BE 4290 Senior Design Mideterm

Theory of Inventive Problem Solving (TRIZ)

- a problem-solving methodology tailored to provide innovative solutions for scientific and engineering problems

Work Breakdown Structure (WBS)

- a tool used to divide a project into manageable segments to ensure that the complete scope of work is understood -lists the tasks that need to be done in the form of outcomes (deliverables) instead of planned actions -outcomes are listed instead of actions because they are easier to predict accurately at the beginning of a project

Affinity Diagram

- identifies the inherent similarity between items -used to organize ideas, facts, and opinions into natural grouping (See notes for image example)

Quality function deployment (QFD)

- is a planning and team problem-solving tool that has been adopted by a wide variety of companies as the tool of choice for focusing a design team's attention on satisfying customer needs throughout the product development process. -is a largely graphical method that aids a design team in systematically identifying all of the elements that go into the product development process and creating relationship matrices between key parameters at each step of the process is a tool for multiple stages of the design process.

Product design specifications (PDS)

- is the basic control and reference document for the design and manufacturing of a product -a document that contains all the facts related to the outcome of the product development

Brainstorming

- the most common method used by design teams for generating Ideas - a well done _____ session is and is an enthusiastic session of rapid free flowing Ideas -allows for different viewpoints

passive leader

- this type of leader is very hands off - they give their group too much freedom -the lack guidance and direction -extreme empowerment -very uninvolved -a figurehead

What is design?

- to fashion after a plan -to synthesize new or arrange existing things in a new way to satisfy a recognized need of a society -establishes and defines a solution to and pertinent structures for problems not solved before or a new solution to problems which have previously been solved in a different way

How-How Diagram

-A useful technique for suggesting solutions -tree diagram that starts with a proposed solution and asks the question "How do we do that ?"

Dissatisfaction (storming)

-In this stage of team development the challenge of forming a cohesive team becomes real -differences in personalities , working and learning styles, cultural backgrounds, and available resources make themselves known -meetings may be characterized by criticism, interruptions, poor attendance or even hostility

resolution (norming)

-In this stage of team development the dissatisfaction abates when team members establish group norms, either spoken or unspoken, to guide the process, resolve conflicts,and focus on common goals.

Orientation (forming)

-In this stage of team development the members are new to the team -they are probably both anxious and excited, yet unclear about what is expected of them

Termination (adjourning)

-In this stage of team development the task is completed -the team prepares to disband. -This is the time for joint reflection on how well the team accomplished its task, and reflection on the functioning of the team

Design Process Phases

-Phase I: Conceptual Design -Phase II: Embodiment Design -Phase III: Detail Deisgn

Embodiment Design Phase (Preliminary Design Phase)

-Structured development of the design concept occurs -design phase that decisions are made on strength, material selection, size, shape, and spatial compatibility

Network Logic Diagram

-The longest path through the project from start to end of testing can be found from inspection -clearly shows the dependence of one task on other tasks -shows preceding relationships -but loses a strong correspondence with time -effects of delays and slack time not displayed

Gantt Chart

-The simplest and most widely used scheduling tool - can show the time sequence of various tasks and overlapping times -fails to relate the true dependence of one task over the suceeding task -fails to capture the effect of delays on certain tasks on the overall project completion date

Production (performing)

-This stage of team development is what we have worked for -The team is working cooperatively with few disruptions. -People are excited and have pride in their accomplishments, -There is high orientation toward the task, and demonstrable performance and productivity.

Critical Path Method (CPM)

-a graphical network diagram that focusing on identifying the potential bottlenecks in a project

morphological analysis

-a method for representing and exploring all the relationships in multidimensional problems - is a way of creating new forms

Team Facilitator

-a person trained in group dynamics who assists the leader and the team in achieving its objectives by: --coaching them in team skills --problem solving tools --assisting in data collection activities -functions as a team member but he/she must remain neutral in all team discussions -keeps group focused on its task

Benchmarking

-a process for measuring a company's operations against the best practices of companies both inside and outside their industry -operates most effectively on a quid pro quo basis

Force Field Analysis

-a technique that identifes those forces that both help (drive) and hinder (restrain) the implementation of the solution of a problem -it is a chart of the pros and cons of a solution, and as such, it helps in developing strategies for implementation of the solution

Why- Why Diagram

-can be used as an alternative to the cause-and effect diagram, but more commonly it is used to dig deeper about one of the more likely root causes -should extend to four levels, counting the problem statement as the first level which should ask why does this problem exist -Root causes are identified by causes that begin to repeat themselves on several branches

Modified Gantt Chart

-clearly shows the dependence of one task on other tasks -shows preceding relationships -shows coorespondance to time and "Network Critical Path" -Slack time is displayed

Conceptual Design Phase

-design is the phase that requires the greatest creativity, involves the most uncertainty, and requires coordination among many functions in the business organization

mental block

-is a mental wall that prevents the problem solver from correctly perceiving a problem or conceiving its solution -an event that inhibits successful use of normal cognitive processes to come to a solution

Cause and Effect Diagram

-is a powerful graphical way of identifying the factors that cause a problem -The main categories of causes, "ribs of the fish," are drawn at an angle to the backbone, and labeled at the ends then ask what causes the cause you just recorded, so the branches develop subbranches and the whole chart begins to look like the bones of a fish

Pareto Chart

-is a way of analyzing the data that identifes the vital few in contrast to the trivial many -is a bar chart used to prioritize causes or issues, in which the cause with the highest frequency of occurrence is placed at the left, followed by the cause with the next frequency of occurrence, and so on

Ashby Charts

-material selection charts that are very useful in comparing a large number of materials during conceptual design -based on a large computerized material property database

Product Dissection

-observing a product during its use is one of the most natural ways to gather information about it -the process of taking apart an object to see how it works -also called "reverse engineering"

Pareto Principle

-principle which states that a few causes account for most of the problem, while many other causes are relatively unimportant -often stated as the 80/20 rule, that roughly 80% of the problem is caused by only 20% of the causes

Conceptual Design Phase

-the process by which the design is initiated, carried to the point of creating a number of possible solutions, and narrowed down to a single best concept

Facilitative Leader

-this type of leader creates an open enviornment -encourages suggestions -provides guidance -embraces creativity -considers all ideas -maintains focus; weighs goals vs criteria

Traditional Leader (dictator)

-this type of leader is directive and controlling, -they don't ask questions just do it, -they retain all decision-making authority -nontrusting -ignores input -autocratic

Weighted decision matrix

-to do this it is necessary to convert the values obtained for different design criteria into a consistent set of values -the simplest way of dealing with the design criteria expressed in a variety of ways is to use a point scale

Interrelationship Diagraph

-tool that explores the cause-and-effect relationships among issues and identifies the root causes -used to reduce the possible root causes to a single root cause

Pugh Chart

-useful method for identifying the most promising design concepts among the alternatives generated -is a relative comparison technique

Functional representation: standard flow classes and member flow

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House of qualities 4 Room Configuration

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House of qualities 8 Room Configuration

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Flow Chart

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Industrial Design

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Mental blocks

Barriers to Creative Thinking

-Availability -size limitations and tolerance on available material shapes and form -excessive variability in properties -low environmental impact, including ability to recycle the material -cost

Business Issues

-team goals are just as important as individual goals -the team understands the goals and are committed to them -trust replaces fear and people feel comfortable taking risks - respect, collaboration and open mindedness are prevalent -team members communicate readily -decisions are made by consensus and have the acceptance and support of the members of the team

Characteristics of an Effective Team

-easy to disassemble -able to be recycled -contains recycled materials -uses identifiable and recyclable plastics -reduces use of energy and natural materials in its manufacturing -avoids use of hazardous materials -reduces product chemical emissions -reduces product energy consumption

Characteristics of an Environmentally Responsible Design

-*expecters*: basic attributes one would expect to see in the product -*spokens*:specific features that customers say they want in a product -*unspokens*:product attributes that the customer does not talk about but remains important to him/her -*exciters*: oftern known as delighters, product features that make the product unique and distinguished it from the competition

Classifying the 4 levels of Customer Requirements:

-achievement of performance requirements -life-cycle issues -social and regulatory issues.

Considerations of a Good Design

-An *activity* is a time-consuming effort that is required to perform part of a project. An activity is shown on an arrow diagram by a directed line segment with an arrowhead pointing in the direction of progress in completion of the project. -An *event* is the end of one activity and the beginning of another. An event is a point of accomplishment and/or decision. However, an event is assumed to consume no time. A circle is used to designate an event. - Every activity in a CPM diagram is separated by two events.

Definitions and Rules for constructing the CPM Diagram:

Selection Design

Design form consists of selecting the components with the need for performance, quality, and cost from catalogs of potential vendors

Earliest Finish TIme (EF)

EF = ES + D

1. problem definition 2. cause finding 3. solution finding and implementation

Effective Strategy for Problem Solving (problem solving tools)

-performance -time -cost -risk

Four major decisions made over the life cycle of a project:

1. *Preparation*- elements of problem are examined and their interrelations are studied 2. *Incubation*- You "sleep on the problem". Sleep disengages your mind allowing the unconscious mind to work on the problem freely. 3. *Inspiration*- a solution or a pathway toward the solution emerges 4. *Veification*- the inspired solution is checked against the desired result

Four-Stage Model of Creative thinking Process & Problem Solving

-tasks shown sequentially on vertical axis -horizontal axis show estimated time -vertical dashed lines-current time -completed tasks dark ,future tasks gray -indicate milestone events

Gantt Chart Components:

-performance -features -reliability -durability -serviceability -conformance -aesthetics -perceived quality

Garvin's 8 Demensions of Quality:

-performance characteristics (properties) -processing (manufacturing) characteristics -environmental profile -buisness considerations

General Criteria for Selection

Rank of 1: physiological needs Rank of 2: safety and security needs Rank of 3: social needs Rank of 4: psychological needs Rank of 5: self-fufillment needs

Hierarchy of human needs:

engineering characteristics

House of Quality translates customer requirements into quantifiable design variables called __________

-Six Key questions -Five Whys to get to the root cause -checklists -Fantasy or Wishful thinking

Idea generating techniques beyond brain storming

-decisions made in the design process cost very little in terms of the overall product cost but have major effects on the cost of the product -you cannot compensate in manufacturing for defects introduced in the design phase -the design process should be conducted so as to develop quality, cost competitive products in the shortest time possible

Importance of the Engineering Design Process

Latest Finish Time (LF)

LF = LS + D

Emotional Block

Mental Blocks that are concerned with the psychological safety of the individual. They reduce the freedom with which you can explore and manipulate ideas. They also interfere with your ability to conceptualize readily

Intellectual Block

Mental blocks that arise from a poor choice of the problem-solving strategy or having inadequate background and knowledge

Perceptual Block

Mental blocks that have to do with not properly defining the problem and not recognizing the information needed to solve it.

-Duration(D) -Earliest Start (ES) -Latest Start (LS) -Earliest finish time(EF) -Latest Finish time(LF) -Total float(TF)

Methodology for Finding the Longest Path:

1. divide the overall design problem into simpler subproblems 2. generate solution concepts for each subproblem 3. systematically combine subproblem solutions into different complete solutions and evaluate combinations

Morphological Method for Design Steps

1. discover the operational requirements for the product 2. examine how the product performs its function 3. determine the relationship between parts of the product 4. determine the manufacturing and assembly processes used to produce the product

Product Dissection Process Activities include:

Physical Decomposition

Sketching the parts of a system, a subassembly, or a physical part is a way to represent the product and begin accessing all the relevant knowledge about the product _________ means separating the product or subassembly directly into its subsidiary subassemblies and components and accurately describing how these parts are joined together to create the behavior of the product

- *Fear of being perceived* as a copier - *Fear of yielding* competitive advantages if information is traded/shared -*Arrogance*: a company may feel that there is nothing useful to be learned by looking outside the organization -*Impatience*: companies that engage in an improvement program often want to begin making changes immediatly - *Fear of Failure*

Sources of resistance to benchmarking are:

-identification of customers needs -problem definition -gathering information -concept generation -evaluation of concepts - Refinement of the PDS (product design specification) -design review

Steps to consider in the Conceptual Design Phase (Phase I)

-detailed engineering drawings completed in 2D/3D CAD -prototype verification testing done -Assembly drawings and assembly instructions done - detailed product specifications prepared -Part supplier or source list/ manufacture in-house? -detailed cost estimate -review design before handing it to manufacturing -make a list for purchasing

Steps to consider in the Detail Design Phase (Phase III)

-determining product architecture - configuring design of parts and components -parametric design of parts

Steps to consider in the Embodiment Design Phase (Phase II)

1. Develop a creative attitde 2. Unlock your imagination 3. Be persistent 4. Develop and open mind 5. Suspend your judgement 6. Set problem boundaries

Steps to enhance creative thinking:

-Creative cognition: sucessful use of thought processes and existing knowledge to produce creative ideas - use regular cognitive operations to solve problems in a novel way

Supports to creative thinking

-direct assignment -objective tree -Analytic Hierarchy Process (AHP)

Systematic Method for Determining Weighted Factors

Total Float (TF)

TF = LS - ES

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TRIZ Contradiction Matrix

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TRIZ list of 39 Engineering Parameters

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TRIZ list of 40 Inventive Principles

-increase the ideality of the product or system -identify the products place in its evolution to ideality and force the next step -identify key physical or technological contradictions in the product and revise the design to overcome them using inventive principles -model a product or system using a substance-field analysis and apply candidate modifications

TRIZ offeres 4 different stratagies for generating an innovative solution to a design problem

1. Orientation 2. Dissatisfaction 3. Resolution 4. Production 5. Termination

The Five stages of team development:

-Creativity -Complexity -Choice -Compromise

The Four C's of Design

Earliest Start (ES)

The earliest time an activity can start

Duration (D)

The estimated time to complete the activity

Latest Start (LS)

The latest time an activity can be initiated without delaying the minimum completion time for a project

deployment

The term ______ in QFD refers to the fact that this method determines the important set of requirements for each phase of PDP planning and uses them to identify the set of technical characteristics of each phase that most contribute to satisfying the requirements.

Environmental Block

These are blocks that are imposed by the immediate physical or social environment.

Redesign (Variant Design)

This engineering design is employed to improve an existing design.

Original Design (innovative Design)

This form of design employs an original, innovative concept to achieve a need. Example: microprocessor and Apple's touch screen Iphone

Adaptive Design

This form of design occurs when the design team adapts known solutions to satisfy a different need to produce a novel application Example: 3D printer from Inkjet technology

Traditional leader Passive Leader Facilitative Leader

Three types of leadership

False creating a PDS *Finalizes* the process

True/False: Creating a PDS starts the process of establishing the customer needs and wants, prioritizing them, and beggining to cast them into a technical framework so that design concepts can be established

False- Data becomes information when its creator adds meaning not the other way around

True/False: Information becomes data when its creator adds meaning

True

True/False: Material Selection is a key element shaping the total life cycle

True

True/False: One way to help brainstorming is to break the normal thought pattern by using a checklist (SCAMPER) to help develop new ideas

True

True/False: WBS cannot show the dependence of one task on complete or progress of another task . Overlapping times of various tasks cannot be isolated.

True

True/False: the design cost is only about 5% of the total cost to produce a product

True

True/False: the design process should be conducted so as to develop quality, cost competitive products in the shortest time possible

False

True/False: you can compensate in manufacturing for defects introduced in the design phase.

-material first approach -process first approach

Two Different Approaches to Material Selection

-Original Design -Adaptive Design -Redesign -Selection Design -Industrial Design

Types of Design

-Perceptual Block -Emotional Block -Intellectual Block -Enviormental Block

Types of Mental Blocks

- *Contextualized*: we know for what purpose the data was gathered. - *Categorized*: we know the units of analysis or key components of the data - *Calculated*: the data have been analyzed mathematically or statistically. - *Corrected*: errors have been removed from the data. - *Condensed*: the data have been summarized in a more concise form.

Ways Data becomes Information

- *Comparison*: how does this situation compare to other situations we have known? - *Consequence*: what implications does the information have for decisions and actions? - *Connections*: how does this bit of knowledge relate to others? - *Conversation*: what do other people think about this information?

Ways Information becomes Knowledge

-Why has the machine stopped? -why was there an overload? -why wasn't there enough lubrication? -why wasn't the pump working? -why was there an abrasion?

What are the 5 Whys to get to the root cause?

Who? What? When? Where? Why ? How?

What are the 6 key questions used in idea generating techniques beyond brainstorming?

-Pareto Chart -Cause-effect Diagram -Why-why diagram - interrelationship diagram

What charts/diagrams are used in the *Cause Finding* step of the problem solving tools?

- How-How diagram - Force field analysis

What charts/diagrams are used in the *Solution Planning and Implementation* step of the problem solving tools?

-Pareto Chart -Affinity Diagram

What charts/diagrams are used in the *problem definition* step of the problem solving tools?

Substitute Compare Adapt Modify/Magnify/Minify Put to other uses Eliminate Rearrange/Reverse

What does SCAMPER stand for?

SCAMPER is a checklist of questions used to aid in Brainstorming

What is SCAMPER used for?

- take responsibility - deliver on commitments -be a contributor to discussions - give your full attention to the person speaking develop techniques for getting your message across - learn to give and receive useful feedback

What is the set of attitudes and work habits you need to adopt to be a GOOD TEAM MEMBER?

Cause Finding

What problem solving tools including: +*Gathering data* ---Interviews ---Focus groups ---Surveys +*Analyzing data* ---Checksheets ---Histograms ---Flowchart ---Pareto charts +*Search for root causes* ---cause and effect diagram ---why-why diagram ---Interrelationship digraph

Solution Finding and Implementation

What problem solving tools including: +*Solution Finding* ---brainstorming ---How how diagram ---Concept selection +*Implememtaion* ---Force field analysis ---Written Implementaion plan

Problem Definition

What problem solving tools including: -Brainstorming -Affinity diagram - Pareto Chart

-the importance of cost is in determining what is feasible in an engineering design is emphisized -Keeping costs and resources within approved limits is one of the chief functions of the project manager.

Why is cost one of the major decisions made over the life cycle of a project?

Risks are inherent in anything new. Acceptable levels of risk must be established for the parameters of performance, time, and cost, and they must be monitored throughout the project.

Why is performance one of the major decisions made over the life cycle of a project?

the design must possess an acceptable level of operational capability or the resources expended on it will be wasted

Why is performance one of the major decisions made over the life cycle of a project?

in the early stages of a project, the emphasis is on accurately estimating the length of time required to accomplish the various tasks and scheduling to ensure that sufficient time is available to complete those tasks

Why is time one of the major decisions made over the life cycle of a project?

Scope of Work

Work breakdown Structure with extreme level of detail

Knowledge

_____ is broader, deeper, and richer than data or information. Because of this it is harder to defne. It is a mix of experience, values, contextual information, and expert insight that provides a framework for evaluating and incorporating new experiences and information

Information

_______ is data that has been treated in some way that it conveys a message _______ is meant to change the way the receiver of the message perceives something originally meant "to give shape to"

Standards

_______ is less prescriptive and can be defined as a set of technical definitions and guidelines and establishes a basis for comparison.

Problem definiton

_______ is the most important step in Product Development Process (PDP); also known as the need identification step

Specifications

________ describes how a system should work, and is usually is much more specific and detailed than a standard, but sometimes it is difficult to differentiate between the documents

Data

________ is a set of discrete, objective facts about an event

Codes

_________ is a set of rules for performing some task

Redesign (Variant Design)

_________ is achieved by changing some of the design parameters without any change in the working principle or concept of the original design

Fix

a design modification that is required due to less than acceptable performance once the product has been introduced into the market place.

Design Review

a retrospective study of the design up to that point in time - the essence of a technical review of the design is to compare the findings against the Product Design Specifications (PDS)

Ashby plot

a scatter plot which displays two or more properties of many materials or class of materials

updates

are usually planned as part of the product's life cycle before the product is introduced to the market

Product Development Process (PDP)

begins by determining what the needs are that a product must meet

Pugh's Method

compares each concept relative to the reference or datum concept and for each criterion determines whether the concept in the question is better than, poorer than, or about the same as the reference concept

Phase 1 of PDP

concept development considers the different ways the product and subsystem can be designed

Phase 3 of PDP

detailed design is the phase where the design is brought to the state of a complete engineering description of a tested and producible product

Product Design Specifications

detailed document that describes what the design must be in terms of: -performance requirements -environment in which it must operate -product life -quality -reliability -cost -host of other design requirements

redesign

has two categories: 1. fixes 2. updates

morphological methods

have been recorded in science as a way to enumerate and investigate solution alternatives

functional structure

is a block diagram depicting flows of energy, material, and signal as labeled as arrows taking paths between functional blocks

decision matrix

is a method of evaluating competing concepts by ranking the design criteria with *weighting factors* and *scoring the degree* to which each design concept meets the criterion.

Analytic Hierarchy Process (AHP)

is a problem solving methodology for making a choice from among a set of alternatives when the selection criteria represents multiple objectives, have a natural hierarchical structure or consist of qualitative and quantitative measurements. is a decision analysis tool that is used throughout a number of fields in which the selection criteria used for evaluating competing solutions that do not have exact calculable outcomes.

Life cycle trade off

minimum cost and maximum durability

QDF

process known as a methodology for infusing the voice of the customer into every aspect of the design process

Functional decomposition

produces a diagram called a functional structure

Phase 5 of PDP

production ramp up is when manufacturing operations begins to make and assemble the product using the intended production system

compromise

requires balancing multiple and sometimes confliting requirements

Creativity

requires creation of something that has not existed before of has not existed in the designer's mind before

complexity

requires decisions on many variables and parameters

choice

requires making choices between many possible solutions at all levels, from basic concepts to the smallest detail in shape

-some influences on the practice of engineering design due to the increased societal awareness of technology -ABET Code of Ethics

societal considerations in engineering design

-greater influence of lawyers on engineering decisions -more time spent in planning and predicting -emphasis on defensive research and development -more effort expended in research, development and engineering in environmental control and safety

some influences on the practice of engineering design due to the increased societal awareness of technology:

Total Life Cycle

starts with the conception of a need and ends with the retirement and disposal of a product

Phase 2 of PDP

system-level design is where the functions of the product are examined, leading to the division of the product into various subsystems

Phase 4 of PDP

testing and refinement is concerned with making and testing many preproduction versions of the product.

Slack time

the amount of time by which an activity can exceed its estimated duration, before failing to complete the activity becomes critical.

Material First Approach

the designer begins by selecting a material class and narrowing it down as described previously

Process First Approach

the designer begins by selecting the manufacturing process, guided by the same factors and material firt approach

Black box

the most generic functional structure (a single function block) is called a ___________ representation of a device

Phase 0 of PDP

the planning that should be done before the approval of the project development project

Product designing process

the results of the design planning process that governsthe engineering design tasks are complied in the form of a set of product design specifications (PDS)

Detail Design Phase

this design phase the design is brought to the stage of a complete engineering description of a tested and producible product

Direct Assignment

this method is only recommended for design teams where there are many years of experience designing the same product line

Analytic Hierarchy Process (AHP)

this method is the least arbitrary method for determining weighting factors.

Objective Tree

this method relies on some experience with the importance of the criteria in the design process