Unit 8: Engineering Design

Unit code: Y/600/0258

QCF Level 3: BTEC National
Credit value: 10
Guided learning hours: 60

Aim and purpose

This unit gives learners the opportunity to explore the design process and how it is applied within an
engineering context.

Unit introduction

An understanding of how the design process operates within an engineering business is important for
anyone considering a career in the design and manufacture of products. This unit provides learners with the
opportunity to consider design in a holistic way. It combines study of the technical aspects of engineering
design with wider issues such as the environment, sustainability and legislation.
The unit introduces and develops the concept of design for manufacture. It is crucial that the design process
be effective. Success in the marketplace can be achieved only if products are fit for purpose, marketable
and meet customer requirements. The importance of market research, generation of new ideas and the
consequences of poor design are investigated.
Learners will also investigate the issues which influence whether a design proposal should be developed into a
final solution suitable for manufacture. These issues include the impact of legislation and standards, the need to
conform to environmental and sustainability requirements, materials selection and the types of manufacturing
process available. On completion of the unit learners will understand the wider implications of engineering
design and the reasons why it cannot be carried out in isolation from the rest of the manufacturing/production
process.
The unit content is linked together through a practical task which starts with learners interpreting the
requirements of a customer and producing a product design specification (PDS). This is followed by an
investigation into the legislation, standards and reference sources that are used by designers who work
in manufacturing engineering. This knowledge is then used to influence the production of their own
design proposals. These proposals are refined and developed into a final design solution which meets the
requirements of the customer. Design ideas will have been communicated using a number of techniques
including sketching and formal engineering drawing, design calculations and written commentary.

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 Learning outcomes
On completion of this unit a learner should:
1 Know how the design process operates when dealing with customers
2 Know the impact that legislation, standards and environmental and manufacturing constraints can have
on the design function
3 Be able to prepare design proposals that meet the requirements of a product design specification
4 Be able to produce and present a final design solution.

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Unit content

1 Know how the design process operates when dealing with customers
The design process: triggers eg market pull, demand, profitability, technology push, innovation, market
research; process of design for manufacture; decision making; use of new technologies eg computer
aided design (CAD), simulation, rapid prototyping, computer integrated manufacture (CIM); lines of
communication
Customer: customer/client relationship; types of customer eg external, internal; requirements of customer
eg performance specifications (physical dimensions, mass), compliance to operating standards, reliability
and product support, end of life disposal, production quantities (custom built, modification to an existing
product, small batch, large volume)
Product design specification (PDS): analysis of customer requirements; production of an agreed PDS;
documentation eg physical dimensions, materials, mass, operation and performance

2 Understand the impact of legislation, standards and environmental and

manufacturing constraints on the design function
Legislation and standards: relevant and current legislation, standards and codes of practice eg British
Standards (BS), electromagnetic compatibility (EMC) directive, European legislation (European Conformity
(CE marking))
Environmental and sustainable constraints: energy efficiency; environmental impact; constraints eg
Environmental Protection Act, Waste Electronic and Electrical Equipment Directive; end-of-life disposal eg
refurbishment, recycling, disassembly, material recovery, non recyclable components
Manufacturing constraints: availability of resources eg labour, material, equipment; influence of physical and
mechanical properties of a material in relation to manufacturing methods; cost effective manufacture eg
set up cost (jigs, tools), production quantities; health and safety in the workplace eg Health and Safety at
Work Act, Control of Substances Hazardous to Health (COSHH) Regulations

3 Be able to prepare design proposals that meet the requirements of a product

design specification
Requirements of a PDS: interpretation of technical requirements eg operating performance, physical
dimensions; interpret economic requirements eg production quantities, product life, market place
positioning
Prepare design proposals: ideas generation eg research into existing products, freehand sketching,
simulation, flow charts; realistic design proposals eg fitness for purpose, manufacturability, aesthetics,
ergonomics
Design reference material: manufacturers’ catalogues eg screw fixings, bearings, seals, electrical connectors,
drive belts, gear drives; materials databases eg mechanical properties, physical properties; design
databases eg structural beam sections, corrosion protection, anthropometric data

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4 Be able to produce and present a final design solution
Final design solution: evaluation of proposals and selection of most appropriate for further development
eg suitability for available manufacturing processes, cost effectiveness, contribution to profits, visual
appearance; development of design proposal into a feasible solution suitable for prototype manufacture
eg specify materials, appropriate manufacturing processes, estimation of manufacturing cost, quality;
conformity to relevant legislation and design standards
Presentation techniques: 2D engineering drawings eg general arrangement drawing, assembly drawing,
detail drawings, circuit diagrams, flow diagrams, schematic diagrams; drawing conventions and relevant
British Standards eg BS308, BS8888, BS7307, BS3939, BS2197; documentation eg design diary, logbook,
product specification; design calculations eg sizes of materials to meet strength requirements, electric
motor power, electronic circuit performance, battery life

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Assessment and grading criteria
In order to pass this unit, the evidence that the learner presents for assessment needs to demonstrate that
they can meet all the learning outcomes for the unit. The assessment criteria for a pass grade describe the
level of achievement required to pass this unit.

Assessment and grading criteria

To achieve a pass grade the To achieve a merit grade the To achieve a distinction grade
evidence must show that the evidence must show that, in the evidence must show that,
learner is able to: addition to the pass criteria, in addition to the pass and
the learner is able to: merit criteria, the learner is
able to:
P1 describe the operation of M1 explain the possible D1 evaluate the impact of
the design process in an impact of a poor customer legislation and standards on
engineering company design process on the design process in relation
customer relationships and to the profitability of the
requirements business
P2 interpret the requirements M2 explain the importance of D2 evaluate a final design
of a given customer and using a range of accurate solution against customer
produce a product design design reference materials requirements and a PDS, and
specification when developing design suggest improvements.
[IE1] proposals
P3 describe the appropriate M3 explain the issues which
legislation and standards influence whether a
which apply to the design of design proposal should be
two different products developed into a final solution
suitable for manufacture.
P4 describe the environmental,
sustainability and
manufacturing constraints
which influence the design of
a given product
P5 produce design proposals
which meet the requirements
of a given PDS
[CT1]
P6 extract reference information
from component
manufacturers’ catalogues
and materials and design
databases
P7 use a range of techniques
to present a final design
solution which meets the
requirements of a given PDS
and relevant legislation and
design standards
[CT5].

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PLTS: This summary references where applicable, in the square brackets, the elements of the personal,
learning and thinking skills applicable in the pass criteria. It identifies opportunities for learners to demonstrate
effective application of the referenced elements of the skills.

Key IE – independent enquirers RL – reflective learners SM – self-managers

CT – creative thinkers TW – team workers EP – effective participators

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Essential guidance for tutors

Delivery
There are strong links between the four learning outcomes and the delivery strategy should ensure that these
links are emphasised. Learners need to gain a coherent view of the design process within engineering and
understand that for a business to remain profitable it is crucial that the design process is effective. Learners
must be made aware that success in the marketplace can be achieved only if manufactured products are fit for
purpose, marketable and meet customer requirements.
Delivery of the unit should start with some case study analysis. This is best done in the form of a group
discussion examining example products that learners are familiar with. It is important to contrast successful
design icons, like the Dyson Vacuum Cleaner™ and the Apple iPod™, with those that have failed, such as the
Sinclair C5. A wider discussion could follow about why some products are hugely successful whereas others
are not. It would also be useful to provide an overview of the design process as it applies to automotive
engineering, starting with the initial ‘concept’ and following through to the production model for the mass
market. Why is the production model different to the designer’s original? Tutors need to get across the idea of
compromise in the design process – the trade off between what we would like and what we can actually have
when economics, legislation, manufacturability etc are taken into account.
To effectively cover learning outcome 1, learners will benefit from a visit to the design department of an
engineering company in order to find out about the systems in place and the links between design and
manufacture. If learners are employed it may be useful to base their research on their own company. Delivery
should be, as far as possible, activity based, but care must be taken when covering learning outcome 2. There
is a huge amount of data available which relates to the impact of legislation, standards and the environment
on the design process, so learners will need to be given guidance when searching for information. Tutors
need to consider how this data will be presented as evidence because there is a danger that some learners
might include large amounts of unedited material. Learning outcomes 3 and 4 are best covered by a learner-
centered activity, based around a single assignment which will produce evidence for grading criteria P5, P6
and P7. Learners should be applying knowledge gained from Unit 10: Properties and Applications of Engineering
Materials, particularly from the learning outcome covering material selection.
There is scope here for learners to be given a PDS that is tailored to their particular interest but it may be
more interesting to give them all the same one and to treat the activity as a design competition. The tutor
would assume the role of customer with each learner pitching to get their final design solution accepted.
There may be scope to develop this activity into a group discussion with all the design solutions being
evaluated and learners using it as a lead into what is required for the evaluation in criterion D2.
Note that the use of ‘eg’ in the content is to give an indication and illustration of the breadth and depth of the
area or topic. As such, not all content that follows an ‘eg’ needs to be taught or assessed.

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Outline learning plan
The outline learning plan has been included in this unit as guidance and can be used in conjunction with the
programme of suggested assignments.
The outline learning plan demonstrates one way in planning the delivery and assessment of this unit.

Topic and suggested assignments/activities and/assessment

Whole-class teaching:
● introduction to unit content, scheme of work and assessment
● introduction to the design process
● the customer/client relationship, case studies of innovative design and the triggers and market conditions
necessary
● examples of customer requirements and the generation of a PDS.
Case study:
● generating a PDS from given customer requirements.
Preparation for and carrying out Assignment 1: Design Report (P1, P2 and M1).
Whole-class teaching:
● standards and legislation.
Small-group exercise:
● researching relevant standards for given products.
Whole-class teaching:
● environmental and sustainable constraints.
Paired activity:
● researching and reporting on legislation and environmental issues for given consumer products.
Whole-class teaching:
● manufacturing constraints
● an investigation into the appropriate manufacturing techniques for a range of component parts and assemblies
including health and safety requirements.
Preparation for and carrying out Assignment 2: Product Evaluation (P3, P4, and D1).

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 Topic and suggested assignments/activities and/assessment
Whole-class teaching:
● interpreting a PDS – key technical requirements and economic considerations
● design proposals, methods for presenting solutions, worked examples and case studies.
Case study:
● presenting design proposals for a given PDS.
Individual activities:
● learners to generate design proposals from simple PDS requirements using a range of techniques.
Whole-class teaching:
● using design reference material
● identifying components and data from reference material
● final design solutions – evaluation of proposals and selection techniques.
Small-group activity:
● presenting design solutions and using appropriate techniques to evaluate and select a final design.
Topic and suggested assignments/activities and/assessment.
Preparation for and carrying out Assignment 3: Design Proposals (P5, P6, P7, M2, M3 and D2).
Feedback on assessment and review of unit delivery.

Assessment
Assessment of this unit could be covered through three assignments. To achieve a pass grade learners are
expected to describe how the design process operates in an engineering company and its links to other
aspects of the business. It is suggested that during the first assignment the evidence for P1 could be gained
by learners visiting the design department of an engineering company, carrying out an interview with an
engineering designer and preparing a short report. It is important that learners understand that design cannot
be carried out in isolation and that it is an income-generating function with the customer having the final say.
After the visit or similar activity, a written task for P2 should be given that asks learners to produce a PDS from
the requirements of a given customer.
A second assignment could involve a research activity. Two different products need to be given to each
learner and research carried out to allow them to describe the legislation and standards that apply to each
product (P3) and the environmental, sustainability and manufacturing constraints that influenced the design of
one of these products (P4).
Learners will need to demonstrate a basic mastery of design and drawing skills and they should be producing
sketches and drawings which are broadly in line with British Standards and which use simple drawing
conventions. There should be some evidence of design calculations when presenting evidence for P5, P6 and
P7.
For assessment of these criteria a third assignment could be set where a PDS should be given and learners
asked to produce a range of design proposals (P5). Three proposals would generally be sufficient although,
if the solutions are complex, two would be enough. In doing this, it is important that learners use design
reference material (P6) and a range of techniques to present the final solution (P7). The techniques used are
dependent on the solution (for example if it involves an electronic system then circuit diagrams will be needed
as well as perhaps general arrangement drawings).

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Learners will demonstrate a basic understanding of the use of information sources such as books, technical
reports, data sheets, catalogues, CD ROM and online databases. They should be selecting, interpreting and
applying data extracted from a limited range of sources and will have been given guidance on what to look for.
Design work must show good evidence of knowledge gained from the linked units so that learners can be
critical about their evolving designs and adapt them, rather than pursue a single idea. Grading criteria P5 and
P6 link the extraction of reference information about materials and components to the design proposals being
put forward by the learner. This will give more focus when gathering resource material. It is intended that the
assessment evidence for criterion P6 is based on development ideas generated in P5.
To achieve a merit grade learners will need to apply evaluative skills and explain the impact of poor design. To
achieve M1 the manufacturer/client relationship should be explored in some depth with evidence supported
by examples taken from case studies based on real products. These could be discussed during the visit in the
first assignment.
M1 builds on knowledge used to achieve P1 and P2 and may be best attempted in the first assignment.
To achieve M2 learners should support their reasons for having accurate reference material by using examples
taken from documented sources of products which are mission critical (for example correct specification of
dimensions and material for a load bearing structure such as a roof beam). As such, a further written task
could be set in assignment three to facilitate M2.
M3 builds on P5 and P7 and a further written could be set task in assignment 3. There should be evidence
of thought being given to economic issues and the pressure on a designer to design to a price in order to be
competitive. Explanations should be supported by examples relating to real products that learners are familiar
with.
To achieve a distinction grade learners should be able to focus on specific legislation and standards when
working towards D1. There are strong links here to learning outcome 3 from Unit 7: Business Operations in
Engineering. Learners should support their evaluation of the impact of legislation and standards on the design
process with examples drawn from documented sources (for example businesses that have either lost market
share by being caught out by changes in legislation or others that have benefited through anticipating changes
and beating competitors in the market). As such, a task targeting D1 could be set as part of assignment 2.
To achieve the criterion D2, evaluation could relate to a design solution provided by the tutor but it may
be better to link with P7 so that learners evaluate their own work. A written task in assignment 3 may be
appropriate for this.

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Programme of suggested assignments
The table below shows a programme of suggested assignments that cover the pass, merit and distinction
criteria in the assessment and grading grid. This is for guidance and it is recommended that centres either
write their own assignments or adapt any Edexcel assignments to meet local needs and resources.

Criteria covered Assignment title Scenario Assessment method

P1, P2 and M1 Design Report An activity requiring learners to A report containing written
research and/or visit a design responses about the design
department and investigate the process and its impact on
relationship between designer customer relationships. In
and customer. addition a PDS should be
generated from a given
customer specification.
P3, P4 and D1 Product Evaluation An activity requiring learners A report containing written
to research legislation and responses outlining legislation
standards that apply to two and standards that apply to
different products as well as the two different products and an
manufacturing, environmental evaluation of the manufacturing,
and sustainability constraints for environmental and sustainability
one of them. constraints for one of them in
terms of profitability for the
business.
P5, P6, P7, M2, Design Proposals An activity requiring learners A portfolio of design solutions
M3 and D2 to interpret a given PDS and, and a written report explaining
by using appropriate research how a final design solution
techniques, present a final has been selected. In addition
design solution from a selection explanations of the importance
of design proposals. of accurate design reference
materials and an evaluation of
the chosen design solution with
reference to the given PDS.

Links to National Occupational Standards, other BTEC units, other BTEC

qualifications and other relevant units and qualifications
This unit forms part of the BTEC Engineering sector suite. This unit has particular links with the following unit
titles in the Engineering suite:

Level 1 Level 2 Level 3

Using Computer Aided Drawing Business Operations in Engineering
Techniques in Engineering
Properties and Applications of
Engineering Materials
Engineering Drawing for Technicians
Computer Aided Drafting in
Engineering
Engineering Secondary and Finishing
Techniques and Processes
Computer Aided Manufacturing

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The unit has been mapped against the SEMTA National Occupational Standards and current NVQs at Level 3.
Achievement of the learning outcomes of this unit will contribute skills, knowledge and understanding towards
the following units from the Level 3 NVQ in Engineering Technical Support:
● Unit 2: Using and Interpreting Engineering Data and Documentation
● Unit 47: Producing Technical Information for Engineering Activities
● Unit 58: Developing and Maintaining Effective Customer Relationships.

Essential resources
To meet the needs of this unit it is essential that learners have, or have access to, some if not all of the
following:
● a range of customer design requirements
● a range of products to investigate design requirement features
● manual drawing equipment
● 2D commercial CAD software
● extracts and illustrations from appropriate drawing standards and conventions
● access to reference material which provides information about the physical and mechanical properties of
materials
● access to legislation and design standards
● component and material suppliers’ catalogues.

Employer engagement and vocational contexts

The use of vocational contexts is essential in the delivery and assessment of this unit. Much of the work can
be based around real engineering design requirements and drawings/specifications. In addition the use of
engineering artefacts from local and national employers is to be encouraged.
There are a range of organisations that may be able help centres engage and involve local employers in the
delivery of this unit, for example:
● Work Experience/Workplace learning frameworks – Centre for Education and Industry (CEI, University of
Warwick) – www.warwick.ac.uk/wie/cei/
● Learning and Skills Network – www.vocationallearning.org.uk
● Network for Science, Technology, Engineering and Maths Network Ambassadors Scheme –
www.stemnet.org.uk
● National Education and Business Partnership Network – www.nebpn.org
● Local, regional Business links – www.businesslink.gov.uk
● Work-based learning guidance – www.aimhighersw.ac.uk/wbl.htm

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Indicative reading for learners
Textbooks
Dieter G and Schmidt L – Engineering Design (McGraw-Hill, 2008) ISBN 0071263411
Simmons C, Maguire D and Phelps N – Manual of Engineering Drawing (Butterworth-Heinemann, 2009)
ISBN 0750689854
Tooley M and Dingle L – BTEC National Engineering (Newnes, 2002) ISBN 0750651660

Delivery of personal, learning and thinking skills

The table below identifies the opportunities for personal, learning and thinking skills (PLTS) that have been
included within the pass assessment criteria of this unit.

Skill When learners are …

Independent enquirers evaluating customer requirements to produce a product design specification
Creative thinkers generating design proposals
presenting final design solutions
explaining issues which influence design solutions.

Although PLTS are identified within this unit as an inherent part of the assessment criteria, there are further
opportunities to develop a range of PLTS through various approaches to teaching and learning.

Skill When learners are …

Reflective learners reviewing the progress made against individual tasks and assignments.

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 Functional Skills – Level 2

Skill When learners are …

ICT – Use ICT systems
Select, interact with and use ICT systems using a CAD system to create a variety of design solutions
independently for a complex task to meet a
variety of needs
ICT – Find and select information
Select and use a variety of sources of using online or electronic reference materials
information independently for a complex task
ICT – Develop, present and
communicate information
Present information in ways that are fit for plotting/printing a variety of designs generated using CAD
purpose and audience
English
Writing – write documents, including describing the design process
extended writing pieces, communicating
writing a PDS
information, ideas and opinions, effectively
and persuasively describing environmental, sustainability and manufacturing
constraints
describing legislation and standards.

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