Product Dissection Course Materials
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
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
Course Information intro.doc
Introductory Lecture intro.ppt
Shop Rules shoprule.doc
Sample Syllabus syllabus.doc
Skills Matrix matrix.doc
Team Building Slides Part 1 team1.ppt
Team Building Slides Part 2 team2.ppt
Team Building Slides Part 3 team3.ppt
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
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
Recent publications about this course:
- The Learning Factory - A new approach to integrating design
and manufacturing into engineering curricula, J. S. Lamancusa,
J.E. Jorgensen, J.L. Zayas-Castro, J. Ratner, 1995 ASEE Conference
Proceedings, June 25-28, 1995, Anaheim, CA, pp 2262-2269.
Adobe Acrobat .pdf file
- Learning Engineering by Product Dissection, J. S. Lamancusa,
M. Torres, V. Kumar, J. Jorgensen, 1996 ASEE Conference Proceedings,
June 23-26, 1996, Washington DC.
Adobe Acrobat .pdf file
- Product Dissection - A Tool for Benchmarking in the
Process of Teaching Design, Jens E. Jorgensen, James Fridley, and
John S. Lamancusa, Proceedings of 1996 Frontiers in Education Conference
, Salt Lake city, UT, November, 1996.
Adobe Acrobat .pdf file and Appendix
- Benchmarking: A Process for Teaching Design, James Fridley, Jens Jorgensen,
and John Lamancusa, Proceedings of the
Frontiers in Education Conference, Pittsburgh, PA, November 1997.
Adobe Acrobat .pdf file
John Lamancusa - Penn State (firstname.lastname@example.org)
Miguel Torres - University of Puerto Rico, Mayaguez (email@example.com)
Vipin Kumar - University of Washington (firstname.lastname@example.org)
Jens Jorgensen - University of Washington (email@example.com)
Jim Fridley - University of Washington
Product Dissection at Other Universities:
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20 August 1999