2.2
Product Development Path
14
2.3
Manual Work System
16
2.4
Workers-Machine System
17
2.5
Automated Systems
18
2.6
Keropok Lekor Structure
20
2.7
Manual Cutting of Keropok Lekor
21
2.8
Example of Forces in Equilibrium
23
2.9
Force applied and force exerted during cutting keropok lekor
23
2.10: A real cut notch in cutting process
24
2.11: Types of electric motor
26
2.12
31
Symbols for common relay logic diagram
2.13: An example for relay logic diagram
33
2.14: Pneumatic Cylinder
37
2.15: 3D modeling using SolidWorks
40
2.17
House of Quality
42
2.18
The push pull gauge
47
3.1:
Flowchart of the study
50
3.2
Design optimization using CosmosXpress
56
4.1
The eight stages of chapter 4
60
4.2
HOQ for this project
62
4.3
Experimental analysis of keropok lekor manual cutting
66
4.4
The keropok lekor has been cut
66
4.5
Cutting keropok lekor in various measurements
67
4.6
Cam and follower cutting mechanism
69
4.7
Pneumatic cutting system
70
4.8
Worm gear concept
71
4.9
Rack and pinion mechanism
72
4.10
Cylinder bore
76
4.11
Pneumatic cylinder from SMC
77
4.12
The displacement of feeding mechanism
80
x
4.13
Cutting mechanism
87
4.14
Feeding mechanism
89
4.15
Complete design of keropok lekor cutting machine
90
4.16
Drive and driven system
91
4.17
Operation of the system
92
4.18
The electrical circuit for keropok lekor cutting machine
95
4.19
Cutter blade
96
4.20
Conveyor frame which produced using bending process
98
4.21
Supported leg of the machine
99
4.22
Drive shaft of the machine
100
4.23
Supporting plate been produced using face milling process
100
4.24
Result of keropok lekor cutting process
102
4.25: Keropok lekor cut manually
103
4.26: Keropok lekor cut using machine
103
5.1:
Manual cutting of keropok lekor
105
5.2:
Keropok lekor cutting machine (front view)
106
5.3:
Repeated applied and exerted force caused keropok lekor to twist 108
5.4
The twelve degree of freedom
109
5.5:
The push pull gauge withstand the backward exerted force
110
5.6:
Push pull gauge use to justify exerted force to the right side guard 111
5.7:
Manual Cutting of Keropok Lekor (In Ambient Temperature)
115
5.8:
Manual Cutting of Keropok Lekor (After Stored In A Fridge)
118
xi
LIST OF ABBREVIATIONS
3D
3 Dimension
ABET
Accreditation Board for Engineering and Technology
AC
Alternating Current
ADAMS
Automated Dynamic Analysis of Mechanical System
CAD
Computer Aided Design
DC
Direct Current
HOQ
House of Quality
MOA
Memorandum of Agreement
PDI
Product Development Institute
PDMA
Product Development and Management Association
PSM
Projek Sarjana Muda
QFD
Quality Function Deployment
RPM
Rotation per Minute
TPG
Taiwan Precision Gear
SMI
Small and Medium Industry
vSCC
Speed of slat chain conveyor
xii
CHAPTER 1 INTRODUCTION
The research entitled “Development of an Automated Keropok Lekor Cutting Machine Using Pneumatic System”. Generally this chapter provides information about background, problem statement, objectives and scopes of the study. Besides that, outline of this study also included in this chapter.
1.1
Project Background
Nowadays, Small and Medium Industry sector (SMI) have been expanded widely and play an important role in generating Malaysian economy. SMI products have been spread widely and become popular rather than well-known imported product. Previously, foods like nugget, burger, frankfurter, and fish ball are imported or very hard to find in the market but currently can be easily found. The development of SMI has influenced many local foods such as keropok lekor, otak-otak, and many confectionary products to be commercialized. Therefore, SMI entrepreneurs need a machine to increase their productivity in order to fulfill market requirement. Unfortunately, special machine to automate the process in SMI still not widely discovered.
From the given project title, the background of the study can be defined in 2 category, namely keropok lekor and cutting mechanism.
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1.1.1.
Keropok Lekor
Keropok lekor is a famous snack food which is originated from East-Coast of Malaysia Peninsular. It is a speciality of Terengganu and now has been widely commercialized to entire country. Generally, keropok can be categorized as a type of snack which is made of flavored with fish or shrimp. The mixture is being handrolled into a sausage form. Ingredients of the mixture are fish (mackerel), sago flour, salt, water, ice cubes, and pandan leaves.
There are two methods to eat keropok lekor which are eat freshly after it has been boiled or by deep frying it. Usually, the huge and long sausages are cut into smaller pieces and thrown into the pan to be deep-fried until they turn crispy gold. Another option to take keropok lekor is to just steam it. This gives it a fishier flavor but tastes as good as the crispy ones according to some people. A completely different kind of keropok is keropok keping and it comes in different flavors: fish, squid, and prawn. Here, the keropok is shaped into even bigger tubes and cut into thin slices to let it dry in the sun. Keropok lekor ready to be served with their chili sauce, or with own home-made chili sauce if one prefers or shrimp-based sauce is also common. The best way to eat the keropok lekor is by take it right after frying when it is still hot, crispy on the outside and tender at the inside.
1.1.2.
Cutting System
Cutting is the separation of a physical object, or a portion of a physical object, into two portions or more, through the application of directed force. An implement commonly used for cutting is the knife or scissor for lightweight material, while axe is used for heavyweight task. Nevertheless, any sufficiently sharp object is capable of cutting if it has a hardness sufficiently larger than the object being cut, and if it is applied with sufficient force. Cutting also describes the action of a saw which removes material in the process of cutting. In the scope of this study, cutting mechanism is the way how to separate keropok lekor to the small pieces.
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Theoretically, cutting process is a combination of compressive and shearing phenomenon. It will only occur when the total stress generated by the cutting implement exceeds the ultimate strength of the material of the object being cut. The simplest applicable equation is stress = force/area. In the cutting process, the forces will acts on a body; there is an accompanying change in shape or size of the body (keropok lekor). Here, can be assumed that the stress generated by a cutting implement is directly proportional to the force which it is applied, and inversely proportional to the area of contact. Hence, the less force is needed when cutting small area, higher force is needed when cutting higher surface area.
1.2
Problem Statement
Keropok lekor, a popular fish based snack, is usually molded from kneaded fish meat and dough. Usually keropok lekor prepared using traditional methods with some mechanical equipment such as horizontal mixer and horizontal mince to knead the fish meat. Meanwhile degutting and deboning of the fresh fish is done manually. The job to roll the kneaded fish meat and boil is also done manually. More, keropok lekor itself should be cut into smaller size before being fry and this job also done manually because no proper machine has been created. The high requirements of keropok lekor in the market urge entrepreneurs to increase their production but they facing a lot of problem to fulfill market requirement.
The entrepreneurs faced a problem to increase production volume because a lot of process in producing keropok lekor has been done manually. In manual cutting and current practice, mass production for keropok lekor is not suitable. Material characteristics of keropok lekor which is well-known as sticky, glutinous, and gummy have influenced to the time taken to cut the keropok lekor itself. If the entrepreneurs want to increase their production, major of the process should be done in automated way. Besides, the use of automated equipment compensates for the labor cost disadvantage relative to competitors. More, automations can decreases production cycle times, and increases product quality and consistency. This statement was firmly proved that if the keropok lekor entrepreneurs want to increase their product volume, the best 3
Nowadays, invention of machine that would cut keropok lekor to small pieces or specific size still not widely discovered in Malaysia. Thus, the invention of keropok lekor cutter machine should be done to help the keropok lekor entrepreneurs to automate cutting process. As a consequence, their volume production will increase and the product itself can be commercialized and exported to worldwide.
1.3
Objectives
The objectives of this study are: (a) To design pneumatic system for cutting mechanism. (b) To develop an automated cutting machine for keropok lekor entrepreneur.
1.4
Scopes of This Project
In order to meet the objectives listed, the scopes of this project have been defined. There are: (a) To design an automated keropok lekor cutting machine using SolidWorks 2007 software. (b) To define value of force applied using push pull gage. (c) To optimize design of the keropok lekor cutter using COSMOXpress.
The study is involved in development of automated cutting machine that will be used to cut keropok lekor into specific size and uniform shape required by the customer. The entire machine consist of two mechanisms; feeding and cutting mechanism. Both mechanisms will be automated, because that is one of the objectives of this invention. Upon a completion of this study, feeding mechanism will be implement using conveyor while cutting mechanism will be done using pneumatic system.
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1.5
Benefits of The Project
There are a few benefits of this project either directly or just influenced by this new invention. The benefits are:
(a) University as a learning centre has done their responsibility in implementing research and innovation at the specific area thus can be applied for human to increase quality of lifestyle. (b) Student learned a knowledge about invention of machinery especially which is related to SMI. Student also gains knowledge to conduct a project with proper procedure and write a thesis in correct format. (c) The company can adapt and commercialized the research and innovation has been done by university academician via memorandum of agreement (MOA).
1.6
Project Planning
The project report should be arranged systematically in order to convey better understanding entire of the study. So that, an outline of the project has been constructed to briefly explain and summarize the content of every chapter. Overall of this study are divided into six chapters. They are:
(a) Chapter 1: Introduction This chapter covers the background of the project, problem statement, objectives and scope of the study. In addition, the benefits and the outlines of the project are included here.
(b) Chapter 2: Literature Review This chapter briefly explained about history, theory, and concept of the development of automated keropok lekor cutting machine, as well as with the mechanism and implementation of the project. There are many resource can be used in order to find supporting details for this chapter such as books, journals, and articles.
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(c) Chapter 3: Methodology This chapter includes flowchart which cover overall stage involve of this study. Then, every stage in the flowchart is explained briefly, covering PSM 1 and PSM 2.
(d) Chapter 4: Results & Analysis This chapter covers the analysis of the study. The result consist of customer requirements which have been simplified in the house of quality, selection of conceptual design using Pugh Method, detail design, and 3D modeling of the machines as well as the he finish product. Besides, a few analysis will be conduct here as a supporting details of related data in order to develop this machine. The analysis consists of theory and experiment, so that the machines develop will be firmly fulfill the criteria and standard restricted.
(e) Chapter 5: Discussion This chapter discussed the data analysis based on the result obtain in previous 4. Firstly, discussion will be focused on the simulation of the pneumatic cutting system, and then the discussion is about the performance of the machine that will be developed whether it success or not. A critical discussion should will de done here to reveal the key factor of success or failure of this project.
(f) Chapter 6: Conclusion Generally, this chapter concludes the main findings of the study. Recommendation for further study which related to the development of automated keropok lekor cutting machine also will be included in this chapter.
The progress of the study should be emphasized to ensure the project could be completed according to the time constraint. Gantt chart of the study has been created as references of the progress of the study. The Gantt chart of the study is such in Figure 1.1 and Figure 2 in the next consecutive page.
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CHAPTER 2 LITERATURE REWIEW
This chapter briefly explains about the definition and information of design, automated, cutting mechanism, motor, keropok lekor characteristics, pneumatic system and software; their scope, features, and relationship among them in implementation of this project. Besides, a few techniques which are related with the invention such as Pugh Method and House of Quality (HOQ) also will be explained at this chapter. Generally, this chapter focused on a single question which tries to identify, appraise, select and synthesize all high quality research evidence relevant to this project
2.1
Design
Numerous definitions have been proposed for the word design. According to the Norton (1999), the word design is derived from Latin word „designare‟, which means “to designate, or mark out”. Meanwhile, Madara & Kremer (2004) proposed that design can be identified in artistic or technical category. Artistic design is based on the personal expression which includes painting, sculptures, and landscapes. Meanwhile, technical design focused on the development of a product or process. Generally, design can be divided into conceptual design and detail design. Both are categorized as an engineering design.
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2.1.1
Engineering Design
Engineering design is the systematic, intelligent generation and evaluation of specifications for artifacts whose form and function achieve stated objectives and satisfy specified constraints (Dym and Lewit, 1991). Besides, engineering design has been defined as the process of applying the various techniques and scientific principles for the purpose of defining a device, a process or a system in sufficient detail to permit realization (Norton, 1999). He also stated that design may be simple or enormously complex, easy or difficult, mathematical or nonmathematical which may involve a trivial problem or one of the great importances.
Meanwhile, according to Madara & Kremer (2004), engineering design is the application of technical knowledge with knowledge of from non-technical disciplines and the use of design and analysis tools to synthesize a product or system that solves a particular problem or meet a specific need. Both academicians also agreed with the statement of The US Accreditation Board for Engineering and Technology (ABET, 1995) which identifies engineering design as the process of deriving a system, component, or process to meet desired need. It is a decision making process (often iterative), in which the basic sciences, mathematics, and engineering sciences are applied to convert resources optimally to meet a stated objective. Among the fundamental elements of design process are the establishment of the objectives and criteria, synthesis and analysis, construction, testing and evaluation. Further, engineering design is entailed to include a variety of constrains such as economic factors, safety and reliability, aesthetics, ethics and social impacts.
Researches about engineering design have been conducted by many scientists who have successfully identified and classified the design category in very detail. The most impressive and very detail design classification has been made by Erdman and his colleagues on 2001 which have emphasized and specified engineering design into 7 stages. He also created a flowchart of the 7 stages of engineering design. The first stage is confrontation and source of information. Second stage consists of formulation of problem and applicable information and assumptions.
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Then, design concepts listed in third stage. Stage four is synthesis while fifth is analyzable model. Analysis, experiment, and optimization located at stage six, while presentation listed at the last stage. The seven stage of engineering design produced by Erdman and his colleagues is such in Figure 2.1 below.
Figure 2.1: The seven stages of engineering design (Erdman, et. al, 2001)
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