Design Thinking Final

Spatial Constraints

"envelope" of a product - products have to fit in a particular area, products have to be used in a confined area

High Quality Product

"its quality measure stay on target regardless of parameter variation due to manufacturing, aging, or the environment" Works as It Should, Lasts a Long Time, Easy to Maintain

Procedural or Process Knowledge

"knowing what to do next"

Deliverable

"thing" that the parties involved my be ready for deliver from the design team to the decision makers on a certain date.

Form

(physical product) The shape, color, texture that the product takes

How to come up with a reasonable factor of safety?

1. Build high fidelity models 2. carry out empirical testing when feasible, understand the materials used, 3. understand the solid mechanics, loading, etc based on geometry and how the forces are applied

3 Main Charges of Negligence

1. Design defects 2. Design did not include proper safety devices 3. Designer did not foresee possible alternative uses of the product

Three Phases of Product Definition

1. Discover what projects to do 2. Choose which projects are worth spending time and resources pursuing 3. Plan how to spend time and resources on the project

Ways to mitigate risk

1. Document all considerations in the design process 2. Use commonly accepted standards 3. Use proven evaluation techniques for proving the quality of design before it goes to production 4. Follow a proven, rational design process.

Canons of Engineering Ethics

1. Hold paramount the safety, health, and welfare of the public 2. Perform services only in areas of their competence 3. Issue public statements only in an objective and truthful manner 4. Act for each employer or client as faithful agents or trustees 5. Avoid deceptive acts 6 Conduct themselves honorable, responsibly, ethically, and lawfully so as to enhance the honor, reputation and usefulness of the profession

Failure Modes and Effects Analysis (FMEA)

1. Identify the Function Affected 2. Identify Failure Modes 3. Identify the Effect of Failure 4. Identify the Failure Causes or Errors 5. Identify the Corrective Action

Steps for Helping to Simulation/Physical prototype decision

1. Identify the Output Responses that Need to be Measured 2. Note the Needed Fidelity 3. Identify the Input Signal, the Control Parameters and their Limits, and Noises 4. Understand Analytical Modeling Capabilities 5. Understand the Physical Modeling Capabilities 6. Select the Most Appropriate Modeling Method 7. Perform the Analysis or Experiments and Verify the Results.

Evaluation of Product Performance

1. Must result in numerical measures of the product for comparison with the engineering specifications and targets 2. Should give some indication of which product features to modify and by how much in order to meet the targets 3. Procedures must include the influence of variations due to manufacturing, aging, and environmental changes

Cost, Quality, and Time to Market

3 Measures of Design Success

Technology Push

A new technology is developed before there is a customer demand

refining

Activity of making an object less abstract

Functional Decomposition Techniques

Aids in further refining the functional requirements

Concept Variant Generation

Aids in transforming the functions to concepts

Professional Society

An organization that seeks to develop a particular profession through research, skill development, scholarships, etc

Creeping Specifications

As the project progresses, the specifications change, resulting in delays, added costs, and sometimes the complete redesign of a product

Guidelines for DFS

Be aware of the environmental effects of the materials and processes used in products; design the product with high separability; design components that can be reused/recycled, Be aware of the environmental effects of the material not reused or recycled.

Reshaping

Changing the shape of something to lead to creative and space saving solutions.

Nominal Length

Changing this usually does not increase the cost substantially

Selective Design

Choosing a product or object from already existing possibilities

PDP - Product Development Process

Clear procedure for planning and managing product design projects - each company has their own name, acronym, and process for it

Market Pull

Customer demand for new products or features

Stage Gate PDP

Decision "gates" between design stages which are defined; Gates are generally design reviews

Morphology

Decompose the function, develop concepts for each function, and combine concepts.

decreases

Design freedom _______________ as knowledge of the design problem increases

Redesign

Design of a new product starting with the design of a currently existing product

Modular Design

Design of one component to improve flexibility and allow for the integration of new technology

Design for Sustainability (DFS)

Design the product to have low impact on the environment throughout the entire life cycle of the product

Design for Test and Maintenance (DFT, DFM).

Design the product to make it easy to diagnose problems and perform maintenance; ex is a car check engine light

Why you should update models that were used earlier in the design process

Designers gain a greater understanding of the actual function and how the user interacts with it; functional problems can be detected

Sensitivity Analysis

Determines which parameters are most important in terms of product performance; often tested with a rough prototype

How to come up with a reasonable combined factor of safety

Develop factors of safety for the various aspects that contribute to the overall factor of safety, then combine them.

Designer

Develops CAD models for the system

Technician

Develops the testing procedures and apparatus

Assembly Drawings

Drawing to show how the components fit together, refers back to the Bill of Materials

Detail Drawings

Each individual component is drawn with all dimensions, with materials and manufacturing detail. Follow format for standard developed by the company

Contradictions

Engineering trade offs, (making a part stronger by adding material also makes it heavier)

Sources of Variation in operating the Part

Environmental (heat, moisture, etc), user induced, age and wear.

Magnifying/minifying

Exaggerating the size or number of a feature often increases understanding of the feature and its limitations and constraints

Parametric Design

Finding values for the features that characterize the object being developed

Closure Style

Flexible (going with the flow and being adaptive, making it difficult to make a decision) or Decisive (making decisions with minimal stressed in a scheduled/controlled manor)

Stress

Force applied over a cross sectional area; force/area

Spiral PDP

Generally suited to software, initial prototype is developed very rapidly, spiraling outward towards a better product but revisits each stage during this process. (alpha, beta, version 1.0)

TRIZ - Theory of Inventive Machines

Gives 40 principles that are generic suggestions for developing a new product using predictable patterns

Quality Control

Has training to ensure that the product is manufactured according to specification

Proof of Product Prototype

Helps refine the components and assemblies, often done through 3D printing

Design Maturity

How long the design has gone virtually unchanged

Concept

Idea that is sufficiently developed to evaluate the physical principles that govern its behavior

Variant Design

Improving a design that already exists

Trade-Off Management

Improving one performance metric can often cause a decrease in another

Noise Parameters

In contrast to controllable parameters, impossible to control or can be controlled only at a prohibitive cost.

Domain specific knowledge

Information on the form or function of an individual object or a class of objects

General Knowledge

Information that most people know and apply regardless of their expertise and experience

Energy Source

Internal or External (Introversion or Extroversion)

Manufacturing Engineer

Knows the manufacturing capabilities of the company and what other capabilities are available in the industry

Waterfall PDP

Linear process where each stage is "like a place for water to pool before going to next stage"

Bill of Materials

List of parts with the manufacturer, part number, part description, supplier, quantity, and cost

Stiffening (types of patching)

Make something more rigid (or less depending on need)

Deliberation style

Making decisions either objectively (logically or analytically) or subjectively (relying on interpersonal involvement or circumstances)

Extrusion

Manufacturing process of forming that forces material through an opening and creates a shape

Pressing

Manufacturing process of forming that involves bending metal using a large press and some type of mold

Stamping

Manufacturing process of forming that involves pushing a shape through a sheet of metal to stamp out a part; uses shearing to cut through the metal

Evaporating Cloud

Method for resolving contradictions

Design for Cost (DFC)

Minimize the overall cost of producing and selling the product

Additive Manufacturing

Opposite process of machining, material is added in thick layers building up a part from nothing Originally called rapid prototyping, now called 3D Printing Can also be used with titanium and biological materials in the near future.

Design for Manufacture (DFM)

Optimize the design to make manufacturing efficient, low-cost, and high quality

Design for Assembly (DFA)

Optimize the design to simplify the assembly procedure

Fixed Costs

Overhead costs and tooling and equipment that is only purchased one time

Basic P-Diagram

P stands for Product or Process (could be a subcomponent), evaluates product on various parameters (see slides for drawing, April 22)

Margin

Percentage above actual cost that the company sells the product

Prior Action (TRIZ)

Perform required changes to an object completely or partially in advance.

Analyst

Performs mathematical analyses to model system performance

Prototypes

Physically building and testing an actual version of the product, ,provides better data on actual performance but is often time consuming and expensive

Casting

Pouring molten material into a mold and allowing it to harden to produce a part Pros/Cons: - Ability to create complex shapes quickly -molds are expensive, so it is more cost effective for large lot sizes -metal is not as strong as forged metal

Decision Matrix Method

Powerful method for comparing alternatives when making any decision. Metrics are all quantitative, so you can sum them up and give one score.

Informational Management Style

Preferring to work with facts or possibilities

Configuration Design

Preliminary selection of materials and manufacturing processes

Design for Reliability (DFR)

Produce products that will be of high quality and last a long time

Variation

Quantifying the difference between instances of the same product (when manufacturing multiple instances of the product, each instance differs slightly from every other instance)

Engineering Specifications

Quantitative, measurable, criteria that the product is designed to satisfy. Must contain a metric, target value, and engineering units for the target value (discriminatory, measurable, orthogonal, universal, and external)

Information Language

Receiving information verbally (through words or equations) or visually (through pictures, diagrams, graphs, prototypes, etc).

Machining

Removing material through drilling holes, making screw threads, simply removing material to make a shape

System Definition Review (SDR)

Report at the end of the conceptual design phase, examining the proposed system architecture and functional elements

Critical Design Review (CDR)

Report that demonstrates that the technical effort is on track to complete the product

Systems Requirements Review (SRR)

Report that occurs at the end of the product definition phase, and ensure the functional and performance requirements will satisfy the needs

Preliminary Design Review (PDR)

Report with the designs proposed, evaluated, and one chosen, outlining next steps for budget, timeline, and product testing

Industrial Engineer

Responsible for the product's aesthetics and how it interacts with the consumer

Decision Matrix

Score alternative concepts on how well the meet each of the requirements

ISO 9000

Set of international standards on quality management and quality assurance, critical to international business

Optimization

Setting up cost functions into mathematical formulas, then using a formal process to find the optimal values for the independent variables.

Ways to Model the Product to Evaluate Performance

Simulation and Prototypes

Factor of Safety

Strength of Material / Maximum Stress

Additive Tolerance Stack-Up

Takes the worst-case scenario of tolerances and adds them up

Physical

The actual object, or the model/prototype representing the object (Design Language)

Tolerances

The amount of variation that is allowable for the part to function in a high quality way; communicates information to manufacturing that is essential in helping to determine which manufacturing processes can or should be used and to establish quality control guidelines. Making these tighter to reduce variation usually induces increased costs.

Overhead Costs

The cost of doing business

Graphical

The drawing or CAD model of the object (Design Language)

Analytical

The equations, rules, or procedures representing the object (Design Language)

Product Definition

The goal of this is to understand the problem and lay the foundation for the remainder of a design project. Engineering Specifications are set.

Function

The logical flow of energy, material, or information between objects or the change of state of an object caused by one or more flows tells WHAT the function must do

Semantic

The verbal or textual representation of the object (Design Language)

Behavior

The way the product actually performs

Function

The way the product is intended to perform

Hannover Principles

These principles allow for the designer to design a product for sustainability

Inversion

Think of the opposite or inverse of what is needed to get an idea of what you need to do

Discover Design Products, Choose Design Projects, Plan design projects

Three major activities of the design process

Fault Tree Analysis (FTA)

To graphically develop a tree of all the faults that could happen to cause a system failure, and the logical relationships among these faults

Transition into a New Dimension(TRIZ)

Transition one dimensional movement or placement of objects into two dimensional, or two dimensional to three dimensional, etc

Product Manager

Ultimate responsibility for development of the product; link between product and customer

Proof-of-Concept prototype

Used for developing the function of the product to meet customer needs

Sketches

Used for idea generation

Quality Function Deployment (QFD) - House of Quality

Used to generate and evaluate good engineering specifications based on customer requirements and evaluating the success of competitor products. Ultimately helps determine what to design. Determines WHAT the customer desires

Proof of Process Prototype

Used to verify geometry and manufacturing process of the product, exact materials and processes are used to make the prototypes

Proof of Production prototypes

Used to verify the entire production process, usually generated by a "pre-production" run of the actual manufacturing process.

Trangulation

Using groups of three for stabilization of the form

Sources of Variation in Creating Part

Variation in machinery, machinery producing the part can only repeat to within a certain tolerance, and variation in raw materials

Project Risk

What can go wrong that will cause the project to fall behind schedule, go over budget, or not meet the engineering specifications

Robust Design

When something is designed to be as insensitive to noise as possible; "Determine values for the parameters based on easy to manufacture tolerances and default protection from aging and environmental effects so that best performance is achieved." Based on advanced statistical data collection and analysis, and is focused on reducing the variation in product performance ***identify which parameter most significantly affect product variation

Layout Drawings

Working drawing that supports the development of the major components of the system

Design Review

Written report that documents the choices made, lists the proposed next steps, and proposes a timeline and budget for next step

Risk

a function of uncertainty, an expected value, a probability that combines the likelihood of something happening multiplied by the consequences of it happening

patent

a government authority or license conferring a right or title for a set period, especially the sole right to exclude others from making, using, or selling an invention.

CNC Machining

a little robot thing with a special drill/drill bit that removes bits of material as a it moves

Performance

a measure of function and behavior

Sub-system

a small, discrete portion of the system

Degree of Freedom

ability to either move in one direction along a straight line axis (x, y, z) or to rotate around a straight line axis (roll, pitch, yaw)

trade study

activity of a multidisciplinary team to identify the most balanced technical solutions among a set of proposed viable solutions Goals: develop a series of cost functions, rate the proposed viable solutions using the cost functions to identify the best overall solution

patching

activity of changing a design without changing its level of abstraction

Mechanical failure

any change or any design or manufacturing error in the size, shape, or material properties of a component, assembly, or system that renders the product incapable of performing its intended function

Reliability Engineering

area of the design process that involves the testing predicting the expected failure rate; commonly measured by the mean time between failures (MTBF)

Product liability

branch of law dealing with alleged personal injury or damage to property or environment resulting from a product defect

Form Development

breaking down the final form into sub-systems or components

Design Build Test

building then testing physical prototypes

Random error

causes variation when the actual mean is close to the target value

bias error

causes variation when the actual mean is farther away from the target value.

Reversing (types of patching)

changing the component view often leads to more understanding

Form (structure)

conveys HOW a product will do something

Indirect Costs

costs that are necessary to run the business, but cannot be traced directly or exclusively to the specific component or product Includes overhead, marketing and selling expenses, profit, and discounts

Direct Costs

costs that can be traced directly to a specific component or product; includes materials, purchased components, tooling specific to a part, and labor costs, and some overhead costs

Variable Costs

costs that naturally fluctuate depending on the market

robust design

decisions that are as insensitive as possible to the uncertainty, incompleteness, and evolution of the information that they are based on; evaluated on belief map

Shape of Normal Distribution

depends on the values of the mean and the standard deviation Smaller standard deviation, more consistent and concentrated data values closer to the mean value.

Decomposing (types of patching)

divide a component into multiple subcomponents or assemblies

Segmentation (TRIZ)

divide an object into independent parts, make an object sectional, and increase the degree of an object's segmentation

deterministic models

each variable is represented by a single value

Quality Measures

engineering requirement targets identified in the house of quality and result in customer satisfaction

Diverging Flow

flow is divided into two or more bodies

Cost Function

function relating cost of production to level of output and other variables that the firm can control (check powerpoint)

Design Structure Matrix (DSM)

helps the design team identify functional dependence among various components in a product

Substituting (Types of Patching)

identify other concepts, components, or features that could replace the current idea

Assembly manager

in charge of putting all the subcomponents together and packaging the final product

Converging Flow

joining of multiple materials

Injection molding

like casting for plastics

Combining (types of patching)

make 1 component serve multiple functions or replace multiple components

manufacture

making the components

Through Flow

material is manipulated to change its position or shape

Composite Materials

material made of fibers and a matrix resin; has high strength and stiffness and good shear properties, its also low density

Reliability

measure of how the quality of a product is maintained over time

Rolling

metal is forced between giant rollers producing successively thinner sheets of rolling metal; often categorized by temperature

Reverse Engineering

method of dissecting a product to determine how it functions

stochastic

non-deterministic, variable parameter

Assembly

physical sub-system that must be joined to the main system

Vacuum forming

placing a sheet of heated plastic over a mold to form the shape

Gantt Charts

planning charts used to schedule resources and allocate time

Electrical failure

product does not function as expected because of an electrical problem, such as wiring coming loose or some component burning out

Software failure

product does not function because of a problem with the software

Design patents

protect the form or physical characteristics of the object

Utility patents

protect the function of a product

assembly

putting together the final product by combining and connecting the components

Rearranging (types of patching)

reconfiguring the components' positions or function

Permutations

reordering the functions to see what will happen

Simulations

require a detailed understanding of the system, requires the building of a high-fidelity model that predicts behavior accurately, much less expensive than physical prototypes.

Product Design Engineer

responsible for overall product design and ensures solution meets requirements

Forming

shaping of metal using localized compressive forces which are provided by a hammer or by a press Tend to be stronger than cast parts

Component

single part of an overall system

Turning (machining)

spinning a part about an axis, then having a blade press into the spinning object form its side.

SWOT analysis

strengths, weaknesses, opportunities, threats; Matrix for making project portfolio decisions

Configuration

the architecture, structure, or arrangement of the components and assemblies of components in the product

Product Decomposition (Reverse Engineering)

the careful disassembly of a product part-by-part to determine how it is made

Decision Risk

the chance that the choices made will not turn out as expected

Accuracy

the correctness or truth that the model is capable of predicting (high fidelity usually means high accuracy)

Original Design

the development of an entirely new product, process, or assembly

System

the entire product

Gross Wages

the portion of annual salary paid for this period or based on the number of hours worked multiplied by an hourly rate

executive summary

the section of a design report that provides the key information that will be included and documented in the rest of the report

Components

two subsystems connected by an interface

Failure

unsatisfactory behavior

Design Test Build

using mathematical/physical models to simulate product behavior

Noise Variation

variations due to the operating environment (including the operator and age of the product); a product is considered high quality if this has little effect on product performance